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MBE 4000 APPLICATION AND INSTALLATION

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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 .

and modulates the fuel system accordingly to ensure efficient engine operation. The DDEC-ECU receives data (such as temperature and speed). All information subject to change without notice. Filter screens are used at the fuel inlet openings to prevent relatively coarse foreign material from entering the injector. 8-3 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . Fuel is then pumped through the main fuel filter (secondary filter) and through a check valve (if included) to the cylinder head.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. Fuel enters the EUP through the two fuel inlet filter screens located around the injector body. and to deliver this fuel at the correct pressure to the electronic unit pump (EUP). analyzes this data. Primary and secondary filters may be combined in some applications. 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. The DDEC-ECU sends a signal which activates the injector solenoid and determines the timing and amount of fuel delivered to the engine.

7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . see Figure 8-1.FUEL SYSTEM For a schematic diagram of a typical fuel system. Figure 8-1 MBE 4000 Fuel System Schematic Diagram 8-4 All information subject to change without notice.

aluminum.MBE 4000 APPLICATION AND INSTALLATION 8.2. All information subject to change without notice.1 FUEL TANK Fuel tanks must be made of the correct material. 8-5 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . The fuel tank(s) must not be galvanized internally under any circumstances. The inside(s) should be clean and free from all impurities likely to contaminate the fuel. 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 tank(s) should have a readily accessible drain valve at the bottom for easy removal of contaminants. 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.2 FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES Fuel Tank Fuel Filters Fuel Lines Optional Devices The following installation guidelines cover: 8. Material Satisfactory fuel tank material is steel. or a reinforced plastic suitable for diesel fuel 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). be properly designed and located. NOTICE: Do not use a fuel storage tank or lines or fittings made from galvanized steel. and be adequately sized regardless of the fuel tank configuration being used. The fuel tank(s) or piping may be galvanized or painted on the outside only to prevent corrosion.

Position a removable wire screen of approximately 1. The tank(s) capacity must be at least 5% greater than the maximum fill level to allow for fuel expansion.) mesh in the fill neck(s) to prevent large particles of foreign material from entering the tank(s). Figure 8-2 Properly Designed Fuel Tank Capacity Carefully choose the capacity of the fuel tank(s) to suit the specific engine installation. 8-6 All information subject to change without notice. Fuel capacity of the tank(s) should be appropriate for the specific application involved. The design of tanks in mobile applications must include the supply pipe so that adequate fuel is available under all operational gradients.FUEL SYSTEM The location of the fill neck(s) should be a clean. The tank(s) must have a vent which meets applicable regulations. A properly designed fuel tank may be seen in the following illustration (see Figure 8-2).6 mm (. 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. Consideration should be given to length of operation without the need to refuel. accessible location with sufficient height and room for an average size fill can or tanker truck hose.062 in. Fuel coolers may be used. 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . A stand pipe in the tank fuel return must be utilized on MBE 4000 engines.

) to 50 mm (2 in. All information subject to change without notice. passing through an 800 µm strainer. Install a shutoff valve for use when changing the primary filter if the fuel tank(s) is above the primary filter.4 metres (4.g. There are some fuel systems which are over the maximum fuel restriction. Locate the fuel tank(s) away from any excessive heat source. 8-7 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . An electric fuel pump (not supplied by DDC) maybe needed for bigger suction heights. The fuel tank(s) should not be located higher than the fuel pump.7 in. The difference in height between the fuel tank(s) and engine supply pump is kept to a minimum. Therefore. The position of the fuel tank(s) should ensure the following whenever possible. 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. The filling point is easy to access and simple to use.5 ft). The fuel pump attached to the engine has a suction height of 1. Hg. 17. This will prevent the tank(s) from draining.MBE 4000 APPLICATION AND INSTALLATION Position The position of the fuel tank(s) is an important factor in any application.5 ft) below the fuel pump (The fuel pump should not be more than 1. This prevents an overflow at the filter housing during maintenance work. the fuel return line should not extend into the fuel supply so that siphoning cannot occur in case a leak occurs in the line.4 metres (4. when their use is unavoidable. the bottom of the fuel tank must not be more than 1. A check valve in the fuel spill prevents supply side fuel from draining back into the tank(s) in a tank-below-engine installation. With a raised tank (5 metres maximum).4 metres (4. The length of fuel feed pipe is kept to a minimum.2 in. (600 mbar). e. in machinery. because of the location of the fuel tank with respect to the engine regardless of the size of the fuel lines. The fuel should be extracted at a point approximately 30 mm (1. The fuel return line must incorporate a check valve.) above the bottom edge of the tank. the supply and return pipe must be provided with a shutoff and drainage valve as close to the engine as possible. However.5 ft) above the lowest fuel level possible in the fuel tank).

prefilter and main filter with water separator.7 in. sharp bends. Remote mounting of the filters is acceptable. given proper line sizing. The fuel temperature and suction limits are DDC requirements. 10. i. The fuel inlet restriction must be measured before the main filter.FUEL SYSTEM 8. A hand priming pump is available with each filter option. Minimize the number of connections. Extending the return line to this level prevents siphoning of fuel on the supply side back to the tank.3 FUEL LINES The following guidelines apply to supply and return lines between the fuel filter header and the tank(s) only.29 in. 8-8 All information subject to change without notice. All lines should be in protected areas. or waxing of fuel in cold conditions. Hose plug connections must be used for plastic lines.e. 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . These guidelines apply regardless of which fuel tank configuration is being used. depending on the ambient temperature in the engine compartment. Contact DDC Application Engineering for remote filter mounting. Do not modify or tamper with any fuel lines supplied with the engine. Steel pipes must be connected using screwed pipe connections with conical nipples in accordance with DIN 3824. Hg (600 mBar) under any condition. in accordance with DIN 7728. polyamide 11. A water and fuel sensor is included with on-engine water separator options.7 in. For on-highway MBE 4000 engines there are multiple on-engine fuel filter options. Take the necessary precautions to ensure that the inlet line connections are tight so air cannot enter the fuel system. Care should be taken not to exceed the maximum engine fuel inlet restriction17. Hg (350 mBar) maximum for clean filters. or other features that could lead to air trapping. Hg (600 mBar) under any conditions. Avoid excessively long runs. The careful selection of line routing cannot be overemphasized. Steel pipes may have to be used. known as PA. The fuel inlet restriction must be measured before the main filter. 8. excessive resistance to flow.2 FUEL FILTER CONFIGURATION Fuel filter requirements for the MBE 4000 engines may be found in DDC publication 7SE270. Care must be taken when remote mounting the secondary filter not to overlook the fuel temperature and pressure sensors where utilized. and prefilter and main filter with water separator and heating. Design The lines leading from the fuel tank to the engine (prefilter) must be made from scale-free steel piping or plastic.2. The fuel inlet restriction cannot exceed 17.2. The supply and return lines must extend to the low level of useful tank volume. and securely clipped in position to prevent chaffing from vibration. cap nuts in accordance with DIN 3870 and banjo bolts in accordance with DIN 7644 or 7624. These areas should be free from possible damage. These options include prefilter and main filter only.

The supply line should be at the center of the tank to compensate for angular operation (see Figure 8-2). Plastic lines must be made of a reinforced plastic suitable for diesel fuel applications.5 in. The supply and return lines must be well supported within the tank. All information subject to change without notice. 8. The determinant of fuel line size is the restriction measured at the inlet of the engine. The return lines must be 10 mm ID or larger. Material DDC does not approve the use of copper tubing because copper becomes brittle due to cold working when subjected to vibration.) if the pipe lengths exceeds 6 m.29 in. The restrictions imposed between the tank and fuel supply pump inlet determine the required fuel supply line diameter. The total fuel inlet system may not exceed the maximum restriction of 10.90 bar (100 psi) without bursting. Hg (350 mBar).2. Hg (600 mBar) for all applications. Size The fuel supply lines must be 10 mm ID or larger. mildew. and abrasion. The lines must withstand a maximum suction of 17. and temperatures between -40 C (-40 F ) and 149 C (300 F). Fuel Water Separator A fuel water separator is required.4 OPTIONAL DEVICES The optional devices for the fuel system that may be used are a fuel cooler and a fuel water separator. Flexible hosing must be resistant to fuel oil. inside the tank to prevent mixing of hot return fuel with cold in tank fuel. 8-9 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . Cracks on the supply side can cause the entrance of air and a subsequent loss of power.7 in. The maximum allowable inlet restriction is 17. a pressure of 6. and must be reinforced. The supply and return lines must be separated by at least 12 in. Hg (600 mBar) without collapsing. Allow 5% clearance volume above the bottom of the tank. The minimum nominal diameter must be 12 mm ID (0.7 in. Fuel Cooler If the engine fuel inlet temperature exceeds 80 C (176 F) under anticipated operating conditions. a fuel cooler is required. lubricating oils.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.

long engine life. refer to DDC publication 7SE270.3 FUEL SELECTION The quality of fuel used is a very important factor in obtaining satisfactory engine performance. “Lubricating Oil.FUEL SYSTEM 8.” 8-10 All information subject to change without notice. For information on fuel selection. 7SA250 0403 Copyright © 2004 DETROIT DIESEL CORPORATION . Fuel and Filters. and acceptable exhaust emission levels.