Troubleshooting and Repair Manual QSK23 Series Engines CTM C.800 - Cummins (644 KBr)Te Gg 006-003 Air in Fuel General Information A CAUTION A Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. There are two good methods to check for air in the fuel. * Sight glass method * Gear pump drain method. Test Sight Glass Method Remove the fuel inlet line connecting the &Ra fuel filter head to the fuel pump.Replace the fuel line with the fuel sight glass, Part Number 3164387, and adapter hose, Part Number 3165146, or equivalent. Operate the engine at high idle with no load. Asmall air leak will have a “milky” appearance. A large air leak will look like bubbles in the fuel. Ifan air leak is found, perform the following + Tighten the hose connections and the fuel filter. * Check the drop tube in the fuel tank for damage. * Check the fuel fitting supply o-rings for damage. Continue to test and look for a source of air until no air bubbles are visible. Remove the sight glass. Tighten the fuel inlet hose. Torque Value: 88 nm [65 ft1b] Gear Pump Drain Method To perform a pressure side air in fuel test, use the following items: * Quick disconnect fitting, Part Number3376859 High pressure hose Pressure valve (capable of 2758 kPa [400 psi) Clean tubing Clean container. Connect the equipment to the quick- connect fitting at the fuel pump outlet. Put the end of the clear hose in the clean container. Close the pressure valve. ap & Operate the engine at high idle with no load. Slowly open the valve until a steady stream of fuel is visible. ® High Idle Put the end of the hose below the surface of the fuel. Ifthere is an air leak, bubbles will be visible.Ifan air leak is found, perform the following * Tighten the hose connections on the fuel filter. * Check the drop tube in the fuel tank for damage * Check the fuel supply fiting o-rings for damage Continue to test and look for air leaks until @) ¥ e there are no bubbles visible. Remove the test equipment. i Last Modified: 15-Sep-2003 Copyright © 2000-2010 Cummins Inc. All rights reserved,Te Gg 006-012 Fuel Drain Line Restriction Measure Remove the fuel drain hose. &Ra Zs Install the adapter, Part Number 3376719, and pressure gauge, Part Number ST- 7 1273, between the engine fuel drain fitting \ } and the fuel drain hose. Ifthe engine has a drain side check valve, install the adapter and pressure gauge between the check valve outlet and fuel drain hose & High tt Start and operate the engine at high idle, @& ace no load. Fuel Drain Line Restriction kpa_—_ psi With check valve 21 MAX 3 Without check valve 30 MAX 5All QSK23 engines are built without check valves. If the fuel drain line restriction is above specifications, inspect the fuel drain line. Refer to Procedure 006-013 Remove the pressure gauge. Install the fuel drain line Tighten the fuel line. Torque Value: 95 n.m [70 fHlb] Last Modified: 23-Sep-2003 Copyright © 2000-2010 Cummins Inc. Allrighis reserved,Te Gg 006-013 Fuel Drain Lines Remove Remove the engine-to-fuel tank fuel drain hose from the engine. Remove the steel fuel drain line connecting the duel intake manifolds. NOTE: Power generation engines use a one piece intake manifold and do not have this steel line. Clean and Inspect for Reuse Inspect the inside of the engine-to-fuel tank fuel drain hose * The inner lining of the hose can separate from the center hose section * A separation of the inner lining can cause a restriction in the fuel flow. Inspect for any pinches in the hose that would obstruct the flow.Make sure the engine-to-fuel tank hose and the steel fuel manifold line are free of pinches or loops that would obstruct the flow. A WARNING & Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Clean and inspect the steel fuel manifold drain line. Use compressed air to flush the line and remove any loose dirt or particles. Install Install and tighten the steel fuel manifold drain line Torque Value: 44 nm [33 ft1b] Install and tighten the engine-to-fuel tank drain hose Torque Value: 95 n.m [70 ftlb]Last Modified: 17-Mar-2003 Copyright® 2000-2010 Cummins Inc. Allrights reserved,Te Gg 006-015 Fuel Filter (Spin-On Type) Remove A WARNING & Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. Close the fuel line shutoff valve before changing the fuel filters. The overhead tank can drain, causing a fuel leak. Remove the fuel filter with a filter wrench, Part Number 3376807, or equivalent. Install & Use a clean lint-free towel to clean the a sealing surface on the filter head A fuel-water separator or fuel filter and = water separator combination filter must beinstalled. Refer to Section V for fuel filter specifications. Apply a light coating of clean engine oil to the surface of the filter gasket. Fill the filter with clean fuel. Install the filter on the filter head. Tum the filter until the gasket touches the surface of the filter head Tighten the filter an additional % to % ofa turn after the gasket touches the filter head surface. Open the fuel line shutoff valve and check for leaks. Last Modified: 23-Sep-2003 Copyright © 2000-2010 Cummins Inc. Alrights reserved,Te Gg 006-020 Fuel Inlet Restriction Measure Use a Compucheké fitting and a vacuum gauge, Part Number ST-434-12, Connect the gauge to the Compuchek@ fitting on the fuel pump inlet fitting, Start and operate the engine at high idle @) High tale no load Fuel inlet Restriction mm-hg — in-hg With clean filters 102 MAX 4 With dirty fitters 229 MAX 9 Ifthe restriction is above specifications, * Change the fuel filters. Refer to Procedure 006-015. * Inspect the fuel lines, Refer to Procedure 006-024ee Last Modified: 17-Mar-2003 Copyright © 2000-2010 Cummins Inc. Allrights reserved,Te Gg 006-024 Fuel Supply Lines Preparatory Steps Remove as much of the engine wiring hamess and brackets as necessary to gain access to the fuel tubes. Refer to Procedure 019-043 in the Fuel System Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, and QSK60 Engines, Bulletin 3666113 Remove Use two wrenches to remove the fuel tubes and hoses. Support the mating fitiings with a wrench Loosen the fuel tube nuts with the other wrenchTank to Fuel Filter Remove the fuel filter inlet hose and related clamps. Fuel Pump Inlet Line Remove the fuel pump inlet line and line clamp Discard the o-rings. Control Supply Line Remove the fuel control supply line and line clamp Discard the o-rings. Timing Supply LineRemove the fuel timing supply line and line clamp Discard the o-rings and banjo fitting washers. Rail Supply Line Remove the fuel rail supply line and line clamp Discard the o-rings and banjo fitting washers. Clean and Inspect for Reuse A WARNING & Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Use compressed air to flush the lines and remove any loose dirt particles,Inspect the inside of the hose. + The inner lining of the hose can separate from the center hose section * A separation of the inner lining can cause a restriction in the fuel flow. Inspect for bends in the line that can restrict fuel flow. Inspect the line for cracks that can cause a @& pressure loss. Inspect the metal fuel lines for sharp bends that can cause a pressure restriction Install Install the new o-rings in the fittings. The fuel filter outlet, fuel pump inlet, fuel pump outlet, and fuel control module fittings use face seal o-rings. Make sure the o-rings are properly seated during installationUse two wrenches to install the fuel tubes and hoses. Support the mating fittings with a wrench Tighten the fuel tube nuts with the other wrench, Rail Supply Line Install a new o-ring in the rail supply line fitting and new washers on the banjo fittings. Install the rail supply line. Sleeve nut 27mm — [20 fib] Banjo fitting 34mm — [25 fib] Timing Supply Line Install a new o-ring in the timing supply line fitfing and new washers on the banjo fittings. Install the timing supply line and line clamp Sleeve nut 47mm — [35 feb] Banjo fitting 44mm — [32 fb] Control Supply Line eeInstall new o-rings in the fuel pump outlet and fuel control module inlet fittings. Install the fuel control module supply line. Torque Value: 68 n.m [50 fb] Fuel Pump Inlet Line Install new o-rings in the fuel pump inlet and fuel control module outlet fittings. Install the fuel pump inlet line and line clamp Torque Value: 95 n.m [70 fHlb] Tank to Fuel Filter Install the fuel filter inlet line. Torque Value: 95 nm [70 ft1b]Finishing Steps * Install the engine wiring hamess and brackets, as necessary. Refer to Procedure 019-043 in the Fuel System Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, and QSK60 Engines, Bulletin 3666113. Last Modified: 17-Mar-2003 Copyright © 2000-2010 Cummins Inc. Al rights reserved,