Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Fuel System
Modular Common Automotive Industrial Marine
Rail System (MCRS) Application
Guidelines G-Drive Genset

Filtration Emissions Solution

Date: September 8, 2009 AEB Number 24.45

Engine Models included: QSK19, QSK38, QSK50, QSK60 with MCRS

Author: Andrew Messer Approver: per Procedure 9183OPS-04-10-01 Page 1 of 11

This AEB supersedes AEB

24.45 dated June 24, 2008

Introduction
Common Rail fuel systems have been developed to reduce emissions and fuel consumption and to improve
performance. These fuel systems are capable of providing rapid response to load changes and multiple injection
events per engine cycle for emission control. They operate at pressures approaching 2100 bars (30,500 psi), and
with component match clearances typically from 2 to 5 microns. The Cummins Modular Common Rail System
(MCRS) is designed to enable our engines to meet emission requirements and performance expectations now
and in the future.

The MCRS fuel system’s component life is maximized by supplying fuel to the engine via a Cummins two stage
fuel filtration system which meets an ISO 18/16/13 particle count level or better per ISO Standard 11171. The fuel
supply strategy includes OEM installed fuel tank air vents filtered to at least a 10 micron level to avoid adding
suspended, hard, fine particles to the fuel.

Purpose
This document details the fuel filtration for the engine as well as requirements and recommendations to the
equipment manufacturer in order to have a robust fuel system interface.

Requirements
• Must meet the maximum fuel supply restriction at the OEM inlet connection for dirty filters as published on
the base engine datasheet. This location is down stream of the stage one filtration.
• Must utilize a fuel tank air vent filter of 10 micron or better and provide for an air flow rate equivalent to
the maximum fuel fill rate for the machine
• Fuel component handling must meet Clean Care practices prescribed by Service Engineering
• Must not use a biodiesel blend exceeding 20% (ref. Cummins Service Bulletin 3379001 and AEB21.73)
• Remote filter mounting must meet the vibration profile found in Appendix A

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Recommendations
• Recommended that new machines meet the maximum fuel supply restriction at the OEM inlet connection
for clean filters as published on the base engine datasheet.
• Recommended that new machines meet the maximum clean fuel filter inlet restriction measured at the
diagnostic port of the OEM Fuel Inlet Connection as published on the base engine’s datasheet

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Table of Contents
INTRODUCTION .....................................................................................................................................................................1

PURPOSE...................................................................................................................................................................................1

REQUIREMENTS ....................................................................................................................................................................1

RECOMMENDATIONS...........................................................................................................................................................2

TABLE OF CONTENTS ..........................................................................................................................................................3

FUEL FILTRATION SYSTEM ...............................................................................................................................................4

FILTRATION STRATEGY ............................................................................................................................................................4
FILTRATION HARDWARE MOUNTING .......................................................................................................................................4
Stage One Filter Head Assembly .........................................................................................................................................4
Stage Two/Three Filter Head Assembly...............................................................................................................................4
OEM FUEL PLUMBING .............................................................................................................................................................5
OEM Fuel Inlet Connections ...............................................................................................................................................5
OEM Fuel Inlet Connection Fittings ...................................................................................................................................6
FILTER HEAD PLUMBING AND WIRING .....................................................................................................................................6
Stage One Filter Head Mounting.........................................................................................................................................6
Remote Stage Two Filter Head Mounting............................................................................................................................6
OEM INSTALLATION REQUIREMENTS...........................................................................................................................8
OEM FUEL CONNECTION RESTRICTIONS .................................................................................................................................8
FLEETGUARD INDUSTRIAL PRO STAGE ONE FILTER HEAD .......................................................................................................8
FUEL TANK VENT FILTER .........................................................................................................................................................8
OEM INSTALLATION AND OPERATION RECOMMENDATIONS ..............................................................................8
FUEL RESTRICTION INDICATOR ................................................................................................................................................8
FUEL TANK CLEANING/FLUSH ON NEW MACHINES .................................................................................................................9
SYSTEM PRIMING .....................................................................................................................................................................9
COLD WEATHER OPERATION....................................................................................................................................................9
HIGH ALTITUDE OPERATION ....................................................................................................................................................9
COST EFFECTIVE OPERATION OF LOW EMISSION ENGINES.......................................................................................................9
APPENDIX A: VIBRATION PROFILE .........................................................................................................................................11

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Fuel Filtration System

Filtration Strategy
In order to protect the precision fuel system components, MCRS engines require 3 stage fuel filtration. The first
stage of filtration utilizes 7μ Fleetguard Industrial Pro filter(s) with integrated priming pump located on the suction
side of the gear pump, while the second and third stage employ 3μ dual pass FF5644 filter cans located on the
pressure side of the gear pump. To assure consistent filtration efficiency at the 4μ level, we are specifying 250
hour filter change intervals for fuel supplies of cleanliness level ISO 18-16-13 or better.

The Stage 1 Industrial Pro provides water separation capacity adequate for handling a fuel supply containing up
to 200ppm water.

Filtration Hardware Mounting

The stage one Industrial Pro filter assembly must not be mounted on the engine. See Appendix A: Vibration
Profile to see the maximum allowable vibration profile for remote mounted filter heads. The standard
configuration stage two/three filter head is mounted on-engine and is rubber isolated to reduce the filtration
efficiency loss associated with vibration. There is an option available for remote mounting of the stage 2/3 filter
head.

Stage One Filter Head Assembly

Figures 1, 2 and 3 show the 7μ Industrial Pro filter head assemblies that include the plumbing check valves and
the ECM controlled priming pump. The figures also show the inlet and outlet fitting configuration shipped with all
engines. It is possible to reorient the fittings to suit machine constraints. It is, however, recommended to have
the inlet and outlet fittings installed on the same side of the filter head. This is to maintain optimum flow
characteristics inside the filter assemblies. The lower fittings are inlet, upper fittings are outlet. A fuel heater is
available as an upfit kit from Cummins Filtration. See literature for the FH234 on their website for more details
(www.fleetguard.com).
To maintain ECM control of the pump, a 3m (9.8ft) wiring harness is provided with the engine that will drive the
priming pump and provide connection to the Water in Fuel (WIF) sensor. The WIF sensor should be connected to
the filter assembly farthest from the inlet and outlet ports. Table 1 shows stage one wire harness connector
details in the case when the machine installation cannot utilize the 3m harness. This stage of filtration must meet
the vibration profile given in Appendix A: Vibration Profile.

Figure 1: QSK19 Figure 2:QSK38 Figure 3:QSK50 QSK60

Stage One Industrial Pro Filter Head Assemblies

Stage Two/Three Filter Head Assembly

Figures 4 and 5 show the 3μ stage 2/3 filter head assemblies. The OEM will have the option to mount the stage
2/3 filter head on-chassis. When the remote filter head option is selected, a 3m (9.8ft) wire harness extension is
provided. See Table 2 for stage two harness connector details. If remote mounting the stage two/three filter
head, the OEM is responsible for the hoses to and from the gear pump. See Tables 3-6 for hose and fitting
details.
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Figure 4: QSK19 Figure 5: QSK38/50/60

Stage Two/Three Filter Head
OEM Fuel Plumbing
OEM Fuel Inlet Connections
In order to provide flexibility of the fittings for the OEM fuel inlet connections to the engine, an OEM connection
block is provided on the engine. The location of the OEM inlet connection is engine platform-specific. See Figure
6: QSK19 OEM Inlet Connection Location and Figure 7: QSK38/50/60 OEM Inlet Connection for locations.
Coordinate locations can be found on the respective engine installation diagrams.

Figure 6: QSK19 OEM Inlet Connection Figure 7: QSK38/50/60 OEM Inlet Connection

Because the stage 1 Industrial Pro filter head assembly is chassis-mounted, the location will vary with each
engine application, there are two required OEM fuel hoses for the fuel inlet plumbing; from fuel tank to inlet of the
stage one filter head and from stage one outlet to OEM fuel inlet connection block.

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OEM Fuel Inlet Connection Fittings

The OEM inlet connection block enables an OEM to select from three fitting options: 1-1/16x12 UNF (JIC 37°
flare), 1-3/16x12 UNF (O-Ring Face Seal – ORFS), M30x2 ERMETO Flareless. Selecting the mandatory FI
option will specify the same fitting for the stage one inlet, stage one outlet and the OEM fuel inlet connection
block. This provides a common fitting for each end of the OEM-required hoses.

Filter Head Plumbing and Wiring

Stage One Filter Head Mounting
The wire harness to the filter head is connected to the main engine harness via Deutsch DT series connectors.
See Table 1: Stage One Wiring Harness Connector Details containing part number information for applications
that require different lengths of wire harness.
Table 1: Stage One Wiring Harness Connector Details

Part Number Description Quantity Supplier Location

Female 4 pin connector
121583-0001 1 ITT Cannon
body
Connects to Engine
121668-0022 Female pins 4 ITT Cannon Harness
121668-0032 Female pin wire seal 4 ITT Cannon
- 2 conductor 18AWG wire -
DT series 2 pin connector
DT06-2S-CE13 2 Deutsch
body
Connects to
0462-201-16141 Size 16 socket pin 4 Deutsch WIF/Priming Pump
DT series 2 pin locking
W2S-P012 3 Deutsch
wedge

Remote Stage Two Filter Head Mounting

When remote stage two filter head option is selected, the filter head must still utilize the entire assembly, including
vibration isolators. A 3 meter long harness is available as Cummins part number 4964184.
Table 2: Remote Stage Two Wiring Harness Connector Details

Part Number Description Quantity Supplier Location

Female 7 pin connector
121583-0018 1 ITT Cannon
body
192990-2530 Female pins 5 ITT Cannon
Connects to
121667-0022 Female pin wire seal 5 ITT Cannon Engine Harness
N/A Heatshrink, 24/6 40mm N/A
Connector body cavity
121667-0025 2 ITT Cannon
plug
Female 4 pin connector
121583-0001 1 ITT Cannon
body
121668-0022 Female pins 3 ITT Cannon
121668-0032 Female pin wire seal 3 ITT Cannon Connects to
Connector body cavity Remote Fuel
121668-0034 1 ITT Cannon Pressure Sensor
plug
058-8578-100 Backshell 1 ITT Cannon (see Figure 8 for
1215707 Conduit 10mm 25mm Schlemmer backshell
N/A Cable tie, 2.5mm 1 N/A assembly details)
N/A Heatshrink, 24/6 40mm N/A
3 conductor 18AWG
- -
wire

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Table 2: Remote Stage Two Wiring Harness Connector Details (con’t)

Part Number Description Quantity Supplier Location

12162193 2 pin connector body 1 Delphi Packard Connects to
12124075 Connector pins 2 Delphi Packard Remote Fuel
1215707 Conduit 10mm 25mm Harnessflex Temp Sensor
N/A Heatshrink, 24/6 40mm N/A (see Figure 8 for
2 conductor 18AWG backshell
- -
wire assembly details)

Fuel Pressure Sensor Connector Fuel Temperature Sensor Connector

Figure 8: Backshell Assembly Detail for Fuel Pressure and Temperature Sensors

Table 3: QSK19 Remote Stage Two Fuel Hose Fitting Details

Fitting Size (all are O- Hose Fitting Number

Hose Connection End
Ring Face Seal) Size (Eaton)
Gear pump 13/16-16 UNF-2B 90°
FJ4931-0808S
Gear pump to Stage two Elbow
#8
filter head inlet Stage two filter head 13/16-16 UNF-2B 90°
FJ4931-0808S
Elbow
Stage two filter head 13/16-16 UNF-2B 45°
FJ4968-0808S
Stage two outlet to high Elbow
#8
pressure pump High pressure pump 13/16-16 UNF-2B 90°
FJ4931-0808S
Elbow

Table 4: QSK38 Remote Stage Two Fuel Hose Fitting Details

Fitting Size (all are O- Hose Fitting Number

Hose Connection End
Ring Face Seal) Size (Eaton)
Gear pump 1 -14 UN-2B 90° Elbow FJ4931-1012S
Gear pump to Stage two
Stage two filter head 1-3/16-12 UNF-2B 90° #12
filter head inlet GJ4931-12-12
Elbow
Stage two filter head 1-3/16-12 UNF-2B 90°
Stage two outlet to high GJ4931-12-12
Elbow #12
pressure pump
High pressure pump 1 -14 UN-2B 45° Elbow FJ4968-1012S

Table 5: QSK50 Remote Stage Two Fuel Hose Fitting Details

Fitting Size (all are O- Hose Fitting Number

Hose Connection End
Ring Face Seal) Size (Eaton)
Gear pump 1-14 UN-2B straight FJ6737-1012S
Gear pump to Stage two
Stage two filter head 1-3/16-12 UNF-2B #12
filter head inlet FJ6737-1212S
straight
Stage two filter head 1-3/16-12 UNF-2B 90°
Stage two outlet to high GJ4931-12-12
Elbow #12
pressure pump
High pressure pump 1-14 UN-2B straight FJ6737-1012S

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Table 6: QSK60 Remote Stage Two Fuel Hose Fitting Details

Fitting Size (all are O- Hose Fitting Number

Hose Connection End
Ring Face Seal) Size (Eaton)
Gear pump 1-14 UN-2B straight FJ6737-1012S
Gear pump to Stage two
Stage two filter head 1-3/16-12 UNF-2B #12
filter head inlet FJ6737-1212S
straight
Stage two filter head 1-3/16-12 UNF-2B
Stage two outlet to high FJ6737-1212S
straight #12
pressure pump
High pressure pump 1-14 UN-2B 90° Elbow FJ4931-1012S

OEM Installation Requirements

OEM Fuel Connection Restrictions
Fuel inlet and drain restriction values are published on the engine datasheet. The inlet restriction limit is directly
based on the requirements of the inlet of the gear pump used on the MCRS engines. Failure to meet this limit
can cause engine performance issues. It is acceptable to measure inlet restriction is at the OEM inlet connection.
There is an M14 CompuChek port located on the OEM inlet block for this purpose. There is also an M14
CompuChek port on both the inlet and outlet of the Industrial Pro for restriction measurement before and after the
filter cartridges.

Fleetguard Industrial Pro Stage One Filter Head

The stage one Industrial Pro filter head must be isolated from engine vibration. This is to reduce filtration
efficiency deterioration resulting from vibration. Additionally, the Industrial Pro filters must be mounted so the filter
element is vertical. It will not operate properly when mounted at an angle. If the Industrial Pro is mounted below
the full level of the fuel tank, it is recommended to install a fuel shutoff valve before the inlet. This will allow the
fuel filter elements to be changed with a minimum of fuel loss.

Fuel Tank Vent Filter

A 10μ fuel tank vent filter is required. This filter prevents fine airborne particles from contaminating the fuel tank
as air is drawn in. The fuel tank venting system must accommodate the fastest rate of fuel fill that the vehicle will
experience. There are some mine systems delivering fuel at 160 gallons per minute. Wiggins has a fast fill
system for locomotives operating at 300 gallons per minute.

OEM Installation and Operation Recommendations

Fuel Restriction Indicator
Should fuel filters become overly restrictive, engine fault codes and low power will be experienced. Fuel system
durability can be reduced when inadequate pressure is supplied to fuel system components resulting in cavitation
damage.

A suction side fuel inlet restriction sensor or indicator with cab readout is recommended. The Industrial Pro filter
head assemblies provide an M14 port on the inlet and outlet to provide filter delta p or using the outlet port only,
fuel inlet restriction. The maximum allowable fuel inlet restriction given on the engine datasheet (10inHG)
measured at the on-engine fuel inlet connection block. Pressure drop across the Industrial Pro filter assembly is
designed to be 2.5inHG maximum with clean filters.

There is currently no diagnostic for the pressurized Stage 2/3 filter restriction. The engine will exhibit Fault Code
2215 and 559 if the gear pump discharge pressure falls below normal operating range.

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Fuel Tank Cleaning/Flush on New Machines

It is recommended that the OEM flush the machine’s fuel tank to prevent large particles, such as welding slag and
other materials, from contaminating the fuel system.

System Priming
The Stage 1 Industrial Pro filter head includes an integrated priming pump. This pump is electronically controlled
by the engine control module (ECM) to operate for 120 seconds after “key-on”. The priming pump may not be
capable of priming a “dry” fuel supply system without providing an air vent at the fuel air bleed fitting which goes
to OEM fuel drain fitting or by pressurizing the fuel tank for initial fill. When providing an air vent, it is important to
loosen the hose connection, not the check valve into drain block. See Figure 9 for an illustration of the fitting to
loosen when bleeding a dry fuel system (QSK19 pictured). Care should be taken to collect any fuel leakage.

Note: Ensure line is

cracked prior to the check
valve for proper air bleed

Figure 9: Fitting to Loosen for Air Bleed

Cold Weather Operation
Refer to AEB 174.05 for a complete list of recommendations when operating in cold weather. Pay particular
attention to the fuel hoses and chassis mounted filter heads as there are more hoses in the system. As noted
before, a fuel heater is available as an upfit kit from Cummins Filtration. See literature for the FH234 on their
website for more details (www.fleetguard.com).

High Altitude Operation

Machine operation in high altitudes may require the use of a continuous duty fuel lift pump to maintain adequate
fuel flow with low fuel tank levels. This is determined by the fuel inlet restriction.

Cost Effective Operation of Low Emission Engines

In order to manage operation costs, Cummins recommends the following:
ƒ expectations are placed on fuel vendors for delivery of ISO 18-16-13 or better fuel with less than 200ppm
water
ƒ use of settling tanks and/or continuous filtration of bulk fuel storage
ƒ regular bulk storage tank cleaning
ƒ Regular maintenance fuel tank vent filters
ƒ Regular maintenance of fuel filters and water separation devices
ƒ Clean handling practices of fuel nozzle/receiver
ƒ Daily draining of water and sediment from Industrial Pro filters and vehicle fuel tank

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Change Log

Date Author Description Page(s)

September 8, S Rockey Revised graphics to show updated filter head. Revised 1,5, 6
2009 the use of biodiesel from 5% to 20% , added harness
part number for reference
June 24, 2008 C Hobbs Added information on the fuel tank venting, fuel 8, 9, 2
restriction indicator, and etc.
August 23, 2007 C Hobbs Fuel supply requirements, operation expectations, and All
priming
November 15, C Dew Added G-Drive application, 1,3,5,6
2006 G Koelling Corrected stage one filter head plumbing connections,
Updated wiring harness connector part numbers
August, 2006 A Messer Corrected stage one filter head plumbing connections, 3,5,6
Updated wiring harness connector part numbers
June, 2006 A Messer New All

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0.45

0.4

0.35
Appendix A: Vibration Profile

0.3

0.25

0.2

PSD (G2/Hz)
0.15

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0.1

0.05

0
20 220 420 620 820 1020 1220 1420 1620 1820
Frequency (Hz)
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