¢ | Technical Service Bulletin

Technical Service Bulletin: TSB200182 l Released Date: 25-Aug-2023
Water In the Fuel System and Corrosion on Fuel System Components

Water In the Fuel System and Corrosion on Fuel System
Components

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

The defects outlined in this bulletin are not material or factory workmanship related.
Repairs related to the issues outlined below are not warrantable and should not be submitted under warranty.

Beginning in May, 2022, Cummins Inc. Warranty Quality will begin flagging a limited number of claims in order
to incorporate component analysis into the claim adjudication decision. The component analysis will be related
to certain parts returned as part of the EPR (Enhanced Part Return) process, that are used for failure analysis
today. The intention of the changes is to leverage failure analysis to improve service information such as
diagnostic content and repair procedures, as well as for identifying improvement opportunities related to repair
practices.

If the analysis result supports the failure and replacement of the component, claims will be processed as they
are today, within Cummins Warranty Quality guidelines. If the analysis concludes that the component was
replaced contradictory to published service information or due to not being a defect in Cummins material or
factory workmanship, or if the return shipment of the part is delayed, the claim may be subject to adjustment or
denial.

Product Affected

¢ B4.5 CM2350 B129B
¢ B4.5 CM2350 B146C.
¢ B4.5 CM2350 B147B
¢ B6.7 CM2350 B121B
¢ B6.7 CM2350 B135B
¢ B6.7 CM2350 B136C
¢ B6.7 CM2350 B141B
¢ B6.7 CM2350 B148B
¢ B6.7 CM2350 B157C
¢ B6.7 CM2350 B179B
¢ B6.7 CM2450 B155B
¢ B6.7 CM2670 B167B
¢ ISB/ISD6.7 CM2150 B120

ISB/ISD6.7 CM2150 SN
ISB6.7 CM2150 SQ
ISB6.7 CM2250

ISB6.7 CM2350 B103
ISF2.8 CM2220

ISF2.8 CM2220 AN
ISF2.8 CM2220 ECCF2
ISF2.8 CM2220 ECF2
ISF2,.8 CM2220 F101
ISF2.8 CM2220 F122
ISF2.8 CM2220 F129
ISF2.8 CM2220 IAN
QSB4.5 CM2350 B106
QSB4.5 CM2350 B122
QSB6.7 CM2150 B109
QSB6.7 CM2250 B128
QSB6.7 CM2250 EC
QSB6.7 CM2350 B105
QSB6.7 CM2350 B112
QSB6.7 CM2350 B130
QSB6.7 CM850(CM2850)
QSB7 CM2880 B117
QSF2.8 CM2880 F104
QSF2.8 CM2880 F105
QSF2.8 CM2880 F108
QSF2.8 CM2880 F114

Issue

Water in the fuel systems will cause corrosion on fuel system components. This document outlines ways to
identify corrosion on fuel system components and detect water in the fuel.

Symptom:

¢ Corrosion on fuel system components
e Any of the fault codes found in Table 1 below

Table 1, Fault Codes Related to Fuel System Corrosion

Fault Code Fault Code Description

322 Injector Solenoid Driver Cylinder 1 Circuit - Current
Below Normal or Open Circuit

323 Injector Solenoid Driver Cylinder 5 Circuit - Current
Below Normal or Open Circuit

324 Injector Solenoid Driver Cylinder 3 Circuit - Current
Below Normal or Open Circuit

325 Injector Solenoid Driver Cylinder 6 Circuit - Current
Below Normal or Open Circuit

331 Injector Solenoid Driver Cylinder 2 Circuit - Current

Below Normal or Open Circuit

Table 1, Fault Codes Related to Fuel System Corrosion

Fault Code Fault Code Description

332 Injector Solenoid Driver Cylinder 4 Circuit - Current
Below Normal or Open Circuit
Injector Metering Rail 1 Pressure - Data Valid But

559 Below Normal Operating Range - Moderately Severe
Level

11439 Injector Solenoid Driver Cylinder 1 - Mechanical
System Not Responding or Out of Adjustment

1141 Injector Solenoid Driver Cylinder 2 - Mechanical
System Not Responding or Out of Adjustment

4142 Injector Solenoid Driver Cylinder 3 - Mechanical
System Not Responding or Out of Adjustment

1143 Injector Solenoid Driver Cylinder 4 - Mechanical
System Not Responding or Out of Adjustment

1144 Injector Solenoid Driver Cylinder 5 - Mechanical
System Not Responding or Out of Adjustment

1145 Injector Solenoid Driver Cylinder 6 - Mechanical
System Not Responding or Out of Adjustment

1654 Engine Misfire Cylinder 1 - Condition Exists

1655 Engine Misfire Cylinder 2 - Condition Exists

1656 Engine Misfire Cylinder 3 - Condition Exists

1657 Engine Misfire Cylinder 4 - Condition Exists

1658 Engine Misfire Cylinder 5 - Condition Exists

1659 Engine Misfire Cylinder 6 - Condition Exists

1718 Engine Misfire for Multiple Cylinders - Condition
Exists
Engine Injector Metering Rail 1 Cranking Pressure -

4691 Data Valid But Below Normal Operating Range -
Moderately Severe Level

4713 Engine Fuel Injection Quantity Error for Multiple
Cylinders - Condition Exists - Amber

5895 Engine Misfire Cylinder #1 - Root Cause Not Known

5896 Engine Misfire Cylinder #2 - Root Cause Not Known

5897 Engine Misfire Cylinder #3- Root Cause Not Known

5898 Engine Misfire Cylinder #4 - Root Cause Not Known

5899 Engine Misfire Cylinder #5 - Root Cause Not Known

5911 Engine Misfire Cylinder #6 - Root Cause Not Known
Water in Fuel Indicator - Data Valid But Above

1852 Normal Operating Range - Moderately Severe Level

- Amber

Table 1, Fault Codes Related to Fuel System Corrosion

Fault Code Fault Code Description

5914 Engine Misfire for Multiple Cylinders - Root Cause
Not Known

Root Cause

¢ Water in the fuel system causes damage to the fuel system.
Verification and Resolution

¢ Inspect fuel system components for corrosion.

a. Only if directed by published troubleshooting to remove the specific parts listed below, check parts
listed below for corrosion. Do not remove parts outside of those directed by published
troubleshooting.

b. Parts to inspect for corrosion if directed to remove according to published troubleshooting:

i. Injector fuel supply connector (For example of corrosion, see Figure 2 below)
ii. Fuel pump electronic fuel control actuator (For example of corrosion, see Figure 4 below)
iii. Fuel rail pressure relief valve (For example of corrosion, see Figure 6 below
iv. KUEV (piston overflow) valve. (For example of corrosion, see Figures 12 and 13 below)
¢ Only If corrosion is found on any of the components listed above, proceed to inspect the fuel tank and see
Service Bulletin, Water in Fuel Contamination, Bulletin 5659823 (/qs3/pubsys2/xml/en/bulletin/Examples of
Water in Fuel.html) for restoring the fuel system.
¢ Sample the fuel and inspect for signs of water in the fuel tank.

a. Sample fuel from the lowest point of the fuel tank.

b. Siphon fuel or use fuel tank drain plug and drain fuel into a clear container.

c. Let the fuel sit for 5 minutes.

¢ Check fuel sample for signs of water in the clear container.

a. If free-standing water is found in the bottom of the clear container (See Figure 7 below), see Service
Bulletin, Water in Fuel Contamination, Bulletin 5659823 (/qs3/pubsys2/xml/en/bulletin/5659823. html)
for repair.

b. If no free-standing water is found at the bottom of the container:

i. Print fuel bar chart. Select hyperlink below for fuel bar chart.

Note :
https://quickserve.cummins.com/protected/files/qsol/cms/distillate_fuel_bar_chart.pdf
(https://quickserve.cummins.com/protected/files/qsol/cms/distillate_fuel_bar_chart.pdf)

ii, Place fuel bar chart behind the fuel sample and compare with examples in Figure 8-10.

ili. If Line 1 on fuel bar chart is not visible while looking through fuel sample, see Service Bulletin,
Water in Fuel Contamination, Bulletin 5659823 (/qs3/pubsys2/xml/en/bulletin/5659823.html) for
restoring the fuel system.

Examples of Corrosion:

Signs of corrosion can be seen in the fuel pump electronic fuel control actuator, fuel rail pressure relief valve,
and the injector fuel supply connector. See Figures below for examples.

Figure 1, Normal and Acceptable Corrosion on Injector Connector Above Oring.

Figure 2, Abnormal and Unacceptable Corrosion on Injector Connector Below Oring.

Figure 3, Clean and Acceptable Fuel pump Electronic Fuel Control Actuator.

Figure 4, Corroded and Unacceptable Fuel pump Electronic Fuel Control Actuator.

Figure 5, Clean and Acceptable Fuel Rail Pressure Relief Valve Corrosion.

Figure 6, Corroded and Unacceptable Fuel Rail Pressure Relief Valve Corrosion.

Examples of Water in Fuel

(05r00217

Figure 7, Free Standing Water in Diesel Fuel.

Figure 8, 0 ml of Water Added to Diesel Fuel.

Figure 9, 1 ml [ .0 fl-oz ] Water Added to Diesel Fuel.

Figure 10, 3 ml[ .10 fl-oz ] Water Added to Diesel Fuel.

Figure 11, 5 ml[ .17 fl-oz ] Water Added to Diesel Fuel.

05r00350

Figure 12, Example of Corrosion in KUEV Valve.