NHTSA ID Number: 10231919
Manufacturer Communication Number: TSB220228
TSB/Document Date: 2023-02-21
Summary
This Technical Service Bulletin describes customer complaint of no start. This is due to contaminants in the fuel system clogging the injector which causes no fuel to enter the cylinder and preventing the generator from starting.
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HDZAA Injection Pump (UCV) Contamination Issue
Technical Service Bulletin
Technical Service Bulletin: TSB220228
Released Date: 19-Jan-2023
HDZAA Injection Pump (UCV) Contamination Issue
HDZAA Injection Pump (UCV) Contamination Issue
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
HDZAA Spec F
Issue
Symptom:
Customer complaint of no start.
Root Cause:
Contaminants in the fuel system clogging the injector, causing no fuel to enter the cylinder,
and preventing the generator from starting.
Verification/Confirmation
1. Make sure there is proper fuel flow from the low-pressure fuel pump to UCV.
2. Using UCV signal checking tool (included in tool rental kit from Cummins
field service
engineer (CFSE)) make sure the proper PWM signal to UCV is present.
3. If there is sufficient fuel supply, correct PWM signal at the UCV terminals, and the unit cranks
but does not start, proceed to the resolution section below.
Resolution
Call 1800-Cummins (1-800-286-6467) to escalate issue to CFSE and coordinate repair. An HDS-II
tool is required to perform the repair and will need to be sent to the repair site to complete a
dataset update on unit and is subject to tool availability. See Service Parts availability to order
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replacement UCV (injection pump) PN A072F011
Please see service instructions for repair, manual number A066T114
Service Instructions
Note: After replacing the UCV, the ECM will need to be updated and matched to the new UCV
using the Hatz HDS2 tool.
Make sure new dataset is available on the Hatz server prior to beginning repair by connecting the
unit to a laptop with the HDS2 software installed.
Note: The HDS2 software updates upon computer restart, so restart the computer to see most
recent dataset for the specific serial number. (The update can take a while if it hasn’t been
restarted recently)
Removal
1. Drain the oil.
2. Remove all enclosure panels
3. Pull off the brace on muffler side
Figure 1, Muffler location
4. Remove muffler
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5. Remove insulating panel
Figure 2, Removing the insulation panel
6. Remove air box (do not damage or lose gasket stack)
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Figure 3, Removal of Air box
Figure 4, Gaskets
7. Remove valve cover
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Note: Put rag below to catch oil seepage.
Note: Do not damage valve cover gasket.
Figure 5, Rocker cover
8. Carefully remove gasket (Part number A045W752)
9. Remove return line from top of the injector
10. Remove zip ties from hardline
11. Remove hard line and return line from UCV
12. Remove Banjo supply line and signal wires from the UCV
13. Remove UCV pump
Note: Put rag below to catch oil seepage.
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Figure 6, Removal of container clip
14. Remove the retaining clip securing the injector and remove the injector and hardline assembly
Figure 7, Injector removed
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Note: Make sure the copper sealing washer is removed before installing the new one with the
UCV kit.
Install
1. Install new UCV pump by evenly thread in mounting bolts.
2. Crimp return line on UCV before installing Injector hardline.
Figure 8, New UCV installed
3. Install new injector and hardline assembly
Note: leave new injector installed on hardline during assembly to keep injector clean.
4. Reinstalled return line and clamp on injector
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Figure 9, Installed hardlines
5. Install hardline on UCV
6. Connect UCV signal terminals
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Figure 10, UCV signal terminals
7. Zip tie return line to hard line under cylinder head
8. Install zip tie around UCV signal wires
9. Reinstall the valve cover
10. Install the air box and all associated gaskets.
Note: Make sure the breather hose is reinstalled
11. Install air filter
12. Install air box cover with fan hose
13. Reinstall insulating panel
14. Reinstall muffler
15. Refill the oil.
Dataset Update
Restart computer to update Hatz tool once dataset for serial number has been updated by Hatz
To complete a dataset update on the HDZAA, a HDS2 tool (Figure 11, #1), pigtail harness (Figure
11, #3) and laptop software is required (Connect at #2). Your local CFSE has access to this Hatz
engine tool and software. These tools can be ordered directly from Hatz (Kit Part Number
65545310).
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Figure 11, Pigtail harness
1. Use pigtail wiring harness (#3 from Figure 11) to connect the generator set to the HDS2 tool (#1
from Figure 11).
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Figure 12, Pig Tail Connection
2. Connect the USB end of the HDS2 cable to a laptop (#2 from Figure 12) with the HDS software
installed (available on Cummins Software Shelf).
3. Generator display will need to be powered on after cable is connected to laptop but before
software is opened.
4. Once the software has loaded, a screen with the engine identification will show.
5. Locate the “Dataset Description” in the Identification tab
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Figure 13, Dataset Version Confirmation
6. To update the ECM, go to the “Data set” tab on the left, this screen will show the latest ECM
dataset above the table in the “Flash file” box (green box). Make sure the values under ECU and
Server do not match. If the values match reboot computer.
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Figure 13, Dataset
7. Click “Write dataset” to update the ECM dataset.
8. The remote display will go to sleep you have to cycle the red button to wake the screen. If the
screen is asleep to long the calibration will fail.
9. The screen will now change to show the transfer progress. It will display ‘100’ and “The coding
was executed successfully” when it is done.
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Figure 14, Dataset Update Complete
10. Return to the “Data set” tab to verify the ECM was updated. The Values under ECU and
Server should now match.
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Figure 15, Dataset Update Confirmation
11. The ECM update is now complete.
12. Bench test the unit to make sure functionality
Service Parts Availability
Service parts are available. See Table 1 for part numbers.
Table 1, Service Parts
Part Description
Part Number
UCV (injection pump)
PN A072F011
Document History
Date
Details
2022-11-10
Module Created
2023-1-11
Non-Product Problem Solving (PPS)
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Last Modified: 19-Jan-2023
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TSB/Document ID: TSB220228
Replacement Service Bulletin Number:
MFR Communication Date: 2023-01-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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