Technical Training 2010

ISX15 CM2250
 Origin of the name

■ ISX15 CM2250
– IS – Interact system – name used by Cummins for its full
authority on-highway systems.
– X – Engine family belonging to the heavy-duty market.
– 15 – Displacement
– CM2250 – Electronic control module used in the application.

47 4/17/2023 Cummins Confidential

 Literature support

■ This product is supported by the following literature:

– Owner’s Manual
– Operation and maintenance manual
– Service manual
– Diagnostic manual for fault codes
– Wiring diagram

47 4/17/2023 Cummins Confidential

 Engine Features

■ This engine is a 15-liter inline six-cylinder with a

firing order of 1 – 5 – 3 – 6 – 2 – 4
■ It has a cylinder diameter of 5.4 in. and a stroke of
6.7 in.
■ It has a dry weight of 1,528.2 kg.

47 4/17/2023 Cummins Confidential

 Data plate ■ The data plate has the
following information.
– Engine serial number
– Critical Parts List (CPL)
- Model
– Power and rpm ratio
– Engines equipped
with OBD, as a case,
they carry
OBD ratio

this
one

5 4/17/2023 Cummins Confidential

 Engine serial number

■ In case the data

plate has been
damaged or has been
removed, the engine
serial number can be
located on the rear
right side of the
engine.

47 4/17/2023 Cummins Confidential

 ECM data plate
The ECM data plate shows us
–
information about the ECM and how it is
programmed.
– The following information is available:
ESN 79368378

dm
– Engine
P/N 4993120
serial number
and"
S/N 811
– ECM part number
– ECM serial number
– ECM Date Code
– ECM software code Identify in
in the ECM

7 4/17/2023 Cummins Confidential

Air and exhaust system
Variable geometry turbocharger

■ Controlled
electronically
(smart)
■ Cooled by
refrigerant of the
engine
■ Works through a
engine
electric that works
with a 12 VDC
signal
Air to air aftercooler

■ It requires the use of an aftercooler to lower the

temperature of the intake air, since it is heated through
compression of the same in the
turbo compressor.

47 4/17/2023 Cummins Confidential

Intake manifold

■ New intake manifold with optimized EGR mixing

Location of the Ether outlet

New intake manifold design

Exhaust manifold
■ Various variations in the three-section exhaust
manifold configuration provide the various mounting
options for the turbo.

47 4/17/2023 Cummins Confidential

 EGR

■ This engine has an EGR system with the valve on the

cold side.
■ The cooler is located at the bottom of the
exhaust manifold

47 4/17/2023 Cummins Confidential

 EGR system
Turbo
Aftercooler
Geometry
Valve
EGR
Venturi

Variable
EGR valve

■New cold side EGR

valve design and
associated plumbing
■ It is located on the
right side of the
engine.
EGR valve 2010
EGR Butterfly Valve
 EGR mass flow measurement assembly
■ It is located on one side of the EGR valve
■ Houses the orifice pressure sensor and differential
pressure sensor.

47 4/17/2023 Cummins Confidential

 Air system flow

19 4/17/2023
Cummins Confidential
 Exhaust system flow

20 4/17/2023 Cummins Confidential

 Exhaust system flow

20 4/17/2023 Cummins Confidential

Mechanical components of the engine
Air compressors

HE find
available a
Cummins brand 18.7 cfm
single cylinder
compressor and 37.4 cfm
double cylinder
compressor
It is installed on the front
left side of the engine at
the rear of the front gear
housing.
Cylinder head design
■The cylinder head has a single overhead camshaft
design.
Cylinder block
■The cylinder block has
been designed to be
compatible with
previous engine models
with the use of the
previous gear train
gasket, a new liner, a
unique oil pump and a
unique head gasket.
Block
He
continues
to have
sculpted block
design
wet shirts one

of
 Main bearings
■ The main bearings are
made of a tri-metal material.
■ Upper bearings are
distinguished by oil holes
and the letters UPR
stamped on their backs.
■ The thrust bearing is 360°
and is located in cylinder
position #4

27 4/17/2023 Cummins Confidential

 Crankshaft

■ The crankshaft is designed so that counterweights

on the journals of cylinders 2 and 5 are not
required.
■ The crankshaft gear and 360-point tone ring are
press-fitted to the crankshaft. Both can be serviced.
Refer to service literature for appropriate
procedures.

47 4/17/2023 Cummins Confidential

 Bed covers
■ The crankcase covers are directional and have an
arrow that should be placed towards the front of the
engine.

29 4/17/2023 Cummins Confidential

 Shirts

■ The
shirts
They have a new design
and are
specific to this new block
design.
■ These shirts can be
used on previous block
designs and are
compatible.

47 4/17/2023 Cummins Confidential

 Pistons
■Pistons are one-piece
closed skirt design.

31 4/17/2023 Cummins
Pisto
n This slide shows the
orientation of
piston assembly
 Bed covers

■ The connecting rod

caps are held in
place by four bolts

29 4/17/2023 Cummins Confidential

Con
necti
ng •The connecting rod
rod used in this engine is a
straight impact fracture
design.
•It has a
internal bore for
lubrication of the
pin
 Cooling nozzles

■ The
engine has nozzles of
directed cooling for
lubrication and cooling of
the
piston, pin and bushing.
■ They contain two
alignment legs. These legs
are used to guide the nozzle
along the bottom of the
cylinder liners.
35 Cummins Confidential
 Reinforcement plate

■ It is required to add rigidity to the block

48 4/17/2023 Cummins Confidential

 Oil pump
■The oil pump
was modified to
accommodate the
reinforced mounting
bolts and it is
required if the block
is used in its

■ Also required
supported capacity. for he
Gear tooth game of
adjustment shims of the

47 4/17/2023 Cummins Confidential

•The head gasket has
a flange for easy Head gasket
orientation

and
ID.
•There are three
different types of
gaskets available due
to compatibility, each
with a pattern holes
different based on the
application.
•These holes are
used to control the
flow of coolant from
the block to the head.

Eye
bro
 Cylinder head
■ Unique cylinder
heads defined by the

CPL will be defined,

however there is only
one service part
number for it.

47 4/17/2023 Cummins Confidential

 ■ These must have a
single overhead
camshaft design and
house the valve
assembly and head
bolts.

47 4/17/2023 Cummins Confidential

 Gear housing gasket

■ Required to use with

compatible block.
■ The casing
of
gears were designed for
a single overhead
camshaft.

47 4/17/2023 Cummins Confidential

 Injectors
■ The injectors are
mounted in the center of
the cylinder.
■ These have a special
fixing clip that engages
with some marks on the
injector to ensure correct
operation. orientation
angle between the injector
and its fixing clip.

47 4/17/2023 Cummins Confidential

Head wiring harness

■There is a single wiring harness at the head, where

both the injector and engine brake wiring are shared.

47 4/17/2023 Cummins Confidential

Block heater

■It is mounted to the block at the rear of the pump water

inlet.

47 4/17/2023 Cummins Confidential

Gear Train
Camshaft Gear

Idler Gear (CIG)

Disc of Upper Idler

Gear (UIG)

Tightening sequence
22 ft-lbs + 60° Accessory Control
Gear

Lower Scissor Idler

Gear (LISG)

Fuel Idler Gear

Crankshaft Gear

Gear of
Figure 3: Identification of Gear Train Parts
Gears used in the front gear train
Lubrication system
 Oil fill holes

■ Oil filler necks are available both as the usual one

on the front of the engine
intercepting the front gear housing, as
various options along the block on the side
right engine.

47 4/17/2023 Cummins Confidential

 Bayonets

■ There are different bayonet locations available

depending on customer needs on both sides of the
engine.
■ It is necessary that molded plastic bayonets with a
half-turn bayonet type locking be used.

48 4/17/2023 Cummins Confidential

 Crankcase options

50 4/17/2023 Cummins Confidential

 ■ Are
available
engines with front
and rear sump
options with the
option of sump
standard.

51 4/17/2023 Cummins Confidential

Lubrication Pump
 Oil pump
■ Pump
coupling HE ha
modified due to
the
change in the main
screws.
■ Not
compatible with
models previous
due to
the
interference with the
current gear train
 Lubricating oil filter
This engine uses a single LF9000 or LF9001 oil
filter mounted on the right side of the engine.
This is a venturi-combo, combining full flow and
bypass flow in one element.
Having both types of filtration gives us better
lubrication characteristics that result in longer
engine life.
LF9001

LF9000
 Features of oil filter

■ This filter provides 30 micron filtration in full flow,

capturing 80 or 85% of the flow and 10 microns
in bypass flow, capturing 15 to 20% of the flow.
■ The full flow filter is not as efficient in removing
dirt but provides enough flow capacity needed in
the engine, the bypass flow filter is more efficient
in removing dirt but does not give us enough flow
capacity for the engine.
■ This filter eliminates the need for a separate
bypass as in previous combo oil filters.

54 4/17/2023 Cummins Confidential

 Advantages of using this type of filter

■ This type of filter:

– Increases the amount of time the engine is in
service,
– Increases engine protection,
– Reduces wear
– Lower operating costs

55 4/17/2023 Cummins Confidential

 Bypass valve
■ The bypass valve is
designed to protect the
engine in case of filter
saturation.
■ This valve will open
when the pressure
differential across the
filter is 90 psi.

56 4/17/2023 Cummins Confidential

 Lubrication in the turbo

■ There is a lubrication supply

line to the turbo connected
of the
head from the filter to the
turbo bearing housing and supplies
oil under pressure.
■ It returns through an external turbo
drain line to the crankcase.
Crankcase breather filter

■ The use of an open coalescing

crankcase breather filter located in
57 4/17/2023 Cummins Confidential
 the front gear housing on the left side of the engine is
required.

58 4/17/2023 Cummins Confidential

 Lubricant flow through the turbo

59 4/17/2023 Cummins Confidential

 Lubrication system flow

60 4/17/2023 Cummins Confidential

61 4/17/2023 Cummins Confidential
 Oil flow into the head

62 4/17/2023 Cummins Confidential

Fuel System
Lifting Pump: Works for one minute at a time.
Open the valve to 35 to 40 psi
pressure
His design
may vary
with

he
shown in the
figure
ECM cooling plate

■ This engine has a plate

of
cooling cooled by fuel
integrated with he
high pressure side filter
head.
10 Micron Suction Fuel Filter w/WIF Supplied by OEM
(Fleetguard FS19764)
 5 Micron
Pressure Side Filter (Fleetguard FF5686)
 Gear pump

The gear pump has an internal pressure regulating

valve that regulates to 150 psi at the pump outlet.

68 4/17/2023 Cummins Confidential

New filter head design

■ The filter head features a new thread design that

adds security to the assembly.
High pressure common rail
■ New injection system for this XPI high pressure
common rail engine
■ The pressure rail is a high pressure fuel
accumulator.
 Summary
ISX XPI Fuel System Diagram
High Pressure Pump Assembly
M
Pressure Wave Orifice
PRV

Rail Assembly K
Y
o

1
N
IMV Purge Hole
° °
0 oo Air with Venturi of
or
Gallery Purge
Supply
P(sac) ! • % •

LPP
D-Motor
Control

Plate Side filter Package of1

Lubricating Oil Cam Housing 3
5 mieras .
Cooling Filter side Filtering
ECM 10
microns

TankCo
mb
.
Priming Pump

•Comb Filter. Primary – OEM Supplied – Chassis Mounted – 10 um, Water Drain, Water Sensor, Heater Option, Check Valve.
•Comb Filter. Secondary – Supplied by Cummins – Engine Mounted – 5 um.
•Ent Restriction Max. Gear Pump: 10 inHg at Nominal Flow with Dirty Filter (6 inHg with Clean Filter).
•Gear Pump Pressures (Typical): 1.9 Bar (Running @ 80 RPM), 10 Bar (“Nominal”), 17 Bar (Maximum Peak Pressure).
•Aux Flow Allowable Gear Pump (for the dispenser): 13.7 cc/sec.
•Pressure Filter P Delta Max.: 10 PSI at Nominal Flow.
•Maximum Commanded Rail Pressure: 2600 Bar (37709 PSI) at 1800RPM and above.
•Nominal Maximum Speed (Automotive): 2100 RPM
High Pressure Fuel Pump

-
Summary
- 2 Plungers x 12mm Cam Lift x 8mm . Piston diameter in 3-piston housing
1:1 Right Rotation
 Summary
Air Purge and Venturi
- Air Purge Provides Continuous Leakage to Drain (~50 PPH).
- Air Purge Offers SOME Help for Air Purge.
- Venturi Prevents Self-Priming During Motoring Conditions.
- The Device is Installed on the FPA Adapter (Fuel Pump Adapter) (3 Plunger HD Pumps).
- The Device is Installed in the Cam Housing (2 Plunger HD Pumps).
Drainage Flow

—• Drained from
Venturciofuel to the
tank
LPP fuel supply Post-flow
FPA

Purge Flow
of Air
 Summary – Theory of Operation
Fuel Pump (Pumping Section)
-Passive Inlet and Outlet Check Valves
-Floating Ceramic Plunger Design
-Cam Driven Roller Plunger

Outlet
Check Valve
Inlet Check (OCV) Assembly
Valve (ICV)
Assembly
Floating ceramic pumping plunger
 Internally
Machined Components (FSP)
Pumping Plunger
(ceramics)
■ – Purchased unfinished
Barrel
– Purchased unfinished – Ends ground internally
– Heat treatment i
– Internally hardened threads – Outside Diameter
– Drilling, grinding and polishing internally ground

• Barrel and Plunger (B&P) Assembly

– Internally matched components
 System Function: Injector
Sequence of events for
an injection: Stator
• The current in the coil
Coil
displaces the armature.
Armor
• The movement of the
armature opens the ball
valve, resulting in flow Ball valve
through the control
Control Chamber (with
chamber. inlet and outlet holes)

• The flow of the control

chamber reduce the HPC Port
pressure, lifting the
needle.
• The displacement of Needl
e
the needle opens the
flow passage to allow the
injection event.

Flow of action Injection flow

 Technical Training 2010
and seal Packaging Fuel Pump Actuator
Bomb of Head
connection and O-
Fuel - rings
Also with adapter
Parts of
Service
Packing

Arosello Bomb of
Mesh gears at
150 psi
* - tool is required to install it.
 Fu
el
pu
mp
act
uat
or
The pump actuator
of
Fuel is a valve
Normally open valve
that operates by
PWM signal and
regulates the fuel
inlet to the high
Technical Training 2010
pressure chambers
Fuel Rail
Lines – Service Relief Valve
Parts Fuel of
Pressure and

Rail of
Seal 5
i Fuel

Fuel
Pressure fro
Sensor m
Lines of
Fuel
Technical Training 2010
Injector –
Service Parts

Arosello

Combustion Seal
Fuel return manifold
■ Collect the returns
of fuel
from the pump, the
rail relief valve and
the injectors for
return it to the fuel
tank
 Fuel return
to the tank
■ This engine requires
fuel return come
back
below fuel level in it
tank, as a new
requirement for this
engine, but already used
in others products
Cummins Midrange
Fuel system flow
 Caution for Technician
2010
Normal engine operation
creates very high pressure
fuel in the fuel line which
remains there after the
engine is turned off. Never
open the fuel system when
the engine is running. Before
servicing the fuel system,
always loosen the fuel line
from the pump to the fuel rail
to relieve pressure. Keep
your hands away from the
line when slackening it. High
pressure fuel jet can
penetrate skin resulting in
serious injury or death.
 Service Tool:
Game. For Fuel
System Cleaning Care4919073

CAREFUL
Before servicing any fuel system
component (such as fuel lines, fuel pump,
injectors, etc.) that would expose the fuel
system or internal engine components to
potential contaminants prior to
disassembly, clean the connections,
mounting components, and the area
around the component being removed.
Dirt can enter the fuel system and engine
if the surrounding areas are not cleaned,
resulting in damage to the fuel system and
engine.
 ISX15
Fuel System Checks
■ Low Pressure Fuel System
Health Check
– Used to access the health of Hole of
the low pressure side of the Pressure gauge Purge
fuel system.
• Entry restriction
• Gear pump pressure
• Fuel Filter Pressure Differential
• Air in the fuel
• Drain line restriction
– Service tools
• Bleed hole 3164621
– Purge fuel to create greater flow
• Pressure gauge
• Vacuum gauge at pump inlet
– Banjo Connection 4919057

Vacuum gauge
Spec. in 018-016
Filter Differential Pressure
■ The filter is considered clogged when the pressure
drop exceeds 25 PSI.
 Fuel
System Leak Test
Drained
Injector Leak Test of the
– Used to determine if the Injector
injectors are leaking into
the drain.
– Service tool
• Fuel return hose 3164618.
• Cylinder with graduation
3823705 or equiv.
• Hta. 4919546 to isolate the
cylinders.
• Fuel System Leak.

– INSITE
Spec. in 018-016
Technical Training 2010

Record how long it takes to gather a certain volume of fuel.

Technical Training 2010
The spec. is at 006-026.
 Fuel
System Leak Test
Drained from
Drained from the the
High Pressure Relief High Pressure
Relief Valve
Valve
– Used to determine if
HPRV is leaking to
the drain.
– Hta. service
• Fuel return hose
3164618
• Graduated cylinder
3823705 or equivalent.
– INSITE
• Fuel System Leak Spec. in 018-016
 Leak Test of the
Fuel System
Fuel Pump Head Draining the Fuel Pump
Head
– Used to determine if the
Fuel Pump Head is
leaking excessively to the
drain.
– Hta. service
• Fuel return hose
3164618.
• P 3823705 or equiv.
– INSITE
• Fuel System Leak

Spec. in 018-016
 Failure Analysis Steps
■FC 559 – Rail 1 Injector Dosing Pressure – Data Valid
But Below Normal Operating Range – Moderately Severe
Level.
– Perform the High Pressure Health Check (abatement).
• After idling the engine, turn it off and use INSITE to observe the pressure
bleed/drop (loss of 100 bar in 1 minute).
• If drawdown is found, perform leak checks.
– Injector
– Rail pressure relief valve

– Run the Fuel System Low Pressure Health Check.

– Run failure analysis based on symptoms – when failure occurs.
• Fuel Pump Head Return
• FPAy adapter
• Fuel pump plungers
 Injector Installation
1. Install the injector and fixing clamp.
• Install the clamp screw but do not tighten
it to final torque.
2. Install the Fuel Connector (Head
Mounted).
– A new connector must be installed with
the new injector.

Injector Installation
Cont.
3. Tighten the Fuel Connector retaining
nut.
• Do not tighten to final torque value.
4. Tighten the injector clamp screw to the final torque value.
5. Tighten the Fuel Connector retaining nut to the final
torque value.
 Injector Installation Cont.
Fuel Connector
(Mounted on the Head)
– Guide him with
the
anti-head rotation feature.

Head of
– When installing push down
Injector
on the end of the connector
to lift the tip of the connector
and help it tothis nods
properly against the injector.
 Fuel Rail Pressure Relief Valve (FRPRV)
The fuel rail pressure relief valve is a quick opening valve to
prevent over-pressurization of the system.
- When the valve opens it regulates the rail pressure to around
1010 Bar.
- The valve should reset itself when the engine returns to idle,
after which the system should return to normal operation.
- Opening pressure varies by product.
- ISX15 CM2250-- 3100 Bar
Adjusting the High
Pressure Common Rail
Injector
■This feature has been moved from Features and
Parameters and is now in Advanced ECM Data.
■This feature is used to monitor and change injector
barcodes (Option Code or Trim Code) in the ECM
when necessary.
E INSITE - ISB - CM2150D Simulator - Engine Serial Number - 15012345 - [Advanced ECM Data]
Edl File Edit Yiew Tools Window Help

806808088(0 ► ll •E
Aftertreatment History
n Disconnect from Aftertreatment Maintenance
LECM
Aftertreatment Maintenance
Filter Installation Anti-Theft High Pressure Common Rail Injector Setup
98 Protection Duty Cycle Monitor
Engine Abuse History Engine
This feature is used to monitor and change injector barcodes in the ECM when necessary. The
16003 Fault Codes injector barcode is marked on the injector head when manufactured. Whenever an injector is
Protection installed or replaced, the injector barcode should be updated in the ECM. If an ECM is replaced, the
- Engine Protection Setting injector barcodes must be updated.
Data
Monitor/ Torque Derate RPM
Logger Derate ShutDown

Instructions Show

1. Enter the Injector Barcodes for the respective cylinders)

2, Select Apply to send the new barcodes to the ECM
High Pressure 3, Verify all the new barcodes were set successfully
Conveyor Rail
E Advanced ECM InjectorMonitor
Additional Information
1. The Injector Barcodes can be printed
99 Data Maintenance Setup
Real Time Clk
5AE J193?/multiplexed fault
Data /
Features and
Parameters 5AE JI 93/ Powertrain Control

Calibration
Selection
Cylinder
Cylinder 1
Current Barcode
14H345D2A3
Change Status New Barcode

123456
Follow the
Cylinder 2
14H345D5A3

instructions and
Cylinder 3
14G345D2A3
Cylinder 4
360BD 414H34565H
14H345D2A1

Select the 144545D2A3

click Apply.
ECM Advanced
KT Trip
Data Print

Audit
feature
Inquire Data
Extraction

OBD Monitors

0 Connected to ECM. JÍISB-CM2150D Simulator

Fuel Pump Timing
Cooling system
 Coolant filter
■ This engine has a
part that consists of
the
pump suction and
head filter of
coolant mounted on
rear of pump of
refrigerant

102 4/17/2023 Cummins Confidential

 Coolant pump
■ This engine has a
right side mounted
dual outlet cartridge
type coolant pump
with driving
replaceable

103 4/17/2023 Cummins Confidential

Coolant thermostat housing

■ A new thermostat housing design

is featured that provides a
mounting location for the
thermostat and coolant
temperature sensor suited to the
characteristics of a single
overhead camshaft.
■ Its housing is designed to not
interfere with the EGR transfer
tube passage and has unique
coolant flow characteristics
designed for the single overhead
cam head.
 Thermostat

■ The thermostat is mounted on the thermostat

housing cover.
■ Thermostat seal provides positive sealing

105 4/17/2023 Cummins Confidential

 Cooling system flow chart

106 4/17/2023 Cummins Confidential

 Cooling system flow

107 4/17/2023 Cummins Confidential

 Cooling system flow

108 4/17/2023 Cummins Confidential

Aftertreatment system
Aftertreatment system
■ Includes SCR
aftertreatment system
with a diesel particulate
filter
 Hydrocarbon
dosing device

■ It has
a dispenser of
fuel for engine
mounted aftertreatment
 Aftertreatment Air
Bleed Valve Function
•Sold as an assembly with solenoid and casting.

685306

Aftertreatment Air Purge Actuator

 Equipment Manufacturer Air Supply
Original (OEM)

Air delivery to the

FSOV (Valve. of
operation of the

syste
Fuel)m of
Flow path in sectional view

Air delivery
outlet

Air supply inlet

 Key Features of Air Purge

■ Air purge is controlled using the injector, air actuator, and fuel delivery
actuator.

■ At the end of regeneration, the solenoid closes, there is a small delay,

then the injector opens, there is a small delay and then the Air solenoid
opens. The opening of the injector and air solenoid forces the trapped
fuel volume to bleed out, followed by a period of air flow through the
injector.

■ After the fuel is purged, air is injected to dislodge fuel deposits from the
tip and dry it.
 Key Features of the 2010 HC
Dispenser
■ Removal of several internal components.
■ Removal of heat shielding, screws and spacers.
■ Addition of pre-applied anti-seize to mounting screws.
■ Longer line cord.
■ The HC Doser is not backwards compatible with the 2007
product without a calibration update.
 System
Block Diagram – Dosing System
Air Bleed Valve
Shut-off Valve
Existing Engine Functions of Fuel Injector
 Dosing Pipes
Hydrocarbons
Fuel Passage to
Fuel Line
Exhaust Injector
Connectio
n Pipe

Refrigerant Air Passage to

Lines Fuel Passage
Air Line

Fuel
Dosing Supply Line
Injector

Assembly of
Fuel Shutoff Valve
Ens. Aftertreatment Solenoid
 Ens. Solenoid – 2007 ISX CM871vs
. 2010 ISX15 CM2250
Ens. Solenoid 2010
Ens. Solenoid 2007 •Fuel Supply SOV equal to 2007 product.
• Fuel Supply SOV. •Pressure Sensor same as 2007 product.
• Cummins Fuel Pressure Sensor. The drain port is now used as an Air Intake Port and
• Drain Port and Fuel Drain SOV. the Drain solenoid has been removed. The assembly
also includes internal fuel and air side Check Valves.
 Post-treatment External
HC Dosing System

Because the system is designed to drain fuel at the end of each

regeneration, it needs to be primed at the start of the next
regeneration before any diagnostics can be performed.
Priming consists of performing the pressure test diagnostic
sequence if the priming sequence ends with any failure, then the
pressure test diagnostic is run again before deciding whether it
passed or failed.
The pressure test diagnostic, unlike the 2007 product, only runs
prior to the start of an active regeneration event, minimizing the
number of test cycles resulting in reduced tailpipe emissions.
 Monitoring the Efficiency of the
Doser in Regeneration
Update Efficiency
Beginning of Regeneration from the Dispenser
End of Regeneration (Adjust/Clear
Comp. Dos. OBD error)
Regeneration
/ Time
Diagnosis of the Dosing Monitoring Dosing Efficiency Air Purge
System
Monitoring of the dosing efficiency starts at the beginning of regeneration.
– It is delayed until the air is expelled from the dosing system.
– Monitoring lasts for a short period.
– Monitoring runs once for each regeneration, regardless of key cycles.

■ Improved dosing efficiency accuracy.

– Average the efficiency of the dosing unit during regeneration.
• Calculates the efficiency of the dispenser in each PWM (PWM amplitude modulation)
cycle.
• Update efficiency ONLY with a sufficient number of averaged data.
 Start of Regeneration Pressure Test
Chart
SOR Start of Regeneration Pressure Test

ON/OFF
S14: Air Bleed: Remove Fuel

Note:
Inject air/combustion mixture. @ start up.

Leak
0

Injector
Enc
S16: Post-Regeneration

Injector
Off
Electronic control system
 Distinctive
elements of this
An OEM connector
engine
■ The CM2250 ECM that
can distinguish
oneself
easily from other ECMs by
3 60 pin connectors

Two engine connectors

 Aftertreatment
connector
■ A 14-pin OEM
connector for the post-
treatment
(Inputs, outputs and controls)
 Fuel rail pressure sensor
■It is located in the same and serves so that the ECM
monitors the pressure of the same with respect to
fuel dosage.

130 4/17/2023 Cummins Confidential

 Intake manifold
pressure/temperature sensor.
■ Its reading is used by the ECM to make decisions
regarding
synchronization and
dosing of
fuel.

131 4/17/2023 Cummins Confidential

 Barometric pressure sensor

■ This sensor is used to take

decisions regarding
to
altitude
compensation and
derating related to
high altitudes.

132 4/17/2023 Cummins Confidential

 Crankshaft speed/position sensor

■
This sensor is located
behind the vibration damper and is used to take
signals of both the speed
and position of the
crankshaft.
■ This

sensor is used to make

speed governor decisions
and serves as a backup for
timing decisions.

133 4/17/2023 Cummins Confidential

New location of the camshaft
position sensor
■ It is located at the top of
the front gear train.
■ Detects both camshaft
speed and position.
■ It mainly serves the ECM to
make decisions
synchronization, but
It also serves as a backup
for decisions of
speed governor.
 Turbo speed sensor
■ This sensor is
used by the ECM
to locate

the
speed of
the
turbo and is
variable
reluctance.

135 4/17/2023 Cummins Confidential

 Turbocharger inlet temperature sensor
Its value is used by
the ECM for engine
protection and
emission control.

136 4/17/2023 Cummins Confidential

 Orifice pressure sensor
■ It is mounted on the
assembly of
mass flow
measurement.
■ It is used in
conjunction with the
intake manifold
pressure sensor to
improve the accuracy
of gas flow measurement.

137 4/17/2023 Cummins Confidential

 Differential pressure sensor
■ It is mounted on the mass flow measurement
assembly
.
■ This sensor measures the
pressure drop recorded across
two orifices located in the mass
flow measurement assembly.
■
Its measurement provides
information to the ECM regarding
the exhaust gas flow in the EGR
for opening and closing the EGR valve.

138 4/17/2023 Cummins Confidential

 Exhaust gas temperature sensor

■ Located on the elbow after the mass flow

measurement assembly

139 4/17/2023 Cummins Confidential

 Exhaust gas pressure sensor
■ It is mounted near the thermostat housing
■ Measures the exhaust gas pressure in the exhaust
manifold
■ This information is used
by the ECM for EGR valve
operation.

140 4/17/2023 Cummins Confidential

coolant temperature sensor

■ Itis located in the

casing of the
thermostat
■ Its reading serves
the ECM for engine
protection decisions.

141 4/17/2023 Cummins Confidential

Oil pressure sensor

■ It is located in the block on the left side of the engine

behind the ECM.

142 4/17/2023 Cummins Confidential

Oil temperature sensor

It is located in the
block on the left side
of the engine behind
the high pressure
fuel filter.

143 4/17/2023 Cummins Confidential

Crankcase breather pressure sensor

■ It is located in
the coalescing
filter housing
and serves the
ECM to monitor
the saturation of
the filter itself.

144 4/17/2023 Cummins Confidential

 Ambient air temperature sensor

■ It is installed by the OEM outside the truck tractor

compartment
■ Its reading is required for the functionality of the
SCR system in cold environments.
145N4/17/2023lmenteCumminsConfidential in the mirror
Water in fuel sensor

■ It is located at the bottom of

the fuel filter.
low pressure side.
Detects the presence of water
in the filter collection area
With this information the ECM
illuminates a lamp on the
dashboard alerting the
operator.
the presence of excess water
in the filter and the need to

146 4/17/2023 Cummins Confidential

 drain it.

147 4/17/2023 Cummins Confidential

Sensors present in the DPF

■ There are three temperature sensors:

– Catalytic converter inlet
– Entrance to the DPF
– DPF output
■ Differential pressure sensor
– Measures DPF saturation

148 4/17/2023 Cummins Confidential

NOX sensor.

■
There is an input noise
sensor. to the
post-treatment on one
side of the hydrocarbon
dosing unit of the same
Second NOX sensor

■A second NOX sensor is installed at the outlet of the

SCR system.
 Aftertreatment metering
valve
■ The
valve
dosing machine of
the
SCR post-treatment
is finds
Located in the
decomposition tube
Aftertreatment metering valve
between the diesel
particulate filter and
the catalyst of the
SCR system
 SCR system temperature
sensors
■ The SCR aftertreatment system has two
temperature sensors, one at the inlet and one at the
outlet.
 DEF tank temperature
level sensor
■The OEM must also supply a level sensor and a
Urea temperature sensor inside the tank itself.
Solenoid Assembly

■ A hydrocarbon
dispenser pressure
sensor is available.of
the
aftertreatment and its
corresponding air cut-
off valve on the rear
left side of the engine
 2010 ISX15
CM2250Technical
TrainingSCR
Aftertreatment
System
 Cummins SCR Aftertreatment System

Selective Catalytic Reduction (SCR) Catalyst

Decomposition
Reactor

Diesel
Exhaust Fluid (DEF) Metering Valve

Cummins
Particulat
e
 Cummins Aftertreatment
System Architecture
The DEF
(Urea) Dosing Valve sprays a fine mist of DEF
into the hot exhaust stream.

Cummins Particulate Filter Selective Catalytic Reduction

(SCR) Catalyst
Decomposition occurs in 3
steps within the Decomposition Tube
Step 1: Evaporation
Step 2: Thermolysis
Step 3: Hydrolysis
What is SCR?

■ Selective catalytic reduction is a NOx control

technique for diesel engine exhaust.
■ The process involves injecting Urea CO(NH2)2 (a
nitrogen compound that easily decomposes into
ammonia) into the exhaust through a catalyst.
■ Ammonia reacts with NOx to produce harmless
nitrogen (N2) and water (H2O).
 Cummins Aftertreatment System

EGR=Exhaust Gas Recirculation)

DEF Dosing Valve

Reactor of
Cummins Particulate Filter
Decomposition
Reduction Catalyst
Selective (SCR)

P.M

0.01
 EPA NA Emissions Standards
NOx – g/hp-hr

Particles – g/hp-hr
EPA=US Environmental Protection Agency
 Global Road Standards

5.0

4.5

4.0
NOx – g/HP-hr

3.5

3.0

2.5

2.0

1.5
1.0

0.5

0.0
0.0 0.01 0.02 0.03 0.04 0.04 0.04 0.06 0.07 0.08 0.09 0.10 0.11 0.12
Particles – g/HP-hr
Doing More to Use Less

• Cummins joined the U.S.

Environmental Protection Agency
(EPA) Climate Leaders Program in
2006.

• Our promise is to reduce

emissions of Gases of
Total global greenhouse gas (GHG)
emissions by 25% from 2005 to 2010.
CLIMATEYK
LEADERS A
US Environmental Protection Agency
 Aftercare Components 2010
DPF Aftertreatment
Temperature Sensors Diesel Particulate Filter
Aftertreatment Differential
Diesel Aftertreatment Oxidation Pressure Sensors and
Catalyst (Integrated with Inlet) Tubes

Diesel Particulate Filter

Aftertreatment

Aftertreatment DEF
Aftertreatment Diesel Particulate Dosing Valve and
Filter Temperature Sensor Packing
Interface Module
Post-treatment
decomposition tube
Packaging
•Spheric
al
•Marmon
Aftertreatment SCR Catalytic
Converter Temperature Sensor
SCR Catalytic Converter Interface Module
SCR Aftertreatment Temperature Sensors
Catalyst Post-treatment
DEF – Diesel Exhaust Fluid
Aftercare Components 2010

Diesel Exhaust Fluid

Aftertreatment Dosing Unit
and Filter

Diesel Exhaust Fluid

Aftertreatment Controller
(Also call
dosing control unit)
 Aftertreatment DEF Controller
■ Mounting location: Chassis
■ Temp. Ambient
operating temperature: –
40 to 85 °C
■ Operating voltage: 12 or
24 V
■ 14 analog inputs
■ 4 digital inputs
■ Up to 15 outputs
■ 2 CAN interfaces
■ Current
– ≤ 300 μA after power off
– 28 A max (heating + dosing)
 DEF Aftertreatment Unit

■ Subcomponents
- Bomb
– Reversing valve
– Pressure sensor
– Temperature sensors
– Filter
DEF Dosing System
SM Heater Temp.
SM Heater Sensor

SM Temp Sensor
Pressure
Unit Line Heater
Filter

ECM Datalink Controller

Pressure Sensor

Reverting Valve Pump Motor Return Line Pressure Line

Heater
Suction
Line Heater
Return Line
Suction Line

Tank
Coolant Valve

DosingModule

Electric Wiring
Electric Heaters
Urea Routing Tank Level Tank Temp.
Sensor
Coolant Routing Sensor

Coolant to Engine
Coolant from Engine11 ►.
 Electric Heated DEF Unit

Electric water
heater

Pressure Sensor (New

Position – Clean Side of
Filter)
Main filter (New filter
element, size
reduced)

Diaphragm pump + reversing valve

Laying the conductor
(New orientation on the case, modified
integrated (instead of
interface)
wiring harness)
 Pump Motor
■uni Diaphragm pump
directional
■ Pump delivery: 20 l/h @ 9
bar (gauge)
■ PWM signal driven pump
motor
■ The same PWM signal wire
is used to transmit the DEF
Unit temperature and the DEF
Unit heater temperature to the
DEF Controller.
■ The pump can only operate
after the DEF Unit has defrosted to prevent
damage.
■ Max current: 4 A @ 14 V
 Reversing Valve

■ Allows purging with the uni-

directional pump
■ Current: 3 A @ 16 V, -
15 °C

Normal Operation Purge

SCR 2010 Aftertreatment

Dosing Valve
Diesel Exhaust Fluid
Post-treatment

SCR boat
Metering Valve

Origin of the name 2

Literature support 4
Engine Features 4
Engine serial number 6
Variable geometry turbocharger 9
Air to air aftercooler 10
Intake manifold 11 Water connector
(SAE J2044)
Exhaust manifold 12
EGR 13
EGR mass flow measurement assembly 18
Air compressors 24 Sealed with O-
Cooling adapter (made of
ring (EPDM)
Cylinder block 26 aluminum)
Crankshaft 30
Shirts 32 Cooling
Connecting rod 36 circuit

Cooling nozzles 37
Reinforcement plate 38
Oil pump 39
Cylinder head 43
Gear housing gasket 44
Injectors 45
Head wiring harness 46
 Block heater 47
Gear Train 48
Oil fill holes 51
Bayonets 52
Crankcase options 50
Lubricating oil filter 53
Features of oil filter 54
Advantages of using this type of filter 55
Lubrication in the turbo 57
Crankcase breather filter 57
Lubrication system flow 60
Oil flow into the head 62
Gear pump 67
New filter head design 68
High pressure common rail 69
Internally Machined Components (FSP) 74
System Function: Injector 75
Fuel pump actuator 77
Fuel return manifold 82
Fuel return 83
to the tank 83
Caution for Technician 85
2010 85
ISX15 Fuel System Checks 87
Filter Differential Pressure 88
Fuel System Leak Test 89
Fuel System Leak Test 92
Leak Test of the 93
Fuel System 93
Failure Analysis Steps 94
Injector Installation Cont. 95
Thermostat 105
Flow path in sectional view 114
Key Features of Air Purge 115
Key Features of the 2010 HC Dispenser 116
Aftertreatment connector 132
Fuel rail pressure sensor 130
Intake manifold pressure/temperature sensor. 131
Barometric pressure sensor 132
Crankshaft speed/position sensor 133
New location of the camshaft position sensor 133
Turbocharger inlet temperature sensor 137
Differential pressure sensor 139
Exhaust gas temperature sensor 140
coolant temperature sensor 142
Oil pressure sensor 143
Oil temperature sensor 144
Crankcase breather pressure sensor 145
Ambient air temperature sensor 144
Water in fuel sensor 146
Sensors present in the DPF 148
NOX sensor. 147
 Second NOX sensor 149
Aftertreatment metering valve 150
DEF tank temperature level sensor 153
Solenoid Assembly 155
What is SCR? 160
DEF Aftertreatment Unit 168
Metering Valve 175
NOx Sensor Function 181
INSITE SCR TEST 183
Dosing Unit 187
Visual check 188

■
microns.
■ Water cooled.
NOx sensors
• 2 per vehicle
• In the engine
• Exhaust pipe outlet
• 4 total part numbers

• In the engine/exhaust pipe

NOx Sensor Function
■ A Zirconium Oxide chamber the size of a thumbnail is heated to 600°C. It is
housed in a metal canister that has a hole for the entry of exhaust gases. The
ZrO2 crystal chamber pumps O2 through the wall when a current is applied on both sides
of the chamber wall. There are two chambers. The first chamber is used to
extract the O2 that is present in the exhaust gases. The NO and NO then pass
to the second chamber where the Platinum coating at 600 °C separates the
NO and NO2 into N2 and O2. O2 is measured when exhaled. Without O there is
no NOx.

Post-treatment components
■ OEM Supplied Aftertreatment Parts
– DEF Line Heaters.
– DEF lines.
– DEF Line Relays.
– DEF Tank.
– DEF Tank Temperature/Level Sensor.
– DEF Tank Heater.
– DEF Tank Heater Control Valve – controls the flow of
coolant to heat the DEF Tank.
– Coolant Lines – to tank and to Aftertreatment DEF
Dosing Valve.

INSITE SCR TEST

■ INSITE
– Aftertreatment DEF Dosing Valve Override Test.
• Similar to today's Aftertreatment Fuel Injector test.
• Requires service tool kit 4919573.
• Aftertreatment DEF Line Heater Test.
• Line 1
• Line 2
• Line 3
• Tank Heater.
 2010 Aftertreatment Dashboard Lamps
– High Exhaust Temperature

■ HEST lamp
– Diesel Particulate Filter

■ DPF lamp
■ Diesel Exhaust Fluid Lamp
– Caution for low level

Malfunction Indicator Lamp (MIL)

OBD (On-Board Diagnostics)
MIL lamp Indication of non-compliance with emissions.

Required
Conditions for Dosing
1. 200 degrees C @ at the Inlet and Outlet of
the
Catalyst
2. No ACTIVE Fault Codes Related to the SCR
System
3. Tank DEF level above 6%
4. -3 degrees C (Temp. DEF)
5. Cummins NOx Calibration
 SCR
aftertreatment system maintenance
Dosing Unit

Manufactured by Bosch
Critical mounting position
It purges automatically when the
key is turned off.
Limited serviceability
– Input filter (mesh)
Do not pressure/jet wash.
Recommended only with a damp
cloth
Do not disconnect the connector
when the vehicle batteries are
connected
Do not try to open the
box
Dosing Unit Filter
■ Filters Diesel Exhaust Fluid entering the dosing unit to prevent
clogging of the dosing unit nozzle
■ Whenever removing make sure
the O-ring is in place when
reinstalling the cover
■ Use only water on the O-ring as a
lubricant/retention enhancer during
installation
■ Refer to service literature for
recommended intervals.
Visual check

■ Visually check
aftertreatment urea lines for
leaks.
■The advantage in this case is that the leaks leave
white residue around them.
2010 ISX15 CM2250
Technical Training
Diesel Exhaust Fluid (DEF)
Service Bulletin 4021566
Diesel Exhaust Fluid Specifications for Cummins® Selective
Catalytic Reduction Systems
This service bulletin provides information for Diesel Exhaust Fluid
(DEF), a fluid that may have a slight ammonia odor, which is used with
Cummins® Selective Catalytic Reduction (SCR) systems. The purpose
of this bulletin is to assist the user in understanding the specifications,
proper use and handling of diesel exhaust fluid, which is:
Non-toxic and non-polluting
Non-flammable
Stable and colorless
Composed of urea and water.
Urea is natural and biodegradable.
NOTE: Diesel Exhaust Fluid is the generic name, but is also
commonly known as AdBlue™ and Aqueous Urea Solution (AUS)
32.
 CAUTION
It is illegal to alter or remove any component of the aftertreatment
system. It is also illegal to use diesel exhaust fluid (DEF) that does not
meet the specifications provided or to operate the vehicle/equipment
without diesel exhaust fluid (DEF).

CAUTION
Diesel exhaust fluid (DEF) contains urea. Do not get the substance into your eyes. In
case of contact, immediately flush eyes with plenty of water for at least 15 minutes.
Do not swallow it. If diesel exhaust fluid is ingested, contact a physician immediately.
Please refer to the Material Safety Data Sheet (MSDS) for additional information.
Data Sheet (MSDS) for additional information.
 CAREFUL
Never attempt to create diesel exhaust fluid by mixing agricultural grade urea with water.
Agricultural grade urea does not meet the required specifications and the aftertreatment
system may be damaged.
■ Diesel Exhaust Fluid Specifications
■ The urea content of the solution shall be 32.5% ± 0.7% by weight and shall
meet International Standard ISO 22241-1 for diesel engines. There is no
accepted substitute.
■ NOTE: Some workshops may refer to DIN 70070 standard. The diesel
exhaust fluid specification limits of this standard are identical to ISO
22241-1.
NOTE: Cummins Inc. is not responsible for failure or damage resulting
from what Cummins Inc. determines to be abuse or neglect, including
but not limited to: operation without the properly specified diesel
exhaust fluid, failure to maintain the aftertreatment system, improper
storage or shutdown practices, unauthorized modifications to the
engine and aftertreatment system. Cummins Inc. is also not
responsible for failures caused by the wrong diesel exhaust fluid or by
water, dirt or other contaminants in the diesel exhaust fluid.
For engines using SCR and operating in the United States and Canada, it is also strongly
recommended that the diesel exhaust fluid (DEF) used be certified by the
Yo American Petroleum Institute (API). This would be indicated by a symbol on
the container/dispensing system,
AMERICAN PETROLEUM
as shown.
INSTITUTE
CAREFUL
CERTIFIED
DIESEL EXHAUST Never add water or any other fluid other than what is specified in the diesel exhaust fluid (DEF) tank.
FLUID
The aftertreatment system may be damaged.
■ Adding water to the diesel exhaust fluid tank:
 – will change the concentration levels of the diesel exhaust fluid, which can affect the efficiency
of the SCR.
– can add contaminants and/or affect the chemical properties of the diesel exhaust fluid, which
can damage the aftertreatment system.
– will alter the freezing point and solution characteristics of the diesel exhaust fluid, potentially
leading to damage to diesel exhaust fluid dosing system components during cold weather
operation.
Handling, Storage, and Shelf Life of Diesel Exhaust Fluid
■ Handling: Diesel exhaust fluid is not hazardous to handle, but over time it can be
reactive and/or corrosive to certain materials:
– Carbon steels, zinc-coated carbon steels and mild iron.
– Non-ferrous metals and alloys: copper, copper alloys, zinc and lead.
– Solders containing lead, silver, zinc or copper.
– Aluminum and its alloys.
– Magnesium and its alloys.
– Nickel-coated plastics or metals.
■ If diesel exhaust fluid comes into contact with any of the materials referenced, wipe it
up immediately. Refer to the Diesel Exhaust Fluid Disposal and Cleanup section of
this service bulletin for additional information.
■ Shelf Life: The following conditions are ideal for maintaining the quality and
shelf life of diesel exhaust fluid during extended transportation and storage:
– Storage temperature between - 5 °C to 25 °C [23 °F to 77 °F].
– Store in closed containers to reduce the possibility of contamination.
– Avoid direct sunlight.
■ Under these conditions, diesel exhaust fluid has a minimum expected shelf life
of 18 months. However, every 5°C [9°F] increase above recommended
 temperatures reduces shelf life by 6 months (e.g. 30°C [86°F] = 12 months
shelf life, 35°C [95°F] = 6 months shelf life, etc.).
■ Storage: Long-term storage in a vehicle (more than 6 months) is not
recommended. If long-term storage is necessary, periodic testing of the diesel
exhaust fluid is recommended to ensure that the concentration does not go out
of specification. Please refer to the Testing section of this service bulletin.
■ For detailed information on handling, transport and storage, refer to ISO 22241-
3.
Diesel Exhaust Fluid Cleaning Practices
■ Materials that come into contact with diesel exhaust fluid must be free of
contamination, oil, fuel, dust, detergents and other chemicals.
■ NOTE: Spilled diesel exhaust fluid, if allowed to dry or simply wiped up
with a rag, will leave a white residue. Failure to clean diesel exhaust
fluid from a surface may result in an incorrectly diagnosed leak from the
diesel exhaust fluid dosing system.
■ Before using containers, funnels, etc. that are used to measure, handle or
store diesel exhaust fluid, be sure to wash them thoroughly to remove
contaminants and then rinse them with distilled water.
■ NOTE : No use water from
components that are
the key to wash the
will be used to deliver diesel exhaust fluid. Tap water contaminates
the fluid of exhaust diesel. Yeah Nowater is available
distilled water, wash them with tap water and then rinse them with
diesel exhaust fluid.
■ Disposal and Cleaning of Diesel Exhaust Fluid.
– If there is a spill, diesel exhaust fluid should be transferred to a suitable container or
covered using an absorbent material and then disposed of in accordance with local
environmental regulations. The container must be properly labeled.
 – Do not empty into the drainage system.
– Do not empty/pour into surface water.
– Very small amounts of diesel exhaust fluid can be flushed away with large volumes
of water.

First aid
■ In case of contact with eyes, immediately flush with plenty of water for at least
15 minutes. Do not swallow it. If diesel exhaust fluid is ingested, contact a
physician immediately.

Diesel Exhaust Fluid Alternate Names/References.

The following are other names used for diesel exhaust fluid (DEF):
■ Urea
■ AUS 32 (Aqueous Urea Solution 32)
■ AdBlue™
■ NOx Reducing Agent
■ Solution for the Catalyst
■ Stableguard 32.
■ Regardless of what diesel exhaust fluid is called, it must meet the
requirements as outlined in the specifications section of this service bulletin.
Proof
■ To test the concentration of diesel exhaust fluid, use the Cummins® Diesel
Exhaust Fluid Refractometer, Part Number 4919554. Follow the
instructions provided with this tool of service.

■ For detailed instructions on testing exhaust fluid diesel, consult

he ISO 22241-2.

Freezing
 CAREFUL
Do not add any chemicals/additives to diesel exhaust fluid in an effort to
prevent freezing. If added
chemicals/additives to the diesel exhaust fluid, the aftertreatment system
can be damaged.
■ Diesel exhaust fluid freezes at approximately -11°C [12°F]. The diesel
exhaust fluid system on the vehicle is designed to handle this and does
not require any intervention from the vehicle operator.

■ For more information, consult the diesel exhaust fluid manufacturer's Material
Safety Data Sheet.

DEF Freezing Point

■ Once the DEF has melted, it can be used without any problem. The first
molten drop has the same consistency as defined in the Diesel Exhaust Fluid
specification.

■ The SCR system is designed to provide heating for the DEF tank and supply
lines which reduces the melting time of frozen DEF.

■ If the DEF freezes, normal vehicle starting and operation are not inhibited so
the operator is not impacted.

Properties of DEF

■ It is non-toxic and non-flammable.

■ Safe to handle and store.

■ It does not pose any serious risk to humans, animals, equipment or the
environment if handled appropriately.

■ The product is slightly alkaline with a pH of approximately 9.0.

DEF Infrastructure

■ Large investments are currently being made in the production of DEF to serve
the on-highway market and will be available in the US in 2010.

■ Pilot has announced that it will manage DEF at the pumps.

■ Flying J, Travel Centers of America & Love's will handle the DEF, but are
still determining at what level.

TravelcentersofA
merica
How Much Will DEF Cost?

■ Automotive grade DEF is only slightly more expensive to produce compared to

Agricultural grade DEF.
■ Requires higher purity urea base material and deionized water.

■ Higher DEF prices are associated with smaller containers and low-volume suppliers.

■ DEF prices loosely track natural gas consumer prices.

Diesel Exhaust Fluid (DEF) Availability and
Accessibility
■ Cummins will use the Cummins Customer Support Center: 1-800-DIESELS

■ 1-800-DIESELS will have the tools to quickly locate DEF

for customers.
- DEF Dealer/Distributor locations.
- DEF Locator Websites.
 Current Existence of DEF in North America

Cummins Filtration product.

These products are mixed with high purity synthetic Urea dissolved in deionized
water.

The finished formula is further filtered to protect the internal components of the
SCR system and improve catalyst life.
How Much DEF Will I Use?

■ Approximately 2% DEF consumption.

 How Can I Determine How Much DEF I Will
Use?
Example…Heavy Duty

Miles per year for an average truck = 120,000 miles.

MPG (Miles per gallon) for the average truck = 6 mpg.

120,000 miles / 6 mpg = 20,000 gallons of diesel fuel per year.

DEF usage @ 2% fuel consumption = 400 gallons DEF/year.

400 gallons/20 gallon tank (average size) = 20 DEF fills/year.

Just Example

How Can I Determine How Much I

 Will DEFUse?
Example…Medium Service

Miles per year for the average truck = 50,000 miles.

MPG for the average truck = 10 mpg.

50,000 miles / 10 mpg = 5,000 gallons of diesel fuel per year.

DEF usage @ 2% of fuel consumption = 100 gallons of DEF/year.

100 gallons/10 gallon tank (average size) = 10 DEF fills/year.

Just example
2010 ISX15 CM2250
OBD Technical Training/Fault
Lamps
■ On-Board Diagnostics (OBD) ensures that the
emission control system is operating as designed.
■ OBD is required to detect any engine and
aftertreatment system faults that adversely affect
emissions.
■ The MIL illuminates to inform the operator of the
fault.

■ Travel
– Definition – condition(s) under which the engine must “run” to run
the diagnostic and ends either by turning the key off or with 4 hours
of engine run time.
 – It can be with the key, at idle, stationary regeneration, etc.
– OBD faults require multiple trips for the MIL to turn on.
– After 1 failed trip, the fault code appears as active in INSITE.
– After the MIL turns on the fault appears as inactive after 1 trip has
passed, the MIL turns off once all trips have passed.
• Example – 3 trips to turn on MIL, 3 trips to clear MIL.

■ Delete the MIL

– Almost all cases are instructed to end at least in 1 trip
and verified at the INSITE where the fault code has been
inactive:
• The conditions for the trip are in the fault tree summary under
Conditions to Clear the Fault Code.
• The MIL is cleared with “Clear All Faults” from INSITE.
– In a few cases where the conditions for carrying out the
trip are difficult:
• The MIL is cleared with “Clear All Faults” from INSITE.
Technical Training 2010
Operator Interface
 Low DEF Tank Level Response
Condition Notification * Fault Code Decrease Disable
Power Caution and
EMD+ HD OBD Decrease
Power

>10% full None None None None None

Minimum 10% full 3497 None Fill DEF tank to
(adjustable 10-90%) DEF Continuous DEF Continuous a minimum of
10% above
• •
stage 1
Minimum 5% full DEF Flash 3498 None Fill DEF tank to
(adjustable 5-87.5%) TO
DEF Flash
a minimum of
2 10% above
stage 2
From minimum 2.5% DEF Flash DEF Flash 1673 25% Fill DEF tank to
to before the tank Ábr Continuous A bar Continuous 3714 Decrease in a minimum of
empties (adjustable Torque 10% above
• •
2.585%). -AAAA- ' -AAAA- '---' stage 3
Lack of DEF detected DEF Flash DEF Flash, Amber 1673 25% Fill DEF tank to
by loss of priming. Amber Continuous, 3714 Decrease in a minimum of
Continuous THOUSAND 1682 Torque 10% above
- •3
-AAAA- z
-•c 3547 stage 3
Empty, after DEF Flash, DEF Flash, Amber 1673 25% - The system
intentionally turning Amber Steady, Continuous, 3714 Decrease in returns to
off the engine or or Steady THOUSAND, 1682 Torque and stage 3 after
prolonged idling. 3547 Speed of the the dosing unit
Continuous red
3712 vehicle increases
221 in w limited to 5 pressure**
The use of audible tones with notification is optional and OEM specific.
** The system will attempt to build pressure on a key cycle or after the tank fills to a level that clears stage 3.
Low DEF Tank Level Response
■ Fault Codes
– FC 3497 Aftertreatment Diesel Exhaust Fluid Tank Level - Data Valid But
Below Normal Operating Range - Least Severe Level.
– FC 3498 Aftertreatment Diesel Exhaust Fluid Tank Level - Data Valid But
Below Normal Operating Range - Moderately Severe Level.
– FC 1673 Aftertreatment Diesel Exhaust Fluid Tank Level - Data Valid But
Below Normal Operating Range – Most Severe Level.
– FC 3714 Motor Protection Torque Decrease – Condition Exists.
– FC 1682 Aftertreatment Diesel Exhaust Fluid Dosing Unit Inlet Lines -
Condition Exists.
– FC 3547 Aftertreatment Diesel Exhaust Fluid Tank Empty - Condition
Exists.
– FC 3712 Aftertreatment SCR Operator Decreased – Condition Exists.
 Response to Incorrect Reducing Agent

Condition Notification Fault Code Decrease

EMD+ HD OBD
Correct reducing None None None None
agent
Correct reducing Amber Caution THOUSAND 3543 None
agent, upon detection Lamp (AWL) Steady Enc
*

Correct reducing AWL THOUSAND AWL 3543 25% Decrease in

agent, on detection + Continue Enc Continue 3714 torque
10 hours * (according to
EPA CISD-09-04
guide)

Correct reducing AWL Red Stop THOUSAND AWL 3543 25% Torque
agent, upon detection Continuous Lamp RSL 3714 reduction and
+ 20 hours and after (RSL) Enc Cont. Cont. 3712 vehicle speed
the engine has been Continuous limited to 5 mph
switched off or at oo
prolonged idling*

Response to Incorrect Reducing Agent

– Fault Codes
* Once the incorrect reducing agent has been detected the vehicle must be taken to the service
center to deactivate the caution lights and reductions.
– FC 3543 NOx limits exceeded due to Insufficient Reagent
Quality - Condition Exists.
– FC 3714 Motor Protection Torque Decrease - Condition
Exists.
– FC 3712 Aftertreatment SCR Operator Decrease -
Condition Exists.
 Response to Special Cause of Failures of the
SCR system
Condition Notification Fault Codes Decrease

EMD+ HD OBD

Normal system None None None None

Special cause of SCR AWL THOUSAND either It varies None
system failure detected Continuous AWL
(see list) * Enc † Continuous

Special cause of SCR AWL THOUSAND either Varies 3714

25% decrease in
system failure Continuous AWL torque (according
detected, at detection Enc ** Continuous to EPA CISD-09-04
+ 10 hours * guide)
AWL RSL THOUSAND Varies 3714 3712 25% torque
Special cause of SCR Cont. Cont. either AWL reduction and
system fault detected, RSL vehicle speed
at detection + 40 either either Enc ** Continuous limited to 5 mph
hours and after engine Continuous
off or long idling.

† The MIL turns on when required by the OBD.

decreases are immediately disabled. OBD
*regulations.
Once the condition that led to the SCR failure has been
Theresolved
MIL lamptheisprecautions
deactivatedand
based on the
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

■ DEF Tank Level Sensor Disconnected.

■ DEF dosing line or valve blocked.
■ DEF dosing valve disconnected.
■ DEF pump disconnected.
■ SCR wiring harness disconnected.
■ NOx sensor disconnected.
■ Fault Codes:
– 1673 - Aftertreatment Diesel Exhaust Fluid Tank Level - Data valid but below normal
operating range - Most Severe Level.
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

– 1678 - Aftertreatment Diesel Exhaust Fluid Tank Temperature Sensor - Voltage above
normal or shorted to high source.
– 1682 - Aftertreatment Diesel Exhaust Fluid Dosing Unit Inlet Lines - Condition Exists.
– 1885 – Aftertreatment Intake NOx Sensor Circuit – Voltage below normal or shorted to
low source.
– 1887 – Aftertreatment Outlet NOx Sensor Circuit – Voltage below normal or shorted to
low supply.
– 2771 - Aftertreatment Outlet NOx Sensor - Update Rate
abnormal.
– 3142 - Aftertreatment SCR Intake Temperature Sensor Circuit - Voltage above normal
or shorted to high source.
– 3146 - Aftertreatment SCR Output Temperature Sensor Circuit - Voltage above
normal or shorted to high source.

■ Fault Codes, cont.:

– 3232 - Aftertreatment Intake NOx Sensor - Update Rate
abnormal.
Origin of the name 2
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

Literature support 4
Engine Features 4
Engine serial number 6
Variable geometry turbocharger 9
Air to air aftercooler 10
Intake manifold 11
Exhaust manifold 12
EGR 13
EGR mass flow measurement assembly 18
Air compressors 24
Cylinder block 26
Crankshaft 30
Shirts 32
Connecting rod 36
Cooling nozzles 37
Reinforcement plate 38
Oil pump 39
Cylinder head 43
Gear housing gasket 44
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

Injectors 45
Head wiring harness 46
Block heater 47
Gear Train 48
Oil fill holes 51
Bayonets 52
Crankcase options 50
Lubricating oil filter 53
Features of oil filter 54
Advantages of using this type of filter 55
Lubrication in the turbo 57
Crankcase breather filter 57
Lubrication system flow 60
Oil flow into the head 62
Gear pump 67
New filter head design 68
High pressure common rail 69
Internally Machined Components (FSP) 74
System Function: Injector 75
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

Fuel pump actuator 77

Fuel return manifold 82
Fuel return 83
to the tank 83
Caution for Technician 85
2010 85
ISX15 Fuel System Checks 87
Filter Differential Pressure 88
Fuel System Leak Test 89
Fuel System Leak Test 92
Leak Test of the 93
Fuel System 93
Failure Analysis Steps 94
Injector Installation Cont. 95
Thermostat 105
Flow path in sectional view 114
Key Features of Air Purge 115
Key Features of the 2010 HC Dispenser 116
Aftertreatment connector 132
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

Fuel rail pressure sensor 130

Intake manifold pressure/temperature sensor. 131
Barometric pressure sensor 132
Crankshaft speed/position sensor 133
New location of the camshaft position sensor 133
Turbocharger inlet temperature sensor 137
Differential pressure sensor 139
Exhaust gas temperature sensor 140
coolant temperature sensor 142
Oil pressure sensor 143
Oil temperature sensor 144
Crankcase breather pressure sensor 145
Ambient air temperature sensor 144
Water in fuel sensor 146
Sensors present in the DPF 148
NOX sensor. 147
Second NOX sensor 149
Aftertreatment metering valve 150
DEF tank temperature level sensor 153
 SCR System Special Cause Failures
To ensure tamper-resistant design as per EPA CISD-09-04 guide

Solenoid Assembly 155

What is SCR? 160
DEF Aftertreatment Unit 168
Metering Valve 175
NOx Sensor Function 181
INSITE SCR TEST 183
Dosing Unit 187
Visual check 188

Aftertreatment - Downstream or open circuit.

– 3543 - NOx limits are exceeded due to Insufficient Reagent Quality - Condition Exists.
– 3547 - Aftertreatment Diesel Exhaust Fluid Tank Empty and - Condition Exists.
– 3564 - Aftertreatment Diesel Exhaust Fluid Line Heater Relay - Current below normal
or open circuit.
– 3567 - Aftertreatment Diesel Exhaust Fluid Metering Valve - Downstream or open
circuit.
– 3576 - Aftertreatment Diesel Exhaust Fluid Tank Heater - Downstream or open circuit.
 SCR System Failure Response
(SCR system failures without special cause resulting in SCR shutting down)
Condition Notification Decrease

EMD+ HD OBD
Normal system None None None

SCR system fault AWL THOUSA AWL None

detected* Continuous ND Continuous

either
Enc ‡
SCR system fault AWL THOUSA AWL Torque Decay
detected, (detection + Continuous ND Continuous (According to EPA
20 hours) * CISD-09-04 Guide)
either
Enc **

* Once the condition that led to the SCR failure has been resolved the precautions and derates are immediately disabled. The MIL
lamp is disabled based on OBD regulations.

‡ The MIL turns on when required by the OBD.

Technical Training 2010
Bad Indicator Lamp
Operation (MIL)
 PACCAR Lamps Graphics

TH Check Engine Turn off

OU engine
SA
ND

DPF lamp HEST lamp DEF lamp

 Daimler Lamps Charts
FTL Standard FCCC

Turn off engine (red)

STOP

FTL Standard FCCC

Check Engine (Amber) Kehece ITP

Standard

Wait to
MIL Lamp (Amber)
Boot (Amber)

Standard

Regenerate DPF (Amber)

LK.TRA LO'*
SLLHLIR DIESEL
FUEL ONLT

Low DEF warning

Standard lamp

Exhaust Temperature (Amber)

 Volvo Lamp Charts

TH Check Engine Turn off DEF lamp

OU engine