201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

TechnicalServiceBulletinNumber
TSB150104

TechnicalServiceBulletin

Subject
HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFault
Code559

WarrantyStatement
Theinformationinthisdocumentauthorizesspecificchangestotherepairpracticeforfailures
coveredunderproductwarrantycoverages.

Contents
ProductAffected

ISL9CM2350L101
ISL9CM2350L111
ISX12CM2350X102
ISX15CM2250SN
ISX15CM2250
ISX15CM2350X101
PowerGenQSX15CM2250ECF
QSL9CM2350L102
QSL9CM2350L118
QSX15CM2250ECF
QSX15CM2350X105
QSX15CM2350X106

DescriptionofChange

ThisdocumentannouncestheHighPressureFuelPumpPerformanceTest,whichisanimproved
procedureforhighpressurefuelpumpdiagnosticswhentroubleshootingFaultCode559.

TheHighPressureFuelPumpPerformanceTestwill:

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

ReplacetheHighPressureFuelPumpReturnFlowTestintheFaultCode559troubleshooting
tree.
Testboththefuelvolumeandfuelpressurecapabilitiesofthehighpressurefuelpumpatthe
sametime.

ServiceToolAvailability

CompletionofHighPressureFuelPumpPerformanceTestrequiresthenewfuelpumpperformance
testkit.SeeTable1belowforpartsnumbers.

ContactyourlocalCumminsDistributorwithquestions.

Table1,FuelPumpPerformanceTestKits
Product KitPartNumber PartKitDetailDescription PartNumber
Tester,FuelPump(Figure1,Item1) 5299753
ISX15/QSX15 5299721
Hose,LeakTest(Figure1,Item2) 3164673
Tester,FuelPump(Figure1,Item1) 5299754
ISX12andISL9/QSL9 5299726
Hose,LeakTest(Figure1,Item2) 3164673

Figure1,FuelPumpPerformanceTestKit.

CAUTION
Whennotinuse,thefuelpumpperformancetestservicetoolmustbestoredinaclean
environment.Donotdisassemblethefuelpumpperformancetestservicetoolasitcanbe
damagedbydirtordebris.
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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

ServiceInstructions

AvideoofthefollowingserviceprocedureislocatedonQuickServeOnline.Seethevideolink
below.

NOTE:http://tsb.cumminsvirtualcollege.com/tsb150104.aspx

0:00

Ifashoppossessesthenewfuelpumpperformancetestservicetool,referencetheserviceprocedure
belowforinstructionsonhowtocompletetheHighPressureFuelPumpPerformanceTest.

HighPressureFuelPumpPerformanceTest

InitialSetup

Ifthelowpressurefuelsystemisdegradedorthefuelpressurereliefvalveleakageisoutof
specification,thisHighPressureFuelPumpPerformanceTestwillnotprovideaccurateresults.

Troubleshootthelowpressurefuelsystemandanyhighpressurefuelsystemleakagebefore
performingHighPressureFuelPumpPerformanceTest.

PreparatorySteps

WARNING

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

Normalengineoperationcreateshighlypressurizedfuelinthefuellinewhichwillremaininthefuel
lineafterengineshutdown.Neveropenthefuelsystemwhentheengineisoperating.Before
servicingthefuelsystem,alwaysloosenthepumptorailfuellineattherailtoventthepressure.
Keephandsclearofthelinewhenloosening.Highpressurefuelspraycanpenetratetheskin,
resultinginseriouspersonalinjuryordeath.

WARNING
Highpressurefuelspraycancauseseriousinjuryordeath.

WARNING
Dependingonthecircumstance,dieselfuelisflammable.Wheninspectingorperformingserviceor
repairsonthefuelsystem,toreducethepossibilityoffireandresultingseverepersonalinjury,
death,orpropertydamage,neversmokeorallowsparksorflames(suchaspilotlights,electrical
switches,orweldingequipment)intheworkarea.

Beforeservicingthehighpressurefuelsystem,loosenthepumptoraillineattherailtoventthefuel
pressure.SeeFigure2andFigure3below.

NOTE:Amachinedslotinthisfittingdirectsthefuelspraytowardstheengine.

Figure2,ISX/QSXLooseningPumpToRailLineatFuelRailtoVentPressure.

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

Figure3,ISL/QSLLooseningPumpToRailLineatFuelRailtoVentPressure.

Tightenthefuelrailnut.

ISX/QSXCM2250andCM2350(AllVersions)TorqueValue:47Nm[35ftlb]

ISL/QSLCM2350(AllVersions)TorqueValue:65Nm[48ftlb]

CAUTION
Donotinstallthefuelsystemleaktestertoolatthehighpressurepumpoutletfitting.Severe
enginedamagewillresult.Thistoolcanonlybeinstalledatthefuelrailforthepurposeofisolating
thehighpressurefuelsupplyfromindividualfuelinjectors

WARNING
Whenservicingtheenginedonotusethestartingmotortorotatetheenginewithahighpressure
fuelsystemjointopen.Rotatingtheenginecancreatehighlypressurizedfuelinthefuelsystem.
Highpressurefuelspraycanpenetratetheskin,resultinginseriouspersonalinjuryordeath.

Thistestrequiresfivefuelsystemleaktestertools,SeerequiredpartnumberinformationandFigure4
below.

Blockofffiveinjectorsatthefuelrailinplaceofthehighpressurefuelline.Keeptheinjector
linesupplyportthatismostaccessibleunblocked.

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

Table2,IsolationToolTorquebyProduct
Product IsolationToolPartNumber TorqueValue
ISX/QSX15CM2250andCM2350(AllVersions) 4919546 47Nm[35ftlb]
ISX12CM2350X102 4918563 47Nm[35ftlb]
ISL/QSLCM2350(AllVersions) 4918563 65Nm[48ftlb]

Figure4,FuelSystemLeakTester

InstalltheindicatedfuelpumpperformancetestservicetoolfromTable1,PartNumber(s)5299753or
5299754(SeeFigure1,Item1),attheunblockedfuelrailconnection.

Table3,FuelPumpTesterToolTorquebyProduct
FuelPumpTesterToolPart
Product TorqueValue
Number
ISX/QSXCM2250andCM2350(All 47Nm[35ftlb
5299753
Versions) ]
65Nm[48ftlb
ISL/QSLCM2350(AllVersions) 5299754
]

Measurement

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

CAUTION

Donotcranktheenginefor30secondscontinuously.Cranktheengineinintervalswitha15
secondpausebetweenintervals.Thisreducesthepossibilityofoverheatingthestartingmotor.

NOTE:Ifnecessary,useabatterychargertomaintainpropercrankingspeed.Unitsequipped
withstarterlockoutfeaturesmayrequireadditionalcrankingaids.

Enginecrankingspeedmustbeabove130rpm.

1.Withthefollowingconditionsmet:
Fueldrainline,PartNumber3164673(Figure1,Item2),connectedtohighpressurefuel
pumpservicetool,PartNumber5299753(SeeFigure1,Item1).
Fuelpumpactuatordisconnectedfromelectricalharness.
Injectorpassthroughharnessdisconnectedfromenginewiringharness.
2.Routethehose,PartNumber3164673,intoagraduatedbeaker,PartNumber4919139,for
measurement.
3.ConnectINSITEelectronicservicetool.
4.LogEngineSpeedandFuelRailPressureMeasuredwithINSITEelectronicservicetool.
5.InitialPurge
Crankengineuntilfuelflowexitsthehoseorforamaximumof15seconds.Ifnofuelflow
existsthehoseafterthree15secondcrankcycles,inspectthefuelpumphead.Seethe
correspondingServiceManual.ReferenceProcedure005227FuelPumpHeadinsection
5.
Discardpurgedfuelfromservicetoolhoseinaccordancewithlocalandenvironmental
regulations.
6.30SecondFuelVolumeMeasurementTwo15secondcrankcycles.(Measurementbegins
onlyafterthefuelpumpperformancetestservicetoolopens.Whenopen,apressurepulsecan
beheardandfeltthroughthehighpressurefuelpumpservicetool).
Collectthefuelthatexitsthehighpressurefuelpumpservicetoolduringtheinitial15
secondmeasurementcycle.
Allowthestartingmotortocoolfor15seconds.
Repeatthe15secondmeasurementcycle.
Sumandcollectthetotalfuelvolumeexitingthehighpressurefuelpumpservicetool
duringtheinitial/final15secondmeasurementcycles.
7.RecordtheaverageenginecrankingspeedfromINSITEelectronicservicetoollogging
results.

NOTE:Aftercompletingthehighpressurefuelpumpperformancetest,fuelmayremaininthe
drainline.Emptytheremainingfuelinlineintomeasuringcontainertoobtainaproper
measurement.

Fuelvolumefromthehighpressurefuelpumpservicetoolisdirectlyrelatedtoenginespeed.
Seegraphs,Figure5,6andFigure7below,todeterminetheminimumfuelvolumefromthe
highpressurefuelpumpservicetool.
ForallISX/QSXCM2250andCM2350engines,seeFigure5andFigure6below.
ForallISL/QSLCM2350engines,seeFigure7below.

ForFigures5and6below:

Enginespeedinrpmcanbefoundonthehorizontalaxis.ThisistheaverageengineRPMover
30seconds(two15secondcrankcycles).
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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

Servicetoolfuelvolumeinmilliliterscanbefoundontheverticalaxis.Thisisthevolume
collectedover30seconds.(two15secondcrankcycles).

Figure5,EngineSpeed[rpm]VersusServiceToolFuelVolume[ml]forAllISX/QSXCM2250
Engines.

Figure6,EngineSpeed[rpm]VersusServiceToolFuelVolume[ml]forAllISX/QSXCM2350
Engines.

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

Figure7,EngineSpeed[rpm]VersusServiceToolFuelVolume[ml]forAllISL/QSLCM2350
Engines.

Scenario1

Ifthemeasuredfuelvolumefromthehighpressurefuelpumpservicetoolattherecordedengine
speedisintheupperunshadedregionofthegraph,thefuelpumpisfunctioningproperly.

Scenario2

Ifthemeasuredfuelvolumefromthehighpressurefuelpumpservicetoolattherecordedengine
speedisinthelowerunshadedregionofthegraph,thefuelpumpisnotfunctioningproperly,remove
andinspectthefuelpumpassemblyforcamshaftandtappetrollersdamageordebris.Ifthefuel
pumpdoesnotpassvisualinspection,seeTechnicalServiceBulletin,FuelPumpPlungerand
TappetRollerInspectionandRepair,TSB140019forfurtherrepairdirection.

Scenario3

Ifthemeasuredfuelvolumeisintheshadedpartofthegraphthenverifythefollowing:

Correctspecificationsarebeingused.
Properhighpressurefuelpumpservicetoolinstallation.
Thattherearenoexternalleaks.
Thatalllowpressuresystemchecksweremade,andthenperformthehighpressurefuelpump
performancetestagain.

Ifthetestreadingsarestillintheshadedarea,thefuelpumpheadmustberemovedandthefuel
pumpcamshaftandfuelpumpcamshafttappetsrollersmustbeinspected.Ifthefuelpumppasses
thevisualinspection,contacttechnicalsupport.

FinishingSteps

Removethetestequipment.
Installthefuelinjectorsupplylines.Followtheinstallationsequenceoutlinedinthefuelrail
installationprocedure.SeethecorrespondingServiceManual.ReferenceProcedure006060

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201754 HighPressureFuelPumpPerformanceTestandNewServiceTooltoAssistinTroubleshootingFaultCode559

FuelRailinsection6.
Connectthefuelpumpactuatorelectricalconnector.
Connecttheinjectorpassthroughelectricalconnector(s).

DocumentHistory
Date Details
2015626 ModuleCreated
201577 none
201579 NonProductProblemSolving(PPS)
2015715 ProductProblemSolving(PPS)
2015817 Formatchanges.
201655 UpdatedStep5and6andFigure4and5axisexplanations.AddedFigure7.
2016725 AddedTable2andTable3
201729 UpdatedFigure5andFigure6andcorrespondingscenarios.

LastModified:09Feb2017

Copyright20002010CumminsInc.Allrightsreserved.

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