CUMMINS ENGINE ISX15 ISX CM2250 Service Workshop Manual

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1 Instant Manual Download CUMMINS ENGINE ISX15 ISX CM2250 Service Workshop Manual Download Here CUMMINS ENGINE ISX15 Service Workshop Repair Shop Manual PLEASE NOTE: YOU NEED TO BE CONNECTED TO THE INTERNET TO USE THIS MANUAL, TAKES BETWEEN 2-5 MIN TO LOAD. THIS INSURES YOU HAVE THE MOST UP TO DATE MANUAL WITH ALL BULLETINS. Section i - Introduction ( tr-mixar5) About the Manual ( tr-mixar5) How to Use the Manual ( ) Symbols ( ) Illustrations ( tr-mixar5) General Safety Instructions ( tr-mixar5) General Repair Instructions ( ) General Cleaning Instructions ( ) Acronyms and Abbreviations Section E - Engine and System Identification ( ) Engine Identification ( tr-mixar5) Engine Diagrams Section F - Familiarization ( ) Complete Engine - Overview ( ) Cylinder Block - Overview ( ) Cylinder Head - Overview ( ) Rocker Levers - Overview ( ) Fuel System - Overview ( tr-mixar5) Flow Diagram, Fuel System ( ) Injectors and Fuel Lines - Overview ( ) Lubricating Oil System - Overview ( tr-mixar5) Flow Diagram, Lubricating Oil System ( ) Cooling System - Overview ( tr-mixar5) Flow Diagram, Cooling System ( ) Air Intake System - Overview ( tr-mixar5) Flow Diagram, Air Intake System ( ) Exhaust System - Overview ( tr-mixar5) Flow Diagram, Exhaust System ( ) Compressed Air System - Overview ( tr-mixar5) Flow Diagram, Compressed Air System ( ) Electrical Equipment - Overview

2 ( ) Engine Testing - Overview ( ) Vehicle Braking - Overview ( ) Service Tools and Hardware - Overview Section TS - Troubleshooting Symptoms (99-t tr) Troubleshooting Procedures and Techniques (99-t00-002) Troubleshooting Symptoms Charts ( t004-tr) Air Compressor Air Pressure Rises Slowly ( t005-tr) Air Compressor Cycles Frequently ( t006-tr) Air Compressor Noise is Excessive ( t007-tr) Air Compressor Pumping Excess Lubricating Oil into the Air System ( t008-tr) Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) ( t009-tr) Air Compressor Will Not Pump Air ( t010-tr) Air Compressor Will Not Stop Pumping ( t011-tr) Aftertreatment Diesel Particulate Filter - Excessive Soot Loading ( t012-tr) Aftertreatment Diesel Particulate Filter - Excessive Ash Cleaning ( t013-tr) Alternator Not Charging or Insufficient Charging ( t014-tr) Alternator Overcharging ( t016-tr) Communication Error - Electronic Service Tool or Control Device ( t020-tr) Coolant Loss - External ( t021-tr) Coolant Loss - Internal ( t022-tr) Coolant Temperature Above Normal - Gradual Overheat ( t023-tr) Coolant Temperature Above Normal - Sudden Overheat ( t024-tr) Coolant Temperature Below Normal ( t025-tr) Coolant in the Lubricating Oil ( t027-tr) Crankcase Gases (Blowby) Excessive ( t028-tr) Crankcase Coalescing Filter - Frequent Replacement ( t036-tr) Engine Brake Does Not Operate ( t037-tr) Engine Brake - Low Retarding Power or Slow to Activate ( t038-tr) Engine Brake - One or More Cylinders Braking with Power Switch Off ( t041-tr) Engine Decelerates Slowly ( t046-tr) Engine Fan Does Not Operate, Operates Erratically, Or Operates Continuously ( t047-tr) Engine Noise Excessive ( t048-tr) Engine Noise Excessive - Combustion Knocks ( t049-tr) Engine Noise Excessive - Connecting Rod ( t050-tr) Engine Noise Excessive - Main Bearing ( t051-tr) Engine Noise Excessive - Piston ( t052-tr) Engine Noise Excessive - Turbocharger ( t064-tr) Engine Shuts Off Unexpectedly or Dies During Deceleration ( t068-tr) Engine Speed Surges in PTO or Cruise Control ( t072-tr) Engine Starts But Will Not Keep Running ( t077-tr) Engine Will Not Crank or Cranks Slowly (Air Starter) ( t078-tr) Engine Will Not Crank or Cranks Slowly (Electric Starter) ( t081-tr) Engine Will Not Shut Off ( t084-tr) Fault Code Warning Lamps Do Not Illuminate ( t087-tr) Fuel Consumption Excessive ( t091-tr) Fuel in Coolant ( t092-tr) Fuel in the Lubricating Oil ( t096-tr) Intake Manifold Air Temperature Above Specification ( t097-tr) Intake Manifold Pressure (Boost) is Below Normal ( t101-tr) Lubricating Oil in the Fuel ( t102-tr) Lubricating Oil Consumption Excessive ( t103-tr) Lubricating Oil Contaminated ( t tr) Lubricating Oil Filter Plugged ( t104-tr) Lubricating Oil Pressure High ( t105-tr) Lubricating Oil Pressure Low

3 ( t106-tr) Lubricating Oil Sludge in the Crankcase Excessive ( t107-tr) Lubricating Oil Temperature Above Specification ( t108-tr) Lubricating or Transmission Oil in the Coolant ( t112-tr) PTO or Cruise Control Does Not Operate ( t122-tr) Turbocharger Leaks Engine Oil or Fuel ( t128-tr) Diesel Exhaust Fluid Usage - Abnormal ( t146-tr) Stationary Regeneration - Will Not Activate ( t147-tr) Aftertreatment ddiesel Particulate Filter - Excessive Automatic and/or Stationary Regeneration (132-t00-004) Troubleshooting Overview Section TT - Troubleshooting Symptoms (New Format) (132-t ) Engine Performance Troubleshooting Tree - ISX15 CM2250 (132-feisx10) Fuel Economy Troubleshooting Tree - ISX15 CM2250 (105-t ) Vibration Excessive (00-ttecm) ECM - No Communication Troubleshooting Tree Section DS - Engine Disassembly - Group 00 ( shopds-mixar5) Engine Removal ( shopds-mixar5) Lubricating Oil Filter (Spin-On) ( shopds-mixar5) Coolant Filter ( shopds-mixar5) Pressure Fuel Filter ( shopds-mixar5) Engine Wiring Harness ( shopds-mixar5) Starting Motor ( shopds-mixar5) EGR Crossover Tube ( shopds-mixar5) Drive Belt, Cooling Fan ( shopds-mixar5) Belt Tensioner, Automatic (Water Pump) ( shopds-mixar5) Fan Hub, Belt Driven ( shopds-mixar5) Drive Belt, Refrigerant Compressor ( shopds-mixar5) Idler Pulley, Refrigerant Compressor ( shopds-mixar5) Belt Tensioner, Refrigerant Compressor, Automatic ( shopds-mixar5) Refrigerant Compressor ( shopds-mixar5) Alternator ( shopds-mixar5) Vibration Damper, Viscous ( shopds-mixar5) Crankcase Breather (External) ( shopds-mixar5) Lubricating Oil Fill Tube ( shopds-mixar5) Air Intake Manifold ( shopds-mixar5) Fuel Drain Lines ( shopds-mixar5) Injector Supply Lines (High Pressure) ( shopds-mixar5) Fuel Connector (Head Mounted) ( shopds-mixar5) Fuel Rail ( shopds-mixar5) Bracket, Accessory ( shopds-mixar5) Lubricating Oil Dipstick Tube ( shopds-mixar5) Electronic Control Module (ECM) ( shopds-mixar5) Fuel Filter Head ( shopds-mixar5) Fuel Manifold (Drain) ( shopds-mixar5) Fuel Supply Lines ( shopds-mixar5) Fuel Lift Pump ( shopds-mixar5) Air Compressor Coolant Lines ( shopds-mixar5) Air Compressor ( shopds-mixar5) Fuel Pump ( shopds-mixar5) Fuel Pump Brace ( shopds-mixar5) Aftertreatment Purge Air Actuator ( shopds-mixar5) Aftertreatment Fuel Shutoff Manifold Air Supply Line ( shopds-mixar5) Aftertreatment Fuel Shutoff Manifold ( shopds-mixar5) Bracket, Retaining Brace ( shopds-mixar5) Aftertreatment Injector Lines

4 ( shopds-mixar5) Aftertreatment Fuel Injector ( shopds-mixar5) Aftertreatment Outlet NOx Sensor ( shopds-mixar5) Aftertreatement Adapter Pipe ( shopds-mixar5) Turbocharger Coolant Hoses ( shopds-mixar5) Turbocharger Oil Drain Line ( shopds-mixar5) Turbocharger ( shopds-mixar5) Turbocharger Oil Supply Line ( shopds-mixar5) Exhaust Transfer Connection Elbow ( shopds-mixar5) EGR Mass Measurement Flow Assembly ( shopds-mixar5) EGR Valve ( shopds-mixar5) EGR System Hoses ( shopds-mixar5) Rear EGR Connection Tube ( shopds-mixar5) EGR Cooler Coolant Lines ( shopds-mixar5) EGR Cooler Connection ( shopds-mixar5) EGR Cooler ( shopds-mixar5) EGR Valve Mounting Bracket ( shopds-mixar5) Exhaust Gas Pressure Sensor Tube ( shopds-mixar5) Heat Shield ( shopds-mixar5) Exhaust Manifold, Dry ( shopds-mixar5) Coolant Thermostat Housing ( shopds-mixar5) Coolant Thermostat ( shopds-mixar5) Water Inlet Connection ( shopds-mixar5) Water Pump ( shopds-mixar5) Lubricating Oil Cooler ( shopds-mixar5) Flywheel ( shopds-mixar5) Flywheel Housing ( shopds-mixar5) Alternator/Refrigerant Compressor Mounting Bracket ( shopds-mixar5) Refrigerant Compressor Mounting Bracket ( shopds-mixar5) Crankcase Breather Bracket ( shopds-mixar5) Gear Cover, Upper ( shopds-mixar5) Crankshaft Seal, Front ( shopds-mixar5) Gear Cover, Lower ( shopds-mixar5) Engine Base Timing ( shopds-mixar5) Engine Support Bracket, Front ( shopds-mixar5) Gear Housing, Front ( shopds-mixar5) Crankshaft Adapter ( shopds-mixar5) Crankshaft Tone Wheel ( shopds-mixar5) Rocker Lever Cover ( shopds-mixar5) Internal Actuator Wiring Harness ( shopds-mixar5) Rocker Lever Assembly ( shopds-mixar5) Injector ( shopds-mixar5) Overhead Camshaft, Valve ( shopds-mixar5) Cylinder Head ( shopds-mixar5) Lubricating Oil Pan ( shopds-mixar5) Lubricating Oil Suction Tube (Block-Mounted) ( shopds-mixar5) Block Stiffner Plate ( shopds-mixar5) Lubricating Oil Pump ( shopds-mixar5) Piston Cooling Nozzle ( shopds-mixar5) Piston and Connecting Rod Assembly ( shopds-mixar5) Bearing, Connecting Rod ( shopds-mixar5) Piston Rings ( shopds-mixar5) Crankshaft Seal, Rear ( shopds-mixar5) Crankshaft ( shopds-mixar5) Bearings, Thrust ( shopds-mixar5) Bearings, Main ( shopds-mixar5) Cylinder Liner ( shopds-mixar5) Engine Lifting Brackets

5 Section AS - Engine Assembly - Group 00 ( shopas-mixar5) Engine Lifting Brackets ( shopas-mixar5) Cylinder Liner ( shopas-mixar5) Bearings, Main ( shopas-mixar5) Bearings, Thrust ( shopas-mixar5) Crankshaft ( shopas-mixar5) Crankshaft Seal, Rear ( shopas-mixar5) Piston Rings ( shopas-mixar5) Bearings, Connecting Rod ( shopas-mixar5) Piston and Connecting Rod Assembly ( shopas-mixar5) Piston Cooling Nozzle ( shopas-mixar5) Lubricating Oil Pump ( shopas-mixar5) Block Stiffener Plate ( shopas-mixar5) Lubricating Oil Suction Tube (Block-Mounted) ( shopas-mixar5) Lubricating Oil Pan ( shopas-mixar5) Cylinder Head ( shopas-mixar5) Overhead Camshaft, Valve ( shopas-mixar5) Injector ( shopas-mixar5) Rocker Lever Assembly ( shopas-mixar5) Overhead Set ( shopas-mixar5) Internal Actuator Wiring Harness ( shopas-mixar5) Crankshaft Tone Wheel ( shopas-mixar5) Crankshaft Adapter ( shopas-mixar5) Gear Housing, Front ( shopas-mixar5) Engine Support Bracket, Front ( shopas-mixar5) Engine Base Timing ( shopas-mixar5) Gear Cover, Lower ( shopas-mixar5) Crankshaft Seal, Front ( shopas-mixar5) Gear Cover, Upper ( shopas-mixar5) Crankcase Breather Bracket ( shopas-mixar5) Refrigerant Compressor Mounting Bracket ( shopas-mixar5) Alternator/Refrigerant Compressor Mounting Bracket ( shopas-mixar5) Flywheel Housing ( shopas-mixar5) Flywheel ( shopas-mixar5) Lubricating Oil Cooler ( shopas-mixar5) Water Pump ( shopas-mixar5) Water Inlet Connection ( shopas-mixar5) Coolant Thermostat ( shopas-mixar5) Coolant Thermostat Housing ( shopas-mixar5) Exhaust Manifold, Dry ( shopas-mixar5) Heat Shield ( shopas-mixar5) Exhaust Gas Pressure Sensor Tube ( shopas-mixar5) EGR Valve Mounting Bracket ( shopas-mixar5) EGR Cooler ( shopas-mixar5) EGR Cooler Connection ( shopas-mixar5) EGR Cooler Coolant Lines ( shopas-mixar5) Rear EGR Connection Tube ( shopas-mixar5) EGR System Hoses ( shopas-mixar5) EGR Valve ( shopas-mixar5) EGR Mass Measurement Flow Assembly ( shopas-mixar5) Exhaust Transfer Connection Elbow ( shopas-mixar5) Turbocharger Oil Supply Line ( shopas-mixar5) Turbocharger ( shopas-mixar5) Turbocharger Oil Drain Line ( shopas-mixar5) Turbocharger Coolant Hoses ( shopas-mixar5) Aftertreatment Adapter Pipe

6 ( shopas-mixar5) Aftertreatment Outlet NOx Sensor ( shopas-mixar5) Aftertreatment Fuel Injector ( shopas-mixar5) Aftertreatment Injector Lines ( shopas-mixar5) Bracket, Retaining Brace ( shopas-mixar5) Aftertreatment Fuel Shutoff Manifold ( shopas-mixar5) Aftertreatment Fuel Shutoff Manifold Air Supply Line ( shopas-mixar5) Aftertreatment Purge Air Actuator ( shopas-mixar5) Fuel Pump Brace ( shopas-mixar5) Fuel Pump ( shopas-mixar5) Air Compressor ( shopas-mixar5) Air Compressor Coolant Lines ( shopas-mixar5) Rocker Lever Cover ( shopas-mixar5) Fuel Lift Pump ( shopas-mixar5) Fuel Supply Lines ( shopas-mixar5) Fuel Manifold (Drain) ( shopas-mixar5) Fuel Filter Head ( shopas-mixar5) Electronic Control Module (ECM) ( shopas-mixar5) Lubricating Oil Dipstick Tube ( shopas-mixar5) Bracket, Accessory ( shopas-mixar5) Fuel Rail ( shopas-mixar5) Fuel Connector (Head Mounted) ( shopas-mixar5) Injector Supply Lines (High Pressure) ( shopas-mixar5) Fuel Drain Lines ( shopas-mixar5) Air Intake Manifold ( shopas-mixar5) Lubricating Oil Fill Tube ( shopas-mixar5) Crankcase Breather (External) ( shopas-mixar5) Vibration Damper, Viscous ( shopas-mixar5) Alternator ( shopas-mixar5) Refrigerant Compressor ( shopas-mixar5) Belt Tensioner, Refrigerant Compressor, Automatic ( shopas-mixar5) Idler Pulley, Refrigerant Compressor ( shopas-mixar5) Drive Belt, Refrigerant Compressor ( shopas-mixar5) Fan Hub, Belt Driven ( shopas-mixar5) Belt Tensioner, Automatic (Water Pump) ( shopas-mixar5) Drive Belt, Cooling Fan ( shopas-mixar5) EGR Crossover Tube ( shopas-mixar5) Starting Motor ( shopas-mixar5) Engine Wiring Harness ( shopas-mixar5) Pressure Fuel Filter ( shopas-mixar5) Coolant Filter ( shopas-mixar5) Lubricating Oil Filter (Spin-On) ( shopas-mixar5) Engine Installation Section 0 - Complete Engine - Group 00 ( _00) Service Tools ( tr-mixar5) Engine Removal ( tr-mixar5) Engine Installation ( tr) Engine Storage - Long Term ( tr-mixar5) Engine Storage - Short Term ( ) Engine Painting ( ) Engine Steam Cleaning Section 1 - Cylinder Block - Group 01 ( _01) Service Tools ( tr-mixar5) Bearings, Connecting Rod ( tr-mixar5) Bearings, Main ( tr-mixar5) Bearings, Thrust

7 ( tr-mixar5) Connecting Rod ( tr-mixar5) Crankshaft ( tr-mixar5) Crankshaft Adapter ( ) Crankshaft Gear, Front (Crankshaft Installed) ( tr-mixar5) Crankshaft Pulley ( tr-mixar5) Crankshaft Seal, Front ( tr-mixar5) Crankshaft Seal, Rear ( tr-mixar5) Cylinder Block ( tr-mixar5) Cylinder Block and Liner Seats ( tr-mixar5) Cylinder Liner ( tr-mixar5) Gear Housing, Front ( tr-mixar5) Piston ( tr-mixar5) Piston Cooling Nozzle ( tr-mixar5) Piston Rings ( tr-mixar5) Vibration Damper, Viscous ( tr-mixar5) Piston and Connecting Rod Assembly ( tr-mixar5) Gear Train Backlash, Front ( tr-mixar5) Crankshaft Tone Wheel ( tr-mixar5) Idler Gear, Lower Scissor ( tr-mixar5) Idler Gear, Adjustable ( tr-mixar5) Gear Cover, Upper ( tr-mixar5) Gear Cover, Lower ( tr-mixar5) Bracket, Retaining Brace ( tr-mixar5) Bracket, Accessory ( tr-mixar5) Idler Gear, Fuel Pump ( tr-mixar5) Engine Base Timing ( tr-mixar5) Block Stiffener Plate ( tr-mixar5) Idler Gear, Upper ( tr-mixar5) Camshaft Tone Wheel Section 2 - Cylinder Head - Group 02 ( _02) Service Tools ( tr-mixar5) Cylinder Head ( tr-mixar5) Valve Guide Seal, Cylinder Head ( tr-mixar5) Overhead Camshaft, Valve ( tr-mixar5) Overhead Camshaft Bushings, Valve ( tr-mixar5) Overhead Camshaft End Clearance, Valve ( tr-mixar5) Overhead Camshaft Gear, Valve Section 3 - Rocker Levers - Group 03 ( _03) Service Tools ( tr-mixar5) Crankcase Breather (External) ( tr-mixar5) Overhead Set ( tr-mixar5) Rocker Lever Assembly ( tr-mixar5) Rocker Lever Cover ( tr-mixar5) Crankcase Breather Element ( tr-mixar5) Crankcase Breather Bracket Section 5 - Fuel System - Group 05 ( _05) Service Tools ( ) Fuel Consumption ( tr-mixar5) Fuel Pump ( tr-mixar5) Fuel Pump Gear Pump ( tr-mixar5) Fuel Pump Timing ( tr-mixar5) Fuel Lift Pump ( tr-mixar5) Fuel Pump Head Outlet Fitting ( tr-mixar5) Fuel Pump Head

8 ( tr-mixar5) Fuel Pump Actuator Housing ( tr-mixar5) Fuel System Priming ( tr-mixar5) Fuel Pump Brace ( tr-mixar5) Fuel System Diagnostics Section 6 - Injectors and Fuel Lines - Group 06 ( _06) Service Tools ( tr-mixar5) Air in Fuel ( tr-mixar5) ECM Cooling Plate, Fuel Cooled ( ) Fuel Drain Line Restriction ( tr-mixar5) Fuel Drain Lines ( tr-mixar5) Fuel Filter Head ( tr-mixar5) Fuel Inlet Restriction ( tr-mixar5) Fuel Manifold (Drain) ( tr-mixar5) Fuel Supply Lines ( tr-mixar5) Injector ( tr-mixar5) Injector Supply Lines (High Pressure) ( tr-mixar5) Fuel Connector (Head Mounted) ( tr-mixar5) Fuel Rail ( tr-mixar5) Fuel Pressure Relief Valve ( tr-mixar5) Pressure Fuel Filter ( tr-mixar5) Fuel Filter Suction Section 7 - Lubricating Oil System - Group 07 ( _07) Service Tools ( tr-mixar5) Lubricating Oil Cooler ( tr-mixar5) Lubricating Oil Cooler Element ( tr-mixar5) Lubricating Oil Dipstick ( tr-mixar5) Lubricating Oil Dipstick Tube ( tr-mixar5) Lubricating Oil Filter (Spin-On) ( tr-mixar5) Lubricating Oil Filter Bypass Valve ( tr-mixar5) Lubricating Oil Filter Head Adaptor ( tr-mixar5) Lubricating Oil High Pressure Relief Valve ( tr-mixar5) Lubricating Oil Leaks ( tr-mixar5) Lubricating Oil Pan ( ) Lubricating Oil Pressure Gauge ( tr-mixar5) Lubricating Oil Pump ( tr-mixar5) Lubricating Oil Suction Tube (Block-Mounted) ( tr-mixar5) Lubricating Oil System ( tr-mixar5) Lubricating Oil Thermostat ( tr-mixar5) Lubricating Oil Fill Tube ( ) Lubricating Oil and Filter Analysis ( ) Lubricating Oil Fill Cover ( ) Lubricating Oil Filter Differential Pressure Measurement Test Section 8 - Cooling System - Group 08 ( _08) Service Tools ( tr-mixar5) Drive Belt, Cooling Fan ( tr-mixar5) Drive Belt, Water Pump ( tr-mixar5) Coolant Filter ( tr-mixar5) Coolant Filter Valve ( tr-mixar5) Coolant Heater ( tr-mixar5) Coolant Thermostat ( tr-mixar5) Coolant Thermostat Housing ( tr-mixar5) Coolant Thermostat Seal ( ) Coolant Vent Lines ( tr-mixar5) Cooling System

9 ( tr-mixar5) Cooling System - Air or Combustion Gas Test ( ) Cooling System Service Requirements ( ) Fan Clutch, On-Off ( tr-mixar5) Fan Hub, Belt Driven ( ) Fan Shroud Assembly ( ) Fan, Cooling ( ) Radiator ( ) Radiator Hoses ( tr-mixar5) Radiator Pressure Cap ( ) Radiator Shutter Assembly ( tr-mixar5) Supplemental Coolant Additive (SCA) ( tr-mixar5) Water Pump ( tr-mixar5) Belt Tensioner, Automatic (Water Pump) ( tr-mixar5) Water Inlet Connection ( tr-mixar5) Water Pump Cartridge ( tr-mixar5) Water Transfer Connection Section 9 - Drive Units - Group 09 ( ) Engine Barring Device ( tr-mixar5) Refrigerant Compressor ( tr-mixar5) Drive Belt, Refrigerant Compressor ( tr-mixar5) Belt Tensioner, Refrigerant Compressor, Automatic ( tr-mixar5) Idler Pulley, Refrigerant Compressor ( tr-mixar5) Refrigerant Compressor Mounting Bracket ( tr-mixar5) Alternator/Refrigerant Compressor Mounting Bracket Section 10 - Air Intake System - Group 10 ( _10) Service Tools ( ) Air Inlet Connection ( tr-mixar5) Air Intake Manifold ( tr-mixar5) Air Leaks, Air Intake and Exhaust Systems ( ) Charge-Air Cooler ( ) Air Intake Restriction ( tr-mixar5) Turbocharger ( tr-mixar5) Turbocharger Coolant Hoses ( tr-mixar5) Turbocharger Oil Drain Line ( tr-mixar5) Turbocharger Oil Supply Line ( ) Intake Manifold Pressure ( tr-mixar5) Variable Geometry Turbocharger Actuator, Electric ( tr-mixar5) Air Shutoff Valve Section 11 - Exhaust System - Group 11 ( _11) Service Tools ( tr-mixar5) Exhaust Manifold, Dry ( tr-mixar5) Exhaust Restriction ( tr-mixar5) EGR Cooler ( tr-mixar5) EGR Valve ( tr-mixar5) EGR Cooler Connection ( tr-mixar5) Exhaust Gas Pressure Sensor Tube ( tr-mixar5) EGR Cooler Coolant Lines ( tr-mixar5) Heat Shield ( ) EGR System Hoses ( tr-mixar5) Aftertreatment Selective Catalytic Reduction (SCR) Catalyst ( tr-mixar5) Aftertreatment Diesel Particulate Filter ( tr-mixar5) Aftertreatment Fuel Injector ( tr-mixar5) Aftertreatment Adapter Pipe ( tr-mixar5) EGR Valve Mounting Bracket

10 ( tr-mixar5) Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket ( tr-mixar5) Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes ( tr-mixar5) Aftertreatment Diesel Oxidation Catalyst ( tr-mixar5) Aftertreatment System ( tr-mixar5) Aftertreatment Injector Lines ( tr-mixar5) Aftertreatment Fuel Shutoff Manifold ( tr-mixar5) Aftertreatment Fuel Injector Flow ( ) Exhaust System Diagnostics ( ) Aftertreatment Diesel Exhaust Fluid Controller ( ) Aftertreatment Diesel Exhaust Fluid Dosing Unit ( ) Aftertreatment Diesel Exhaust Fluid Dosing Valve ( tr-mixar5) Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter ( tr-mixar5) Aftertreatment Fuel Injector Coolant Test ( ) Aftertreatment Decomposition Tube ( ) Aftertreatment Diesel Exhaust Fluid Dosing Unit Override Test ( ) Aftertreatment Purge Air Actuator ( tr-mixar5) EGR Mass Measurement Flow Assembly ( tr-mixar5) Aftertreatment Fuel Shutoff Manifold Air Supply Line ( tr-mixar5) Exhaust Transfer Connection Elbow ( tr-mixar5) Rear EGR Connection Tube ( tr-mixar5) EGR Crossover Tube ( ) Exhaust Manifold Turbocharger Mounting Stud Replacement ( ) Aftertreatment Outlet ( ) Air in the Diesel Exhaust Fluid ( ) Aftertreatment SCR Catalyst Temperature Sensor Interface Module Mounting Bracket ( ) Aftertreatment Diesel Exhaust Fluid Controller Calibration Code ( ) Aftertreatment Intake NOx Sensor Bracket ( ) Aftertreatment Diesel Exhaust Fluid System Leak Test Section 12 - Compressed Air System - Group 12 ( tr-mixar5) Air Compressor Carbon Buildup ( tr-mixar5) Air Compressor Coolant Lines ( ) Air Compressor Cylinder Head, Single Cylinder ( ) Air Compressor Unloader and Valve Assembly ( tr-mixar5) Air Compressor ( ) Air Governor (Air Compressor Will Not Pump) ( ) Air Governor (Air Compressor Pumps Continuously) ( ) Air Leaks, Compressed Air System ( ) Air Compressor (Oil Carryover) ( tr-mixar5) Air Pressure Relief Valve ( ) Air Compressor Inlet Tube Section 13 - Electrical Equipment - Group 13 ( _13) Service Tools ( tr-mixar5) Alternator ( tr-mixar5) Drive Belt, Alternator ( ) Alternator Pulley ( ) Batteries ( ) Battery Cables and Connections ( ) Starter Magnetic Switch ( ) Starter Switch ( ) Starter Solenoid ( tr-mixar5) Starting Motor ( tr-mixar5) Belt Tensioner, Automatic (Alternator)

11 ( tr-mixar5) Alternator Spacer ( tr-mixar5) Alternator Idler Pulley Section 14 - Engine Testing - Group 14 ( _14) Service Tools ( ) Dynamometer Worksheet ( tr-mixar5) Engine Testing (Chassis Dynamometer) ( tr-mixar5) Engine Run-in (Chassis Dynamometer) ( ) Engine Run-in (Without Dynamometer) ( tr-mixar5) Engine Testing (Engine Dynamometer) ( tr-mixar5) Engine Run-in (Engine Dynamometer) ( ) Engine Testing (In Chassis) ( ) Engine Testing (Portable Dynamometer or Load Bank) ( tr-mixar5) Crankcase Blowby, Measure ( ) Aftertreatment Testing Section 16 - Mounting Adaptations - Group 16 ( _16) Service Tools ( tr-mixar5) Engine Lifting Brackets ( tr-mixar5) Engine Support Bracket, Front ( tr-mixar5) Flexplate ( tr-mixar5) Flywheel ( tr-mixar5) Flywheel Housing ( tr-mixar5) Flywheel Ring Gear ( ) Engine Mounts Section 17 - Miscellaneous - Group 17 ( ) Capscrew ( ) Cup Plug ( ) Dowel Pin ( ) Flexible Hose ( ) Pipe Plug ( ) Ring Dowel ( tr-mixar5) Straight Thread Plug ( ) Straight Thread Fittings ( ) Banjo Connector Section 19 - Electronic Engine Controls - Group 19 ( _19) Service Tools ( ) Barometric Air Pressure Sensor ( ) Battery Ground Circuit ( ) Clutch Pedal Position Switch ( ) Clutch Pedal Position Switch Circuit ( ) Engine Coolant Level Sensor ( ) Engine Coolant Temperature Sensor ( ) Cruise Control or PTO ON/OFF Switch ( ) Cruise Control or PTO ON/OFF Switch Circuit ( ) Cruise Control or PTO ON/OFF Set/Resume Select Switch ( ) Cruise Control or PTO ON/OFF Set/Resume Select Switch Circuit ( ) Diagnostic Test Mode Switch ( ) Diagnostic Test Mode Switch Circuit ( tr-mixar5) Electronic Control Module (ECM) ( ) ECM Calibration Code ( ) Engine Brake ON/OFF Switch ( ) Engine Brake ON/OFF Switch Circuit ( ) Engine Brake Level Switch ( tr-mixar5) Engine Wiring Harness

12 ( ) Fan Control Circuit ( ) Fault Lamp ( ) Fault Lamp Circuit ( ) Idle Adjust Switch ( ) Idle Adjust Switch Circuit ( tr-mixar5) Internal Actuator Wiring Harness ( ) Key Switch Battery Supply Circuit ( ) Engine Oil Pressure Sensor ( ) Engine Oil Temperature Sensor ( ) OEM Wiring Harness ( ) Programmable Features and Parameters Not Correct ( ) Remote PTO Switch Circuit ( ) Remote PTO Switch ( ) Tachometer Circuit ( ) Accelerator Pedal or Lever Position Sensor ( ) Unswitched Battery Supply Circuit ( ) Brake Pedal Position Switch ( ) Brake Pedal Position Switch Circuit ( ) Vehicle Speed Sensor, Magnetic Pick Up ( ) Vehicle Speed Sensor Circuit ( ) Rail Fuel Pressure Sensor ( ) Fuel Pump Actuator ( ) Water in Fuel Sensor ( ) Intake Manifold Pressure/Temperature Sensor ( ) Data Link Circuit, SAE J1939 ( ) Ring Terminal ( ) Fuse, Harness In-Line ( ) Connector, Butt Splice ( ) Weather Pak Connector Series ( ) Metripack Connector Series ( ) Deutsch DRC Connector Series ( ) Deutsch DT Connector Series ( ) Deutsch DTM and DTP Connector Series ( ) Deutsch HD10 Connector Series ( ) Deutsch HDP20 and HD30 Connector Series ( ) Bosch Actuator and Sensor Connector Series ( ) Framatome Connector Series ( ) Power Train Protection Switch ( ) Power Train Protection Switch Circuit ( ) Air Conditioner Pressure Switch ( ) Air Conditioner Pressure Switch Circuit ( ) Accelerator Interlock Switch ( ) Accelerator Interlock Switch Circuit ( ) Cab Switchable Governor Switch ( ) Cab Switchable Governor Switch Circuit ( ) Switched Maximum Operating Speed Switch ( ) Switched Maximum Operating Speed Switch Circuit ( ) Engine Protection Override Switch ( ) Engine Protection Override Switch Circuit ( ) Remote Accelerator Switch ( ) Remote Accelerator Switch Circuit ( ) Engine Torque Limit Control Switch ( ) Engine Torque Limit Control Switch Circuit ( ) Multimeter Usage ( ) Resistance Measurement Using a Multimeter ( ) Component Connector and Pin Inspection ( ) Inactive or Intermittent Fault Code

13 ( ) Camshaft Position Sensor ( ) Crankshaft Position Sensor ( ) EGR Differential Pressure Sensor ( ) Exhaust Gas Pressure Sensor ( ) EGR Temperature Sensor ( ) Fan Control Switch ( ) Fan Control Switch Circuit ( ) Maximum Engine Speed Switch ( ) Maximum Engine Speed Switch Circuit ( ) Turbocharger Speed Sensor ( ) Turbocharger Compressor Intake Air Temperature Sensor ( ) Fuel Lift Pump Circuit ( ) OEM Pressure Sensor ( ) OEM Pressure Sensor Circuit ( ) OEM Temperature Sensor ( ) OEM Temperature Sensor Circuit ( ) ECM ROM Boot ( ) Engine Datalinks ( ) Aftertreatment Diesel Particulate Filter Differential Pressure Sensor ( ) Aftertreatment Fuel Pressure Sensor ( ) Crankcase Pressure Sensor ( ) Aftertreatment Exhaust Gas Temperature Sensor ( tr-mixar5) Aftertreatment Outlet NOx Sensor ( ) EGR Orifice Pressure Sensor ( ) Aftertreatment Diesel Particulate Filter Temperature Sensor Interface Module ( ) Aftertreatment Intake NOx Sensor ( ) Aftertreatment SCR Catalyst Temperature Sensor Interface Module ( ) Bosch Aftertreatment DEF Controller Connector Section 20 - Vehicle Braking - Group 20 ( tr-mixar5) Engine Brake Assembly ( ) Engine Brake Solenoid Valve ( ) Engine Brake Control Valve ( ) Engine Brake Piston Section L - Service Literature ( tr-mixar5) Additional Service Literature ( ) Service Literature Ordering Location ( ) Cummins Customized Parts Catalog Section V - Specifications PLEASE NOTE: YOU NEED TO BE CONNECTED TO THE INTERNET TO USE THIS MANUAL, TAKES BETWEEN 2-5 MIN TO LOAD. THIS INSURES YOU HAVE THE MOST UP TO DATE MANUAL WITH ALL BULLETINS. Download Here

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