JCB Engines Scania 9, 12, 16 PDE Unit Injector (1588862) Workshop Manual - PDF DOWNLOAD

03:04-02 Issue 3 Industrial & Marine Engines

Fuel system 9, 12 and 16 litre engines with PDE unit injector Work description

Art. nr.

1 588 862

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Contents Important information

..................................................................................3

Components in the fuel system

Removing unit injectors............................................4 Fitting unit injectors..................................................8 Adjusting unit injectors...........................................13 Order of adjustment for 9 litre engines ...................15 Order of adjustment for 12 litre engines .................17 Order of adjustment for 16 litre engines .................18 Adjustment of PDE unit injectors 31......................19 Adjustment of PDE unit injectors 32......................23 Feed pump...............................................................27 Fuel filter.................................................................29

Bleeding and pressure measuring the fuel system

12 litre engine .........................................................34 9 and 16 litre engines ..............................................35 Measuring feed pump pressure ...............................36 Pressure relief valve................................................38

Renewing an unpressurised return line

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Important information • The safety precautions and warnings in the work description must be read thoroughly before any work is carried out.

Mind the environment! Use a container to avoid spillage when working on the fuel system.

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Components in the fuel system Unit injector Removal Special tools

Number

Description

99 309

Tool to rotate flywheel

87 596

Slide hammer

Illustration

1. Open the bleed nipple and drain the fuel system by undoing the banjo screw/unions on the back of the fuel manifold.

!

WARNING!

The fuel system must be empty or fuel may run down into the cylinders, which will result in a great risk of liquid hammering.

If fuel runs into the combustion chamber, it must be removed immediately using a pump.

9 and 12 litre engines

16 litre engine 4

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2. Clean the rocker cover and the surrounding area.

3. Remove the top part of the rocker cover.

4. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.

!

WARNING!

Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury.

Important If the spring comes loose from the unit injector, the unit injector must be renewed.

5. Remove the rocker arm shaft.

6. Remove the screw for the fork clamp holding the unit injector in place.

1. Fork clamp 2. Fork clamp bolt 3. Unit injector

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7. Detach the cables on the unit injector. The screws cannot be removed but unscrew them as much as possible.

Important Do not lift the unit injector by the spring. The spring can come loose. If the spring comes loose from the unit injector, the unit injector must be renewed.

8. It is easier to position the slide hammer if one of the lower rocker cover bolts is removed.

9. Turn the unit injector clockwise until it stops. Place slide hammer 87 596 on the inside of the solenoid valve as illustrated.

Note If the slide hammer is placed directly under the solenoid valve, there is a risk of breaking the solenoid valve.

Place the slide hammer as indicated by the arrow.

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10. Withdraw the unit injector. If the unit injector is stuck, tap carefully with a rubber mallet on the solenoid valve housing.

Important The unit injector is not to be dismantled. Renew the entire unit 11. Remove the sealing washer from the bottom of the injector seat, if it was left behind when the unit injector was removed.

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Fitting Specifications

Tightening torques Lock nut on rocker arm

39 Nm

Bolt for fork on unit injector.

20 Nm + 75°

Bearing bracket and rocker arm shaft

105 Nm

Screws for cable connections on unit injector

2 +/- 0,2 Nm

Special tools

8

Number

Description

588 179

Torque screwdriver

Illustration

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Important Check the unit injector spring diameter before adjusting and ensure that the correct tool is used when adjusting the unit injector.

Note All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks. Allow the engine to run until it is running smoothly.

Check and delete any fault codes that are registered in the control unit after the work has been completed.

1. Make sure that the old seal is not at the bottom of the injector seat. Clean the sealing surfaces in the injector seat.

Important Always renew the O-rings and seal on unit injectors that have been removed.

Make sure all sealing surfaces are clean.

2. Lubricate the unit injector O-rings with O-ring grease, part No. 1 402 039.

3. Fit a new sealing washer on the unit injector. A rubber insert will keep the seal in place on the unit injector.

!

WARNING!

Check that there is no fuel left in the cylinder. If fuel runs into the combustion chamber, it must be removed immediately using a pump.

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Note Make sure that the fork clamp and bolt are dry and free of oil.

4. Place the fork clamp with screw in position on the unit injector and insert it into the cylinder head. Press down the unit injector by hand as far as possible.

5. Torque tighten the bolt to 20 Nm and then a further 75°. There are two marks on the rocker cover with a 75° angle between them.

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Important Make sure the pushrods are placed in their correct positions. Make sure the pushrod to the unit injector is firmly secured in its lower position by the retaining ring.

Important If the rocker arms have been removed on more than one cylinder, the rocker arm lock bolts must be completely unscrewed before adjustment commences.

6. Refit the rocker arm shaft. Screw in the bolts alternately so that they are tightened in parallel or one of the bolts may bend.

Tighten the bolts to 105 Nm. 7. Check and adjust the unit injector as described in Adjusting the unit injectors.

Important Make sure that the cable terminals are the right way round when fitting the cables to the unit injector.

118 482

8. Reconnect the cables on the unit injectors.

Their relative position is not important. Use torque screwdriver 588 179 to tighten the screws to 2 Nm.

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Important Use torque screwdriver 588 179 to avoid the risk of shearing off the screws.

The entire unit injector must be renewed if the screws shear off.

9. Refit the upper rocker cover and torque tighten the bolts to 18 Nm. 10. Close the bleed nipple and tighten the banjo screw.

11. Fill and bleed the fuel system. Refer to Bleeding the fuel system.

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Adjusting unit injectors Specifications The unit injectors must be adjusted when they are replaced and when valves are adjusted or checked in accordance with the maintenance chart.

Dimension B, diameter of the spring for unit injector PDE31

36,5 mm

Dimension B, diameter of the spring for unit injector PDE32

38,5 mm

Dimension A for unit injector PDE31 (cold engine).

66,9+/-0,1 mm

Dimension A for unit injector PDE32 (cold engine).

69,9 +/-0,1 mm

Tightening torque Lock nut on rocker arm

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39 Nm

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Special tools

Number

Description

99 309

Tool to rotate flywheel

Illustration

Preparatory work Important Check the unit injector spring diameter, dimension B, before adjusting and ensure that the correct tool is used when adjusting the unit injector.

Important Adjust the spring roughly first with a sliding caliper, then fine adjust. If both adjustments are not carried out, the unit injector may assume an incorrect position, which will result in poor performance and possible breakdown.

Dimension A= PDE31: 66,9 +/- 0,1 mm Dimension A= PDE32: 69,9 +/- 0,1 mm Dimension B = PDE 31: 36,5 mm Dimension B = PDE 32: 38,5 mm

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Order of adjustment for 9 litre engines Rotate the flywheel using tool 99 309 so that the mark on the flywheel is visible in the bottom window according to the table below.

Flywheel seen from the rear of the engine. * Direction of rotation when adjusting.

The continuous line show which sequence the angles should be measured on revolution 1 and the dashed line show the sequence for revolution 2 Mark on flywheel (degrees)

TDC Down 0

Turn

Valve change on cylinder

Adjust injector rocker arm on cylinder

1

2

2

1

144

1

504

2

288

1

648

2

4

72

1

5

432

2

216

1

576

2

4 2 5

3 3 1

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted.

Torque tighten the lock nut to 35 Nm after adjusting.

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If reading cannot be taken from underneath:

Turn the flywheel with tool 99 309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap.

Valve overlap on cylinder

Adjust the valves on cylinder

Adjust unit injector rocker arm on cylinder

TDCdown (0°)

1

5

5

(144°)

2

3

3

(288°)

4

1

1

(432°)

5

2

2

(576°)

3

4

4

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Order of adjustment for 12 litre engines Rotate the flywheel using tool 99 309 so that the mark on the flywheel is visible in the bottom window according to the table below.

Valve change on cylinder

Adjust injector rocker arm on cylinder

TDC Down (0°)

1

2

Valve 2, 5/ 120 480 (120°)

5

4

Valve 3, 4/ 240 600 (240°)

3

1

TDC Down (0°)

6

5

Valve 2, 5/ 120 480 (120°)

2

3

Valve 3, 4/ 240 600 (240°)

4

6

Mark on flywheel (degrees)

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted.

Torque tighten the lock nut to 39 Nm after adjusting.

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Order of adjustment for 16 litre engines

Rotate the flywheel using tool 99 309 so that the mark on the flywheel is visible in the bottom window according to the table below.

Valve change on cylinder

Adjust injector rocker arm on cylinder

TDC Down (0°)

6

4 och 5

TDC Up (180°)

7

2 och 6

TDC Down (360°)

1

3 och 7

TDC Up (540°)

4

1 och 8

Mark on flywheel (degrees)

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted.

Torque tighten the lock nut to 39 Nm after adjusting.

Cylinder numbering.

The illustration shows a 16 litre marine engine

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Adjustment of PDE unit injectors 31

Special tools

Number

Description

Illustration

99 414

Setting tool for PDE 31.

Measuring tool cabinet

Important Check the diameter, dimension B, of the unit injector spring before adjusting: PDE 31: 36,5 mm PDE 32: 38,8 mm Important Adjust roughly first with a sliding caliper and then fine adjust using the setting tool 99 414. If both adjustments are not carried out, the unit injector may assume an incorrect position, which will result in poor performance and possible breakdown.

1. First, measure the distance A between plane a and the top edge of the valve spring washer on the PDE injector using a digital sliding caliper.

2. Dimension A should be 66.9 mm for PDE 31. Dimension B should be 36.5 mm for PDE 31.

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Dimension A= PDE 31: 66,9 +/- 0,1 mm Dimension B = PDE 31: 36,5 mm

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WARNING!

Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause injury if it is released.

3. The dimension is adjusted by undoing the lock nut and screwing the rocker arm adjusting screw to the correct measurement.

4. Position setting tool 99 414 with the metal plate around the unit injector spring.

5. Finely adjust dimension A by simultaneously using a finger to feel that the small piston 2 is level with the flat upper surface of the tool. It is possible to feel differences of less than a tenth of a millimetre.

6. If setting tool 99 414 is not available, a digital sliding caliper can also be used for fine adjustment. Adjust the position of the rocker arm to 66.9 mm with adjusting screw 1.

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7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

8. For the order of checking and adjustment, see For the order of checking and adjustment, see Order of adjustment for 9 litre engine, or Order of adjustment for 12 litre engine or Order of adjustment for 16 litre engine.

Note No further checking or adjustment of the unit injector, such as checking the opening pressure, must be done. Faulty unit injectors must always be replaced complete.

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Setting tool 99 414

Piston above or below the flat surface of the setting tool. Adjustment necessary.

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Piston level with the flat surface of setting tool. Adjustment is correct.

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Enhetsinsprutare

Adjustment of PDE unit injectors PDE 32 Special tools

Number

Description

Illustration

99 442

Setting tool for PDE 32

Measuring tool cabinet

Important Check the diameter, dimension B, of the unit injector spring before adjusting: PDE 31: 36,5 mm PDE 32: 38,8 mm Important Adjust roughly first with a sliding caliper and then fine adjust using the setting tool 99 414. If both adjustments are not carried out, the unit injector may assume an incorrect position, which will result in poor performance and possible breakdown..

1. First, measure the distance A between plane a and the top edge of the valve spring washer on the PDE injector using a digital sliding caliper.

2. Dimension A should be 69,9 mm for PDE 32. Dimension B should be 38,5 mm for PDE 32.

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Dimension A= PDE 32: 69,9 +/- 0,1 mm Dimension B = PDE 32: 38,5 mm

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!

WARNING!

Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pretensioned and can cause injury if it is released.

3. The dimension is adjusted by undoing the lock nut and screwing the rocker arm adjusting screw to the correct measurement.

4. Position setting tool 99 442 with the metal plate around the unit injector spring.

5. Finely adjust dimension A by simultaneously using a finger to feel that the small piston 2 is level with the flat upper surface of the tool. It is possible to feel differences of less than a tenth of a millimetre.

6. If setting tool 99 442 is not available, a digital sliding caliper can also be used for fine adjustment. Adjust the position of the rocker arm to 69,9 mm with adjusting screw 1.

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7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

8. For the order of checking and adjustment, see Order of adjustment for 9 litre engine, or Order of adjustment for 12 litre engine or Order of adjustment for 16 litre engine.

Obs! No further checking or adjustment of the unit injector, such as checking the opening pressure, must be done. Faulty unit injectors must always be replaced complete.

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Setting tool 99 442

Piston above or below the flat surface of the setting tool. Adjustment necessary.

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Piston level with the flat surface of setting tool. Adjustment is correct.

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Feed pump Renewal 1. Clean the outside of the feed pump.

Remove the suction and pressure lines from the feed pump. Fit protective plugs.

12 litre engine

2. Unscrew the bolts and remove the feed pump.

3. Place a new O-ring onto the feed pump and lubricate with O-ring grease.

4. Fit the feed pump.

5. Connect the suction and pressure pipes.

6. Bleed the fuel system; refer to Bleeding the fuel system.

7. Start the engine and check for leaks.

The illustration shows the 12 litre industrial engine, The location is the same on the 12 litre marine engine and the 9 litre industrial engine 16 litre engine

If the feed pump has been changed or if the pipes on the suction and pressure sides of the pump have been removed, the pump may not succeed in pumping the fuel. This is because there is still fuel in the fuel filter. Refer to next page.

The illustration shows the 16 litre industrial engine. The location is the same on the 16 litre marine engine.

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1. Detach the inlet pipe to the filter and bend it downwards.

12 litre industrial and marine engines and 16 litre marine engine 2

1

107 676

2. Pump with the hand pump until resistance is felt and the fuel begins to run out of the pipe.

3. If this does not help, disconnect the outgoing pipe from the feed pump. Pump until fuel begins to run out of the pipe.

1. Inlet pipe 2. Outlet pipe

4. Bleed the fuel system; refer to Bleeding the fuel system.

12 litre marine engine

2

1

9 and 16 litre industrial engines

1. Inlet pipe

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Fuel filter Fuel filter on 12 litre engine and 16 litre marine engine

Removal Special tools

Number

Description

587 025

Filter tongs

Illustration

03_0808

1. Wash the filter and the filter retainer.

03_0809

2. Unscrew the filter. Use filter tongs, e.g. 587 025.

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Fitting

Note All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks. Allow the engine to run until it is running smoothly.

Check and delete any fault codes that are registered in the control unit after the work has been completed.

1. Oil the filter O-ring.

2. Screw on the new fuel filter by hand until the O-ring is against the filter retainer.

3. Then tighten it another half turn without using any tools.

03_0810

4. Check for correct sealing. Fill the fuel system and bleed as described in Bleeding the fuel system.

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Water separating prefilter Note Close the shut-off cock when renewing the filter.

109 700

The same intervals between changes apply as for those for an ordinary fuel filter.

1. Shut-off cock 2. Drain valve

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Fuel filter on 9 and 16 litre industrial engines

Removal Special tools Description

588 475

Sleeve

Illustration

Tool board Maintenance cabinet

118 268

Number

1. Unscrew the filter cover with a closed tool with hexagon driver, e.g. socket 588 475.

Note Do not use an adjustable spanner or other open tool as there is a risk of damaging the filter lid.

2. Lift out the filter cover with filter element from the fuel filter housing. The filter housing will drain automatically once the filter element has been removed.

Note Contaminated fuel will enter the injectors if the drainage does not work.

3. Undo the old filter element from the cover by carefully bending it to one side.

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Fitting Tightening torque Fuel filter cover

25 Nm+/- 5 Nm

Note All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks. Allow the engine to run until it is running smoothly.

Check and delete any fault codes that are registered in the control unit after the work has been completed.

1. Fit a new O-ring on the lid. Lubricate the O-ring with O-ring grease.

2. Make sure the fuel filter drain has emptied the fuel from the filter housing.

Note Contaminated fuel will enter the injectors if the drainage does not work.

3. Press a new filter element into the snap fastener in the lid.

Important Fit the filter element into the cover before placing it in the housing or the filter element might be damaged.

4. Press down the filter element into the housing with the cover. Torque tighten the cover to 25 Nm +/-5 Nm. Important Screw on the cover to the specified torque or the filter element may break.

5. Fill the fuel system and bleed as described in Bleeding the fuel system.

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Bleeding and pressure measuring the fuel system Bleeding the fuel system

12 litre engine 1. Attach a clear plastic hose to the bleeder nipple at the front of the fuel manifold.

2. Open the bleed nipple and pump with the hand pump until fuel free from bubbles comes out of the hose.

• If the system is completely empty, it will take approximately 250 strokes.

• After renewing the fuel filter, it will take approximately 170 strokes.

• Approximately 150 strokes are required to bleed the fuel manifold.

4. Close the bleeder nipple and remove the hose. Pump with the hand pump until the pressure relief valve opens, approximately 20 strokes.

116 545

3. Pump an additional 20 strokes to remove the air.

5. Start the engine and check for leaks.

Note If the engine is difficult to start, repeat steps 2-4 a few times.

Important Do not crank with the starter motor for longer than 30 seconds at a time.

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Bleeding the fuel system

9 and 16 litre industrial engines: 1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing. Run the hose to a container to collect the fuel.

2. Open the bleed nipple and pump with the hand pump until fuel free from bubbles comes out of the hose.

3. Close the bleed nipple and remove the hose

16 litre marine engine: 1. Connect transparent plastic hoses to the fuel rail bleed nipples. Run the hose to a container to collect the fuel.

2. Open the bleed nipples and pump the hand pump until fuel without air bubbles flows out. This may require 130-150 strokes of the pump.

Industrial and marine engines:

116 545

3. Close the bleed nipples and remove the hoses.

4. Continue pumping by hand until a resistance is felt, which will be after approximately: • 20 pump strokes after renewing the fuel filter. • 50 pump strokes after renewing a unit injector.

5. Start the engine and check for leaks.

Note If the engine is difficult to start, repeat steps 2-4 a few times.

Important Do not crank with the starter motor for longer than 30 seconds at a time.

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Measuring feed pump pressure

Specifications Lowest permitted fuel pressure at 1900 rpm

5,5 bar

Lowest permitted fuel pressure at 500 rpm

4,5 bar

Special tools Description

98 113

Pressure gauge

99 362

Pressure gauge

Illustration

Tool board D6

98 113

00 1572

Number

Note All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks. Allow the engine to run until it is running smoothly.

Check and delete any fault codes that are registered in the control unit after the work has been completed.

Two different pressure gauges can be used for measuring the pressure. Pressure gauge 98 113 or pressure gauge 99 362.

Renew the fuel filter and bleed the fuel system before measuring.

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12 litre engines and 16 litre marine engine 1. Connect the pressure gauge to the fuel filter outlet connection.

Connecting pressure gauge 99 362 to a 12 litre engine and a 16 litre marine engine

9 and16 litre industrial engines 1. Connect the pressure gauge to the union on the fuel filter.

2. Start the engine and increase the speed to 500 rpm. Take a pressure reading; the lowest permitted fuel pressure at 500 rpm is 4.5 bar.

116 251

All Connecting pressure gauge 99 362 to a 9 and a16 litre industrial engine

3. Increase the engine speed to 1900 rpm.

Take a pressure reading; the lowest permitted fuel pressure at 1900 rpm is 5.5 bar.

Inspect fuel lines with connections, pressure relief valve, fuel filter and feed pump if the fuel pressure is too low.

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Pressure relief valve Checking Specifications Lowest permitted fuel pressure

4,5 bar

Highest permitted fuel pressure

7,5 bar

Special tools Description

98 113

Pressure gauge

99 362

Pressure gauge

Illustration

Tool board D6

98 113

00 1572

Number

Note All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks. Allow the engine to run until it is running smoothly.

Delete any fault codes that are registered in the control unit when the work is completed.

Two different pressure gauges can be used for measuring the pressure. Pressure gauge 98 113 or pressure gauge 99 362.

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12 litre engines and 16 litre marine engine 1. Connect the pressure gauge to the fuel filter outlet connection.

Connecting pressure gauge 99 362 to 12 litre engines and a 16 litre marine engine 16 litre industrial engines 1. Connect the pressure gauge to the back of the left-hand fuel manifold.

9 litre industrial engine 1. Connect the pressure gauge to the back of the fuel manifold.

All 2. Turn the starter key to the drive position.

3. Pump by hand using the hand pump. The pressure must be at least 4.5 bar before the pressure relief valve opens; if the pressure relief valve opens at a lower pressure, its opening pressure is too low and the valve must be renewed.

4. Start the engine and increase the speed to 1500 rpm.

5. Take a pressure reading; if the pressure is 7.5 bar or above, the pressure relief valve is blocked and must be renewed..

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Replacing an unpressurised return line Special tools

Number

Description

587 258

Pipe cutter

587 956

Pliers

Illustration

12 litre engine Fitting plastic pipe in union 1. Connect pipe with insert sleeve, ferrule and union nut.

1.

2.

3.

4.

5.

Plastic tube Union nut Ferrule Insert sleeve Union

2. Fit union and tighten union nut to the correct tightening torque.

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Diameter

Tightening torque

6 mm

10 Nm

12 mm

20 Nm

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Fitting plastic pipe on banjo union 1. Cut the plastic pipe with pipe cutter 587 258.

See illustration for correct lengths.

A: Length = 106 mm B: Length = 151 mm 2. Hold plastic pipe tightly with pliers 587 956 and fit union.

3. Tap in union with a plastic mallet.

Important Do not use a hammer

Important Avoid sharp bends on plastic pipes.

A kink may develop on the plastic pipe and restrict the fuel flow.

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Diameter

Minimum internal diameter of bend

6 mm

35 mm

12 mm

95 mm

41

16 litre engine The pre-shaped return line is available as a spare part. Fit as illustrated.

Important The pre-shaped return line must not be replaced by plastic pipes sold by the metre because of the risk of wear occurring against other parts.

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