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Cummins ISX15 CM2250 Engine Service Manual

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 Windows software format  Instant download

Covers: Cummins ISX15 CM2250 Engine
Format: Software download
File size: 380mb
Compatibility: Windows XP/Vista/7/8/10 only
Notes: Instant download only.

This manual contains instructions for troubleshooting and repairing the Cummins ISX15 CM2250 in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are also included. Please note fault code/electronic troubleshooting and wiring diagram are sold separately.

This service manual software does not require installation and runs on Windows operating systems only. Search and print functions are not available in this software.

Topics in the Cummins ISX15 CM2250 Engine Service Manual:

General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Acronyms and Abbreviations

Engine Identification
Engine Diagrams

Familiarization
Complete Engine – Overview
Cylinder Block – Overview
Cylinder Head – Overview
Rocker Levers – Overview
Fuel System – Overview
Flow Diagram, Fuel System
Injectors and Fuel Lines – Overview
Lubricating Oil System – Overview
Flow Diagram, Lubricating Oil System
Cooling System – Overview
Flow Diagram, Cooling System
Air Intake System – Overview
Flow Diagram, Air Intake System
Exhaust System – Overview
Flow Diagram, Exhaust System
Compressed Air System – Overview
Flow Diagram, Compressed Air System
Electrical Equipment – Overview
Engine Testing – Overview
Vehicle Braking – Overview
Service Tools and Hardware – Overview

Troubleshooting Symptoms
Troubleshooting Procedures and Techniques
Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly
Air Compressor Cycles Frequently
Air Compressor Noise is Excessive
Air Compressor Pumping Excess Lubricating Oil into the Air System
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously
Air Compressor Will Not Pump Air
Air Compressor Will Not Stop Pumping
Aftertreatment Diesel Particulate Filter – Excessive Soot Loading
Aftertreatment Diesel Particulate Filter – Excessive Ash Cleaning
Alternator Not Charging or Insufficient Charging
Alternator Overcharging
Communication Error – Electronic Service Tool or Control Device
Coolant Loss – External
Coolant Loss – Internal
Coolant Temperature Above Normal – Gradual Overheat
Coolant Temperature Above Normal – Sudden Overheat
Coolant Temperature Below Normal
Coolant in the Lubricating Oil
Crankcase Gases (Blowby Excessive
Crankcase Coalescing Filter – Frequent Replacement
Engine Brake Does Not Operate
Engine Brake – Low Retarding Power or Slow to Activate
Engine Brake – One or More Cylinders Braking with Power Switch Off
Engine Decelerates Slowly
Engine Fan Does Not Operate, Operates Erratically, Or Operates Continuously
Engine Noise Excessive
Engine Noise Excessive – Combustion Knocks
Engine Noise Excessive – Connecting Rod
Engine Noise Excessive – Main Bearing
Engine Noise Excessive – Piston
Engine Noise Excessive – Turbocharger
Engine Shuts Off Unexpectedly or Dies During Deceleration
Engine Speed Surges in PTO or Cruise Control
Engine Starts But Will Not Keep Running
Engine Will Not Crank or Cranks Slowly (Air Starter
Engine Will Not Crank or Cranks Slowly (Electric Starter
Engine Will Not Shut Off
Fault Code Warning Lamps Do Not Illuminate
Fuel Consumption Excessive
Fuel in Coolant
Fuel in the Lubricating Oil
Intake Manifold Air Temperature Above Specification
Intake Manifold Pressure (Boost is Below Normal
Lubricating Oil in the Fuel
Lubricating Oil Consumption Excessive
Lubricating Oil Contaminated
Lubricating Oil Filter Plugged
Lubricating Oil Pressure High
Lubricating Oil Pressure Low
Lubricating Oil Sludge in the Crankcase Excessive
Lubricating Oil Temperature Above Specification
Lubricating or Transmission Oil in the Coolant
PTO or Cruise Control Does Not Operate
Turbocharger Leaks Engine Oil or Fuel
Diesel Exhaust Fluid Usage – Abnormal
Stationary Regeneration – Will Not Activate
Aftertreatment dDiesel Particulate Filter – Excessive Automatic and/or Stationary Regeneration
Troubleshooting Overview

Troubleshooting Symptoms (New Format)
Engine Performance Troubleshooting Tree – ISX15 CM2250
Fuel Economy Troubleshooting Tree – ISX15 CM2250
Vibration Excessive
ECM – No Communication Troubleshooting Tree

Engine Disassembly
Engine Removal
Lubricating Oil Filter (Spin-On
Coolant Filter
Pressure Fuel Filter
Engine Wiring Harness
Starting Motor
EGR Crossover Tube
Drive Belt, Cooling Fan
Belt Tensioner, Automatic (Water Pump
Fan Hub, Belt Driven
Drive Belt, Refrigerant Compressor
Idler Pulley, Refrigerant Compressor
Belt Tensioner, Refrigerant Compressor, Automatic
Refrigerant Compressor
Alternator
Vibration Damper, Viscous
Crankcase Breather (External
Lubricating Oil Fill Tube
Air Intake Manifold
Fuel Drain Lines
Injector Supply Lines (High Pressure
Fuel Connector (Head Mounted
Fuel Rail
Bracket, Accessory
Lubricating Oil Dipstick Tube
Electronic Control Module (ECM
Fuel Filter Head
Fuel Manifold (Drain
Fuel Supply Lines
Fuel Lift Pump
Air Compressor Coolant Lines
Air Compressor
Fuel Pump
Fuel Pump Brace
Aftertreatment Purge Air Actuator
Aftertreatment Fuel Shutoff Manifold Air Supply Line
Aftertreatment Fuel Shutoff Manifold
Bracket, Retaining Brace
Aftertreatment Injector Lines
Aftertreatment Fuel Injector
Aftertreatment Outlet NOx Sensor
Aftertreatement Adapter Pipe
Turbocharger Coolant Hoses
Turbocharger Oil Drain Line
Turbocharger
Turbocharger Oil Supply Line
Exhaust Transfer Connection Elbow
EGR Mass Measurement Flow Assembly
EGR Valve
EGR System Hoses
Rear EGR Connection Tube
EGR Cooler Coolant Lines
EGR Cooler Connection
EGR Cooler
EGR Valve Mounting Bracket
Exhaust Gas Pressure Sensor Tube
Heat Shield
Exhaust Manifold, Dry
Coolant Thermostat Housing
Coolant Thermostat
Water Inlet Connection
Water Pump
Lubricating Oil Cooler
Flywheel
Flywheel Housing
Alternator/Refrigerant Compressor Mounting Bracket
Refrigerant Compressor Mounting Bracket
Crankcase Breather Bracket
Gear Cover, Upper
Crankshaft Seal, Front
Gear Cover, Lower
Engine Base Timing
Engine Support Bracket, Front
Gear Housing, Front
Crankshaft Adapter
Crankshaft Tone Wheel
Rocker Lever Cover
Internal Actuator Wiring Harness
Rocker Lever Assembly
Injector
Overhead Camshaft, Valve
Cylinder Head
Lubricating Oil Pan
Lubricating Oil Suction Tube (Block-Mounted
Block Stiffner Plate
Lubricating Oil Pump
Piston Cooling Nozzle
Piston and Connecting Rod Assembly
Bearing, Connecting Rod
Piston Rings
Crankshaft Seal, Rear
Crankshaft
Bearings, Thrust
Bearings, Main
Cylinder Liner
Engine Lifting Brackets

Engine Assembly
Engine Lifting Brackets
Cylinder Liner
Bearings, Main
Bearings, Thrust
Crankshaft
Crankshaft Seal, Rear
Piston Rings
Bearings, Connecting Rod
Piston and Connecting Rod Assembly
Piston Cooling Nozzle
Lubricating Oil Pump
Block Stiffener Plate
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil Pan
Cylinder Head
Overhead Camshaft, Valve
Injector
Rocker Lever Assembly
Overhead Set
Internal Actuator Wiring Harness
Crankshaft Tone Wheel
Crankshaft Adapter
Gear Housing, Front
Engine Support Bracket, Front
Engine Base Timing
Gear Cover, Lower
Crankshaft Seal, Front
Gear Cover, Upper
Crankcase Breather Bracket
Refrigerant Compressor Mounting Bracket
Alternator/Refrigerant Compressor Mounting Bracket
Flywheel Housing
Flywheel
Lubricating Oil Cooler
Water Pump
Water Inlet Connection
Coolant Thermostat
Coolant Thermostat Housing
Exhaust Manifold, Dry
Heat Shield
Exhaust Gas Pressure Sensor Tube
EGR Valve Mounting Bracket
EGR Cooler
EGR Cooler Connection
EGR Cooler Coolant Lines
Rear EGR Connection Tube
EGR System Hoses
EGR Valve
EGR Mass Measurement Flow Assembly
Exhaust Transfer Connection Elbow
Turbocharger Oil Supply Line
Turbocharger
Turbocharger Oil Drain Line
Turbocharger Coolant Hoses
Aftertreatment Adapter Pipe
Aftertreatment Outlet NOx Sensor
Aftertreatment Fuel Injector
Aftertreatment Injector Lines
Bracket, Retaining Brace
Aftertreatment Fuel Shutoff Manifold
Aftertreatment Fuel Shutoff Manifold Air Supply Line
Aftertreatment Purge Air Actuator
Fuel Pump Brace
Fuel Pump
Air Compressor
Air Compressor Coolant Lines
Rocker Lever Cover
Fuel Lift Pump
Fuel Supply Lines
Fuel Manifold (Drain
Fuel Filter Head
Electronic Control Module (ECM
Lubricating Oil Dipstick Tube
Bracket, Accessory
Fuel Rail
Fuel Connector (Head Mounted
Injector Supply Lines (High Pressure
Fuel Drain Lines
Air Intake Manifold
Lubricating Oil Fill Tube
Crankcase Breather (External
Vibration Damper, Viscous
Alternator
Refrigerant Compressor
Belt Tensioner, Refrigerant Compressor, Automatic
Idler Pulley, Refrigerant Compressor
Drive Belt, Refrigerant Compressor
Fan Hub, Belt Driven
Belt Tensioner, Automatic (Water Pump
Drive Belt, Cooling Fan
EGR Crossover Tube
Starting Motor
Engine Wiring Harness
Pressure Fuel Filter
Coolant Filter
Lubricating Oil Filter (Spin-On
Engine Installation

Complete Engine
Service Tools
Engine Removal
Engine Installation
Engine Storage – Long Term
Engine Storage – Short Term
Engine Painting
Engine Steam Cleaning

Cylinder Block
Service Tools
Bearings, Connecting Rod
Bearings, Main
Bearings, Thrust
Connecting Rod
Crankshaft
Crankshaft Adapter
Crankshaft Gear, Front (Crankshaft Installed
Crankshaft Pulley
Crankshaft Seal, Front
Crankshaft Seal, Rear
Cylinder Block
Cylinder Block and Liner Seats
Cylinder Liner
Gear Housing, Front
Piston
Piston Cooling Nozzle
Piston Rings
Vibration Damper, Viscous
Piston and Connecting Rod Assembly
Gear Train Backlash, Front
Crankshaft Tone Wheel
Idler Gear, Lower Scissor
Idler Gear, Adjustable
Gear Cover, Upper
Gear Cover, Lower
Bracket, Retaining Brace
Bracket, Accessory
Idler Gear, Fuel Pump
Engine Base Timing
Block Stiffener Plate
Idler Gear, Upper
Camshaft Tone Wheel

Service Tools
Cylinder Head
Valve Guide Seal, Cylinder Head
Overhead Camshaft, Valve
Overhead Camshaft Bushings, Valve
Overhead Camshaft End Clearance, Valve
Overhead Camshaft Gear, Valve

Service Tools
Crankcase Breather (External
Overhead Set
Rocker Lever Assembly
Rocker Lever Cover
Crankcase Breather Element
Crankcase Breather Bracket

Service Tools
Fuel Consumption
Fuel Pump
Fuel Pump Gear Pump
Fuel Pump Timing
Fuel Lift Pump
Fuel Pump Head Outlet Fitting
Fuel Pump Head
Fuel Pump Actuator Housing
Fuel System Priming
Fuel Pump Brace
Fuel System Diagnostics

Service Tools
Air in Fuel
ECM Cooling Plate, Fuel Cooled
Fuel Drain Line Restriction
Fuel Drain Lines
Fuel Filter Head
Fuel Inlet Restriction
Fuel Manifold (Drain
Fuel Supply Lines
Injector
Injector Supply Lines (High Pressure
Fuel Connector (Head Mounted
Fuel Rail
Fuel Pressure Relief Valve
Pressure Fuel Filter
Fuel Filter Suction

Service Tools
Lubricating Oil Cooler
Lubricating Oil Cooler Element
Lubricating Oil Dipstick
Lubricating Oil Dipstick Tube
Lubricating Oil Filter (Spin-On
Lubricating Oil Filter Bypass Valve
Lubricating Oil Filter Head Adaptor
Lubricating Oil High Pressure Relief Valve
Lubricating Oil Leaks
Lubricating Oil Pan
Lubricating Oil Pressure Gauge
Lubricating Oil Pump
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil System
Lubricating Oil Thermostat
Lubricating Oil Fill Tube
Lubricating Oil and Filter Analysis
Lubricating Oil Fill Cover
Lubricating Oil Filter Differential Pressure Measurement Test

Service Tools
Drive Belt, Cooling Fan
Drive Belt, Water Pump
Coolant Filter
Coolant Filter Valve
Coolant Heater
Coolant Thermostat
Coolant Thermostat Housing
Coolant Thermostat Seal
Coolant Vent Lines
Cooling System
Cooling System – Air or Combustion Gas Test
Cooling System Service Requirements
Fan Clutch, On-Off
Fan Hub, Belt Driven
Fan Shroud Assembly
Fan, Cooling
Radiator
Radiator Hoses
Radiator Pressure Cap
Radiator Shutter Assembly
Supplemental Coolant Additive (SCA
Water Pump
Belt Tensioner, Automatic (Water Pump
Water Inlet Connection
Water Pump Cartridge
Water Transfer Connection

Engine Barring Device
Refrigerant Compressor
Drive Belt, Refrigerant Compressor
Belt Tensioner, Refrigerant Compressor, Automatic
Idler Pulley, Refrigerant Compressor
Refrigerant Compressor Mounting Bracket
Alternator/Refrigerant Compressor Mounting Bracket

Service Tools
Air Inlet Connection
Air Intake Manifold
Air Leaks, Air Intake and Exhaust Systems
Charge-Air Cooler
Air Intake Restriction
Turbocharger
Turbocharger Coolant Hoses
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Intake Manifold Pressure
Variable Geometry Turbocharger Actuator, Electric
Air Shutoff Valve

Service Tools
Exhaust Manifold, Dry
Exhaust Restriction
EGR Cooler
EGR Valve
EGR Cooler Connection
Exhaust Gas Pressure Sensor Tube
EGR Cooler Coolant Lines
Heat Shield
EGR System Hoses
Aftertreatment Selective Catalytic Reduction (SCR Catalyst
Aftertreatment Diesel Particulate Filter
Aftertreatment Fuel Injector
Aftertreatment Adapter Pipe
EGR Valve Mounting Bracket
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes
Aftertreatment Diesel Oxidation Catalyst
Aftertreatment System
Aftertreatment Injector Lines
Aftertreatment Fuel Shutoff Manifold
Aftertreatment Fuel Injector Flow
Exhaust System Diagnostics
Aftertreatment Diesel Exhaust Fluid Controller
Aftertreatment Diesel Exhaust Fluid Dosing Unit
Aftertreatment Diesel Exhaust Fluid Dosing Valve
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
Aftertreatment Fuel Injector Coolant Test
Aftertreatment Decomposition Tube
Aftertreatment Diesel Exhaust Fluid Dosing Unit Override Test
Aftertreatment Purge Air Actuator
EGR Mass Measurement Flow Assembly
Aftertreatment Fuel Shutoff Manifold Air Supply Line
Exhaust Transfer Connection Elbow
Rear EGR Connection Tube
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

Air Compressor Carbon Buildup
Air Compressor Coolant Lines
Air Compressor Cylinder Head, Single Cylinder
Air Compressor Unloader and Valve Assembly
Air Compressor
Air Governor (Air Compressor Will Not Pump
Air Governor (Air Compressor Pumps Continuously
Air Leaks, Compressed Air System
Air Compressor (Oil Carryover
Air Pressure Relief Valve
Air Compressor Inlet Tube

Service Tools
Alternator
Drive Belt, Alternator
Alternator Pulley
Batteries
Battery Cables and Connections
Starter Magnetic Switch
Starter Switch
Starter Solenoid
Starting Motor
Belt Tensioner, Automatic (Alternator
Alternator Spacer
Alternator Idler Pulley

Service Tools
Dynamometer Worksheet
Engine Testing (Chassis Dynamometer
Engine Run-in (Chassis Dynamometer
Engine Run-in (Without Dynamometer
Engine Testing (Engine Dynamometer
Engine Run-in (Engine Dynamometer
Engine Testing (In Chassis
Engine Testing (Portable Dynamometer or Load Bank
Crankcase Blowby, Measure
Aftertreatment Testing

Service Tools
Engine Lifting Brackets
Engine Support Bracket, Front
Flexplate
Flywheel
Flywheel Housing
Flywheel Ring Gear
Engine Mounts

Capscrew
Cup Plug
Dowel Pin
Flexible Hose
Pipe Plug
Ring Dowel
Straight Thread Plug
Straight Thread Fittings
Banjo Connector

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
Electronic Control Module (ECM
ECM Calibration Code
Engine Brake ON/OFF Switch
Engine Brake ON/OFF Switch Circuit
Engine Brake Level Switch
Engine Wiring Harness
Fan Control Circuit
Fault Lamp
Fault Lamp Circuit
Idle Adjust Switch
Idle Adjust Switch Circuit
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
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
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

Engine Brake Assembly
Engine Brake Solenoid Valve
Engine Brake Control Valve
Engine Brake Piston

General Engine
Fuel System
Lubricating Oil System
Cooling System
Air Intake System
Exhaust System
Electrical System
Compressed Air System
Engine Testing
Drive Belt Tension
Fraction, Decimal, Millimeter Conversions
Weights and Measures – Conversion Factors
Newton-Meter to Foot-Pound Conversions
Capscrew Markings and Torque Values
Pipe Plug Torque Values
Tap-Drill Chart – U.S. Customary and Metric
Barometric Pressure at Altitude

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