Home » ISX11.9 CM2250 - Service Manual » Cummins ISX11.9 CM2250 – Service Manual 005-016   Fuel Pump

Cummins ISX11.9 CM2250 – Service Manual 005-016   Fuel Pump

Preparatory Steps

TOC

 WARNING 

When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
 WARNING 

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
 CAUTION 

Clean all fittings before disassembly. Dirt or contaminants can damage the fuel system.

Before servicing any fuel system components, (such as fuel lines, fuel pump, injectors, etc.), which would expose the fuel system or internal engine component to potential contaminants prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Dirt or contaminants can be introduced into the fuel system and engine if the surrounding areas are not cleaned, resulting in damage to the fuel system and engine. Refer to Procedure 000-009 in Section 0.

Clean the fuel lines connected to the fuel pump, fuel pump gear pump, and mating components with contact cleaner, Part Number 3824510 or equivalent.

To prevent damage from debris and contamination, cover, cap, or plug any openings as soon as possible when servicing the fuel system.  Caps and plugs can be found in Clean Care Kit, Part Number 4919073.

SMALL | MEDIUM | LARGE


 WARNING 

Normal engine operation creates highly pressurized fuel in the fuel line which will remain in the fuel line after engine shutdown. Never open the fuel system when the engine is operating. Before servicing the fuel system, always loosen the pump to rail fuel line at the rail to vent the pressure. Keep hands clear of the line when loosening. High pressure fuel spray can penetrate the skin, resulting in serious personal injury or death.

Before servicing the fuel system, loosen the pump to rail line at the rail to vent the fuel pressure.

Keep hands clear of the line when loosening the fuel rail nut.

Tighten the fuel rail nut.

Torque Value:  65  n.m  [48 ft-lb]

NOTE: A machined slot in this fitting directs the fuel spray toward the cylinder block.

SMALL | MEDIUM | LARGE
   


 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
 WARNING 

Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of sever personal injury or death when working on the fuel system.
 WARNING 

The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious personal injury. Wear gloves and protective clothing.

SMALL | MEDIUM | LARGE
   

Remove

TOC

Remove the two fuel pump mounting brackets by removing the capscrews connecting the brackets to the cylinder block and the bolts connecting the brackets to the fuel pump.

SMALL | MEDIUM | LARGE
   


Remove the two mounting nuts and two mounting capscrews that hold the fuel pump to the gear housing.

Remove the fuel pump.

SMALL | MEDIUM | LARGE
   

Disassemble

TOC

Fuel pump gear replacer kit, Part Number 4919654, is required to remove and install the fuel pump gear.

The kit consists of the following components:

  1. Mounting plate
  2. Locking plate
  3. Two captive washer nuts
  4. Four mounting capscrews.
 
SMALL | MEDIUM | LARGE
   


Use the fuel pump mounting capscrews to attach the mounting plate to the fuel pump housing flange.

Tighten the capscrews.

Torque Value:  50  n.m  [37 ft-lb]

SMALL | MEDIUM | LARGE
   


Place the mounting plate and fuel pump assembly in a large vise.

Place the locking plate over the mounting plate threaded dowels and engage the fuel pump gear teeth with the locking plate gear teeth.

Hand-tighten the two captive washer nuts from the kit onto the two threaded dowels.

 
SMALL | MEDIUM | LARGE
   


Remove the fuel pump nut.

SMALL | MEDIUM | LARGE
   


Remove the fuel pump gear from the fuel pump shaft using a three-jaw puller.

SMALL | MEDIUM | LARGE
   

Inspect for Reuse

TOC

The dowel pin in the fuel pump drive shaft must not be sheared.

If the dowel is sheared, the cam housing or fuel pump must be replaced and the drive gear must be replaced.

Be sure the pilot o-ring is not cut or otherwise damaged.

Be sure the pump oil supply o-ring is not damaged.

SMALL | MEDIUM | LARGE
   

Assemble

TOC

Make certain the o-ring seal for the oil feed orifice is correctly installed.

Clean the nose of the drive shaft and the fuel pump gear inside diameter with contact cleaner, Part Number 3824510, or equivalent.

The fuel pump drive gear inside diameter and the drive shaft outside diameter must be clean and dry before installing the gear.

SMALL | MEDIUM | LARGE
   


Use the fuel pump mounting capscrews to attach the mounting plate to the fuel pump housing flange.

Tighten the capscrews.

Torque Value:  50  n.m  [37 ft-lb]

SMALL | MEDIUM | LARGE
   


Place the drive gear over the fuel pump shaft.

Make certain the dowel pin in the drive shaft lines up with the keyway in the fuel pump gear.

SMALL | MEDIUM | LARGE
   


Place the locking plate over the mounting plate threaded dowels and engage the fuel pump gear teeth with the locking plate gear teeth. Hand-tighten the kit two captive washer nuts onto the two threaded dowels.

Install and tighten the fuel pump gear nut.

Torque Value:  300  n.m  [221 ft-lb]

SMALL | MEDIUM | LARGE
   


Remove the locking plate and mounting plate from the fuel pump.

SMALL | MEDIUM | LARGE
   

Install

TOC

Position the fuel pump over the mounting studs and engage the fuel pump gear.

Hand-tighten the mounting nuts and capscrews.

Tighten the fuel pump mounting capscrews.

Torque Value:  50  n.m  [37 ft-lb]

Tighten the fuel pump mounting nuts.

Torque Value:  50  n.m  [37 ft-lb]

SMALL | MEDIUM | LARGE
   


Install the fuel pump support brackets.

Install the mounting bolts to the cylinder block and the capscrews attaching the support bracket to the pump flange.

Tighten the capscrews that attach the fuel pump support brackets to the cylinder block.

Torque Value:  50  n.m  [37 ft-lb]

Tighten the capscrews attaching the fuel pump support bracket to the pump flange.

Torque Value:  50  n.m  [37 ft-lb]

SMALL | MEDIUM | LARGE
   

Finishing Steps

TOC

 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

SMALL | MEDIUM | LARGE
Last Modified:  27-May-2010