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Service Bulletin Number Date

4022123 -01 30-MAR-2009

Design Application Market Application

Industrial All

Generator Unit AllMarine Propulsion Marine

Service Bulletin

Fuel Sampling For Particle Counting Test

General Information

Engine manufacturers use advanced technologies to meet increasingly stringentemissions requirements. To be able to manage fuel injection with more precision and athigher pressures, these new technologies use more precise components that are less

tolerant of fuel contamination.

Fuel cleanliness has always been part of the overall quality control spectrum for enginecomponent performance and durability. Within the last several years, improved fuelquality has become even more critical to engine performance and durability. Laboratorytesting proves that fuel system durability is inversely proportional to fuel contaminantparticle size and quantity.

Every control plan should start with a measurement system that is reliable andconsistent. The objective of this procedure is to establish a common approach for fuelsampling and to reduce the possibility of external contamination during the fuel sampling

process itself.

This procedure covers fuel sampling for Cummins® high horsepower power (HHP)engines using Modular Common Rail System (MCRS) fuel injection and Industrial Pro™or Sea Pro™ Stage-1 filtration systems. This sampling procedure was designed to obtainthe minimum fuel sample quantity required for a contaminant particle count analysis.

The particle count test consists of measuring particles contained in a given sample.These include metallic and non-metallic particles, dirt, water, and other types ofcontamination. This test provides the distribution of particle quantity by size.

Cummins Inc. and other major engine manufacturers, based on the worldwide fuel chartrecommendation, require a fuel cleanliness level of 18/16/13 or better as per ISO Method4406. In practice, this means a maximum of 2500 particles equal to or larger than 4

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microns(c), a maximum of 640 particles equal to or larger than 6 microns(c), and amaximum of 80 particles equal to or larger than 14 microns(c) per milliliter of fuel sample.

Table 1, ISO Code Standard 4406

ISO Code per 4406 Maximum Particle Count per mL of Fuel Sample

23 80,00022 40,000

21 20,000

20 10,000

19 5000

18 2500

17 1250

16 640

15 320

14 160

13 80

12 40

11 20

10 10

9 5

8 3

7 1.25

6 0.64

5 0.32

4 0.16

3 0.08

2 0.04

1 0.02

e.g. 18/16/13

18 — <= 2500 Particles > 4µm*

16 — <= 640 Particles > 6µm*

13 — <= 80 Particles > 14µm

* Critical particle sizes for injection systems.

Refer to Service Bulletin, Fuels for Cummins® Engines, Bulletin 3379001, for fuelcleanliness information.





Modular Common Rail System (MCRS) engines are found in a variety of markets andapplications. Most high horsepower MCRS engines are equipped with 2-stage filtration,but some original equipment manufacturers (OEMs) choose to install a third (or primary)filtration system, often called Stage “0”. Stage “0” filtration varies from OEM to OEM andfrom application to application. OEM filtration (Stage 0) maintenance practices aredetermined by the OEMs.

To avoid confusion and eliminate variability, this procedure calls for fuel sampling at theinlet of stage 1 filtration. These filters, usually supplied with the engine (Fleetguard® Industrial Pro™ or Sea Pro™), can be found mounted directly to the engine or to aremote location on the equipment.

Materials

Fitting from M14 to 1/4 inch NPT (1).

NOTE: The fittings and other pipingelements (e.g., elbows, etc.) needed foran accessible sampling location are tobe provided by the tester. TheQuickDraw™ valve alone will not fitdirectly into the filter housing.

QuickDraw™ Valve (1/4 inch NPT).

Cummins Filtration™ Part NumberCC2724.

Vacuum Pump






Fuel Analysis Test Kit


Including service for 10 samples:

Particle counting•Karl Fischer water content test (ppm)•

And the following items for each of the 10tests:

4 oz ISO clean sampling jar•Black plastic mailer bottle•Silicone tape•Component registration form•Testing label•Shipping label.•

NOTE: The analysis service is for UnitedStates locations only due to shippingregulations. For non-U.S. locations, thehardware can be used to take samplesfor local analysis. Please check localshipping regulations and request fueltesting to be done according to ISO

4066.

NOTE: The component registration form,testing, and shipping are not coveredoutside of the United States andadditional charges may apply.

Sampling Instructions

Use fittings to install the QuickDraw™oil sampler in one of the available inletports on Stage-1 fuel filter (IndustrialPro™ or Sea Pro™) as specified.

•





NOTE: If more than one filter housing isavailable, samples can be taken fromany of them. This will not affect theresults of the test.

Fuel inlet label.1.

Make sure the sampling area andconnectors are clean and accessiblebefore sampling.

2.

Idle engine at approximately 1000

rpm for 5 minutes or until normaloperating temperature is reached(minimum coolant temperature of 60°C [140°F]).

3.

Shut the engine down and sample assoon as possible, but ideally no laterthan 1 minute after shutdown.

4.

Make sure the vacuum pump andother sampling tools are free of debrisand any other potential contaminants.

5.





Remove the rear metal cap from thepump.

6.

Remove the rubber plug from thesampling needle.

7.

Place a rubber plug in the rear

breathing open area to achievesuction when sampling.

8.

Remove the lid from the black plasticmailer and lay it on a clean areafacing up.

9.





Immediately take the ISO clean jar outof the mailer. Remove the lid of theISO clean jar.

10.

Place the ISO clean jar lid with theblack plastic mailer lid to avoidcontamination while sampling.

11.

Securely screw the jar to the vacuum

pump.

12.

Remove the cap from theQuickDraw™ fitting.

13.





Connect the pump to theQuickDraw™ fitting as illustrated.

14.

Actuate the vacuum pump and fill thesampling jar.

15.

NOTE: Discard the first jar of sampledfuel, in accordance with localenvironmental regulations, to preventcontamination of the sample. If this isnot the first sample taken, in onesampling event, go to step 17.

Do not reuse the jar used for the firstsample (Flushing the system).

Immediately connect a new, clean,ISO clean (C) sampling jar to thepump. Connect the pump to theQuickDraw™ valve, if removed in theprevous step. Actuate the pump andfill the jar 3/4 full. Particle counttesting usually requires 80 ml [3 oz]sample or more.

16.

Remove the jar from the vacuumpump and immediately install the lidfirmly onto the sample jar to preventcontamination.

17.

The lid must be tight so the sample does

not leak.





Return the protective cap to theQuickDraw™ fitting to avoidcontamination, unless more samplesare to be taken.

18.

Keep the vacuum pump and sampling

kit in a clean place (in the vacuumpump case) in order to preventcontamination.

19.

Fill out the testing label with thecorrect identification information.

20.

Stick the identification label on theISO sampling jar that contains thesample. The customer must keep thesection with the tracking number.

21.





Place the sample inside the blackplastic mailer bottle and replace thelid.

22.

Seal the black plastic mailer bottlewith the silicone tape as illustrated.

23.

Fill out the shipping label and stick it

to the black plastic mailer bottle.

24.

Last Modified: 30-Mar-2009

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