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.

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Fuel Pump - Plunger and Tappet Roller Inspection and Repair

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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.

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 007083 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.

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Table 1, Repair Direction Decision Matrix
Symptoms

• Non-wear debris or particles are evident in the
lubricating oil filter element.
• Fault Codes 415 or 143 are logged in the
engine control module (ECM) within the last 8
hours of engine operation.
• Engine is seized, or engine rotating assembly
produces abnormal noise.

Are Any
Symptoms
Present?

Repair
Direction to
Follow

Yes

Repair Direction
A

No

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.
2.
3.
4.

Drain lubricating engine oil. See Procedure 007-037 in Table 3.
Remove lubricating oil pan, and clean thoroughly. See procedure 007-025 in Table 3.
Remove and inspect lubricating oil pump for reuse. See Procedure 007-031 in Table 3.
Remove number 1 and number 4 main bearing caps and main bearings. See
procedure 001-006 in Table 3.
5. Inspect number 1 and number 4 main journals of crankshaft for reuse. See Service
Bulletin Crankshaft Reuse Guidelines for Cummins® Engines, Bulletin 5411180.
◦ If crankshaft meets reuse guidelines:
◾ Inspect number 1 and number 4 main bearings for signs of significant
debris embedding. If significant debris is found, remove number 1 and
number 4 connecting rod bearings for inspection.
◾ If damage is observed on number 1 and number 4 connecting rod bearings,
roll new connecting rod bearings in on all six journals. See Procedure 001006, 001-007, and 001-014 in Table 3.

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Fuel Pump - Plunger and Tappet Roller Inspection and Repair

6.
7.
8.

9.
10.
11.
12.
13.

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◾ Roll new main bearings in on all seven main journals and install new thrust
bearings on number 4 main journal.
◦ If crankshaft does not meet reuse guidelines:
◾ Dealers should contact RAPIDSERVE™ Catastrophic group for preauthorization if engine is under warranty.
◾ Cummins® Distributors should follow their local catastrophic process or
contact RAPIDSERVE™ for repair direction if engine is under warranty.
Replace fuel pump. Table 2 below must be referenced for specific instruction by
product type. See Procedure 005-016 in Table 3 below.
Thoroughly clean lubricating oil cooler housing. See Procedure 007-003 in Table 3.
Replace 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.
Install 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 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 is not required. 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
There is a cost effective option to use a fuel
and fuel pump gear
pump short block service kit. Reference
pump top mount fuel
TSB150033.
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

Reference TSB110064.
New fuel lines are required. Reference
TSB130044.

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Table 2, Fuel Pump Replacement Matrix
Product

Fuel Pump
Variation

Additional Action Needed When Replacing
the Fuel Pump

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

ISX15 CM2350
X101
QSX15 CM2350
X105
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

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Fuel Pump - Plunger and Tappet Roller Inspection and Repair

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Table 3, Associated Procedures
Procedure Title

Procedure Number

Fuel Pump Head

Refer to Procedure
005-227

Service Model
Name
ISX12/ISX11.9
CM2250

Fuel Pump Head

Refer to Procedure
005-227