Scania DC09 User manual

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
01:03 Issue 6.1 en-GB 1
Fuel system
Industrial engines
DC09, DC13, DC16
333 381

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
01:03 Issue 6.1 en-GB 2
Fuel tank...................................................................................................................3
Position................................................................................................................ 4
Fuel tank design .................................................................................................. 6
Main tank and buffer tank ................................................................................... 8
Fuel pipes..................................................................................................................9
Fuel filter ................................................................................................................ 11
XPI engines ....................................................................................................... 11
PDE engines ...................................................................................................... 13
Fuel heater for XPI engines..................................................................................14
Feed pump flow rates ............................................................................................16
XPI engines ....................................................................................................... 16
PDE engines ...................................................................................................... 16
Flow and pressure .................................................................................................17
XPI engines ....................................................................................................... 17
PDE engines ...................................................................................................... 17
Risk of fire.............................................................................................................. 18
Fuel grade and power for PDE engines...............................................................19

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 3
Fuel tank
1. Return pipe. Note: For XPI engines, it should enter below the lowest fuel level
2. Suction pipe
3. Venting
4. Level indication and level sensor
5. Bottom strainer
6. Drain tap with water separator
7. Shut-off cocks
8. Additional water separating fuel filter. Note: Not for XPI engines
9. Flexible fuel hoses
10. Buffer tank
11. Supply line
12. Return pipe
13. Injection pump with feed pump
14. Ventilating valve
15. 3-way valves
16. Feed pump
17. Hand pump
18. Inspection hatch
19. Fuel gauge
20. Overfill protection
21. Filler cap
22. Main tank
23. Drain tap
Example of a fuel system for a stationary industrial engine

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 4
Position
PDE and XPI engines
If the fuel tank is placed higher than the engine feed pump, a shut-off cock should be
installed in the fuel line to the feed pump. During stoppages, this cock should be
closed.
REQUIREMENT!
The highest fuel level in the tank is 3 m in relation to the feed pump.
REQUIREMENT!
Maximum permitted suction height is 2 m for PDE engines and 1 m for XPI engines.
The risk of air leaks in the suction pipe increases with increased vacuum. Suction
height is calculated from the bottom of the tank.
If the fuel tank is mounted lower than the maximum permitted suction height, or if a
large tank is required which cannot be mounted close to the engine, a buffer tank
must be installed at a suitable distance and height.
On stand-by generator sets, it is recommended that the tank always be positioned
above the level of the fuel manifold to prevent the engine's fuel system being drained
in the event of leakage.
If the tank(s) are built in, the space should be well ventilated.

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 5
XPI engines
If the tank is positioned so that suction height exceeds 1 m, a feed pump must be
mounted directly after the tank. The flow for the auxiliary feed pump must be mini-
mum 15% higher than the flows specified in the table found in the section Feed pump
flow rates.
To prevent fuel leakage during filter renewal, a shut-off cock must be installed on the
return pipe if the fuel tank is positioned higher than the engine.
To prevent unfiltered fuel from entering the engine during an inspection, a shut-off
cock must also be installed on the fuel pipe to the feed pump if fuel tank is placed
higher than the engine.
All XPI engines are equipped with a water-separating fuel filter. The water that is
separated follows with the return fuel. For this reason, all tanks must be fitted with a
drain tap for draining water.
The tank should normally be drained once a year, but this may vary depending on the
quality of the fuel.
If the customer requires extra water separation so that the water is not led back to the
fuel tank, a water separating fuel filter can be fitted on the return pipe.
IMPORTANT!
Fitting an extra water separating fuel filter in addition to the Scania prefilter is not
permitted on the fuel pipe to the engine.

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 6
Fuel tank design
The material for the fuel tank should be corrosion-resistant, such as stainless steel or
aluminium.
Note:
Some other materials, such as copper or hot dip galvanised sheet steel, are unsuitable
for use with diesel fuel.
The fuel tanks must be fully welded. When used in mobile installations, the fuel tanks
must be equipped with baffle plates.
Both fuel filling components and the fuel tank must be grounded to prevent sparking
from static electricity.
The fuel tank must have the following devices:
• A drain tap for emptying sludge and water that has sunk to the bottom.
• A connection with the outside air at the upper part of the tank to avoid a vacuum
in the tank. This can consist of a special bleed pipe or a ventilation hole in the fill-
er pipe cover. In dusty environments, this connection should be connected via a
filter to prevent dirt from entering the tank.
• Protection or filter to prevent contaminants entering during filling.
• Fuel pick-up unit with electronic overfill protection to prevent any diesel spillage.
• Main tanks must be fitted with inspection hatches so that they can be inspected
and cleaned inside.
REQUIREMENT!
By law, the label "Ultra Low Sulfur Fuel Only" must be affixed at the filler cap on
all engines certified in accordance with Tier 4. The label is supplied with all indus-
trial engines from Scania.

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 7
New fuel tanks must be thoroughly cleaned and rinsed internally using clean fuel.
They must also be pressure tested to 0.3 bar.
Fuel tanks manufactured from materials which are not resistant to corrosion must be
treated externally with anti-corrosion paint.
Note that the tanks must not be painted internally nor be zinc-coated or galvanised.
Fuel tanks located outdoors should be painted in a bright, heat-reflecting colour, es-
pecially in hot climates with strong sunlight.
It is important that the fuel tanks are positioned in as cool a location as possible since
the return fuel is hot and therefore raises the temperature of the fuel in the tank.
Power correction due to increase in fuel temperature is displayed in the tables in the
section Fuel grade and engine power.
ULTRA LOW SULFUR
EU: 10ppm Sulfur Maximum
USA: 15ppm Sulfur Maximum
FUEL ONLY
338 656

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel tank
01:03 Issue 6.1 en-GB 8
Main tank and buffer tank
If the engine installation has a buffer tank and main tank, these should be designed
as follows:
• The main tank must have a sloped bottom or be on a slight incline (about 3-5°)
and have a tap at the lowest part for draining condensation.
• The pipe fittings must be connected or routed to approximately 50 mm from the
bottom and supplied with a bottom strainer. This applies to both the buffer tank
and the main tank.
• The lines to the buffer tank should be as short as possible and should be mounted
in such a way that they cannot be exposed to mechanical damage.
• Transfer of fuel from the main tank to the buffer tank should be achieved using
an electric pump connected so that it only pumps when the engine is running. This
is to prevent the risk of serious leakage when the engine is not running. The elec-
tric pump must have an overcapacity of approx. 15% over the feed pump flow.
This is to ensure that the quantity of return fuel is sufficient for lubrication and
cooling.
• There must be a return pipe from the buffer tank to the main tank so that any sur-
plus fuel runs back to the main tank.
• For PDE engines, the return pipe from the engine must be routed to the upper part
of the buffer tank.
• For XPI engines, the return pipe should enter below the lowest fuel level in the
main tank.
• The buffer tank must also be fitted with a drain tap for condensation.
• Tanks which are buried should have a drain pipe from the bottom to lead away
sludge and water.
See instructions in the Fuel tank design section for further details.

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel pipes
01:03 Issue 6.1 en-GB 9
Fuel pipes
The fuel lines should be routed so that the fuel cannot be heated by radiated heat from
the engine.
Engine power dependence on fuel temperature is indicated in the table under the sec-
tion Fuel grade and engine power. Maximum permitted fuel temperature in the inlet
pipe is 70°C.
The return line from the overflow valve must be routed to the fuel tank or to the buff-
er tank (if fitted).
Note:
The maximum permitted back pressure in the return line is 350 mbar.
The return line must not be connected to the suction line.
The return line and suction line must have the same diameter.
For PDE engines, the return line is normally connected to the upper part of the tank.
The return line should normally enter above the maximum fuel level.
IMPORTANT!
For XPI engines, the fuel return line should enter below the lowest fuel level in the
fuel tank.
The suction line in the fuel tank should be placed at least 50 mm from the bottom of
the fuel tank. This distance also applies to the suction strainer.
In multi-engine installations, the fuel system should be divided into at least two in-
dependent systems so that a fault in one of the fuel lines does not cause all engines
to stop.

INSTALLATION
MANUAL
©Scania CV AB 2016, Sweden
Fuel pipes
01:03 Issue 6.1 en-GB 10
The fuel lines should not be made of copper as there is a risk of oxidation due to con-
densation. The sulphur content in the fuel can also have a negative effect on the cop-
per.
The minimum inside diameter of the fuel suction line is shown in the table below.
Fuel pipe length
Shorter than 3 m Longer than 3 m
Engine type Inner diameter (mm) Inner diameter (mm)
DC09 9 12
DC13 9 12
DC16 PDE 9 12
DC16 XPI 12 12