MTU Detroit Diesel Series 4000 Common Rail Fuel System Technician Guide Manual PDF DOWNLOAD
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MTU Detroit Diesel Series 4000 Common Rail Fuel System Technician Guide Manual PDF DOWNLOAD
Language : English
Pages : 134
Downloadable : Yes
File Type : PDF
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MTU Detroit Diesel Series 4000 Common Rail Fuel System Technician Guide Manual PDF DOWNLOAD
INTRODUCTION
- The purpose of a properly designed fuel system is to provide clean fuel, free from air, water or dirt, and to deliver fuel to the engine at correct amounts for good combustion to provide optimum power, fuel economy and emissions compliance.
- A unique feature of the Series 4000 is the common rail fuel injection system. This system relies on a single high-pressure fuel pump that provides a continuous supply of fuel, at injection pressure, to all of the injectors at all times.
- This common rail fuel system does not require cam driven unit injectors or injection pumps with separate cam driven plungers to make fuel pressure for each injector.
- The unit injectors in the Series 4000 common rail fuel system do not make fuel pressure. DDECIV Electronics alone control injector timing, the amount of fuel and atomization of fuel being supplied from the high-pressure rails.
- The Common Rail Fuel System provides the Series 4000 with the most advanced fuel system technology available today.
- The Common Rail Fuel System consists of many unusual components not found in other diesel fuel systems. Therefore, the Fuel System Technician Guide is intended to help better understand the Common Rail Fuel System operation and components as well as provide failure analysis to properly maintain this unique system for maximum performance.
- This manual is applicable to all engine sizes and product applications of the Series 4000 and is intended to be expanded upon, as additional information becomes available.
- It is also a good place for the technician to add helpful notes on the fuel system for future reference.
TABLE OF CONTENTS:
MTU Detroit Diesel Series 4000 Common Rail Fuel System Technician Guide Manual PDF DOWNLOAD
Consider the hazards of the job and wear protective gear such as safety glasses, safety shoes, hard hats, hearing protection, etc. to provide adequate protection......................... 7 When using a lifting device, make sure the lifting device is fastened securely. Be sure the item to be lifted does not exceed the capacity of the lifting device......................... 7 Always use caution when using power tools................................................................................................................................................. 7 INTRODUCTION 1............................................................................................................................................................... 8 COMMON RAIL FUEL SYSTEM OPERATION 5.............................................................................................................................................. 8 INTRODUCTION.............................................................................................................................................................................. 9 ......................................................................................................................................................................................11 ..................................................................................................................................................................................11 Description of Fuel System....................................................................................................................................................11 Common Rail Fuel System - A Bank..........................................................................................................................................................11 Description of Fuel System................................................................................................................................................................12 High-pressure Rail - A Bank...........................................................................................................................................................12 High-pressure Rail B Bank.................................................................................................................................................................12 ......................................................................................................................................................................................14 ..................................................................................................................................................................................14 ..............................................................................................................................................................................14 ..........................................................................................................................................................................14 Common Rail Fuel System Operation.....................................................................................................................................14 Cylinder Head View........................................................................................................................................................................15 ......................................................................................................................................................................................18 ..................................................................................................................................................................................18 ..............................................................................................................................................................................18 ..........................................................................................................................................................................18 ......................................................................................................................................................................18 ..................................................................................................................................................................18 Detroit Diesel Electronic Controls............................................................................................................................18 HIGH-PRESSURE FUEL PUMP...........................................................................................................................................18 Detroit Diesel Electronic Controls............................................................................................................................19 Detroit Diesel Electronic Controls............................................................................................................................20 HIGH-PRESSURE FUEL PUMP...................................................................................................................................25 Fig. 21 High-pressure Fuel Pump Leak at Weep hole.....................................................................................................................................30 Fig. 38 NORMAL Fig. 39 (FORMER STYLE TWO PIECE) LEAKING COMBUSTION....................................................................................................42 Fig. 40 Fig. 41 Fig. 42.............................................................................................................................................................43 NORMAL OPERATION OPERATION WITH C-E RING...............................................................................................................................................43 WITH C-E RING OMITTED.................................................................................................................................................................43 Fig. 68 NORMAL Fig. 69 OVERHEATED & CARBONED FROM........................................................................................................................................55 LEAKING C-E RING..........................................................................................................................................................................55 INSPECTION AND ANALYSIS...................................................................................................................................................................63 FLOW-LIMITER VALVE........................................................................................................................................................................63 NORMAL OVERHEATED & CAR- CORRODED FROM WATER.....................................................................................................................................63 ..................................................................................................................................................................................81 ..............................................................................................................................................................................81 PRIMING PROCEDURE.........................................................................................................................................................81 ......................................................................................................................................................................83 ..................................................................................................................................................................83 ..............................................................................................................................................................83 FUEL SYSTEM TROUBLE SHOOTING..............................................................................................................................83 To help determine the root cause of the fuel system problem, A complete DDEC data list or DDDL should be taken at the following three steady state points:....83 PWM3 output...............................................................................................................................................................................83 Hard Starting.............................................................................................................................................................................83 No fuel supply............................................................................................................................................................................83 Bad seat at the high-pressure rail relief valve...........................................................................................................................................83 Engine Fires Erratically After Starting...................................................................................................................................................83 Fuel system is not vented.................................................................................................................................................................83 Fuel injector faulty......................................................................................................................................................................83 ......................................................................................................................................................................................84 ..................................................................................................................................................................................84 ..............................................................................................................................................................................84 ..........................................................................................................................................................................84 FUEL SYSTEM TROUBLE SHOOTING..........................................................................................................................................84 Engine Does Not Reach Full-Load Speed.................................................................................................................................84 Fuel Injectors faulty.....................................................................................................................................................................84 High-pressure fuel pump insufficient pressure.............................................................................................................................................84 ......................................................................................................................................................................................84 ..................................................................................................................................................................................84 ..............................................................................................................................................................................84 ..........................................................................................................................................................................84 Engine Speed Not Steady...............................................................................................................................................84 Fuel Injectors faulty.....................................................................................................................................................................84 High-pressure fuel pump controller faulty.................................................................................................................................................84 Excessive fuel inlet restriction..........................................................................................................................................................84 No battery voltage on 440 circuit to high-pressure pump controller........................................................................................................................84 Short in ECM..............................................................................................................................................................................84 Controller faulty.........................................................................................................................................................................84 Restricted or low fuel supply.............................................................................................................................................................84 ......................................................................................................................................................................................84 ..................................................................................................................................................................................84 ..............................................................................................................................................................................84 ..........................................................................................................................................................................84 ......................................................................................................................................................................84 Replenish.........................................................................................................................................................84 High-pressure pump........................................................................................................................................................................84 ......................................................................................................................................................................................85 ..................................................................................................................................................................................85 ..............................................................................................................................................................................85 ..........................................................................................................................................................................85 FUEL SYSTEM TROUBLE SHOOTING..........................................................................................................................................85 440 Not on it’s own battery post..........................................................................................................................................................85 Controller faulty.........................................................................................................................................................................85 Fuel in oil...............................................................................................................................................................................85 Injector O-ring Leaking...................................................................................................................................................................85 Loose fuel line...........................................................................................................................................................................85 Fuel line connector internal nut adjustment...............................................................................................................................................85 Fuel Leaks at Fuel Rail...................................................................................................................................................................85 Fuel line connector internal nut adjustment...............................................................................................................................................85 Limiter valve seat at high-pressure fuel rail.............................................................................................................................................85 Fuel Pressure Too High....................................................................................................................................................................85 High-pressure fuel sensor faulty..........................................................................................................................................................85 High-pressure fuel pump controller faulty.................................................................................................................................................85 ......................................................................................................................................................................................86 ..................................................................................................................................................................................86 ..............................................................................................................................................................................86 ..........................................................................................................................................................................86 High-pressure Fuel Pump Leaking at Weep Hole..........................................................................................................................86 High-pressure pump leaking fuel...........................................................................................................................................................86 High-pressure pump leaking oil............................................................................................................................................................86 Low Fuel Pressure.........................................................................................................................................................................86 High-pressure fuel pump controller faulty.................................................................................................................................................86 High-pressure rail relief valve leaking...................................................................................................................................................86 High-pressure fuel pump generating insufficient pressure..................................................................................................................................86 DESCRIPTION...........................................................................................................................................................................87 ..................................................................................................................................................................................87 ..............................................................................................................................................................................87 SIZE......................................................................................................................................................................87 COVER-SERIES 4000 FUEL SYSTEM .pdf........................................................................................................................................................ 0 SERIES 4000 COMMON RAIL............................................................................................................................................................... 1 FUEL SYSTEM........................................................................................................................................................................... 1 .................................................................................................................................................................................. 3 ATTENTION..................................................................................................................................................................... 3 SERVICE INFORMATION.pdf................................................................................................................................................................... 0 TECHNICAL SERVICE LETTERS.............................................................................................................................................................89 NO.: 01 TS – 28 May 1, 2001...........................................................................................................................................................89 ..................................................................................................................................................................................89 Injector Response Time (IRT) Long Codes.......................................................................................................................................89 SERVICE INFORMATION BULLETINS.............................................................................................................................................89 Injector Seal Installation Improvement........................................................................................................................................89 Fuel System Cleaning After High-pressure Pump Failure.........................................................................................................................89 New Floating Style Fuel Tubes Replace Brazed Fuel Tubes.......................................................................................................................89 Release of Low-pressure Fuel Tube Support.....................................................................................................................................89 Model Year 2000 Emissions Requirements........................................................................................................................................89 Improved Injector C-E Ring Released...........................................................................................................................................89 Improved Low-pressure Fuel Plumbing System....................................................................................................................................89 MTU SERVICE INFORMATION BULLETINS.........................................................................................................................................89 HP Fuel Lines, Tightening of Thrust Rings after Disassembly...................................................................................................................89 18SP INSTALLATION INSTRUCTIONS............................................................................................................................................89 Installation of DIN Common Rail Fuel Pressure Sensor..........................................................................................................................89
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