NHTSA ID Number: 10085333
Manufacturer Communication Number: TSB140019-070516
TSB/Document Date: 2016-12-01
Summary
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 LEVEL OF PROGRESSIVE DAMAGE TO THE FUEL PUMP AND OTHER ENGINE COMPONENTS WILL VARY WITH 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. THIS IS AN UPDATE TO A PREVIOUSLY SUBMITTED COMMUNICATION.
Fuel Pump - Plunger and Tappet Roller Inspection and Repair
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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
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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.
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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
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Fuel Pump - Plunger and Tappet Roller Inspection and Repair
Symptoms
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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
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Fuel Pump - Plunger and Tappet Roller Inspection and Repair
9.
10.
11.
12.
13.
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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.
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ISX15 CM2350
X101
QSX15 CM2350
X105
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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
Refer to Procedure
005-016
ISX15 CM2250
4022250
Refer to Procedure
005-016
ISX15 CM2250 SN
4310736
Refer to Procedure
005-016
ISX12/ISX11.9
CM2250
2883445
Refer to Procedure
005-016
ISX15 CM2350 X101 4310641
Refer to Procedure
005-016
QSX15 CM2250
ECF
2883557
Refer to Procedure
005-016
QSX11.9 CM2250
ECF
2883561
Refer to Procedure
005-016
QSX15 CM2350
X105
4332667
Refer to Procedure
005-016
QSX15 CM2350
X106
4332712
Fuel Pump Head
Refer to Procedure
005-227
ISX15 CM2250
4022250
Refer to Procedure
005-227
ISX15 CM2250 SN
4310736
Fuel Pump Head
Refer to Procedure
005-227
ISX12/ISX11.9
CM2250
2883445
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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
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Fuel Pump - Plunger and Tappet Roller Inspection and Repair
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TSB/Document ID: TSB140019-070516
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
MFR Component System:
MFR Component Subsystem:
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