IK1201406 Service Bulletin/Repair Instructions

IK1201406 ­ A26 Fuel Gelling
Page 1 of 6
Countries:
CANADA, UNITED STATES Document ID: IK1201406
Availability:
ISIS, NotSIR
Revision:
5
Major System:
ENGINES
Created:
1/9/2018
Current Language: English
Last Modified: 2/13/2018
Other Languages: NONE
Author:
Viewed:
Greg Scheff
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Title : A26 Fuel Gelling

Applies To : Vehicles equipped with A26
CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

02/13/2018 - Feedback Response

02/13/2018 - Updated Step 6 regarding "test after" recommendations.

01/22/2018 - Added reference for Davco Coolant Heat Conversion Article, Updated Parts List.

01/17/2018 - Initial Article Release



DESCRIPTION

This document will guide the user through the steps that need to be followed if a fuel gelling condition is experienced. One common place that

gelling can occur (but not limited to), is the frame mounted Davco 382 filter assembly.
SYMPTOM(s)

Loss of power while driving, possible crank no start.
Possible Diagnostic Trouble Code(s) that may be present if gelling has occurred:
DTC/Light

SPN 157 FMI 1

SPN 157 FMI 18

SPN 2798 FMI 8

SPN 6653 FMI 18

SPN 132 FMI 21
SPN 3251 FMI 15
SPN 3482 FMI 7
SPN 641 FMI 7

SPN 641 FMI 14
Description

Engine Fuel 1 Injector Metering Rail 1

Pressure Most Severe

Engine Fuel 1 Injector Metering Rail 1

Pressure Moderate

Engine Fuel 1 Injector Group 2 : Abnormal

Frequency Or Pulse Width Or Period

Engine Fuel 1 Injector Metering Rail 1 Cold

Start Pressure : Data Valid But Below

Engine Intake Air Mass Flow Rate: Data

Drifted Low.

Aftertreatment 1 Diesel Particulate Filter

Differential Pressure : Data Valid But

Above Normal Operating Range ­ Least

Severe Level.

Aftertreatment 1 Fuel Enable Actuator :

Mechanical System Not Responding Or

Out Of Adjustment.

Engine Variable Geometry Turbocharger

Actuator #1 : Mechanical System Not

Responding Or Out Of Adjustment.

Engine Variable Geometry Turbocharger

Actuator #1 : Special Instructions.
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IK1201406 ­ A26 Fuel Gelling
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Possible Customer Observations or Concerns:

MIL Lamp

Crank No Start

Loss of Power

High Soot Loading

Frequent Regens
SERVICE PARTS INFORMATION
Part Number
Quantity

Required
FS19765
1
25 Micron Rating
Racor Primary Fuel Filter (If Equipped)
2611236C1
1
30 Micron Rating
Secondary Engine Mounted Fuel Filter
2517615C91
1
5 Micron Rating
Description
Davco 382 Primary Fuel Filter
Notes
Diesel Fuel System De-Icer

(Recommended)
Fleetrite FLTDG32
As

Needed
32oz. bottle used for emergency thaw only. Treats up to 30

gallons when de-icing.
Diesel Fuel Anti­Gel (Recommended)
Fleetrite FLTDAG20
As

Needed
20oz. bottle prevents gelling to -40° F. Treats up to 125 gallons of

fuel.
PEAK Brand De­Icer (Optional)
BDEDT32
As

Needed
32oz. bottle used for emergency thaw only.
PEAK Brand Anti-Gel (Optional)
PKDAG32
As

Needed
32oz. bottle treats up to 160 gallons of fuel.
Power Service De­Icer (Optional)
PSP8025
As

Needed
32 oz. bottle used for emergency thaw only. Treats up to 100

gallons of fuel.
Power Service Anti-Gel (Optional)
PSP1025
As

Needed
32oz. bottle for use below 30° F. Treats up to 100 gallons of fuel.
Always follow the De-Icer and Anti-Gel mixing

instructions on the bottle EXACTLY as outlined by the

manufacturer.
DIAGNOSTIC STEP(s)
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IK1201406 ­ A26 Fuel Gelling
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FUEL TYPES

Below is a listing of the most common diesel fuels used in on-highway truck engines.

• Diesel #2 (2-D) - Most common fuel used, also known as "summer fuel". It is a heavier distillate fuel than 1-D. Recommend treating with AntiGel at temperatures below freezing.

• Diesel #1 (1-D) - This is a kerosene like or lighter distillate fuel, and has a lower wax content. Used in applications running in extreme cold.

• BioDiesel ­ Typically a blend from 5 to 20% Bio (produced from organic materials such as vegetable oil) and conventional diesel fuel.

• Winter Blend - Typically a blend of #1 and #2 fuels to help reduce (not eliminate) the risk of gelling.
Fuel blends can vary wildly depending on geographic location. Consult with your fuel

supplier for details on the fuel blend they are providing, and treat accordingly.
Step Action

1
Decision
DIAGNOSTIC: What is Gelling?
Yes. Continue to Step 2
The gel point is the temperature at which diesel or biodiesel fuel freezes solid and

can no longer flow by gravity or be pumped through fuel lines. This phenomenon

happens when a fuel reaches a low enough temperature whereby enough wax

crystals have formed to prevent any flow of the fuel.
No. Return to fuel sytem diagnostics.
Different stages of Gelling:
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IK1201406 ­ A26 Fuel Gelling
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Does this vehicle exhibit this condition?
Step Action

DIAGNOSTIC: Visual Inspection

To confirm the condition of the fuel in the tank, a sample will be needed to see its

current state. Using the device of your choice, take a sample directly from the tank

and put it in a clear container. Do not pull the sample from the bottom of the tank.
Decision

1. Is the fuel frozen? Reference picture 2

and 3 above.
Continue to step 3
What is the condition of the fuel?

2
2. Is the fuel Cloudy? Reference right side

picture 2 above.
Continue to step 4
Step Action

DIAGNOSTIC: Frozen Fuel
Decision

1. Continue to Step 5
To repair a frozen fuel condition, a De-Icer will need to be added to the fuel system

and both fuel filters replaced. Follow the manufacturers guidelines of the De-Icer for

correct procedure.

Note: De-Icer seperates water from diesel fuel, this water will be trapped by the fuel

water seperator. Its important to replace fuel filters and drain the separator daily to

prevent water accumulation.

3
Step Action

DIAGNOSTIC: Cloudy Fuel
Decision

1. Continue to step 5
Add Anti-Gel per the manufacturers guidelines, and replace both fuel filters.

NOTE: Follow the Anti Gel manufacturers instructions closely for correct mixing with

fuel. Do not over concentrate.
4
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IK1201406 ­ A26 Fuel Gelling
Step Action

DIAGNOSTIC: Options to Prevent Reoccurence
Page 5 of 6
Decision

1. Continue to step 6
Depending on the operation conditions of the vehicle, different components and

treatments are available to help prevent fuel from gelling. The following are some

recommendations.

Operating Temperatures at or below 32° F:

- Use an Anti-Gel additive (See service parts section).

- Consider using a "winter blend" fuel (See fuel types section above).

- Educate the driver to use the type of fuel that is correctly blended for the operating

climate.

- Drain water separator frequently.

- If equipped, use the 120v block and fuel heaters when possible.

­ Coolant heated Davco primary fuel filter system.**

Operating Temperatures at or below 15° F:

5
- Use a "winter blend" fuel with Anti-Gel additive.

- Winter Front- Recommended at 15° F or below, see IK1201009.

- Artic Fox Tank Heater.

- Coolant heated Davco primary fuel filter system.**
Fuel System Treatment (See Service Parts Section):

- Anti Gel - Recommend treating fuel with Anti-Gel if operating below 32° F.

- De-Icer - To be used ONLY in removing gelled fuel from systems already frozen.

Not recommended to use as a routine additive.
** If the current Davco primary filter system is equipped with return fuel routed

through the base, it can be converted to coolant heat. See IK1500091.
Step Action
Decision
DIAGNOSTIC: Test After Repair

Once the fuel system has been thawed or treated and repairs are complete, it is

recommended to verify that no further concerns are present prior to releasing the

truck back to service. This should be done by performing a stationary regen

and reviewing the results with a service tool. Many times the ability to regen and

engine performance are both effected by gelled fuel. Doing this procedure is the best

way to determine if any further issues exist.

If any DTC's are noted, follow the appropriate FCAP and make repairs as needed.

6
OTHER RESOURCES

Master Service Information Site
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Copyright © 2018 Navistar, Inc.
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