Fuel System T4F

XPI Fuel System
Scania U.S.A. Inc. Tier4F

Abbreviations
 ECU = Electronic Control Unit

 XPI = Extra High Pressure Injection
 HPP = High Pressure Pump
 LPP = Low Pressure Pump
 MDV = Mechanical Dump Valve
 HPC = High Pressure Connection
 IMV = Inlet Metring Valve

General about Scania XPI
 XPI = Extra high Pressure Injection
 Scania XPI is a new generation Common Rail system
 Implemented in all Tier 4i and Tier 4F Industrial engines
 Average operating pressure 26000 PSI (1800 bar)

Max operating pressure 35000 PSI (2400 bar)

Benefits with Scania XPI
 Injection timing or duration independent of camshaft

position
 Higher average injection pressure compared to unit

injector and inline pump systems
 Injection pressure can be regulated independently of

engine speed and amount of fuel injected
 Simplified valve train since the pushrods for unit

injectors are no longer needed
 Multiple injections are possible

Safety
 Due to the high fuel pressure, leakage can cause jets of fuel that
penetrates through the skin!
 Always consider the high pressure part of the system

(accumulator and high pressure lines) as pressurized. The
pressure could be as high as 35,000 PSI (2400 bar). This applies
also to an engine that is not running!
 Before working on any of the fuel system compenents: De-

pressurize the system with SDP3 and then loosen the cylinder
high pressure line nut at the accumulator of the cylinder you are
going to work on. Cover the nut with a cloth during the operation.
Use safety glasses and gloves.
 Avoid standing closer than 3 feet (1 m) to an engine at first start

up after fuel system work has been conducted. Fuel jets will
diverge within this distance from the source and become less
harmful.

6
Scania XPI
Fuel Rail Mechanical Dump Valve

High Pressure Connectors
Pressure Sensor Injector

High Pressure
Line
Bleed
Hand Pump
Inlet Metering Valve
Fuel Manifold Fuel Heater 350W,
40-75deg F (5-24 deg C)
Fuel Filter 1
10 microns
Fuel Filter 2
3 microns
Low Pressure Pump High Pressure Pump

7
DC 16 Fuel System
4
3
2
1. Water Separating, Suction Filter
2. Pressure Filter
3. Low Pressure Pump 1
4. High Pressure Pump
Scania USA Inc A. Fritz 1/8/2015

XPI System Pressures
Low Pressure
High Pressure
Return

XPI System Schematic
1.Fuel tank
2.Hand pump with check valves
3.Fuel filter, water separating
suction filter
4.Control unit cooler
5.Feed pump
6.Fuel filter, pressure filter
7.Fuel metering valve
8.Check valve
9.High pressure pump
10.Check valve
11.Restriction
12.Accumulator
13.High pressure connection
14.Injectors
15.Fuel pressure sensor
16.Safety valve
17.Fuel manifold for return fuel
18.Return line with check valve
19.Draining the water

10
Inlet from low

pressure pump
Venturi housing
Return to the Outlet to HPP Inlet from return manifold

fuel tank
Fuel Filter Replacement
1,000 Hours
New tools for fuel filter replacement
36 mm socket Suction tool Suction hose

#588 475 #588 793 #588 960

1,000 Hours
A. Water separating suction filter

B. Pressure filter

1,000 Hours
 Unscrew the water separating

suction filter 3 to 4 turns.
 Wait two minutes for the fuel to
drain out of the filter housing.

1,000 Hours
 Remove the filter.

 Remove any remaining fuel and
particles with the suction tool.
 Keep the suction tool in the water
separating filter housing.

1,000 Hours
 Unscrew the pressure filter cover

3 to 4 turns.
 Use the suction tool to remove
any fuel that drains into the water
separating filter when the
pressure filter is loosened.
 Wait two minutes for the fuel to
drain out of the filter housing.

1,000 Hours
 Remove the pressure filter.

 Remove any remaining fuel and
particles from the filter housing
with the suction tool.

1,000 Hours
Bleed screw
 Install new o-rings to the covers

 Snap the new filters to the covers
 Open the bleed screw on the filter
housing to prevent back pressure
 Install the new filters
 Tighten filter cover to 18.5 ft.lb.
25(Nm)
 Close the bleed screw

Bleeding The Fuel System
 Open the bleed screw at the high

pressure pump
 Attach the suction hose to the
bleed screw
 Use the suction tool to bleed the
fuel system

19
XPI HPP, Cut away view

Inlet fuel from IMV
IMV
Inlet metering valve
Barrel
LPP
Low pressure pump
Camshaft

XPI HPP Head Assembly
Inlet fuel from IMV
Outlet fuel to
accumulator
Inlet checkvalve
Outlet
checkvalve Drain drilling
Barrel
Seal washer
Drain channel Steel Plunger
Spring Plunger lift roller
2-bump
camshaft

21
Fuel Rail
Fuel pressure sensor
connection
Accumulator chamber
High pressure line

connections
Mechanical dump valve

(safety valve)

Safety Valve Function
Bleeding >3000bars
=1000bars
+/-300
Engine stopped
After the accumulator pressure is reduced the valve resets automatically.

23
Injector assembly
High Pressure
Connector

24
High pressure connector

HPC notch
HPC seat
O-ring
(connects to injector)

XPI Injector
Stator Spring
Spring Retainer
Stator Spacer
Spring Washer
Over travel Spring
Ball Retainer
Ball
Stroke Shim
Plunger Seal
Floating Sleeve
Spring
Plunger
Nozzle
Nozzle Retainer

Injectors:Individual adjustment code
 Each injector has an individual adjustment code. This code

has to be entered into the ECU by SDP3 when an injector is
changed.
 The purpose of the individual adjustment code is to reduce

variation between injectors. The result is an engine that runs
smoother and delivers the correct power output.
 After changing the injectors you need to, CLEAR fuel data with
SDP3.

Benefits of multiple injection
access to desired timing and pressure
-360 Before TDC TDC After TDC 360
Pilot Main Post

injection injection injection
Reduce noise Control combustion Reduce exhaust emissions
2015-01-08
Scania XPI

Cleanliness
 Several parts in the system are sensitive to dirt and water.

This is due to extremly tight clearances, surface finish
requirements and extremely high pressure.
Cleanliness is more important than ever!

Pilot Valve Seat
Dual Angle Seat
0.016 inch (0,4 mm) drilling

31
Pilot Valve
The thickness of a human hair is 85 microns.
The pilot valve stroke is 47 microns!
Stroke = 47 microns
Pilot valve
seat
1000 microns = 1mm

(0.039 inch)
Ball Retainer
Human hair = 85 microns Ball

Seat

32
Needle Seal
The size of the holes in the needle seal are
0.012 inch (0.3 mm).
0.039 inch
(1 mm)
Plugged hole = uncontrolled fuelling

33
High Pressure Lines
Examples of burrs on a high pressure line.

34
General Cleanliness
 Do not use compressed air for cleaning purposes.
 Use only lint-free cleaning cloths on the fuel system.
 When removing and fitting components, do not use materials

like cotton cloths, cardboard or wood.
 Use undamaged tools (not with split chrome surfaces)
 Do not remove parts from their original enclosure until

immediately before assembly.
 If you need to send the part somewhere: use a new plastic bag
and seal it properly. If possible, use the original packing of the
new part.

35
Pressure Lines
Parts must be protected from dirt by suitable plugging!
OK

36
High Pressure Connector
Example of plugging during disassembly
OK

Troubleshooting XPI

38
XPI fuel system

Trouble shooting
A number of trouble shooting trees with their
associated descriptions are provided in
“XPI fuel system, Trouble shooting 03:14-01”.
IMPORTANT! Always wash the engine before

starting work on the fuel system.

39
Troubleshooting: Tools
Scania pressure measurment kit (P/N 99362)
Pressure sensor + amplifier Multimeter
Note: Pressure is displayed in Volt. 0.1V = 1 bar

40
Troubleshooting: Feed pressure
If engine is not firing:

Start with checking the
feedpressure from the
Low presure pump.

41
Troubleshooting:
Return fuel manifold pressure
If the railpressure is
too low:
Check the return fuel
rail pressure.

SDP3 Fuel system test
 Cylinder balancing
 Cylinder shut-off
 Leak testing the safety valve
 Checking the fuel inlet metering valve
 Cylinder output test
 Checking fuel pressure in the accumulator
 Checking internal leakage

Cylinder balancing
The ECM constantly adjusts the fuel volume for each cylinder,
so the engine runs smooth.
This check shows how the ECM is compensating for each
cylinder.

Cylinder shut-off
With this check one or more cylinders can be shut off to help
diagnose a bad injector.

Leak testing the safety valve
This test will raise the fuel rail pressure to 2400 bar and increase
the engine speed to 1400 rpm.
The maximum allowed leakage from the safety valve is 3 drops/min.

Checking the fuel inlet metering valve
This test should be used to check the fuel inlet metering valve.
The test will increase and decrease accumulator pressure in

increments from 500 to 2000 bar and then compare the fuel
pressure sensor values. The biggest difference between the
requested and the measured value is calculated and shown.

Cylinder output test
1 3 5 2 4

Checking fuel pressure in the accumulator
This test shows the pressure difference between the fuel

pressure in the fuel rail and the requested fuel pressure.
At a constant engine speed the pressure difference should be

zero.

Checking internal leakage
This check will raise the fuel rail pressure to 2400 bar and shut the
engine off.
The rail pressure will be measured after the engine has been shut off at 5
and 30 seconds, the ECM will compare the two measurements. The
maximum allowed pressure difference is 300 bar.

SDP3 Fuel system test
 The fuel system test should be combined to help troubleshoot

the fuel system.
 By using multiple test leaking injectors or high pressure
connectors can be found.

Fuel System T4F

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fuel System T4F

Uploaded by

Copyright:

Available Formats

XPI Fuel System

Scania U.S.A. Inc. Tier4F

 ECU = Electronic Control Unit

Scania U.S.A. Inc. Tier4F

 XPI = Extra high Pressure Injection

 Scania XPI is a new generation Common Rail system

 Implemented in all Tier 4i and Tier 4F Industrial engines

 Average operating pressure 26000 PSI (1800 bar)

Scania U.S.A. Inc. Tier4F

 Injection timing or duration independent of camshaft

 Higher average injection pressure compared to unit

 Injection pressure can be regulated independently of

 Simplified valve train since the pushrods for unit

 Multiple injections are possible

Scania U.S.A. Inc. Tier4F

 Always consider the high pressure part of the system

 Before working on any of the fuel system compenents: De-

 Avoid standing closer than 3 feet (1 m) to an engine at first start

Scania U.S.A. Inc. Tier4F

Fuel Rail Mechanical Dump Valve

Pressure Sensor Injector

Low Pressure Pump High Pressure Pump

Scania U.S.A. Inc. Tier4F

Scania USA Inc A. Fritz 1/8/2015

Scania U.S.A. Inc. Tier4F

Scania U.S.A. Inc. Tier4F

Inlet from low

Return to the Outlet to HPP Inlet from return manifold

New tools for fuel filter replacement

36 mm socket Suction tool Suction hose

Scania U.S.A. Inc. Tier4F

A. Water separating suction filter

Scania U.S.A. Inc. Tier4F

 Unscrew the water separating

Scania U.S.A. Inc. Tier4F

 Remove the filter.

Scania U.S.A. Inc. Tier4F

 Unscrew the pressure filter cover

Scania U.S.A. Inc. Tier4F

 Remove the pressure filter.

Scania U.S.A. Inc. Tier4F

 Install new o-rings to the covers

Scania U.S.A. Inc. Tier4F

 Open the bleed screw at the high

Scania U.S.A. Inc. Tier4F

XPI HPP, Cut away view

Scania U.S.A. Inc. Tier4F

Drain channel Steel Plunger

Spring Plunger lift roller

Scania U.S.A. Inc. Tier4F

High pressure line

Mechanical dump valve

Scania U.S.A. Inc. Tier4F

After the accumulator pressure is reduced the valve resets automatically.

Scania U.S.A. Inc. Tier4F

Scania U.S.A. Inc. Tier4F

High pressure connector

Scania U.S.A. Inc. Tier4F

Scania U.S.A. Inc. Tier4F

 Each injector has an individual adjustment code. This code

 The purpose of the individual adjustment code is to reduce

Scania U.S.A. Inc. Tier4F

-360 Before TDC TDC After TDC 360

Pilot Main Post