TSB140168-092515

New Cummins® Service Tool Fuel Return Hose and Updated Procedure for ISX and QS...
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Technical Service Bulletin Number
TSB140168
Technical Service Bulletin
Subject
New Cummins® Service Tool Fuel Return Hose and Updated Procedure for ISX and QSX
Engines with Common Rail Fuel Systems
Warranty Statement
The information in this document has no effect on present warranty coverage or repair
practices, nor does it authorize TRP or Campaign actions.
Contents
This document announces a new Cummins® service tool fuel return hose and updated service
manual procedure.
Product Affected






















ISX12/ISX11.9 CM2250
ISX12 CM2350 X102
ISX15 CM2250
ISX15 CM2250 SN
ISX15 CM2350 X101
QSX11.9 CM2250 ECF
QSX15 CM2350 X105
QSX15 CM2250 ECF
QSX15 CM2350 X106
PowerGen QSX15 CM2250
PowerGen QSX15 CM2250 ECF
Reason for Change
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New Cummins® Service Tool Fuel Return Hose and Updated Procedure for ISX and QS...
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To decrease the occurrence of falsely identifying leaking fuel pressure relief valves.
Service Tools Available
To complete the fuel pressure relief valve return flow measurement at the fuel rail, a new
Cummins® service tool has been released. Cummins® service tool, fuel return hose, Part
Number 5299319, must be used to perform the fuel pressure relief valve return flow
measurement.
Publications Affected
The fuel pressure relief valve return flow test has been revised to state that the fuel pressure
relief valve return flow should be measured at the fuel rail and not at the fuel drain manifold.
Measurement of the fuel pressure relief valve return flow at the fuel drain manifold is
acceptable if there are accessibility issues. If the fuel pressure relief valve return flow is
measured at the fuel drain manifold and the fuel flow is found out of specification, the fuel
pressure relief valve return flow measurement must be repeated at the fuel rail.
The following procedures have been revised:






















For ISX12/ISX11.9 CM2250 Service Manual, Bulletin 2883445. Refer to Procedure 005236 in Section 5.
For ISX12 CM2350 X102 Service Manual, Bulletin 4310646. Refer to Procedure 005-236
in Section 5.
For ISX15 CM2250 Service Manual, Bulletin 4022250. Refer to Procedure 005-236 in
Section 5.
For ISX15 CM2250 SN Service Manual, Bulletin 4310736. Refer to Procedure 005-236 in
Section 5.
For ISX15 CM2350 X101 Service Manual, Bulletin 4310641. Refer to Procedure 005-236
in Section 5.
For QSX11.9 CM2250 ECF Service Manual, Bulletin 2883561. Refer to Procedure 005236 in Section 5.
For QSX15 CM2350 X105 Service Manual, Bulletin 4332667. Refer to Procedure 005236 in Section 5.
For QSX15 CM2250 ECF Service Manual, Bulletin 2883557. Refer to Procedure 005-236
in Section 5.
For QSX15 CM2350 X106 Service Manual, Bulletin 4332712. Refer to Procedure 005236 in Section 5.
For PowerGen QSX15 CM2250 Service Manual, Bulletin 4310664. Refer to Procedure
005-236 in Section 5.
For PowerGen QSX15 CM2250 ECF Service Manual, Bulletin 4310661. Refer to
Procedure 005-236 in Section 5.
Document History
Date
2014-12-1
2015-9-25
Details
Module Created
Non-Product Problem Solving (PPS)
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New Cummins® Service Tool Fuel Return Hose and Updated Procedure for ISX and QS...
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Last Modified: 01-Oct-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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005-236 Fuel System Diagnostics
General Information
WARNING
Wear appropriate eye and face
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
WARNING
When using a steam cleaner, wear
safety glasses or a face shield, as well
as protective clothing. Hot steam can
cause serious personal injury.
CAUTION
Clean all fittings before disassembly.
Dirt or contaminants can damage the
fuel system.
CAUTION
Hold banjo fittings while tightening the
banjo bolt to prevent fitting rotation.
Allowing the banjo fitting to rotate may
damage the fuel line.
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Before servicing any fuel system
components, (such as fuel lines, fuel
pump, injectors, etc.) which would expose
the fuel system or internal engine
component to potential contaminants prior
to disassembly, clean the fittings,
mounting hardware, and the area around
the component to be removed. Dirt or
contaminants can be introduced into the
fuel system and engine if the surrounding
areas are not cleaned, resulting in
damage to the fuel system and engine.
Refer to Procedure 000-009 in Section 0.
To prevent engine damage from debris or
contamination, cover, cap, or plug any
openings as soon as possible when
servicing the fuel system. Caps and plugs
can be found in Clean Care Kit, Part
Number 4919073.
The following procedures are used to
diagnose fuel system issues. These
checks and measurements are referenced
throughout the applicable troubleshooting
and fault code trees as needed.
This procedure is not intended to take the
place of the troubleshooting tree repair
direction.
Refer to the appropriate troubleshooting
symptom tree for repair direction.
NOTE: The fuel line from the engine
control module (ECM) cooling plate to
the high-pressure fuel pump contains a
filter screen at the high-pressure fuel
pump banjo fitting. The screen must be
examined and cleaned, or the banjo
bolt replaced, if the screen is damaged.
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Low-Pressure System Check
The low-pressure system check consists of a
number of measurements and checks to
make sure that the low pressure fuel system
is functioning properly. These checks will
vary, depending on whether or not the engine
will start.
The fuel line from the ECM cooling plate to
the high-pressure fuel pump contains a filter
screen at the high-pressure fuel pump banjo
fitting. The screen must be examined and
cleaned, or the banjo bolt replaced, if the
screen is damaged.
Measurement - Engine Will Start
Verify the fuel system has been primed.
Refer to Procedure 005-234 in Section 5.
Check for air in the fuel. Refer to
Procedure 006-003 in Section 6.
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Measure the fuel inlet restriction. Refer to
Procedure 006-020 in Section 6.
Measure Fuel Pressure










Remove the threaded plug from the
outlet side of the fuel filter head and
install a Compuchek™ fitting, Part
Number 3100221, or equivalent.
Install the orificed diagnostic fuel
line, Part Number 3164621, at the
Compuchek™ fitting.
Install a 0 to 2068 kPa [0 to 300 psi]
pressure gauge at the Compuchek™
fitting at the inlet to the fuel filter
head.
Install a 0 to 2068 kPa [0 to 300 psi]
pressure gauge at the Compuchek™
fitting at the outlet to the fuel filter
head.
Wait for the lift pump cycle to
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complete (approximately 60
seconds).
Operate the engine at high idle and
observe the filter inlet pressure.
Operate the engine at high idle and
observe the filter outlet pressure.
Measurements
kpa
Fuel Filter Restriction
(max)
69
psi
10
If the difference between the filter inlet
pressure and filter outlet pressure is
greater than the specification, replace the
fuel filter.
Operate the engine at high idle and
observe the fuel gear pump pressure at
the fuel filter inlet.
Measurements
kpa
Gear Pump Pressure
1000
at High Idle (min)
psi
145
Measurement - Engine Will Not Start
Verify the fuel system has been primed.
Refer to Procedure 005-234 in Section 5.
Check for air in the fuel. Refer to
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Procedure 006-003 in Section 6.
Install a 0 to 207 kPa [0 to 30 psi] pressure
gauge at the Compuchek™ fitting at the
inlet to the fuel filter head.
Turn the keyswitch to the ON position to
active the lift pump. Repeat this action, if
necessary.
Measure the fuel lift pump pressure
Measurements
kpa
Fuel Lift Pump
69
Pressure (min)
psi
10
Install a 0 to 207 kPa [0 to 30 psi] pressure
gauge at the Compuchek™ fitting at the
inlet to the fuel filter head.
Disconnect the lift pump electrical
connector, if equipped.
Crank the engine and observe the fuel
gear pressure.
Measurements
kpa
Gear Pump Pressure
While Cranking at a
69
psi
10
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Minimum of 150 rpm
for 10 seconds (min)
Fuel Drain Line Restriction
CAUTION
Hold banjo fittings while tightening the
banjo bolt to prevent fitting rotation.
Allowing the banjo fitting to rotate may
damage the fuel line.
Measure the fuel drain line restriction. Refer
to Procedure 006-012 in Section 6.
NOTE: Engines with excessive return
restriction in the high-pressure fuel pump
return circuit may also display Fault Code
1911. This fault code is a result of the fuel
pressure relief valve coming open.
High-Pressure System Leak Down Test
NOTE: This test can not be performed if
the engine will not start.










Connect INSITE ™ electronic
service tool.
Operate the engine.
Perform INSITE™ electronic service
tool Fuel System Leakage Test.
Monitor the fuel rail pressure. Fuel
rail pressure will rise and stabilize.
This could take up to 5 minutes.
Shut the engine OFF and wait for it
to completely stop.
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Turn the keyswitch ON quickly.
Record the Fuel Rail Pressure
Measured value.
Monitor for 30 seconds.
Record the Fuel Rail Pressure
Measured value again.
Subtract the second measured value
from the first measured value.
A decay in fuel pressure greater than
1500 bar [21776 psi] in 30 seconds
is an indication of a high-pressure
fuel system leak.
Reference the appropriate
troubleshooting symptom tree for
repair direction.
High-Pressure Fuel Pump Return Flow Test
Initial Setup
CAUTION
Hold banjo fittings while tightening the
banjo bolt to prevent fitting rotation.
Allowing the banjo fitting to rotate may
damage the fuel line.
NOTE: If the unit is equipped with an air
bleed fuel transfer tube, it must be
removed from the engine prior to
performing the High-Pressure Fuel
Pump Return Flow Test. Use the
following procedure to identify the air
bleed fuel transfer tube. Refer to
Procedure 200-001 in Section F. Use
Part Number 3678921 from the fuel
system service tools kit to plug the
outlet of the fuel filter head. Attach the
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banjo flow adapter fitting to the highpressure fuel pump return line. Use the
following procedure for the torque
value during installation of the air bleed
fuel transfer tube. Refer to Procedure
006-013 in Section 6.
Return fuel is routed from the injectors, the
fuel rail pressure relief valve, and the fuel
pump head through three different drain
lines. Measurement of fuel injector
leakage requires the use of a fuel return
hose, Part Number 3164618. The fitting
has a closed end, four holes in the smooth
section near the hex, and a male threaded
section that attaches to the flexible hose.
The tool is used to isolate the leakage
from just the fuel pump, so it can be
measured with a graduated cylinder.
Obtain a graduated cylinder that is marked
in cubic centimeters. Use graduated
cylinder, Part Number 4919139, or
equivalent.
Remove the banjo bolt from the fuel pump
head drain line at the fuel drain manifold.
Install the banjo flow adapter fitting, Part
Number 3164618, at the fuel drain
manifold.
Route the hose into a collection device.
Use graduated cylinder, Part Number
4919139, for measurement when directed.
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Measurement - Engine Will Start




















Close the engine cover while
performing this measurement.
Operate the engine until it is at
operating temperature.
Allow the engine to idle with fuel
flowing into a collection device
(bucket).
Perform INSITE™ electronic service
tool Fuel System Leakage Test.
Monitor the fuel pressure rise on the
screen.
Allow the pressure to stabilize and
create a steady stream of flow. This
could take up to 5 minutes.
Move the banjo flow adapter line
from the collection device (bucket) to
the graduated cylinder, Part Number
4919139.
Allow fuel to flow into the graduated
cylinder for exactly 30 seconds.
Immediately return the banjo flow
adapter line back to the collection
device (bucket).
Record the volume of fuel collected
in the graduated cylinder. Compare it
to the specification below.
Maximum Fuel Volume Measurement
During High Pressure Leakage Test
Time
ml/cc
30 seconds
450
If 450 ml/cc pump head drain flow is
collected in less than 30 seconds, the fuel
pump head has malfunctioned and must
be replaced.
NOTE: This specification is valid for
engines operating on diesel fuels. Low
fuel viscosity will increase the leakage
rate; for example, kerosene or aviation
fuels will result in excessive leakage.
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Verify the fuel type being measured
before replacing a fuel pump head for
excessive leakage.
Measurement - Engine Will Not Start
NOTE: Do not crank the engine for 30
seconds continuously. Crank the
engine in 15 second intervals with a 15
second pause between intervals. This
reduces the possibility of overheating
the starting motor.
























Fuel pump diagnostic line connected
at the fuel drain manifold.
Lift pump disconnected.
Route the hose into a collection
device (bucket)
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
Close the engine cover while
performing this measurement.
Begin cranking the engine.
Obtain a steady stream of fuel flow
from the drain line.
Move the drain line to the graduated
cylinder for 15 seconds then back to
the bucket.
Stop cranking and allow the engine
to rest for 15 seconds.
Repeat the three steps above a total
of two times.
Record the amount of fuel flow from
the injector drain line in 30 seconds
while the engine is cranking.
Record the volume of fuel collected
in the graduated cylinder. Compare it
to the specification below.
Maximum Fuel Volume Measurement
During High Pressure Leakage Test
Time
ml/cc
30 seconds
320
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If 320 ml/cc pump head drain flow is
collected in less than 30 seconds, the fuel
pump head has malfunctioned and must
be replaced.
NOTE: This specification is valid for
engines operating on diesel fuels. Low
fuel viscosity will increase the leakage
rate; for example, kerosene or aviation
fuels will result in excessive leakage.
Verify the fuel type being measured
before replacing a fuel pump head for
excessive leakage.
High-Pressure Injector Return Flow Test
Initial Setup
CAUTION
Installation of the banjo flow adapter at
any place other than the fuel drain
manifold can cause damage to high
pressure fuel system components.
Return fuel is routed from the injectors, the
fuel rail pressure relief valve, and the fuel
pump head through three different drain
lines. Measurement of fuel injector
leakage requires the use of a fuel return
hose, Part Number 3164618. The fitting
has a closed end, four holes in the smooth
section near the hex, and a male threaded
section that attaches to the flexible hose.
The tool is used to isolate the leakage
from just the injectors, so it can be
measured with a graduated cylinder.
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Obtain a graduated cylinder that is marked
in cubic centimeters. Use graduated
cylinder, Part Number 4919139, or
equivalent.
CAUTION
Hold the banjo fittings while tightening
the banjo bolt to prevent the fitting from
rotating. Allowing the banjo fitting to
rotate may damage the fuel line.
NOTE: Make sure the engine is at
operating temperature before
beginning this test.








Remove the banjo bolt from the
injector drain line at the fuel drain
manifold.
Install banjo flow adapter fitting, Part
Number 3164618, at the fuel drain
manifold.
Route the hose into a collection
device (bucket).
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
Measurement - Engine Will Start






Close the engine cover while performing
this measurement.
Perform INSITE™ electronic service tool
High-Pressure Leakage Test.
Connect INSITE™ electronic service
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tool.
Start the engine and allow it to idle with
fuel flowing into a collection device.
Wait for the lift pump cycle to complete
(approximately 60 seconds).
Operate engine until it is at operating
temperature.
Begin the High-Pressure Leakage Test.
NOTE: Make sure a steady flow of fuel is
present at the drain line before beginning
the measurement. Air in the line and
movement of the hose during
measurement can result in inaccurate
measurements.














Monitor the fuel pressure rise on the
screen.
Allow the pressure to stabilize and
create a steady stream of flow. This
could take up to 5 minutes.
When fuel pressure stabilizes, allow fuel
to flow into the collection device for 60
seconds.
Move the banjo flow adapter line
from the bucket to the graduated
cylinder, Part Number 4919139.
Allow fuel to flow into the graduated
cylinder for exactly 60 seconds.
Immediately return the banjo flow
adapter line back to the collection
device (bucket).
Record the volume of fuel collected
in the graduated cylinder. Compare it
to the specification below.
Maximum Injector Return Flow
Measurement
Time
ml/cc
60 seconds
120
NOTE: Fuel temperature and fuel type
will influence this measurement. For
example as the engine is warmed up
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Fuel System Diagnostics
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and the injectors become hot, the
leakage rate will increase. Also, low
viscosity fuels, such as kerosene or
aviation fuels, will cause the leakage
rate to increase. The above
specification is correct for on-highway
diesel fuels, where the diesel fuel inlet
temperature is less than 49°C [120°F].




After recording the fuel leakage
quantity, record the Fuel Rail
Pressure Measured value.
Stop INSITE™ electronic service tool
High-Pressure Leak Test and turn
the keyswitch to OFF.
If injector drain flow is excessive, it will be
necessary to isolate the injector(s) or fuel
connector(s) that are damaged or worn.
Measurement - Engine Will Not Start
NOTE: Do not crank the engine for 30
seconds continuously. Crank the
engine in 15 second intervals with a 15
second pause between intervals. This
reduces the possibility of overheating
the starting motor.








Injector drain line connected at the
fuel drain manifold.
Lift pump disconnected.
Route the hose into a collection
device (bucket)
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
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Close the engine cover while
performing this measurement.
Begin cranking the engine.
Begin cranking the engine until fuel
exits the drain line.
Move the drain line to the graduated
cylinder for 15 seconds then back to
the bucket.
Stop cranking and allow the engine
to rest for 15 seconds.
Repeat the three steps above one
more time.
Record the amount of fuel flow from
the injector drain line in 30 seconds
while the engine is cranking.
The leakage should only be a few
drops.
If injector drain flow is excessive, it
will be necessary to isolate the
injector(s) or fuel connector(s) that
are damaged or worn.
High-Pressure Injector Return Flow Isolation Test
Initial Setup
WARNING
Normal engine operation creates highly
pressurized fuel in the fuel line which
will remain in the fuel line after engine
shutdown. Never open the fuel system
when the engine is operating. Before
servicing the fuel system, always
loosen the pump-to-rail fuel line at the
rail to vent the pressure. Keep hands
clear of the line when loosening. Highpressure fuel spray can penetrate the
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skin, resulting in serious personal injury
or death.
NOTE: Make sure the engine is at
operating temperature before
beginning this test.
Before servicing the high-pressure fuel
system, loosen the pump-to-rail line at the
rail, to vent the pressure.
Keep hands clear of the line when
loosening the rail line.
Tighten the fuel rail nut.
Torque Value:
1. 47 n.m [35 ft-lb]
2. Rotate 60 degrees.
NOTE: A machined slot in this fitting
directs the fuel spray toward the
engine.
CAUTION
Do not install the isolation tool at the
high pressure pump outlet fitting.
Severe engine damage will result. This
tool must only be installed at the fuel
rail for the purpose of isolating the highpressure fuel supply from individual
injectors.
CAUTION
Make sure the keyswitch is in the OFF
position (engine not operating) when
loosening or tightening high-pressure
fuel lines.
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Use leak test isolation tool, Part Number
4918563, to isolate excessive fuel drain
from injectors or fuel connectors.
Follow the pressure relief step (shown in
the previous step) prior to every
installation of the isolation tool.
Isolate the injector and fuel connector for
each cylinder by installing the isolation tool
at the fuel rail in place of the high-pressure
fuel line that supplies the fuel connector.
Torque Value:
1. 10 n.m [89 in-lb]
2. Rotate 60 degrees.
Measurement - Engine Will Start






















Engine at operating temperature.
Lift pump disconnected.
Injector drain line connected at the
fuel drain manifold.
Route the hose into a collection
device (bucket).
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
Close the engine cover while
performing this measurement.
Connect INSITE™ electronic service
tool.
Start the engine and allow it to idle
with fuel flowing into a collection
device (bucket).
Begin the High-Pressure Leakage
Test.
Monitor the fuel pressure rise on the
screen.
Allow the pressure to stabilize and
create a steady stream of flow. This
could take up to 5 minutes.
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Page 19 of 25
Record the fuel rail pressure
Measure Value.
Move the banjo flow adapter line
from the bucket to the graduated
cylinder, Part Number 4919139.
Allow fuel to flow into the graduated
cylinder for exactly 60 seconds.
Immediately return the banjo flow
adapter line back to the collection
device (bucket).
Record the quantity of fuel collected
in the graduated cylinder. Compare it
to the specification below.
Do this up to six times; once while each
injector is isolated.
NOTE: Make sure a steady flow of fuel
is present at the drain line before
beginning the measurement. Air in the
line and movement of the hose during
measurement can result in inaccurate
measurements.
Maximum Injector Return Flow
Measurement








Time
ml/cc
60 seconds
120
If isolating any single injector results
in a significant Increase in fuel rail
pressure measured or a reduction in
the maximum injector return flow
measurement, check or tighten that
fuel connector. Refer to Procedure
006-052 in Section 6.
Remove the isolation tool.
Run the High-Pressure Injector
Return Flow Test.
If there is a significant increase in
fuel rail pressure measured or
maximum injector return flow
measurement is now within
specification, the leak was caused by
a leaking fuel connector.
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Fuel System Diagnostics


Page 20 of 25
If the leak remains, the fuel injector
should be replaced.
Do this up to six times; once while each
injector is isolated.
NOTE: Make sure a steady flow of fuel
is present at the drain line before
beginning the measurement. Air in the
line and movement of the hose during
measurement can result in inaccurate
measurements.
Measurement - Engine Will Not Start
NOTE: Do not crank the engine for 30
seconds continuously. Crank the
engine in 15 second intervals with a 15
second pause between intervals. This
reduces the possibility of overheating
the starting motor.






















Injector drain line connected at the
fuel drain manifold.
Lift pump disconnected.
Route the hose into a collection
device (bucket)
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
Close the engine cover while
performing this measurement.
Begin cranking the engine.
Obtain a steady stream of fuel flow
from the drain line.
Move the drain line to the graduated
cylinder for 15 seconds then back to
the bucket.
Stop cranking and allow the engine
to rest for 15 seconds.
Repeat the three steps above a total
of four times.
Record the amount of fuel flow from
the injector drain line in 1 minute
while the engine is cranking.
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If isolating a single injector results in a
significant decrease in the injector return
flow measurement or the engine starts,
check or tighten that fuel connector. Refer
to Procedure 006-052 in Section 6.
Perform the High Pressure Injector Return
Flow Test again. If a significant Increase in
Fuel Rail pressure measured, or the
leakage is now only a few drops, the leak
was caused by a leaking fuel connector.
If the leak remains, the fuel injector should
be replaced.
Do this up to six times; once while each
injector is isolated.
NOTE: Make sure a steady flow of fuel
is present at the drain line before
beginning the measurement. Air in the
line and movement of the hose during
measurement can result in inaccurate
measurements.
Fuel Pressure Relief Valve Return Flow Test
Initial Setup
CAUTION
Installation of the banjo flow adapter at
any place other than the fuel drain
manifold can cause damage to high
pressure fuel system components.
Return fuel is routed from the injectors, the
fuel rail pressure relief valve, and the fuel
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Fuel System Diagnostics
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pump head through three different drain
lines. Measurement of fuel injector
leakage requires the use of a fuel return
hose, Part Number 5299319.
The tool is used to isolate the leakage
from just the fuel pressure relief valve, so
it can be measured with a graduated
cylinder.
Obtain a graduated cylinder that is marked
in cubic centimeters; example: graduated
cylinder, Part Number 4919139, or
equivalent.
Remove the banjo bolt from the drain line
at the fuel pressure relief valve.
Install banjo flow adapter fitting, Part
Number 5299319, at the fuel pressure
relief valve.
Route the hose from this adapter to a
collection device.






Alternatively, fuel return hose Part
Number 3164618, can be installed at
the fuel drain manifold.
If the fuel rail return flow does not meet
the specification when checking at the
fuel drain manifold, then measure the
fuel rail return flow at the fuel rail
pressure relief valve, not at the fuel
drain manifold.
If the fuel rail return flow does not meet
specification at the fuel rail pressure
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Fuel System Diagnostics
Page 23 of 25
relief valve, then a malfunctioning fuel
rail relief valve has been detected.
Measurement - Engine Will Start




























Engine at operating temperature.
Fuel Pressure Relief valve line
connected at the fuel pressure relief
valve.
Route the hose into a collection device
(bucket).
Use graduated cylinder, Part Number
4919139, for measurement when
directed.
Close the engine cover while performing
this measurement.
Connect INSITE™ electronic service
tool.
Start the engine and allow it to idle with
Fuel Pressure Relief valve line in a
collection device (bucket).
Perform INSITE™ electronic service tool
High-Pressure Leakage Test.
Monitor the fuel pressure rise on the
screen.
Allow the pressure to stabilize. This
could take up to 5 minutes.
Move the Fuel Pressure Relief valve line
to a graduated cylinder, Part Number
4919139,
Allow fuel to flow into the graduated
cylinder for 60 seconds.
The leakage must be less than 10 drops
per minute.
Replace the Fuel Pressure Relief Valve
if leakage is greater than 10 drops in 60
seconds.
NOTE: If Fault Code 449 or 2311 is active,
do not replace the fuel pressure relief
valve without first determining the cause
of the fault condition. Use the appropriate
fault code troubleshooting tree in Section
TF, in the Fault Code Troubleshooting
Manual, Bulletin 4022225.
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Fuel System Diagnostics
Page 24 of 25
NOTE: A steady leak from the fuel
pressure relief valve can be an indication
that the valve seat is worn. This condition
will often coincide with Fault Code 1911
and/or Fault Code 3727.
Use the appropriate fault code
troubleshooting tree in Section TF in the
following manuals:








PowerGen QSX15 CM2250 Fault Code
Troubleshooting Manual, Bulletin
4310740.
PowerGen QSX15 CM2250 ECF Fault
Code Troubleshooting Manual, Bulletin
4310739.
ISB6.7 CM2250, ISC8.3 CM2250, ISL9
CM2250, ISX12/ISX11.9 CM2250, and
ISX15 CM2250 Fault Code
Troubleshooting Manual, Bulletin
4022225.
QSB6.7 CM2250, QSL9 CM2250,
QSX11.9 CM2250 ECF, QSX15
CM2250 ECF Fault Code
Troubleshooting Manual, Bulletin
2883477.
Measurement - Engine Will Not Start
NOTE: Do not crank the engine for 30
seconds continuously. Crank the
engine in 15 second intervals with a 15
second pause between intervals. This
reduces the possibility of overheating
the starting motor.










Fuel Pressure Relief valve line
connected at the fuel pressure relief
valve.
Lift pump disconnected.
Route the hose into a collection
device (bucket).
Use graduated cylinder, Part
Number 4919139, for measurement
when directed.
Close the engine cover while
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Fuel System Diagnostics














Page 25 of 25
performing this measurement.
Begin cranking the engine.
Move the drain line to the graduated
cylinder for 15 seconds then back to
the bucket.
Stop cranking and allow the engine
to rest for 15 seconds.
Repeat the three steps above a total
of four times.
Record the amount of fuel flow from
the Fuel Pressure Relief valve line in
1 minute while the engine is
cranking.
The leakage should be less than 10
drops per minute.
Replace the Fuel Pressure Relief
Valve if leakage is greater than 10
drops in 60 seconds.
NOTE: If Fault Code 449 or 2311 is
active, do not replace the fuel pressure
relief valve without first determining the
cause of the fault condition
Use the appropriate fault code
troubleshooting tree in Section TF in the
following manuals:








PowerGen QSX15 CM2250 Fault
Code Troubleshooting Manual,
Bulletin 4310740.
PowerGen QSX15 CM2250 ECF
Fault Code Troubleshooting Manual,
Bulletin 4310739.
ISX15 CM2250 Fault Code
Troubleshooting Manual, Bulletin
4022225.
QSB6.7 CM2250, QSB6.7 CM2250
EC, QSL9 CM2250, QSX11.9
CM2250 ECF, and QSX15 CM2250
ECF Fault Code Troubleshooting
Manual, Bulletin 2883477.
Last Modified: 16-Sep-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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