MBE 4000 APPLICATION AND INSTALLATION

FUEL SYSTEM
Page FUEL SYSTEM DESCRIPTION .............................................................. FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES ................ FUEL SELECTION .................................................................................. 8-3 8-5 8-10

Section 8.1 8.2 8.3

All information subject to change without notice.

8-1

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

FUEL SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

8-2

All information subject to change without notice.

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

MBE 4000 APPLICATION AND INSTALLATION

8.1

FUEL SYSTEM DESCRIPTION

The purpose of the fuel system is to keep the fuel clean and free from air or water, and to deliver this fuel at the correct pressure to the electronic unit pump (EUP). A fuel system consists of: A fuel tank Fuel prefilter Fuel supply pump Main fuel filter Fuel lines Electronic unit pump (EUP) Engine-resident control unit (DDEC-ECU) Injector nozzles Check fuel valve All necessary piping Fuel is drawn from the fuel tank through a fuel prefilter (primary fuel filter) by the fuel pump. Fuel is then pumped through the main fuel filter (secondary filter) and through a check valve (if included) to the cylinder head. Primary and secondary filters may be combined in some applications. Fuel enters the EUP through the two fuel inlet filter screens located around the injector body. Filter screens are used at the fuel inlet openings to prevent relatively coarse foreign material from entering the injector. The DDEC-ECU receives data (such as temperature and speed), analyzes this data, and modulates the fuel system accordingly to ensure efficient engine operation. The DDEC-ECU sends a signal which activates the injector solenoid and determines the timing and amount of fuel delivered to the engine.

All information subject to change without notice.

8-3

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

FUEL SYSTEM

For a schematic diagram of a typical fuel system, see Figure 8-1.

Figure 8-1

MBE 4000 Fuel System Schematic Diagram

8-4

All information subject to change without notice.

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

MBE 4000 APPLICATION AND INSTALLATION

8.2

FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES

Fuel Tank Fuel Filters Fuel Lines Optional Devices

The following installation guidelines cover:

8.2.1

FUEL TANK

Fuel tanks must be made of the correct material, be properly designed and located, and be adequately sized regardless of the fuel tank configuration being used.

Material
Satisfactory fuel tank material is steel, aluminum, or a reinforced plastic suitable for diesel fuel applications. The inside(s) should be clean and free from all impurities likely to contaminate the fuel. NOTICE: Do not use a fuel storage tank or lines or fittings made from galvanized steel. The fuel will react chemically with the galvanized coating to form powdery flakes that will quickly clog fuel filters and cause damage to the fuel pump and injectors Fuel tanks must be properly cleaned after manufacturing so no manufacturing debris gets into the fuel. The fuel tank(s) must not be galvanized internally under any circumstances. The fuel tank(s) or piping may be galvanized or painted on the outside only to prevent corrosion.

Design
Baffles must be positioned to separate air from fuel and to prevent fuel from sloshing between the ends of the tank(s) in mobile applications. The baffles should extend from the top to the bottom of the tank(s). These baffles should have passageways which allow the fuel to maintain an even level throughout the tank(s). The tank(s) should have a readily accessible drain valve at the bottom for easy removal of contaminants.

All information subject to change without notice.

8-5

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

FUEL SYSTEM

The location of the fill neck(s) should be a clean, accessible location with sufficient height and room for an average size fill can or tanker truck hose. Position a removable wire screen of approximately 1.6 mm (.062 in.) mesh in the fill neck(s) to prevent large particles of foreign material from entering the tank(s). A recess on the bottom edge prevents sludge and condensation from mixing with the fuel again. A sludge drain must be provided at the lowest point. The tank(s) must have a vent which meets applicable regulations. A stand pipe in the tank fuel return must be utilized on MBE 4000 engines. A properly designed fuel tank may be seen in the following illustration (see Figure 8-2).

Figure 8-2

Properly Designed Fuel Tank

Capacity
Carefully choose the capacity of the fuel tank(s) to suit the specific engine installation. Consideration should be given to length of operation without the need to refuel. The design of tanks in mobile applications must include the supply pipe so that adequate fuel is available under all operational gradients. The tank(s) capacity must be at least 5% greater than the maximum fill level to allow for fuel expansion. Fuel capacity of the tank(s) should be appropriate for the specific application involved. Fuel coolers may be used.

8-6

All information subject to change without notice.

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

MBE 4000 APPLICATION AND INSTALLATION

Position
The position of the fuel tank(s) is an important factor in any application. The position of the fuel tank(s) should ensure the following whenever possible. The difference in height between the fuel tank(s) and engine supply pump is kept to a minimum. The length of fuel feed pipe is kept to a minimum. Locate the fuel tank(s) away from any excessive heat source. The filling point is easy to access and simple to use. The fuel pump attached to the engine has a suction height of 1.4 metres (4.5 ft). Therefore, the bottom of the fuel tank must not be more than 1.4 metres (4.5 ft) below the fuel pump (The fuel pump should not be more than 1.4 metres (4.5 ft) above the lowest fuel level possible in the fuel tank). There are some fuel systems which are over the maximum fuel restriction, 17.7 in. Hg. (600 mbar), because of the location of the fuel tank with respect to the engine regardless of the size of the fuel lines. An electric fuel pump (not supplied by DDC) maybe needed for bigger suction heights. The fuel should be extracted at a point approximately 30 mm (1.2 in.) to 50 mm (2 in.) above the bottom edge of the tank, passing through an 800 m strainer. With a raised tank (5 metres maximum), e.g. in machinery, the supply and return pipe must be provided with a shutoff and drainage valve as close to the engine as possible. This prevents an overflow at the filter housing during maintenance work. The fuel tank(s) should not be located higher than the fuel pump. However, when their use is unavoidable, the fuel return line should not extend into the fuel supply so that siphoning cannot occur in case a leak occurs in the line. The fuel return line must incorporate a check valve; the fuel inlet must incorporate a shutoff valve of the needle or globe type construction and must not impose any undue restriction to fuel flow. Install a shutoff valve for use when changing the primary filter if the fuel tank(s) is above the primary filter. This will prevent the tank(s) from draining. A check valve in the fuel spill prevents supply side fuel from draining back into the tank(s) in a tank-below-engine installation.

All information subject to change without notice.

8-7

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

FUEL SYSTEM

8.2.2

FUEL FILTER CONFIGURATION

Fuel filter requirements for the MBE 4000 engines may be found in DDC publication 7SE270. Care should be taken not to exceed the maximum engine fuel inlet restriction17.7 in. Hg (600 mBar) under any conditions, 10.29 in. Hg (350 mBar) maximum for clean filters. The fuel inlet restriction must be measured before the main filter. Remote mounting of the filters is acceptable, given proper line sizing. Care must be taken when remote mounting the secondary filter not to overlook the fuel temperature and pressure sensors where utilized. Contact DDC Application Engineering for remote filter mounting. The fuel temperature and suction limits are DDC requirements. The fuel inlet restriction must be measured before the main filter. For on-highway MBE 4000 engines there are multiple on-engine fuel filter options. These options include prefilter and main filter only, prefilter and main filter with water separator, and prefilter and main filter with water separator and heating. A hand priming pump is available with each filter option. A water and fuel sensor is included with on-engine water separator options.

8.2.3

FUEL LINES

The following guidelines apply to supply and return lines between the fuel filter header and the tank(s) only. These guidelines apply regardless of which fuel tank configuration is being used. Do not modify or tamper with any fuel lines supplied with the engine. The fuel inlet restriction cannot exceed 17.7 in. Hg (600 mBar) under any condition.

Design
The lines leading from the fuel tank to the engine (prefilter) must be made from scale-free steel piping or plastic, i.e. polyamide 11, known as PA, in accordance with DIN 7728. Steel pipes may have to be used, depending on the ambient temperature in the engine compartment. Steel pipes must be connected using screwed pipe connections with conical nipples in accordance with DIN 3824, cap nuts in accordance with DIN 3870 and banjo bolts in accordance with DIN 7644 or 7624. Hose plug connections must be used for plastic lines. All lines should be in protected areas. These areas should be free from possible damage, and securely clipped in position to prevent chaffing from vibration. Take the necessary precautions to ensure that the inlet line connections are tight so air cannot enter the fuel system. The careful selection of line routing cannot be overemphasized. Avoid excessively long runs. Minimize the number of connections, sharp bends, or other features that could lead to air trapping, excessive resistance to flow, or waxing of fuel in cold conditions. The supply and return lines must extend to the low level of useful tank volume. Extending the return line to this level prevents siphoning of fuel on the supply side back to the tank.

8-8

All information subject to change without notice.

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

MBE 4000 APPLICATION AND INSTALLATION

The fuel supply line must be above the bottom of the tank to ensure that dirt and sediments are not drawn into the fuel system. Allow 5% clearance volume above the bottom of the tank. The supply and return lines must be well supported within the tank. Cracks on the supply side can cause the entrance of air and a subsequent loss of power. The supply and return lines must be separated by at least 12 in. inside the tank to prevent mixing of hot return fuel with cold in tank fuel. The supply line should be at the center of the tank to compensate for angular operation (see Figure 8-2).

Material
DDC does not approve the use of copper tubing because copper becomes brittle due to cold working when subjected to vibration. Plastic lines must be made of a reinforced plastic suitable for diesel fuel applications. Flexible hosing must be resistant to fuel oil, lubricating oils, mildew, and abrasion, and must be reinforced. The lines must withstand a maximum suction of 17.7 in. Hg (600 mBar) without collapsing, a pressure of 6.90 bar (100 psi) without bursting, and temperatures between -40 C (-40 F ) and 149 C (300 F).

Size
The fuel supply lines must be 10 mm ID or larger. The return lines must be 10 mm ID or larger. The minimum nominal diameter must be 12 mm ID (0.5 in.) if the pipe lengths exceeds 6 m. The restrictions imposed between the tank and fuel supply pump inlet determine the required fuel supply line diameter. The determinant of fuel line size is the restriction measured at the inlet of the engine. The maximum allowable inlet restriction is 17.7 in. Hg (600 mBar) for all applications.

8.2.4

OPTIONAL DEVICES

The optional devices for the fuel system that may be used are a fuel cooler and a fuel water separator.

Fuel Cooler
If the engine fuel inlet temperature exceeds 80 C (176 F) under anticipated operating conditions, a fuel cooler is required.

Fuel Water Separator

A fuel water separator is required. The total fuel inlet system may not exceed the maximum restriction of 10.29 in. Hg (350 mBar).

All information subject to change without notice.

8-9

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION

FUEL SYSTEM

8.3

FUEL SELECTION

The quality of fuel used is a very important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. For information on fuel selection, refer to DDC publication 7SE270, Lubricating Oil, Fuel and Filters.

8-10

All information subject to change without notice.

7SA250 0403 Copyright 2004 DETROIT DIESEL CORPORATION