E 2 3 M a r i n e P r o j e c t G u i d e 4.

Fuel System
4 - Fuel System

4.1 GENERAL
The engine fuel system consists of the following:
• Engine driven fuel pump
• Fuel manifold
• Engine mounted fuel filters
• Wiring harnesses
• Sensors
• Fuel injectors controlled by EMDEC
Fuel is drawn from the supply tank by the fuel pump through a suction
strainer and is delivered to the engine mounted fuel filters through a fuel
manifold housing.

Fuel system components are furnished by EMD and by others as follows:

• On-Engine Components, furnished by EMD and mounted on the engine
• Off-Engine Components, furnished by EMD and remote mounted
• Off-Engine Components, not furnished by EMD, and remote mounted
The EMD scope of supply of fuel system components varies with the
Configuration Type. Configuration Types include:
• Type 1 - EMD Engine and EMD Accessory Rack (accessory module)
• Type 2 - EMD Engine and EMD Marine Loose Accessories Package
• Type 3 - EMD Engine Only
The interface Diagrams below illustrate the EMD scope of supply for the different
Configuration Types.

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4.2 CONFIGURATION TYPES -

INTERFACE AND FLOW DIAGRAMS
The fuel system is illustrated for all three configuration types in two formats;
interface diagrams and flow diagrams.
Fuel System

4.2.1 INTERFACE DIAGRAMS

The interface diagrams show all of the fuel components on and off the engine in
simple block diagram format.

4.2.1.1 TYPE 1 - ENGINE & ACCESSORY RACK

Figure 4.1 - Fuel System - Interface Diagram - Type 1

Configuration Type 1 includes on-engine fuel system components and components

mounted on the EMD Accessory Rack (accessory module). The EMD Accessory
Rack Mounting Kit includes piping between the engine and the Accessory Rack.

Other system components, Not Supplied by EMD, are installed in the vessel as
required by the application.

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4.2.1.2 TYPE 2 - ENGINE & LOOSE ACCESSORIES

Fuel System
Figure 4.2 - Fuel System - Interface Diagram - Type 2

Configuration Type 2 includes on-engine fuel system components and ship-loose

components included as part of the Marine Loose Accessories Package.

Other system components, not supplied by EMD, are installed in the vessel as
required by the application.

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4.2.1.3 TYPE 3 - ENGINE & NON-EMD LOOSE ACCESSORIES

Fuel System

Figure 4.3 - Fuel System - Interface Diagram - Type 3

Configuration Type 3 includes only those on-engine fuel system

components indicated.

Other system components, not supplied by EMD, are installed in the vessel as
required by the application.

4.2.2 FLOW DIAGRAMS

The general arrangement and fluid flow of the fuel system is illustrated in the
system flow diagram for each Configuration Type.

In the flow diagrams below components supplied by EMD are represented by

physical images. ISO symbols represent components supplied by others.

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4.2.2.1 ENGINE & ACCESSORY RACK - TYPE 1

Fuel System
Injectors

Fuel Manifold

Fuel Strainer

VIEW A

Manual
Prime Pump Fuel
Return Fuel Pump Fuel In

Figure 4.4 - Fuel System - Flow Diagram - Type 1

Configuration Type 1 includes on-engine and accessory rack fuel system

components. Piping between the engine and accessory rack is included.

Other system components, not supplied by EMD, are installed in the vessel as
required by the application.

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4.2.2.2 ENGINE & LOOSE ACCESSORIES - TYPE 2

Fuel System

Injectors

Fuel Manifold

Fuel Pump

VIEW A Fuel In

Fuel
Return
Manual
Prime Pump

Fuel Strainer

Figure 4.5 - Fuel System - Flow Diagram - Type 2

Configuration Type 2 includes on-engine and marine loose accessories and fuel
system components.

Other system components, not supplied by EMD, are installed in the vessel as
required by the application.

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4.2.2.3 ENGINE & NON-EMD LOOSE ACCESSORIES - TYPE 3

Fuel System
Injectors

Fuel Manifold

Fuel Pump Fuel Strainer Fuel In

VIEW A

Fuel
Return
Manual
Prime Pump

Figure 4.6 - Fuel System - Flow Diagram - Type 3

Configuration Type 3 includes only the on-engine fuel system

components indicated.

Other system components, not supplied by EMD, are installed in the

vessel as required by the application.

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4.3 ON-ENGINE COMPONENTS

Following are the EMD fuel components mounted on engine.

4.3.1 FUEL PUMP

Fuel System

Figure 4.7 - Fuel Pump (Left Hand Rotating Engine)

Figure 4.8 - Fuel Pump Location

The engine-driven, positive displacement fuel pump is mounted on and is

directly driven by the lube oil scavenging pump. The pressure is limited by relief
valves located in the fuel filter assembly manifold block.

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4.3.2 FUEL MANIFOLD AND FILTERS

Fuel System
Fuel Selector Valve

Fuel Filters

Figure 4.9 - Fuel Manifold And Filters

Figure 4.10 - Fuel Manifold And Filters Location

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The engine mounted (secondary) duplex fuel filter assembly is attached to a

manifold installed at the front end of the engine. Fuel enters the filter assembly
through an anti-flood, spring-loaded check valve set at 69 kPa (10 psi).

Fuel returning from the injectors passes through the “return fuel” section of the
Fuel System

filter assembly manifold (block). A relief valve establishes fuel back pressure at
the injectors for improved operation. The “return fuel” relief valve is rated at 345
kPa (50 psi).

As the elements of the filter assembly become dirty, the fuel pressure increases.
When fuel pressure in the filter assembly manifold reaches the cracking pressure
of the “by-pass” relief valve, the valve opens allowing fuel to return to the fuel
tank. The “by-pass” relief valve is rated at 827 kPa (120 psi).

The disposable spin-on filters are rated at 5 microns and mounted directly to the
filter manifold.

A manually operated selector valve on the filter manifold directs the fuel to
either or both filter elements. One spin-on filter element can be replaced without
stopping the engine.

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4.3.3 FUEL SUPPLY & RETURN MANIFOLDS

Supply Line
to Injectors

Fuel System
Return Line
from Injectors

Figure 4.11 - Fuel Supply & Return Manifolds

Figure 4.12 - Fuel Supply & Return Manifolds Location

The Fuel Supply and Return Manifolds transport fuel from the engine-mounted
fuel filter assembly to and from the individual cylinder fuel injectors. There is one
supply and one return manifold for each bank of the engine.

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4.3.4 EMDEC INTERFACE

Electro-Motive Diesel Engine Control (EMDEC) connects to sensors that
monitor the pressure of the fuel entering the fuel filter and the temperature of the
fuel entering the engine. See the Electronic System section for more details.
Fuel System

4.3.5 FUEL SENSORS

Figure 4.13 - Fuel Sensors

Figure 4.14 - Fuel Sensor Locations

Two Fuel Pressure Sensors (FPS), are provided and mounted on the fuel filter
manifold. One sensor monitors fuel supply pressure into the fuel filters. The other
sensor monitors fuel supply pressure entering the engine. The ECM monitors the
data from the fuel pressure sensors.
A Fuel Temperature Sensor (FTS) is provided and also mounted on the fuel filter
manifold. It monitors the temperature of the fuel as it enters the engine.
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4.3.6 EUI FUEL INJECTORS

Fuel System
Fuel
Inlet

Fuel
Outlet

Figure 4.15 - Electronically Controlled Fuel Injector

In the electronic unit injectors (EUI), the metering and timing of fuel injection are
controlled by the Electronic Control Modules (ECM’s) based on inputs received
from the EMDEC engine control system. EMDEC is responsible for controlling
engine speed against varying load conditions. It accomplishes this by varying the
amount of fuel injected into the cylinders.

EMDEC receives speed signals from the vessel control system. These signals are
converted to an RPM request by the interface module. The RPM request in the
ECM’s establishes the desired engine speed. Actual engine speed is determined
by use of magnetic pick-ups and timing plates mounted on the ring gear. Desired
speed is compared to actual speed by the ECM’s and fuel is adjusted accordingly.

The camshafts perform only one function for fuel injection, which is providing
the force necessary to pressurize the fuel for injection. Timing and pulse width
modulation is controlled entirely by the ECMs.

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Fuel System

Figure 4.16 - Electronically Controlled Fuel Injector Locations

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4.4 OFF-ENGINE COMPONENTS

Following are the EMD fuel components not mounted on engine. These
components are most commonly located on the EMD Accessory Rack or they
may be shipped as individual components (ship loose components).

Fuel System
4.4.1 FUEL STRAINER & ISOLATION VALVES

Fuel
Outlet

Fuel
Inlet

Figure 4.17 - Fuel Strainer & Isolation Valves

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Fuel System

Figure 4.18 - Fuel Strainer Location - Type 1

The fuel suction strainer is available mounted on the accessory rack. It is also
available as a ship-loose component in Type 2 configurations. It is located in the
fuel system to remove contaminants from the fuel being drawn from the fuel
supply. The fuel is drawn through the strainers either by the manually operated
fuel priming pump or by the engine driven fuel pump. Either pump forces fuel to
the engine-mounted duplex fuel filter and from the filter to the engine injectors.

Isolation valves are provided for the fuel suction strainer to facilitate maintenance
of the filter elements.

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4.4.2 FUEL PRIMING PUMP

The fuel priming pump is used to fill the engine fuel system prior to routine
engine start, or after fuel system maintenance activities, or an extended
shutdown period.

Fuel System
The fuel priming pump is available in either a manually-operated type or an
electric motor-driven version, depending on application requirements. The
manual pump is included in the EMD scope of supply with an Accessory Rack
(Type 1) or shipped loose (Type 2). The electric motor-driven version is an
available option.

4.4.2.1 FUEL PRIMING PUMP - MANUAL

Fuel
Outlet

Fuel
Inlet

Figure 4.19 - Fuel Prime Pump - Manual

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Fuel System

Figure 4.20 - Fuel Prime Pump - Manual Location

The fuel hand priming pump is available mounted on the accessory rack. It is
also available as a ship-loose component for Type 2 configurations. The pump
circulates fuel to the engine mounted fuel filters and fuel injectors before starting
the engine after extended shutdown. The pump capacity is 53 L/min. (14 gpm) at
115 RPM. Approximate weight is 10.4 kg (23 lbs.).

4.4.2.2 FUEL PRIMING PUMP - ELECTRIC

An electric Fuel Prime Pump is an available option for Type 1 and Type 2
configurations. The purpose of the pump is to circulate fuel oil to the fuel filters
and fuel injectors before starting the engine after extended shutdown.

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4.5 FUEL SYSTEM DESIGN CONSIDERATIONS

Diesel fuel supply systems must ensure a continuous and clean supply of fuel to
the engine’s fuel system. The engine’s fuel system is designed for distillate fuel,
requiring viscosity ranging from 1.4 cSt to 20 cSt at 38 °C (100 °F).

Fuel System
The diesel fuel supply system typically has three major components:
• a fuel storage system,
• a fuel transfer system and
• a fuel filtration system
Each of these systems demands careful attention to ensure the success of each installation.

4.5.1 FUEL RECOMMENDATIONS

EMD fuel requirements for the Series 710 engine family are set forth in EMD
Maintenance Instruction (MI) 1750 – DIESEL FUEL RECOMMENDATIONS.
Generally, EMD recommends fuels meeting the specifications associated with
grades No. 2-D diesel fuel and No. 2 fuel oil.
Biodiesel up to a B5 level is acceptable. Please refer to Maintenance Instruction
(MI) 1750 for greater detail.

Fuel with CIMAC designation DB, commonly referred to as Marine Diesel

Oil (MDO), is an acceptable fuel, provided the fuel complies with EMD fuel
recommendations from M.I. 1750.

4.5.2 FUEL STORAGE SYSTEM

To ensure safe and efficient operation, the fuel storage system requires the
following important considerations:

4.5.2.1 TANK LOCATION

The maximum fuel level inside the tank should not exceed 15 feet above the
centerline of the crankshaft. If the fuel level exceeds 15 feet, then the standard 10
psi anti-flood check valves must be replaced by higher rated valves in the engine
fuel manifold. Refer to the 2D fuel system schematic at the end of this chapter for
additional details.

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4.5.2.2 DAY TANK

A typical day tank capacity should range from 1892 to 3786 liters (500 to 1000)
gallons and be located in or near the engine room.
EMD recommends routing the return fuel line from the engine to the main fuel
tank to avoid heating the engine fuel supply.
Fuel System

Fuel level in the day tank must be maintained within the following range:
• Maximum height above the centerline of the crankshaft is 4.6 m (15 ft)
• Minimum height below the centerline of the crankshaft is the height
necessary to maintain a Net Positive Suction Head Requirement (NPSHR)
of 1 meter (3.2 ft) of liquid.

4.5.3 FUEL TRANSFER SYSTEM

The fuel supply and the return fuel piping, not supplied by EMD, must be no
smaller than the engine connection. The engine fuel connections are:
• Supply - 1" tubing or black pipe
• Return - 1" tubing or black pipe
The maximum inlet fuel flow restriction is 20 kPa (3 psi) at rated speed.

Return fuel leaving the engine should be routed to the top of the main fuel tank
without shutoff valves.

Air in the fuel system must be avoided. Air in the fuel system causes hard
starting, erratic engine operation, and injector erosion. Vent lines must be
installed in all fuel tanks. Refer to the 2D fuel system schematic at the end of
this chapter for additional detail.

4.5.4 FUEL FILTRATION SYSTEM

The fuel filtration system requires the following important considerations to
ensure proper engine operation:
• Primary Fuel Filter
• Water Separation

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4.5.4.1 PRIMARY FUEL FILTE R

The primary fuel filter should be rated at a maximum of 15 micron and be
located between the fuel supply tank and the engine driven fuel pump.
Minimum flow rates are defined in Chapter 3 Technical Data.

Fuel System
4.5.4.2 WATER SEPARATION
EMD recommends the installation of a water separator and sediment removal
device in the fuel supply prior to the EMD furnished fuel system components.

4.5.5 ISO STANDARD CONDITIONS

Engine power and fuel consumption declarations are in accordance with ISO
15550 & 3046 Standards. Standard ambient conditions are
• Air Temperature 298 K or 25 °C 77 °F
• Barometric Pressure 100 k Pa 29.61 in Hg
Operation of the engine at other than ISO Standard Conditions will impact fuel
consumption and may impact the “fuel stop” power available.

4.5.5.1 FLEXIBLE CONNECTIONS

EMD recommends the use of flexible hoses for the supply & return fuel
connections to the engine. Hoses should be located directly at the ports
provided to accommodate engine motion during operation. EMD recommends
checking your marine classification society rules in regards to flexible hose type
and length.

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4.5.5.2 FUEL TEMPERATURE

For optimal performance EMD recommends the temperature of the fuel
delivered to the engine be in the range from 21 °C to 38 °C (70 °F to 100 °F).
If the aforementioned temperatures cannot be maintained, 4 °C to 49 °C (40 °F to
120 °F) is acceptable but may result in reduced performance. A fuel pre-heater or
Fuel System

fuel cooler may be required depending on ambient conditions.

4.5.5.3 FUEL PRE-HEATERS

The use of fuel pre heaters can help avoid plugging of secondary fuel filters
during low ambient conditions. The use of a fuel pre-heater should not introduce
any flow restrictions into the system.

4.5.5.4 FUEL COOLERS

The use of a fuel cooler can help to reduce fuel temperatures during high ambient
conditions, thereby maintaining engine performance. The use of a fuel cooler
should not introduce any flow restrictions into the system.

4.5.5.5 DRIP PANS

The International Association of Classification Societies (IACS) commonly
requires drip pans under components such as fuel filters. EMD does not supply
these drip pans. The drip pans are typically installed by the shipyard.

4.5.5.6 SPRAY SHIELDS

The International Association of Classification Societies (IACS) commonly
requires shielding of all fuel line connections. EMD believes that shielding should
be applied after engine installation to ensure the shielding does not mask a
potential leak that could developed during installation. Because of this shielding
is typically installed by the shipyard.

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4.6 SYSTEM SCHEMATICS

This section includes typical fuel system schematics for each Configuration Type.

4.6.1 TYPE 1 - ENGINE & ACCESSORY RACK

Fuel System

Figure 4.21 - System Schematic - Type 1 - Ene & Accessory Rack

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4.6.2 TYPE 2 - ENGINE & LOOSE ACCESSORIES

Fuel System
Figure 4.22 - System Schematic - Type 2 - Engine & Loose Accessories

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4.6.3 TYPE 3 - ENGINE & LOOSE ACCESORIES BY OTHERS

Fuel System

Figure 4.23 - System Schematic - Type 3 - Engine & Loose Accessories By Others

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