Trucking fleets around Australia are reporting a rash of fuel-related seal failures linked to the recent introduction of diesel fuel with a lower sulphur and aromatics content. The seals in question are fuel injection and throttle-shaft O-rings and gaskets made with a rubber compound. Some of these seals are reportedly failing after as little as 3 weeks exposure to the new low sulphur diesel fuel. Engines with rotary injector pumps use diesel for lubrication, as contrasted with in-line pumps which use crankcase oil. As a result, engines with rotary pumps are, at this time, the hardest hit.
Apparently, one source of the trouble is that there are many ways to remove the sulphur content. The cheapest of these involves hydrotreating, a process that removes sulphur by treating it with hydrogen. Unfortunately, hydrogen is highly reactive and also reduces the lubricity, or lubrication properties, of the end-product diesel. Another factor in the equation is the initial content of sulphur in the base crude oil; crude from Alaska tends to be very high sulphur, Venezuelan relatively low, for example. As a result the lubrication properties of the fuel could be different for each oil refinery and can even change as a particular refinery's crude oil sources change.
Cummins engines seem to be among those hardest hit by the failures. Bob Scholtz, the director of fuel systems and electronics service engineering for Cummins Engine Company (U. S. ), said that he has received "reports of rapid, almost instantaneous occurrences of throttle-shaft O-ring leakage". Although the only leak point which Cummins confirms is their fuel pump throttle shaft, U. S. national trucking companies have reported leaks at other locations on Cummins equipment, as well as with other brands of engines. Blaine Johnson, director of maintenance for Ryder Truck Rental, said "This is not just a Cummins problem, it is a seal problem. We've verified seal failures on Navistar 743 engines, Cat 3208 engines, Mack transfer pumps... in all cases it involved a few Buna-N
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If you operate diesel equipment, even if you have not switched from high sulphur to low sulphur fuel, we recommend that you take some steps to minimize the potential effects of this problem. The first step is to put B100 into your fuel. Second, instruct your drivers and maintenance personnel to watch for any pooling of fuel under both the chassis and auxiliary engines. If some is discovered, get it fixed immediately. Some reports have been made of fuel leaks so bad that they gushed diesel onto the ground; if allowed to get to this point it could necessitate an environmental cleanup cost.
Leakage can also occur into your oil, so also have maintenance monitor oil usage closely. If your oil level increases, or doesn't go down over time as usual, you may have an internal leak. Unfortunately, until the leakage amount becomes large enough to notice as an increase in dipstick level, a relatively expensive chemical analysis is the only way to determine that diesel is mixing with crankcase oil.
As far as we could find out, refineries aren't yet or going to putting in a lubricity additive. The cost is remarkably small, on the order of one cent per litre. Ask your fuel distributor if a lubricity additive such as B100 is being put into the diesel you are buying. If it isn't, encourage your distributor to start putting in B100.
You also might check to make sure your parts supplier has fuel injector and throttle O-rings in stock for your engines. Since the parts themselves are so inexpensive, you should consider keeping an extra set in stock yourself. If you have questions, call your engine manufacturer(s) directly to find out the latest on this situation, and find out if there are any precautions which pertain to your particular models.