QSB6.

7 & QSL9
CM2250 Fuel Systems
 HPCR Fuel System Safety

Wear your safety glasses

Use cardboard or paper for
identifying/troubleshooting high-pressure leaks ...
Never use your hands or fingers

1800 bar = 26,106 PSI

2 Bar (30 PSI) is enough to penetrate human skin
and cause a pressure injection.

Always wait at least 10 minutes following engine
shut down before opening the high pressure fuel
system for QSB6.7. The QSL9 fuel system can be
safely vented when the procedure is followed.

If possible, use INSITE to monitor the fuel pressure
to ensure it is safe to open the system

Never place your hands near fuel system fittings
when loosening them

2
 Fuel System Clean Care

Clean all fuel system fittings, lines, and

components before disassembly.

Make sure that no dirt or debris enters
the fuel system components to prevent
the passing of contaminants to the high
pressure fuel rail and injectors.

Small amounts of dirt and debris can
cause a malfunction of these
components.

QSB6.7 & QSL9 CM2250 have clean
care kits available

3
 Clean Care Review

Questions:

What is a micron?

What are potential sources of fuel
system contamination?

What can you as the technician do
to prevent fuel system
contamination?

Do you always pre-fill fuel filters?

4
 Fuel Specifications

Engines equipped with exhaust aftertreatment must

operate on ultra-low sulfur diesel (ULSD), with a
maximum sulfur content of 15 ppm in the US and
Canada, and 10 ppm in Europe. Failure to do so will
result in damage to the aftertreatment system.

The machine OEM is required to display readily visible
labels on the dashboard (or instrument panel), and near
all fuel fill inlets that states "Use Ultra Low-sulfur Diesel
Fuel Only" or "Ultra Low-Sulfur Diesel Fuel Only".

ULSD / Biodiesel blends up to B20 (20% biodiesel)
supplied by a BQ9000 certified supplier are acceptable.

5
 Ultra Low Sulfur Diesel Fuel

Could today’s fuel be used in Tier 4 Interim engines?

Tier 4 Interim engines must use ULSD. It is not possible to comply with
the legally required PM emissions standard with today’s off-highway fuel
which has a higher sulfur content.
What happens if higher sulfur fuel is inadvertently used?

A one time inadvertent tank of diesel fuel with greater than 15-ppm sulfur
content will not damage the engine and aftertreatment system. The
system will clean itself out when ULSD is re-introduced.

Continued improper fuel use of sulfur levels greater than 15-ppm with
Cummins Tier 4 Interim engines can permanently damage the engine and
aftertreatment systems within a short period of time.
Is the engine warranty affected if ULSD is not used?

Yes. Improper fuel use of sulfur levels greater than 15-ppm with Cummins
Tier 4 Interim engines can result in denial of warranty coverage for any
damage caused by using fuel with sulfur content greater than 15 ppm.

6
 Pressure Side Fuel Filtration

Provided by Cummins

5 Micron rating QSB

3 Micron rating QSL

Engine or remote mounted
options

Must never be prefilled

7
 Why is pre-filling pressure-side fuel
filters not recommended?

Normal System
operation

Fuel from the
suction side filter
has been filtered, Dirty Side of
but not at the Filter
micron level the Clean Side
fuel system of Filter
requires
Fuel entering filter head and filter

Fuel passing through the filter media

Fuel cleaned to the final micron level

8
 Contamination happens that
quickly
Continued … Both sides of the filter media are
exposed to unfiltered fuel

What really happens Critical system parts are now at
during pre-filling? risk

During pre-filling the
“clean side” of the
filter is exposed to
any contamination in
the fuel supply
source

Fuel from pre-fill source

Fuel passing through the filter media

9
 QSB6.7 CM2250 Fuel System
Specifications

High-pressure common rail (HPCR) system

1800 Bar System Pressure

Single-Stage High Pressure Relief Valve

Full authority electronic control of injectors

Manually primed fuel system

Engine mounted and off engine mounted suction side fuel
filter options

The suction side fuel filter must include:
– Water separator
– Water-in-fuel (WIF) sensing features

Optional 12 or 24 VDC fuel heater is available from Cummins

10
 Priming Pump

– QSB6.7 CM2250 engines do

not utilize an electric motor
driven lift pump.
– The OEM installed hand
priming pump is used to prime
the fuel system. It can be
remote or mounted on the
engine.
– During normal engine
operation, the gear pump
mounted on the fuel pump will
draw fuel from the OEM fuel
tank

11
QSB6.7 CM2250 Fuel System Flows
Supply Fuel
25 Micron Filtered Fuel
5 Micron Filtered Fuel
High Pressure Fuel
Return Fuel
 QSB6.7 Fuel Flows

Shop Activity
– Review Fuel System Flows on Training Engine
• ISB6.7 CM2150 and ISB6.7 CM2250 engines have an
identical fuel system

13
 QSL9 CM2250 Fuel System
Specifications

Cummins Designed and Manufactured System
– 2100 Bar Operation Pressure
– Dual Stage Fuel Rail Relief Valve (Like QSC/L CM850)
– Cummins Injectors
– New Block-off tool required 4918563

Fuel Pump has modular repair options
– Pump assembly
– Cam & Cam housing
– Actuator or Actuator and Actuator Housing
– Gear Pump
– Fuel Pump Head

14
 Fuel Pressure Relief Procedure
As the highFuel
pressure supply
Pressure line is
Relief
After pressure has been safely vented
loosened from the Fuel
Machining on Rail
the any
cylinder
from the fuel rail repair or diagnostic
pressure inhead
the rail
sidewill
of have
the a Rail
Fuel
work can begin
controlled leak path

Cylinder Head Side of Fuel Rail

15
 Fuel Pressure Relief Procedure
– Due to the design of the CM2250
fuel system, residual pressure
may remain on the high pressure
side of the fuel system after
engine shutdown
– Before servicing any components
on the high pressure side of the
fuel system, the system pressure
should be vented by loosening
the fuel pump to fuel rail fuel line
• A machined slot in the fitting will
direct the fuel spray towards the
engine block

16
 QSL CM2250 Fuel Pressure Relief Valve

– Dual Stage
• Opens at approximately 2600
bar
• Regulates to approximately
850 bar when in open position
– Location at the flywheel end of
the fuel rail

17
 QSL CM2250 Fuel Pressure Relief Valve

18
 QSL CM2250 Fuel Pressure Relief Valve Normal
Operation

19
 QSL9 Fuel Pressure Relief Valve

20
 QSL9 Fuel Pressure Relief Valve

21
 Cummins ISC/L CM850, QSC/L CM850/2250, ISL CM850 & ISC/L CM2150

-
+

0.043 Diagnostic Orifice

Diagnostic Drain Flow

High
OEM Responsibility Pressure
Pump
OEM Inlet

Pressure
Suction Side Filter
OEM Supply Tank Side
Filter
Fuel Rail Relief Valve Return
High Pressure Pump Return
Injector Return

OEM Return
22
 QSL9 CM2250 Fuel Flows

Shop Activity
– Review fuel flows on training engine
• ISC8.3CM2150, ISL8.9 CM2150, ISC8.3 CM2250, and
ISL9 CM2250 have an identical fuel system

23
 QSB/L Fuel System Troubleshooting

Major changes to troubleshooting procedures

from QSB/L CM850 to QSB/L CM2250
– Both engines feature higher fuel system pressures
– QSL is now an all Cummins fuel system
– INSITE Fuel System Leakage Test now commands a
higher pressure to find higher performance related
leaks
– New tools

24
Cummins High
Pressure Common
Rail

Injector Theory of Operation

• Injector Solenoid is not
energized. The solenoid
spring forces the +
solenoid in the closed
position
-
• Equal fuel pressure is
exerted on both the
plunger (1) and
shoulder area (2) of the
needle
• The greater surface
area of the plunger (2) 1
results in more hydraulic
advantage keeping the
injector in the closed
position
2
• When the ECM
requires fuel for a
cylinder a voltage is +
driven to the injector
solenoid
-
• This creates an
electromagnetic force
that is greater than
the force of the spring
•This forces the
solenoids metal core
to move upward
• As the solenoid lifts Fuel from the
a leak path is opened leak path drains
in the fuel injector through a
passage in the
cylinder head
• The leak results in
the shoulder of the
injector needle now +
seeing a greater
hydraulic force than
the plunger (due to
-
the leak path)
• This allows the
needle to lift from the
closed position
• Fuel is then injected
into the cylinder
through the nozzles
• When fuel is no longer
needed the injector
solenoid is de-energized +
by the ECM
• The electromagnetic -
force is removed
allowing the spring to
force the solenoid to the
closed position
• When the solenoid is
in the closed position
the leak path is
removed
• With the leak path
removed the greater
surface area of the
plunger causes the
plunger/needle to reseat
and end fuel injection
• Equal fuel pressure
is again sent to both
the plunger (1) and +
shoulder of the
needle (2)
-
• The greater surface
area of the plunger
(1) results in more
hydraulic force
keeping the injector in
the closed position
until the ECM 1
determines fueling is
again needed

2
• Fuel System
cleanliness is very
important for High +
Pressure Common Rail
Systems
-
• Contaminants can
lodge in the small
passages in the injector
preventing critical flows
• If the contaminate
particle lodges in the
passage to the plunger
area
•The result is the injector
will remain in the open
position and cause
engine damage due to
uncontrolled fueling of
the cylinder
 Fuel Injector / Connector

The high-pressure connector and injector
must be replaced if failure is observed
• The high-pressure connector should be
replaced anytime the injector is replaced

Be sure not to over torque the connector
retaining nut. Over torquing the retaining
nut may cause the connector to rotate
out of the connector retaining slot.
High Pressure Connector
 Fuel Injector Supply Lines
Injector supply lines designed
for the 1600 Bar fuel rail
pressure

No isolators or external
supports

Injector supply line torque
value is critical

A crow's foot and socket

extension may be required
to remove and install the
fuel line fitting to the fuel
connector.
Anytime a high pressure
injector supply line is
removed from the engine,
the fuel connector nut at the
cylinder head must be re-
torqued.
Fuel System
Diagnostics
Fuel System Service Tools
Fuel System Leak Tester

Commonly called a “Block-

off tool”
Used to isolate individual
cylinders to determine the
location of any system
leakage
Should be cleaned with
contact cleaner prior to use
to prevent high pressure fuel
system contamination
Fuel System Service Tools

Fuel Return Flow Hose

Used to check leakage form

the high pressure fuel rail’s
high pressure relief valve
Fuel System Service Tools

Fuel Return Flow Test Kit

Allows isolation of high
pressure fuel pump and
injector return fuel flows
Fuel System Service Tools

Fuel Drain Hoses

Male and female drain

hoses are available
Allows testing from quick
disconnect 5/16” fuel fittings
Fuel System Service Tools

Fuel Tube Plug

Used to plug male 5/16”

quick disconnect fuel lines
during system testing
Fuel System Service Tools

Torque Wrench

Special torque wrench used

for tightening injector
terminal nuts
13 in-lb Specification
Over tightening the terminal
nuts can result in injector
solenoid damage
The solenoid is not a
serviceable part
Fuel System Service Tools

Fuel Connector Remover

Used to remove high pressure

connectors from the cylinder
head
Prevents damage to connector
bore and connector from
improvised tools
Should be cleaned with
contact cleaner prior to use to
prevent high pressure fuel
system contamination
 High Pressure Common Rail

CYL
Head
Fuel Rail
QSB CM2250 Pressure Injectors
Engine Relief Valve

High Pressure Fuel

Line to Rail
High Pressure
Connectors

Pressure
Filter Fuel
Return Fuel
Return

Fuel
Return
Fuel
Hand Primer Pump Return
Fuel Out

Suction
Filter
Fuel Gear Fuel Tank

H.P. Fuel Pump Pump

 High Pressure Common Rail

CYL
Head
Fuel Rail
QSB CM2250 Pressure Injectors
Engine Relief Valve

High Pressure Fuel

Line to Rail
High Pressure
Connectors

Pressure
Filter Fuel
Return

Hand Primer Pump

Fuel Out
Suction

HP Pump

HP Relief

Injector
Filter

Return

Return
Return
Fuel Gear Fuel Tank

H.P. Fuel Pump Pump

 High Pressure Common Rail

CYL
Head
Fuel Rail
ISB CM2150 Pressure
Block
Engine Relief Valve Off Injectors
Tool

High Pressure Fuel

Line to Rail
High Pressure
Connectors

Secondary
Filter Fuel
Return

Hand Primer Pump

Fuel Out
Primary

Injector
Filter

Return
Fuel Gear Fuel Tank

H.P. Fuel Pump Pump

 HPCR Theory of Operation

OUT IN

Pressure-Side
Filter

Return

Supply
 Shop Activity

Perform Procedure 005-236 Fuel System

Diagnostics

Discuss differences between QSB and QSL
systems

47
 QSL9 On-Engine Dual Filter Option

Return to Supply

48
 QSL Fuel System Leakage Testing
with On-Engine Filter Option

4918679 can be used to

isolate the relief valve

3164618 can be used to

isolate the injector return

3164618 can be used to

isolate pump return from
other returns

49