TSB150038-031715
Service Bulletin Details
Public Details for: TSB150038-031715
This technical service bulletin describes the proper troubleshooting and repair steps for egr cooler leaks. This is address egr coolers that are erroneously replaced due to signs of moisture in the egr cooler or egr crossover tube and hard
- 9999 -
Models from 9999
9999 CUMMINS ISXL G |
9999 CUMMINS WESTPORT ISX12 G |
Improper Exhaust Gas Recirculation (EGR) Cooler Replacement with No Failure Found Page 1 of 2 Technical Service Bulletin Number TSB150038 Technical Service Bulletin Subject Improper Exhaust Gas Recirculation (EGR) Cooler Replacement with No Failure Found Issue Exhaust Gas Recirculation (EGR) coolers returned to the factory, stated to be failed because of internal coolant leaks, were tested and found to be within specification. The EGR coolers tested by the factory were found to have acceptable measured pressure loss and no continuous formation of bubbles near the gas tubes or bulkhead while performing the EGR cooler pressure test found in Procedure 011-019 in the ISX12 G CM2180 EJ Service Manual. The EGR coolers, incorrectly stated to be failed because of internal coolant leaks, were replaced for the following reason(s): Signs of moisture in the EGR cooler Signs of moisture in the EGR crossover tube Hard to diagnose low coolant level fault codes Verification Product Affected: ISX12 G CM2180 EJ The EGR cooler pressure test must be performed to determine if the EGR cooler is leaking coolant. Moisture in the EGR crossover tube or EGR cooler may be water condensation and is not adequate evidence that the EGR cooler is leaking. Use the following procedure in the https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2015/tsb150038.html 4/1/2015 Improper Exhaust Gas Recirculation (EGR) Cooler Replacement with No Failure Found Page 2 of 2 ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 011-019 in section 11. Resolution The EGR cooler should only be replaced for the following reason(s): EGR cooler does not pass the EGR cooler pressure test EGR cooler does not meet the reuse guidelines defined in the clean and inspect for reuse section of Procedure 011-019 in section 11 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. Document History Date 2015-3-18 2015-3-20 Details Module Created none Last Modified: 20-Mar-2015 Copyright © 2000-2010 Cummins Inc. All rights reserved. https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2015/tsb150038.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 1 of 7 Technical Service Bulletin Number TSB140019 Technical Service Bulletin Subject ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fuel Pump - Ceramic 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 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 ISX12/ISX11.9 CM2250 2883445 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 Head Refer to Procedure 005-227 ISX15 CM2250 4022250 Refer to Procedure ISX12/ISX11.9 Fuel Pump Head https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 2883445 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 2 of 7 005-227 CM2250 Fuel Pump Head Refer to Procedure 005-227 QSX15 CM2250 ECF 2883557 Fuel Pump Head Refer to Procedure 005-227 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Cooler Refer to Procedure 007-003 ISX15 CM2250 4022250 Lubricating Oil Cooler Refer to Procedure 007-003 ISX12/ISX11.9 CM2250 2883445 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 Element Refer to Procedure 007-007 ISX15 CM2250 4022250 Lubricating Oil Cooler Element Refer to Procedure 007-007 ISX12/ISX11.9 CM2250 2883445 Lubricating Oil Cooler Element Refer to Procedure 007-007 QSX15 CM2250 ECF 2883557 Lubricating Oil Cooler Element Refer to Procedure 007-007 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX15 CM2250 4022250 Lubricating Oil Filter (SpinOn) Refer to Procedure 007-013 ISX12/ISX11.9 CM2250 2883445 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 Bypass Valve Refer to Procedure 007-014 ISX15 CM2250 4022250 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 QSX15 CM2250 ECF 2883557 Lubricating Oil Filter Bypass Valve Refer to Procedure 007-014 QSX11.9 CM2250 ECF 2883561 Lubricating Oil Thermostat Refer to Procedure ISX15 CM2250 4022250 https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 3 of 7 007-039 Lubricating Oil Thermostat Refer to Procedure 007-039 ISX12/ISX11.9 CM2250 2883445 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 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 This document, in conjunction with the information provided within the manuals listed in the table above, provides the inspection and repair practice when ceramic plungers are found to be fractured (see Figure 1) and/or tappet roller damage is found on fuel pumps with ceramic plungers (see Figure 2). Ceramic plungers can be identified by their white color. See Procedure 005-227 in the Associated Procedures Table for removal of the fuel pump head. https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 4 of 7 Figure 1: Fractured Fuel Pump Ceramic Pumping Plunger https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 5 of 7 Figure 2: Fuel Pump Tappet Roller Assemblies If the ceramic plungers are fractured (see Figure 1), but no damage is found on the fuel pump tappet rollers (see Figure 2), no further inspection is needed. Perform the following steps for the appropriate engine (ISX15 CM2250, QSX15 CM2250 ECF, ISX12/ISX11.9 CM2250, or QSX11.9 CM2250 ECF): 1. Replace the fuel pump. See Procedure 005-016 in the Associated Procedures Table. a. For ISX15 CM2250 or QSX15 CM2250 ECF: Refer to TSB110064 (New TwoCylinder High-Pressure Fuel Pump Assembly) if replacing a three-cylinder twopiston pump with a two-cylinder pump. b. For ISX15 CM2250 or QSX15 CM2250 ECF: New fuel lines are required if replacing a fuel pump gear pump with bottom mount fuel lines. See Technical Service Bulletin, New Fuel Pump Gear Pump with Revised Fuel Line Locations, TSB130044. 2. Change the engine lubricating oil and lubricating oil filter. See Procedure 007-013 in the Associated Procedures Table. If the fuel pump tappet rollers are damaged (see Figure 2), perform the following steps for the appropriate engine (ISX15 CM2250, QSX15 CM2250 ECF, ISX12/ISX11.9 CM2250, or QSX11.9 CM2250 ECF): https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 6 of 7 1. Replace the fuel pump. See Procedure 005-016 in the Associated Procedures Table. a. For ISX15 CM2250 or QSX15 CM2250 ECF: See Technical Service Bulletin, New Two-Cylinder High-Pressure Fuel Pump Assembly, TSB110064, if replacing a three-cylinder two-piston pump with a two-cylinder pump. b. For ISX15 CM2250 or QSX15 CM2250 ECF: New fuel lines are required if replacing a fuel pump gear pump with bottom mount fuel lines. See Technical Service Bulletin, New Fuel Pump Gear Pump with Revised Fuel Line Locations, TSB130044. c. For ISX15 CM2250 engines not covered by warranty, there is an option to use a fuel pump short block service kit. See Technical Service Bulletin, New Fuel Pump Short Block Service Kit, TSB150033. 2. Drain the engine lubricating oil and remove the lubricating oil filter. See Procedure 007013 in the Associated Procedures Table. 3. Thoroughly clean the oil cooler housing. See Procedure 007-003 in the Associated Procedures Table. 4. Replace the lubricating oil cooler element. See Procedure 007-007 in the Associated Procedures Table. 5. Replace the oil filter bypass valve. See Procedure 007-014 in the Associated Procedures Table. 6. Replace the lubricating oil thermostat. See Procedure 007-039 in the Associated Procedures Table. 7. Install a new lubricating oil filter. See Procedure 007-013 in the Associated Procedures Table. 8. Fill the engine with new lubricating oil. 9. Perform an aftertreatment diesel particulate filter regeneration. See Procedure 014-013 in the Associated Procedures Table. 10. Perform a second lubricating oil and lubricating oil filter change. See Procedure 007-013 in the Associated Procedures Table. 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. Document History https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015 ISX15 CM2250, QSX15 CM2250 ECF, ISX12 CM2250, and QSX11.9 CM2250 ECF Fu... Page 7 of 7 Date 2014-2-14 2014-9-4 2014-10-24 2014-10-29 2015-1-7 2015-3-17 Details Module Created none Broken link typo Procedure steps need updated Added the fuel pump short block service kit TSB reference Last Modified: 19-Mar-2015 Copyright © 2000-2010 Cummins Inc. All rights reserved. https://qsol2.cummins.com/qs3/pubsys2/xml/en/tsb/2014/tsb140019.html 4/1/2015