TSB140019-070516
Service Bulletin Details
Public Details for: TSB140019-070516
This document, in conjunction with the information provided within the manuals listed in table 1 provides inspection and repair guidelines following the malfunction of an xpi fuel pump pumping plunger and/or roller tappet assembly. The lev
- 9999 -
Models from 9999
| 9999 CUMMINS ISX12 |
| 9999 CUMMINS ISX15 |
Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 1 of 11 Technical Service Bulletin Number TSB140019 Technical Service Bulletin Subject Fuel Pump - Plunger and Tappet Roller Inspection and Repair Warranty Statement The information in this document has no effect on present warranty coverage or repair practices, nor does it authorize TRP or Campaign actions. Contents Product Affected ISX12 CM2350 X102 ISX12/ISX11.9 CM2250 ISX15 CM2250 ISX15 CM2250 SN ISX15 CM2350 X101 PowerGen QSX15 CM2250 PowerGen QSX15 CM2250 ECF QSX11.9 CM2250 ECF QSX15 CM2250 ECF QSX15 CM2350 X105 QSX15 CM2350 X106 This document, in conjunction with the information provided within the manuals listed in Table 1 provides inspection and repair guidelines following the malfunction of a fuel pump pumping plunger and/or roller tappet assembly. The level of progressive damage to the fuel pump and other engine components will vary with https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 2 of 11 every incident; however, the repair direction will depend on only a few key criteria. Previous versions of this document provided specific repair directions according to the vintage of the fuel pump and type of pumping plungers. Repair directions have now been made common and apply to all fuel pumps regardless of vintage, pumping plunger type, or tappet roller assembly type. Figure 1, Fractured Fuel Pump Ceramic Pumping Plunger. https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 3 of 11 Figure 2, Fuel Pump Tappet Roller Assemblies. Preliminary Inspection and Repair Direction for all Fuel Pump Malfunctions Inspect and verify the condition of the fuel pump tappet rollers. Reference Figure 2 above and Procedure 005-227 in Table 3 below. Scenario 1: The fuel pump tapper rollers are damaged: Remove, cut open, and inspect the lubricating oil filter for debris. See Procedure 007-083 in Table 3. Connect INSITE™ electronic service tool to the service tool data link and review any logged fault codes. Reference Table 1 below for repair direction. Scenario 2: The fuel pump tappet rollers are not damaged: Connect INSITE™ electronic service tool to the service tool data link and review any logged fault codes. Reference Table 1 below for repair direction. Table 1, Repair Direction Decision Matrix https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Symptoms Page 4 of 11 Are Any Symptoms Present? Non-wear debris or particles are evident in the lubricating oil filter element. Yes Fault Codes 415 or 143 are logged in the engine control module (ECM) within the last 8 hours of engine operation. No Engine is seized, or engine rotating assembly produces abnormal noise. Repair Direction to Follow Repair Direction A Repair Direction B CAUTION Immediately upon removal of the lubricating oil cooler assembly, a plug must be inserted into the housing and cylinder block oil passage drillings. Failure to insert the oil passage plug can result in a bearing failure, crankshaft failure, or both. CAUTION Do not allow dirt or foreign material to enter oil passages in the cylinder block when cleaning the gasket sealing surfaces. Connecting rod bearing failures can be caused if debris is introduced into the cylinder block or lubricating oil cooler housing oil passages. Therefore, use of power tools combined with abrasive pads to clean gasket surfaces is not recommended. Repair Direction A: 1. Replace the fuel pump. Table 2 below must be referenced for specific instruction by product type. See Procedure 005-016 in Table 3 below. 2. Drain the lubricating engine oil. See Procedure 007-037 in Table 3. 3. Thoroughly clean the lubricating oil cooler housing. See Procedure 007-003 in Table 3. 4. Replace the following lubricating oil system components: Lubricating oil cooler element. See Procedure 007-007 in Table 3. Lubricating oil filter bypass valve. See Procedure 007-014 in Table 3. Lubricating oil thermostat. See Procedure 007-039 in Table 3. 5. Remove the lubricating oil pan, and clean thoroughly. See procedure 007-025 in Table 3. 6. Remove and inspect the lubricating oil pump for reuse. See Procedure 007-031 in Table 3. 7. Remove number 1 and number 4 main bearing caps and main bearings. See procedure 001-006 in Table 3. 8. Inspect number 1 and number 4 main journals of the crankshaft for reuse. See Service Bulletin Crankshaft Reuse Guidelines for Cummins® Engines, Bulletin 5411180. If the crankshaft meets reuse guidelines: Inspect number 1 and number 4 main bearings for signs of significant debris https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair 9. 10. 11. 12. 13. Page 5 of 11 embedding. If significant debris is found, remove the number 1 and number 4 connecting rod bearings for inspection. If damage is observed on the number 1 and number 4 connecting rod bearings, roll new connecting rod bearings in on all 6 journals. See Procedure 001-006, 001-007, and 001-014 in Table 3. Roll new main bearings in on all 7 main journals and install new thrust bearings on number 4 main journal. If the crankshaft does not meet reuse guidelines: Dealers should contact RAPIDSERVE™ Catastrophic group for preauthorization if the engine is under warranty. Cummins® Distributors should follow their local catastrophic process or contact RAPIDSERVE™ for repair direction if the engine is under warranty. Install the lubricating oil pan and other components removed to access main bearings. See procedure 007-025 in Table 3 Install a new lubricating oil filter. See Procedure 007-013 in Table 3. Prime and fill the engine with new lubricating oil. See Procedure 007-037 in Table 3. Perform an aftertreatment diesel particulate filter (DPF) regeneration. See Procedure 014-013 in Table 3. Perform a second lubricating oil and lubricating oil filter change. Priming the lubricating oil system a second time is not required. See Procedure 007-013 and 007-037 in Table 3. Repair Direction B: 1. Replace the fuel pump. Table 2 below must be referenced for specific instruction by product type. See Procedure 005-016 in Table 3. 2. Drain the engine lubricating oil and remove the lubricating oil filter. See Procedure 007013 and 007-037 in Table 3. 3. Replace the lubricating oil filter bypass valve. See Procedure 007-014 in Table 3. 4. Fit a new lubricating oil filter and refill the engine lubricating oil system. Priming the lubricating oil system isnotrequired. See Procedure 007-013 and 007-037 in Table 3. Table 2, Fuel Pump Replacement Matrix Product Fuel Pump Variation Additional Action Needed When Replacing the Fuel Pump ISX15 CM2250 Two-cylinder pumps and fuel pump gear pump top mount fuel PowerGen QSX15 lines CM2250 ISX15 CM2250 SN PowerGen QSX15 Three cylinder, two CM2250 ECF piston fuel pumps QSX15 CM2250 Fuel pump gear pump with bottom mount fuel lines There is a cost effective option to use a fuel pump short block service kit. Reference TSB150033. Reference TSB110064. New fuel lines are required. Reference TSB130044. https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair ISX15 CM2350 X101 QSX15 CM2350 X105 Page 6 of 11 None There is a cost effective option to use a fuel pump short block service kit. Reference TSB150033. If fuel pump head assembly, Part Number 4307004, does not meet reuse guidelines; replace. None None QSX15 CM2350 X106 ISX12 CM2350 X102 ISX12/ISX11.9 CM2250 QSX11.9 CM2250 ECF Table 3, Associated Procedures Procedure Title Procedure Number Service Model Name Bulletin Number Fuel Pump Refer to Procedure 005-016 ISX15 CM2250 4022250 Fuel Pump Refer to Procedure 005-016 ISX15 CM2250 SN 4310736 Fuel Pump Refer to Procedure 005-016 ISX12/ISX11.9 CM2250 2883445 Fuel Pump Refer to Procedure 005-016 ISX15 CM2350 X101 4310641 Fuel Pump Refer to Procedure 005-016 QSX15 CM2250 ECF 2883557 Fuel Pump Refer to Procedure 005-016 QSX11.9 CM2250 ECF 2883561 Fuel Pump Refer to Procedure 005-016 QSX15 CM2350 X105 4332667 Fuel Pump Refer to Procedure 005-016 QSX15 CM2350 X106 4332712 Fuel Pump Head Refer to Procedure 005-227 ISX15 CM2250 4022250 Fuel Pump Refer to Procedure 005-227 ISX15 CM2250 SN 4310736 Fuel Pump Head Refer to Procedure 005-227 ISX12/ISX11.9 CM2250 2883445 https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 7 of 11 Fuel Pump Head Refer to Procedure 005-227 ISX15 CM2350 X101 4310641 Fuel Pump Head Refer to Procedure 005-227 QSX15 CM2250 ECF 2883557 QSX11.9 CM2250 ECF 2883561 Fuel Pump Head Refer to Procedure 005-227 Fuel Pump Head Refer to Procedure 005-227 QSX15 CM2350 X105 4332667 Fuel Pump Head Refer to Procedure 005-227 QSX15 CM2350 X106 4332712 Lubricating Oil Cooler Refer to Procedure 007-003 ISX15 CM2250 4022250 Lubricating Oil Cooler Refer to Procedure 007-003 ISX15 CM2250 SN 4310736 Lubricating Oil Cooler Refer to Procedure 007-003 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Cooler Refer to Procedure 007-003 ISX15 CM2350 X101 4310641 Lubricating Oil Cooler Refer to Procedure 007-003 QSX15 CM2250 ECF 2883557 Lubricating Oil Cooler Refer to Procedure 007-003 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Cooler Refer to Procedure 007-003 QSX15 CM2350 X105 4332667 Lubricating Oil Cooler Refer to Procedure 007-003 QSX15 CM2350 X106 4332712 Lubricating Oil Cooler Element Refer to Procedure 007-007 ISX15 CM2250 4022250 Lubricating Oil Cooler Element Refer to Procedure 007-007 ISX15 CM2250 SN 4310736 Lubricating Oil Cooler Element Refer to Procedure 007-007 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Cooler Element Refer to Procedure 007-007 ISX15 CM2350 X101 4310641 Lubricating Oil Cooler Element Refer to Procedure 007-007 QSX15 CM2250 ECF 2883557 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Cooler Element Refer to Procedure 007-007 https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 8 of 11 Lubricating Oil Cooler Element Refer to Procedure 007-007 QSX15 CM2350 X105 4332667 Lubricating Oil Cooler Element Refer to Procedure 007-007 QSX15 CM2350 X106 4332712 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX15 CM2250 4022250 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX15 CM2250 SN 4310736 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX15 CM2350 X101 4310641 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 QSX15 CM2250 ECF 2883557 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 QSX15 CM2350 X105 4332667 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 QSX15 CM2350 X106 4332712 Lubricating Oil System Refer to Procedure 007-037 ISX15 CM2250 4022250 Lubricating Oil System Refer to Procedure 007-037 ISX15 CM2250 SN 4310736 Lubricating Oil System Refer to Procedure 007-037 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil System Refer to Procedure 007-037 ISX15 CM2350 X101 4310641 Lubricating Oil System Refer to Procedure 007-037 QSX15 CM2250 ECF 2883557 Lubricating Oil System Refer to Procedure 007-037 QSX11.9 CM2250 ECF 2883561 Lubricating Oil System Refer to Procedure 007-037 QSX15 CM2350 X105 4332667 Lubricating Oil System Refer to Procedure 007-037 QSX15 CM2350 X106 4332712 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 ISX15 CM2250 4022250 https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 9 of 11 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 ISX15 CM2250 SN 4310736 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 ISX15 CM2350 X101 4310641 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 QSX15 CM2250 ECF 2883557 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 QSX15 CM2350 X105 4332667 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 QSX15 CM2350 X106 4332712 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 ISX15 CM2250 4022250 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 ISX15 CM2250 SN 4310736 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 ISX15 CM2350 X101 4310641 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 QSX15 CM2250 ECF 2883557 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 QSX11.9 CM2250 ECF 2883561 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 QSX15 CM2350 X105 4332667 Lubricating Oil and Filter Analysis Refer to Procedure 007-083 QSX15 CM2350 X106 4332712 Lubricating Oil Thermostat Refer to Procedure 007-039 ISX15 CM2250 4022250 Lubricating Oil Thermostat Refer to Procedure 007-039 ISX15 CM2250 SN 4310736 Lubricating Oil Thermostat Refer to Procedure 007-039 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Thermostat Refer to Procedure 007-039 ISX15 CM2350 X101 4310641 https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair Page 10 of 11 Lubricating Oil Thermostat Refer to Procedure 007-039 QSX15 CM2250 ECF 2883557 Lubricating Oil Thermostat Refer to Procedure 007-039 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Thermostat Refer to Procedure 007-039 QSX15 CM2350 X105 4332667 Lubricating Oil Thermostat Refer to Procedure 007-039 QSX15 CM2350 X106 4332712 Aftertreatment Testing Refer to Procedure 014-013 ISX15 CM2250 4022250 Aftertreatment Testing Refer to Procedure 014-013 ISX12/ISX11.9 CM2250 2883445 Aftertreatment Testing Refer to Procedure 014-013 QSX15 CM2250 ECF 2883557 Aftertreatment Testing Refer to Procedure 014-013 QSX11.9 CM2250 ECF 2883561 Main Bearings Refer to Procedure 001-006 ISX15 CM2250 4022250 Main Bearings Refer to Procedure 001-006 ISX15 CM2250 SN 4310736 Main Bearings Refer to Procedure 001-006 ISX12/ISX11.9 CM2250 2883445 Main Bearings Refer to Procedure 001-006 ISX15 CM2350 X101 4310641 Main Bearings Refer to Procedure 001-006 QSX15 CM2250 ECF 2883557 Main Bearings Refer to Procedure 001-006 QSX11.9 CM2250 ECF 2883561 Main Bearings Refer to Procedure 001-006 QSX15 CM2350 X105 4332667 Main Bearings Refer to Procedure 001-006 QSX15 CM2350 X106 4332712 Document History Date 2014-2-14 2014-9-4 2014-10-24 Details Module Created none Fixed broken link. https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016 Fuel Pump - Plunger and Tappet Roller Inspection and Repair 2014-10-29 2015-1-7 2015-3-17 2015-10-19 2016-4-5 2016-7-5 Page 11 of 11 Typo corrected. Procedure steps updated. Added the fuel pump short block service kit TSB reference. Modified the fuel pump tappet rollers are damaged section step 1 and options a, b, and c. Modified title. Added Product Affected section. Updated repair direction and Table 3. Removed "Ceramic" from title. Modified Table 2. Last Modified: 06-Jul-2016 Copyright © 2000-2010 Cummins Inc. All rights reserved. https://qsol.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 8/1/2016