Tmo 1033 PDF
Tmo 1033 PDF
ECM
ECM Inputs
ECM Outputs
Understanding Cummins vs. OEM Responsibility
Differences between MR & HD engines
Public vs. Private Datalinks
Troubleshooting
2
CM2250 ECM
Identification
3
1 10
CM2250
51 60
51 1 51 1
60 10 60 10
4
ISB, ISC, & ISL Sensors & Switches
5
ISX Specific Sensors & Switches
Ambient Air Temperature Sensor
Overview
Detects the vehicle’s external ambient air temperature.
Used by the ECM to make control decisions for OBD and the allowance of
automatic or manual overrides of the Idle Shutdown feature.
Controls DEF line heater relays
Installation location is OEMs choice:
On the vehicle, in a shaded position away from radiant heat sources.
Example installation for the sensor would be underneath the truck’s fifth wheel
trailer coupling or in an area on the inner frame rail above the rear axle.
Operation
The OEM Ambient Air Temperature Sensors are Thermistors that convert
temperature into resistance
The ECM uses ambient air temperature for various diagnostic and control
algorithms.
Can be multiplexed
6
Speaker Notes
ISX Specific Sensors & Continued …
7
ISX Specific Sensors continued …
Overview
– Measures EGR pressure before the differential
pressure sensor
– References that the right pressure is being read
8
OEM Installed/Supplied Sensors
9
Dual Analog Throttle Pedal
Operation
The Dual Analog Accelerator Position Sensor is typically
mounted to a pedal assembly that provides two
independent pedal position signals to the ECM. The
ECM uses the two voltage signals to validate the pedal
position and control engine operation.
Troubleshooting
Exactly like ’07. Some OEMs will multiplex throttle
signals from VCU
10
Coolant Level Sensor
Overview
The Engine Coolant Level Sensor determines if the proper level of
coolant is maintained in the vehicle cooling system. When the coolant
level is below normal the ECM will indicate the need for maintenance at
the ADD condition or Engine Warning for a critically low condition.
Operation
The sensor signal must provide the critical low output condition when the
level of the coolant is such that air begins to be introduced into the
cooling system.
A multi-level sensor may also provide an output to indicate when the
coolant is below the “add” level such that a driver or maintenance
technician can add coolant to the system at the next convenient time.
11
Aftertreatment
Switches
Diesel Particulate Filter
Regeneration Inhibit Switch
INSITE calls it a Permit switch
Overview
The DPF Regeneration Inhibit switch allows a switch input to inhibit active
regeneration of the diesel particulate filter.
Operation
The DPF Regeneration Inhibit Switch has two positions: Open and Closed.
An open switch inhibits an active regeneration of the Cummins Particulate
Filter.
A closed switch permits an active regeneration of the Cummins Particulate
Filter when all required entry conditions are satisfied.
Overview
The DPF Regeneration start switch starts a stationary regeneration
of the particulate filter if all required entry conditions are met.
Operation
The normally open DPF Regeneration Start Switch has two
positions: RELEASED and PRESSED. The PRESSED position
indicates a closed switch, while the RELEASED position indicates
an open switch.
When the operator cycles the switch from RELEASED to
PRESSED to RELEASED the ECM initiates the stationary
regeneration of the particulate filter.
The DPF Regeneration Start Switch Input is also shared with the
Diagnostic On/Off Switch.
14
Diagnostics Switch
15
ECM Outputs
EGR Valve
17
Fuel Pump Actuators
18
Injector Drivers
19
Variable Geometry Turbocharger
Actuators
Turbo troubleshooting
– Essentially the same as ’07
– Faults don’t drive red lamps now (not really that bad)
20
Lift Pumps
21
ISX Specific ECM Outputs
ISX Aftertreatment Fuel Shutoff Valve
– Controls fuel to aftertreatment hydrocarbon doser
22
ISB, ISC, & ISL Specific ECM Outputs
23
Relays
25
NOx Sensors Relay
Overview
For ISB, C, L, X Cummins requires an OEM switched battery
power relay to control the battery power for the intake NOx
sensor and outlet NOx sensor
For ISX the OEM relay also provides power to the lift pump
relay Pin 30
Operation
The switched battery power relay coil is energized by the Key
Switch. When the Key Switch is on, the outlet NOx sensor and
intake NOx sensor are energized
ISX lift pump relay is also powered by the OEM relay and runs
for one minute. (The CM2250 ECM controls the lift pump relay
through pins 85 and 86, then the lift pump is energized through
pins 30 and 87.
26
Relays/Solenoids
RQD
27
Exhaust Aftertreatment
System
Exhaust Aftertreatment System
Sensors
Aftertreatment Diesel Oxidation Catalyst Intake Temperature
Aftertreatment Diesel Particulate Filter Intake Temperature
Aftertreatment Diesel Particulate Filter Outlet Temperature
Aftertreatment Diesel Particulate Filter Differential Pressure
Aftertreatment SCR Catalyst Intake Temperature
Aftertreatment SCR Catalyst Outlet Temperature
Aftertreatment Intake NOx Sensor
Aftertreatment Outlet NOx Sensor
Aftertreatment DEF Tank Temperature & Level Sensors
29
Thermistor & Differential Pressure
Sensor Troubleshooting
Thermistors troubleshoot same as 2007, but have different
connectors and lengths to prevent incorrect installation
– 2 more Thermistors for SCR catalyst
– Names changed from “Inlet” to “Intake”
Interface modules are new for 2010
– Aftertreatment Diesel Particulate Filter Temperature Sensor Interface Module
– Aftertreatment SCR Temperature Sensor Interface Module
• Can fail like a harness
• No repair options, replace only
DPF Differential pressure sensor is not like ‘07
– Now performs differential pressure and outlet pressure
– New faults associated with sensor
– Shop exhaust system may cause a fault when in for service
30
NOx Sensors Service
12 and 24 VDC NOx sensors
– 24 VDC versions have a longer controller
body
Non serviceable
– Sensor, harness, & processor are sold as
one part
Copper based anti-seize (not lead based)
Do not disconnect during key on
Intake and Outlet sensors have unique keying
– Cannot be cleaned or interchanged (J1939
address)
Repair connectors in 2010 kits
Self diagnosing intelligent device
Both communicate over private datalink
MR engines have an option of remote mount
Intake NOx sensor assembly
31
Aftertreatment DEF Controller (CM2220)
32
Aftertreatment DEF Dosing Unit
12 or 24 VDC systems
– Different connectors on 12 and 24 VDC versions
Cummins supplied (OEM installed)
Black box – do not open
Hard wired to Aftertreatment Diesel Exhaust Fluid Controller
Any failures are diagnosed by the DEF Controller and communicated
by the J1939 private data link to CM2250
Has an internal heating element controlled by the DEF Controller
33
Aftertreatment DEF Dosing Valve
34
Aftertreatment Control Parts not
supplied by Cummins
35
CM2250 Diagnostics
Diagnostic Changes
2 60 pin engine connectors vs 1 on CM2150, 876, & 871
No 4 pin OEM power connector to use as an INLINE power supply
1 OEM harness connector at ECM (60 pin)
1 OEM harness connector on engine harness (14 pin)
Over-foam harness on MR
Engine harness checks at connector very difficult
37
Fault Code Troubleshooting Manual
38
New Fault Codes
Fault Codes 553 or 559
– Fuel System faults
Fault Codes 1981 and 1922
– Both have new service strategy
– Procedural changes following extensive testing
– A DPF can be cleaned of soot and successfully regenerated after a 1981
or 1922
– DOC and/or DPF reuse following coolant intrusion
3582 SCR Efficiency
– External leaks, buildup etc
– INSITE Aftertreatment DEF Dosing Unit Override Test
– INSITE stationary regen includes an SCR catalyst efficiency test
• Stationary regens may take longer to complete
NOx sensor troubleshooting
– Each sensor is supported by unique diagnostics
39
Wiring Harness Repair
40
On Board Diagnostics (OBD) Requirements
41
O.B.D. Continued …
HD-OBD for EPA 2010
– Restricted to ISX15 450 HP or less
– EPA 2013 all products
– Different than passenger vehicle OBD or Euro OBD
Nothing new for driver other than a lamp
Nothing new for the technician
– Troubleshooting process same as regular faults
– More steps to clear some inactive faults
Extinguishing Lamp
– Clear all faults using INSITE
– Trip definitions/conditions for clearing faults
42
INSITE & “New” CM2250
OEM Programmable
Parameters
INSITE Electronic Service Tool
44
Importing Injector Bar Codes
INSITE 7.3 FP2 or newer
Must have an ECM image for the ESN
being worked on
– ESN specific process
Go to advanced ECM data
– Click “import”
– Import barcodes from your work order
– Once found, click “OK”
– Make sure to click “apply”
Works on:
– 2010 C,L, & X
– ’07 C &L
Help file link also provides steps
45
Engine Over-Crank Protection
“Starter Lockout” is a new adjustable feature
– Default setting is “enabled” in all MR engines with Cummins branded
starters
How it works:
– If starting motor is engaged for 30 seconds continuously the starter will be
locked out from operation for 2 minutes before cranking can resume
– All cranking time is counted by the ECM and counts towards an Over-Crank
protection timer
– When cranking stops, the protection timer begins its countdown. The longer
you crank, the longer the timer will need to count down
– Wait to Start Lamp (if equipped) will flash for 2 minutes when Over-Crank
protection begins
– When lamp stops flashing, the starter can again be operated
46
Over-Crank Protection Continued …
By moving the key away from the start position the protection
timer starts its countdown. After the 15 seconds at rest the timer is
reset
47
New Adjustable Features & Parameters
Air Intake Shut Off Valve New for 2010 Y=Enable N=Disable
(Oil and Gas Markets only) N=Disable
ASO Valve Parking Brake New for 2010 Y=Enable N=Disable
Interlock N=Disable
48
New Adjustable Features & Parameters
Fan Type Fan types 0,1,4, & 6 - 6 is new (datalink 0, 1, 4, & 6 0=on/off
output)
Type 2 is no longer valid
Fan On with Remote Accelerator New for 2010 Y=Enable N=Disable
N=Disable
Fast Idle Warm-up Programmable for 2010 Y=Enable Y=Enable
N=Disable
High Soot Load Idle Shutdown New for 2010 Y=Enable Y=Enable
(Page 73 of Programing AEB) N=Disable
Idle Shutdown Service Brake New for 2010 Y=Enable N=Disable
Switch N=Disable
Enhanced Auxiliary Shutdown New for 2010 Y=Enable N=Disable
Switch N=Disable
Enhanced Auxiliary Shutdown New for 2010 0=Open Engage 1
Switch Logic 1=Closed Engage
49
New Adjustable Features & Parameters
50
Wiring Repair Kit
Contents
Wiring Repair Kit Options
52
53
54
55
Wiring harness Test Leads
“ The difference between troubleshooting,
and trouble causing”
Version 2.0
Why are test leads needed?
Use of incorrect or improvised test leads and multimeter probes can
damage connectors in wiring harness by spreading pins
– Some harnesses such as HHP, EPA 2010 Midrange and EPA Tier 4 Midrange cannot
be repaired
– Warranty does not pay for physical damage you cause. Should your customer?
Use of alligator clips, incorrect, or improvised test leads can also remove
the precious metal plating of the wiring harness or ECM pins
– Shortens life of harness or ECM
– May cause intermittent or temporary connection (Comebacks & rework)
– Complicates troubleshooting efforts
• New problems can be caused by wrong test leads (Comebacks & rework)
• Wrong test lead (bad connection) can put you in a troubleshooting loop
Use of incorrect test lead, improvised test lead, or multimeter pins can
cause testing errors
– Electrical measurements can be in specification, but only due to increased tension or
abnormal contact
– Testing with the correct test lead produces the identical contact relationship of the
sensor and harness (Identify the root cause)
57
Electrical Test Lead Kit
Part 4919115
Contains 29 Test Leads
PDF in toolbox cover
– Aids in selecting the right test lead for the
connector/sensor being tested
– Aids in identifying part number for lost or damaged
test leads
So what does it cost?
A lot less than an engine harness or ECM and the
associated labor to remove and replace the part you
damaged
A lot less than writing off a few hours ineffective
troubleshooting
58
Why as a technician handout vs.
required service tool?
60
Specific Wiring Harness
Test Lead Usage
4919351 (Tyco - Sumitomo)
Used on combination
sensors/actuators such as: 4919351 Test lead
– Intake manifold temperature/pressure
sensor
– Ambient air temperature/pressure
sensor
– ISB/C/L CM2150/CM2250 EGR control
valve
This is NOT intended for use at the DEF Controller Small Socket
Aftertreatment DEF controller
connector
If you force it, the test lead will fit inside
the socket, but the socket will lose all
tension
Repair of the Aftertreatment DEF
controller connector is possible, but
difficult
– 4919564 repair pigtail in CM2250 wiring
62 harness repair kits
Aftertreatment DEF Controller OEM
Connectors
Amp/Bosch/Delphi Male
test lead on the small
sockets
– Always hold this test lead
when it is inserted into a
socket or it may break off or
damage the socket
63
Delphi Connector
64
Sumitomo Connector
• Different Styles
• Utilized for:
• Combination sensors
• NOx sensors
65
Tyco Connector
DEF Doser
Unit
Injector &
Brake Pass
Through
66
Bosch Connectors
67
Framatome Connectors
Multiple Locations
68
Danfoss Connector
69
Communication via the
3-Pin On-Engine
Connector
Background Information
71
Solution
72
Where to Connect on ISB/QSB
CM850/2150/2250
Location
– Front of engine on the fuel
pump side
73
Where to Connect on ISC/L
CM850/2150/2250 & QSC/L CM850/2250
Location
– Front gear housing on
the fuel pump side
74
Where to Connect on ISX11.9 &
ISX15 CM2250
Location
– Fuel pump side of engine
above the air intake
connection
75
The Recommended Tools
76
3165141 3-Pin Cable
New version of
cable has molded
connectors
2-Pin Power
Connector
2-Pin J1708
Connector
25-Pin Datalink
Adapter Connector
3-Pin Connector for
engine mounted
datalink
77
Gender Changer & Mini-Backbone
3163096 Mini-Backbone
– Required on some 1998-2006
vintage engines to connect to
the 3-Pin engine harness
connector
– Has termination resistor
3163597 Gender Changer
– Required on some engines to
connect
– Does not have a termination
resistor
Some engines may require
both
78
Power Adapter Options
3162849
– Allows power connection at
vehicle cigar lighter
– May be supplied with 3-pin Cable
(depends on kit)
3164653
– 4-Pin power connection at the
ECM (OEM 4-Pin connector)
– Allows OEM power supply from
CM850, CM2150, CM876,
CM871, CM875, and CM870
– New CM2250 does not have 4-
Pin OEM power connector
79
CM2250 DEF Controller
Calibration
The current DEF Controller calibration (software)
information is located at the bottom of the Feature and
Parameters
81
Do’s and Don’ts and be Aware
Make sure the version of INSITE is current
Make sure the INLINE adaptor firmware is current
Always utilize the Deutsch triangular three pin when
calibrating the DEF Controller
Then on PDD
83
1. Choose calibration file location
84
Once the calibration process completes, a pop-
up will appear announcing that the calibration
was successful
85
Questions?
86