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Cummins ISX 11.9 CM2250 Engine Service Repair Manual

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Product Description

 Software format  Instant download

Covers: Cummins ISX11.9 CM2250 Engine
Format: Software download
Compatibility: Windows XP/Vista/7/8/10 only
File size: 431mb

This manual contains instructions for troubleshooting and repairing the Cummins ISX11.9 CM2250 in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are also included. This repair manual software does not require installation and runs on Windows operating systems only.

Topics in the Cummins ISX 11.9 CM2250 Service Repair Manual Software:

Engine and System Identification
Engine Identification
Engine Diagrams

Familiarization
Complete Engine – Overview
Cylinder Block – Overview
Cylinder Head – Overview
Rocker Levers – Overview
Cam Followers/Tappets – 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

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
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
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
Aftertreatment Diesel Particulate Filter – Excessive Automatic and/or Stationary Regeneration
Troubleshooting Overview

Troubleshooting Symptoms (New Format)
Engine Performance Troubleshooting Tree – ISX11.9 CM2250
Fuel Economy Troubleshooting Tree – ISX11.9 CM2250
Vibration Excessive
ECM – No Communication Troubleshooting Tree

Engine Disassembly
Aftertreatment System
Engine Removal
Lubricating Oil System
Lubricating Oil Filter (Spin-On
Coolant Filter
Pressure Fuel Filter
Starting Motor
Drive Belt, Cooling Fan
Drive Belt, Refrigerant Compressor
Cooling Fan Belt Tensioner
Belt Tensioner, Refrigerant Compressor, Automatic
Alternator
Refrigerant Compressor
Alternator/Refrigerant Compressor Mounting Bracket
Fan Pulley
Fan Hub, Belt Driven
Engine Wiring Harness
Electronic Control Module (ECM
Lubricating Oil Dipstick Tube
EGR Crossover Tube
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Aftertreatment Injector Lines
Turbocharger Coolant Hoses
Aftertreatment Fuel Injector
Aftertreatment Intake NOx Sensor
Aftertreatment Intake NOx Sensor Bracket
Aftertreatment Adapter Pipe
Turbocharger
EGR Mass Measurement Flow Assembly
EGR Valve
Rear EGR Connection Tube
EGR Cooler Coolant Lines
EGR Cooler Connection
EGR Cooler
EGR Valve Mounting Bracket
Water Inlet Connection
Coolant Bypass Tube
Coolant Thermostat
Coolant Filter Head
Water Pump
Exhaust Manifold, Dry
Engine Lifting Brackets
Aftertreatment Fuel Shutoff Manifold Air Supply Line
Aftertreatment Fuel Shutoff Manifold
Fuel Drain Lines
Fuel Supply Lines
Aftertreatment Purge Air Actuator
Fuel Manifold (Drain
Air Compressor Inlet Tube
Air Intake Connection
Fuel Lift Pump
Fuel Filter Head
Crankcase Breather Tube
Crankcase Breather (External
Air Intake Manifold
Air Compressor Coolant Lines
Crankcase Breather Bracket
Injector Supply Lines (High Pressure
Fuel Rail
Rocker Lever Cover
Engine Brake
Push Rods or Tubes
Rocker Lever Assembly
Crosshead
Fuel Connector (Head Mounted
Injector
Internal Actuator Wiring Harness
Rocker Lever Housing
Gear Cover, Front
Hydraulic Pump Drive
Lubricating Oil Cooler
Lubricating Oil Filter Head
Lubricating Oil Fill Tube
Air Compressor
Fuel Pump Gear Pump
Fuel Pump
Water Manifold
Cylinder Head
Cam Follower Assembly
Lubricating Oil Pan
Lubricating Oil Suction Tube (Block-Mounted
Oil Transfer Connection
Lubricating Oil Transfer Tube
Lubricating Oil Pump
Flexplate
Flywheel
PTO, Front
Crankshaft Pulley
Vibration Damper, Viscous
Engine Support Bracket, Front
Crankshaft Seal, Rear
Crankshaft Seal, Front
Idler Gear, Hydraulic Pump
Idler Gear, Camshaft
Camshaft Cover Plate
REPTO
Flywheel Housing
Idler Gear, Camshaft Rear
Camshaft Gear, Rear
Camshaft
Block Stiffener Plate
Piston Cooling Nozzle
Piston and Connecting Rod Assembly
Bearings, Connecting Rod
Piston Rings
Gear Housing, Front
Gear Housing, Rear
Front Cover Seal Plate
Coolant Heater
Water Header Plate, Cylinder Block
Lubricating Oil Fill Cover
Front Lubricating Oil Transfer Cover
Crankshaft
Bearings, Thrust
Bearings, Main
Cylinder Liner

Engine Assembly
Cylinder Liner
Bearings, Main
Bearings, Thrust
Crankshaft
Front Lubricating Oil Transfer Cover
Lubricating Oil Fill Cover
Water Header Plate, Cylinder Block
Coolant Heater
Front Cover Seal Plate
Gear Housing, Rear
Gear Housing, Front
Piston Rings
Bearings, Connecting Rod
Piston and Connecting Rod Assembly
Piston Cooling Nozzle
Block Stiffener Plate
Camshaft
Camshaft Gear, Rear
Idler Gear, Camshaft Rear
Flywheel Housing
REPTO
Camshaft Cover Plate
Idler Gear, Camshaft
Idler Gear, Hydraulic Pump
Crankshaft Seal, Front
Crankshaft Seal, Rear
Engine Support Bracket, Front
Vibration Damper, Viscous
Crankshaft Pulley
PTO, Front
Flywheel
Flexplate
Gear Housing, Front
Lubricating Oil Pump
Lubricating Oil Transfer Tube
Oil Transfer Connection
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil Pan
Cam Follower Assembly
Cylinder Head
Water Manifold
Fuel Pump
Fuel Pump Gear Pump
Air Compressor
Lubricating Oil Fill Tube
Lubricating Oil Filter Head
Lubricating Oil Cooler
Hydraulic Pump Drive
Gear Cover, Front
Rocker Lever Housing
Internal Actuator Wiring Harness
Injector
Fuel Connector (Head Mounted
Crosshead
Rocker Lever Assembly
Push Rods or Tubes
Engine Brake
Overhead Set
Rocker Lever Cover
Fuel Rail
Injector Supply Lines (High Pressure
Crankcase Breather Bracket
Crankcase Breather (External
Crankcase Breather Tube
Air Compressor Coolant Lines
Fuel Filter Head
Fuel Lift Pump
Air Intake Manifold
Air Intake Connection
Air Compressor Inlet Tube
Fuel Manifold (Drain
Aftertreatment Purge Air Actuator
Fuel Supply Lines
Fuel Drain Lines
Aftertreatment Fuel Shuoff Manifold
Aftertreatment Fuel Shuoff Manifold Air Supply Line
Engine Lifting Brackets
Exhaust Manifold, Dry
Water Pump
Coolant Filter Head
Coolant Thermostat
Coolant Bypass Tube
Water Inlet Connection
EGR Valve Mounting Bracket
EGR Cooler
EGR Cooler Connection
EGR Cooler Coolant Lines
Rear EGR Connection Tube
EGR Valve
EGR Mass Measurement Flow Assembly
Turbocharger
Aftertreatment Adapter Pipe
Aftertreatment Intake NOx Sensor Bracket
Aftertreatment Intake NOx Sensor
Aftertreatment Fuel Injector
Turbocharger Coolant Hoses
Aftertreatment Injector Lines
Turbocharger Oil Supply Line
Turbocharger Oil Drain Line
EGR Crossover Tube
Lubricating Oil Dipstick Tube
Electronic Control Module (ECM
Engine Wiring Harness
Fan Hub, Belt Driven
Fan Pulley
Alternator/Refrigerant Compressor Mounting Bracket
Refrigerant Compressor
Alternator
Belt Tensioner, Refrigerant Compressor, Automatic
Cooling Fan Belt Tensioner
Drive Belt, Refrigerant Compressor
Drive Belt, Cooling Fan
Starting Motor
Pressure Fuel Filter
Coolant Filter
Lubricating Oil Filter (Spin-On
Lubricating Oil System
Engine Installation
Aftertreatment System

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
Camshaft
Camshaft Bushings
Camshaft Cover Plate
Camshaft Gear (Camshaft Installed
Camshaft Gear (Camshaft Removed
Connecting Rod
Crankshaft
Crankshaft Gear, Rear (Crankshaft Installed
Crankshaft Pulley
Crankshaft Seal, Front
Crankshaft Seal, Rear
Cylinder Block
Cylinder Block and Liner Seats
Cylinder Liner
Gear Cover, Front
Gear Housing, Front
Gear Housing, Rear
Idler Gear, Camshaft
Idler Gear, Hydraulic Pump
Piston
Piston Cooling Nozzle
Piston Rings
Vibration Damper, Viscous
Water Header Plate, Cylinder Block
Piston and Connecting Rod Assembly
Gear Train Backlash, Front
Camshaft Thrust Bearing
Engine Dataplate
Camshaft End Clearance
Camshaft Gear, Rear
Engine Base Timing
Block Stiffener Plate
Rear PTO Idler Gear
Front Lubricating Oil Transfer Cover
Idler Gear, Camshaft Rear
Front Cover Seal Plate

Cylinder Head
Service Tools
Crosshead
Cylinder Head

Rocker Levers
Service Tools
Crankcase Breather (External)
Overhead Set
Rocker Lever Assembly
Rocker Lever Cover
Rocker Lever Housing
Crankcase Breather Tube
Crankcase Breather Element
Crankcase Breather Bracket

Cam Followers/Tappets
Service Tools
Cam Follower Assembly
Push Rods or Tubes

Fuel System
Service Tools
Fuel Consumption
Fuel Pump
Fuel Pump Gear Pump
Fuel Pump Timing
Fuel Lift Pump
Stall Speed Test
Fuel Pump Head Outlet Fitting
Fuel Pump Head
Fuel System Priming
Fuel System Diagnostics

Injectors and Fuel Lines
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

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

Cooling System
Service Tools
Drive Belt, Cooling Fan
Coolant Bypass Tube
Coolant Filter
Coolant Filter Head
Coolant Heater
Coolant Thermostat
Coolant Thermostat Housing
Coolant Thermostat Seal
Coolant Vent Lines
Cooling System
Cooling System – Air or Combustion Gas Test
Cooling System Diagnostics
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 Manifold
Water Pump
Water Inlet Connection
Cooling Fan Belt Tensioner
Fan Pulley
Water Pump Cartridge

Drive Unit
Service Tools
Hydraulic Pump Drive
PTO, Front
REPTO
Engine Barring Device
Refrigerant Compressor
Drive Belt, Refrigerant Compressor
Belt Tensioner, Refrigerant Compressor, Automatic
Alternator/Refrigerant Compressor Mounting Bracket
Idler Pulley Mounting Bracket

Air Intake System
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
Air Intake Connection
Turbocharger Compressor Outlet Connection
Variable Geometry Turbocharger Actuator, Electric
Air Shutoff Valve

Exhaust System
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
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
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 Intake NOx Sensor Bracket

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

Electrical Equipment
Service Tools
Alternator
Drive Belt, Alternator
Alternator Pulley
Batteries
Battery Cables and Connections
Starter Magnetic Switch
Starter Switch
Starter Solenoid
Starting Motor
Key Switch
Alternator Spacer

Engine Testing
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

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

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

Electronic Engine Controls
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 Set/Resume Select Switch
Cruise Control or PTO 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
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 Conditioning Pressure Switch
Air Conditioning 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
Pressure Sensor
Pressure Sensor Circuit
Temperature Sensor
Temperature Sensor Circuit
ECM ROM Boot
Engine Datalinks
Aftertreatment Diesel Exhaust Fluid Dosing Unit
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
INSITE™ Communication Errors
Bosch Aftertreatment DEF Controller Connector

Vehicle Braking
Engine Brake Solenoid Valve
Engine Brake

Specifications

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