{"id":12462,"date":"2021-10-03T12:06:33","date_gmt":"2021-10-03T10:06:33","guid":{"rendered":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/?p=12462"},"modified":"2021-10-03T12:06:33","modified_gmt":"2021-10-03T10:06:33","slug":"fuel-system","status":"publish","type":"post","link":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/2021\/10\/03\/fuel-system\/","title":{"rendered":"Keys to efficient fuel system performance"},"content":{"rendered":"

Fuel filtration best practices and additive considerations to help address fuel-related issues in commercial vehicles.<\/p>\n

Fuel contaminants, and sub-par fuel in general, can cause problems for fleets. The good news is that a few simple steps can be taken to help avoid many issues.<\/p>\n

\u201cImpurities in a fuel system will reduce engine power and fuel efficiency and cause uneven engine performance,\u201d said Phil Cary, southeast regional fleet service manager for Mack Trucks, a manufacturer of heavy-duty trucks, engines, and transmissions. \u201cChemical or dirt debris can also cause significant damage to all fuel-carrying components, from the fuel tank to the injectors.\u201d<\/p>\n

\u201cDiesel fuel impurities can also lead to fuel system deposit formation, plugged fuel filters, and the growth of microbes in the fuel,\u201d said Eric Trimble, product manager at Lubrication Specialties Inc.<\/a> (LSI), maker of Hot Shot\u2019s Secret fuel and oil additives. \u201cImpurities can also lower a fuel\u2019s lubricity properties.\u201d<\/p>\n

\u201cWater in the system can cause frozen or gelled fuel in filters and lines, which results in reduced power or even the engine shutting down,\u201d said Clay Parks, vice president of development at Rislone<\/a>, a maker of additives and treatments for fuel, engine oil, and transmission fluid.<\/p>\n

<\/div>\n

All of these issues can financially impact a fleet in various ways. Mechanical failures require expensive part replacements, not to mention the cost of extensive downtime. \u201cConsistent water contamination and microbial growth in bulk tanks can lead to additional treatment costs, like a biocide or water dispersant,\u201d Trimble added.<\/p>\n

In addition to water and microorganisms, Cary pointed out that diesel fuel can contain other contaminants including wax in cold weather, hard particles, debris, and other sediments. Diesel exhaust fluid (DEF), accidentally added to the fuel tank instead of the DEF tank, is another source of contamination that happens all too often.<\/p>\n

\n
\n
\n
\n
\n
\n
Photo courtesy of Lubrication Specialties, Inc.<\/div>\n<\/div>\n
\n
\n
\n
<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/figure>\n<\/div>\n<\/div>\n<\/div>\n
\n
\n
\n
\n
\n
\n
\n
\n
<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n
\n
\"Hot<\/div>\n<\/div>
Hot Shot\u2019s Secret Diesel Extreme can help reduce the need for DPF regen cycles by reportedly restoring lost engine power by up to 87%.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n

Warning signs to watch for<\/h3>\n

There are steps a fleet can take to help prevent fuel issues from turning into fuel system issues.<\/p>\n

\u201cI always stress the importance of solid driver-technician feedback to help identify intermittent issues,\u201d said Nick Rivera, a commercial vehicle lubricants application engineer with ExxonMobil Fuels and Lubricants<\/a>. \u201cWith any potential fuel-related issue, I would first ask the driver if he or she has detected a significant loss of performance. A driver would likely notice some kind of derated engine output such as stumbling, erratic idle, poor acceleration, excess smoking, and even more frequent aftertreatment regen sets.\u201d<\/p>\n

Aside from gathering driver feedback, technicians have other steps they can take to identify fuel-related issues.<\/p>\n

\u201cPerforming a simple visual check of the fuel separator is important,\u201d Rivera said. \u201cIs there excess sludging? Is water showing up periodically? Another thing to look at is if there are any signs of film inside the tank, whether that\u2019s water or some kind of microorganism that\u2019s growing.\u201d<\/p>\n

Fuel injectors represent another area technicians should pay close attention to.<\/p>\n

\u201cHigh-pressure common rail fuel injectors are susceptible to abrasive wear particles typically found in the 4- to 15-micron range,\u201d said Jay Stephenson, North American training leader for Cummins Filtration<\/a>, a global leader in air, fuel, hydraulic, and lube filtration. \u201cSacrificing filter performance to save a few dollars can come back to haunt a fleet when the fuel system starts experiencing problems.\u201d<\/p>\n

Stephenson pointed to an example where failing injectors can lead to fuel washing the lubricating oil off the cylinder walls, which enables metal-on-metal contact between the power cylinder components during combustion.<\/p>\n

\u201cInjectors that are not maintaining correct injection pressures will spray as a fine mist, struggling to atomize fuel properly,\u201d Stephenson said. \u201cThe first signs of injector wear are hard engine starts and rough idling. But as this continues, increased fuel consumption, loss of horsepower, and increased emissions are common signs that injector wear is in advanced stages and may be nearing failure.\u201d<\/p>\n

Malfunctioning injectors can also lead to an abundance of soot due to over-fueling. \u201cThat can prematurely clog the diesel particulate filter (DPF) and cause the aftertreatment system to throw codes,\u201d Stephenson said. \u201cIn terms of the filter directly, if premature plugging or short filter life are experienced, it\u2019s often an indication that the cleanliness of the diesel fuel in the tank is poor.\u201d<\/p>\n

Tips on proper fuel filtration<\/h3>\n

As Cummins Filtration\u2019s Stephenson pointed out, the only proven method for combating dirty fuel is through effective filtration techniques using a combination of multi-stage filtration fuel filters when possible: stage 2 (on-engine), stage 1 (fuel-water separators which are typically chassis-mounted), and stage 0 (bulk fuel storage tanks) fuel filters.<\/p>\n

For fuel fill-ups on the road, stage 0 filtration is not realistic. But for fleets operating their own fueling sites, Stephenson said stage 0 filtration and routine bulk tank storage cleaning are best practices for ensuring cleaner fuel.<\/p>\n

For any fleet, Stephenson said it is always imperative to use a stage 1 fuel filter\/water separator, such as a DAVCO Diesel Pro or Fuel Pro unit, in combination with a stage 2 on-engine fuel filter, to ensure that the stage 2 fuel filter can achieve its rated service interval. \u201cWithout a stage 1 fuel filter\/water separator, the stage 2 filter will take the brunt of all fuel contamination and will be quickly overwhelmed,\u201d Stephenson explained.<\/p>\n

Some Cummins Fleetguard stage 1 fuel\/water separator filters are constructed with a three-stage water-removal architecture to combat the severe challenges of water in diesel fuel. Stephenson said this filter design also helps fleets meet the requirements for advanced water removal on 2017 and newer U.S. EPA model engines.<\/p>\n

Even when utilizing premium-quality fuel filters, technicians must still adhere to proper filter maintenance and changeout intervals.<\/p>\n

\u201cEngines that have a fuel\/water separator should be drained on a periodic basis,\u201d ExxonMobil\u2019s Rivera said. \u201cThe frequency depends on the amount of fuel the truck consumes, as well as the amount of fuel a fleet with on-site storage purchases. As a general rule, the fuel\/water separator should be drained at the same time the regular fuel filter is changed.\u201d<\/p>\n

Fuel filter replacement intervals will vary based on several factors. \u201cHow often a fuel filter must be changed depends on geography, fuel type, and other factors,\u201d Rivera said. \u201cI see recommended intervals ranging from 12,000 to 25,000 miles depending on the OE. Know what the recommended interval is, and always use an OE or OE-quality filter.\u201d<\/p>\n

Before a technician even touches a fuel filter, River said it\u2019s critical to clean the filter housing and surrounding area to remove any dirt or other contaminant buildup. \u201cIt\u2019s really important to have good housekeeping procedures to prevent contamination of the new filter you\u2019re installing,\u201d Rivera added.<\/p>\n

A little additive can go a long way<\/h3>\n

Clean, high-quality fuel is key to maximizing vehicle performance. Trimble, of Hot Shot\u2019s Secret, said fleets should search for a fuel that is consistently strong in the following categories:<\/p>\n