Review Date:

Review Revision Number:

CARs Number:-

Title:
Distributorship:

Author :

☞ Note:- This report is proprietary of CUSTOMER NAME and shall not be disclosed to others in either
electronic or hard copy without the consent of the compiling distributor or his customer without prior
consent

Photograph of Equipment

Engine and Vehicle details

Engine model:
Engine shop order:
Engine Serial Number:
Engine power rating:
OEM equipment model number:
OEM Location:

Doc: 26th May 2009 Rev 7.2

PREFACE CUMMINS

Cummins review of this unit was intended to assist in the identification of any installation defects which may impact on
the overall equipment reliability and durability.

The following factors are considered beyond the scope of the installation review and, unless specifically noted in the
report, have not been evaluated:

Component quality, workmanship, assembly practices and endurance characteristics.

Acceptability to end users of subjective characteristics such as equipment vibration and noise levels.

Conformance of the equipment to legislated or regulatory requirements regarding such areas as design, safety and
noise levels.

Engine or equipment application with regard to transmission, equipment performance and type of service.

Cummins engines have been tested and certified with a complex integrated system. This system is comprised of
several emissions control devices including, but not limited to, a Diesel Particulate filter (DPF) and a Selective Catalyst
Reduction (SCR) system. The OEMs have worked exclusively with Cummins to adhere to strict requirements for
installation of these devices.

The body builder must not modify or relocate any devices included in the emission control system, unless preapproved
by the OEM. In these cases, the OEMs will provide a kit or a list of instructions that will allow for relocations and ensure
proper operation of the system.

The OEM chassis manufacturer is responsible for the final installation of the aftertreatment, emission and OBD
components. All questions and concerns must be routed back through the (OEM) chassis manufacturer.

Any unapproved modifications by the body builder could negatively effect emissions certification and void warranty.
EMEA / CIS Application Engineering Approval Signatures
Customer xxx - eg ISBe5 6.7 300ps
Engine model:
Engine shop order:
Engine Serial Number:
Engine power rating:
OEM equipment model number:
OEM Location:

APPROVERS NAME SIGN AND DATE

Chief Engineer - Customer Engineering

Customer Engineering - Manager (DEP)

Customer Engineer (D/OEM)

Customer Representative
TE
Review Summary
Fill in only yellow cells
System Compliance Complies with requirements

Engine mounting Yes No

Engine drive line Yes No

Cooling system Yes No

Cooling trial and CAC test Yes No

N
Charge air cooling Yes
o
Yes N
Air intake o
Yes N
Exhaust system o

Yes N
Fuel system o
Ye
Lubrication system s No

Air compressor Yes Not applicable

o
Yes N
Cranking and charging system o
Yes N Not
Controls and Monitoring o applicable
N Not
Aftertreatment Yes
o applicable
N
Accessories (driven off engine) Yes Not applicable
o

Service Accessibility Yes No

Comments & Recommendations on non-compliant systems

Cooling system AEB's - refer to GCE
Fill in only yellow cells
Type of cooling system Tick applicable
Fully dearating with integral top tank
Fully dearating with remote top tank
Dearating with coolant recovery system
Non-dearating

Radiator details
Location in vehicle (Front, Rear, Side Mounted, etc) hh
Make and model number
Core dimensions (Height, Width, Thickness) (mm)
Number of fins per 50 mm
Leading edge of fan to radiator core (mm)

Fan Details
Ye
Is this Engine mounted? No
s

Is the same fan used for radiator and Charge Air Cooler? Yes No
If No, complete the CAC section below: Radiator Charge Air Cooler
Is this a Cummins factory supplied component, if so enter the
option number?

If the fan is not supplied as part of specification quote, complete the Radiator Charge Air Cooler
radiator section and CAC section if applicable, for the following:
Fan supplier
Part number
Fan type (Axial, Radial or Mixed)
Fan drive - Mechanical, Hydraulic, Electric
Fan installation (Sucker, Blower)
Fan diameter (mm)
Number of fan blades
Projected width of fan blades (mm)
Fan mass (kg)
Spacer length (mm)
Bending moment

Shroud details
Shroud type (Venturi, Ring, Box, Other, None)

Hoses and clamps details

Type of clamps used (Worm Drive or Spring Band Clamps)
Do the hose specifications on the installation meet AEB Ye
requirements No
s
If No please provide specification and justification
Deaerating tank design details, complete one of the following:

Deaerating tank design A) Integrated with radiator

B) Separate header tank

C) Coolant recovery system

A) Integrated with radiator

Size (Height, Width, Length) (mm)
Location of fill line & size (Central, Left, Right, Diameter) (mm)
Internal diameter of engine vent connection (mm)
Pressure cap setting (kPa)
Design incorporates 6% expansion space Yes No
Ye
Is a coolant level sensor present? No
s

B) Separate header tank

Size (Height, Width, Length) (mm)
Location of fill line & size (Central, Left, Right, Diameter) (mm)
Internal diameter of engine vent connection (mm)
Internal diameter of radiator vent connection (mm)
Pressure cap setting (kPa)

Design incorporates 6% expansion space? Yes No

Physical location of tank relative to centre point on top of radiator

(Height above and Distance from) (mm)
Is a coolant level sensor present? Yes No

Is the minimum coolant level above the top of the radiator? Yes No

C) Coolant recovery system, ref AEB

Correct pressure cap fitted to radiator Yes No

Capacity of bottle (litres)

Physical location of the recovery bottle, please state point
measured from (mm)

Hose size radiator to recovery bottle (mm)

Note: A drawdown test is not required with this type of system

Note: All engine and radiator vent & fill lines are to be routed as per AEB recommendations.

Note: Ensure all hoses do not foul other components and are correctly clamped

Other cooling systems details

Transmission oil cooler used? Yes No

Location
Hydraulic oil cooler used? Yes No
 Yes No

Location
Air conditioning cooler present? Yes No

Location
Additional application specific cooling pack present Yes No

Detail type of cooler

Location

Cooling system compliance Yes No

Cooling system photographs
Cooling Trial / Test Results AEBs - refer to GCE
Fill in only yellow cells

Fill, Deaeration and Drawdown Units ` Limit

Fill rate (initial) Litre / Min
Fill time Minutes
Volume not filled at initial fill Litre
Pressure at water pump inlet kPa
Deaeration time Minutes 25 minutes
Drawdown capacity Litres
Cooling system capacity (total) Litres

Cooling Trial Test Conditions

Specify the thermostat condition for the cooling trial?
(Modulating / Blocked open)
Cooling fan operating mode for the cooling trial?
(Locked in / modulating)
What controls the switching point for the cooling fan?
(e.g. coolant temperature, OEM temperature)
What was the vehicle loading during test?
e.g. 100% loading or typical duty cycle if so attached
full cooling trial log file
Describe the test cycle, and engine load
e.g. transmission lockup / torque convertor
hydraulic load etc.

Note: Cummins recommends that cooling trials are performed at 21 deg C as per AEB 21.54

Cooling Trial Measurements Test Condition

1 2 3 4
Rated Power Peak Torque
Speeds Units
Vehicle Speed mph
Engine Speed rpm

Air Temperatures Units

Turbo Compressor Inlet deg C
Charge Cooler Inlet deg C
Intake Manifold (IMT) deg C
Ambient Air deg C
LAT correction factor for low ambient
temperature
Charge air Limiting Ambient Temperature
(LAT) deg C

Engine Temperatures Units

Engine Coolant Out (Top Tank) deg C
Design Maximum Coolant Temperature deg C
Correction factor for low ambient
temperature (LAT)

Coolant Limiting Ambient Temperature (LAT) deg C

Cooling Trial Compliance Yes No

Comments

Additional data (optional) Units 1 2 3 4

Ambient Air Pressure kPa
Fan Speed rpm
Fuel Flow Rate kg/hr
Air Filter Intake deg C
Charge Cooler Outlet deg C
Radiator Coolant Out deg C
Engine Coolant In deg C
Engine Oil Pan deg C
Air On Radiator (Average) deg C
Engine Compartment deg C
Charge Air cooling system
Fill in only yellow cells
Charge air cooler
Make and model
Size, Height, Width, Thickness (mm)
Material
Location (tick applicable)
In front of radiator
Between radiator and fan
Along side radiator
Remote location
Connection sizes
Charge air inlet mm
Charge air outlet mm

Charge air pipe work

Engine to charge air cooler
Diameter mm
Length mm
Material
Does the material specification meet AEB requirements? Yes No

Charge air cooler to engine

Diameter mm
Length mm
Material

Does the material specification meet AEB requirements? Yes ● No

Flexible hoses

Hoses of the correct type / material Yes

N
Clamps are in line with recommendations Yes o

Do the hoses specifications meet the AEB requirements Yes No

Results Units Measurement Limit

Pressure drop across charge cooler at rated power kPa
Intake manifold temp - ambient temp delta at rated power degC

N
Charge air cooling compliance Yes o
Photographs of CAC.
Fuel System AEB 24.10
Fill in only yellow cells
Fuel Tank
Fuel level relative to engine fuel pump (Above, Below, Meters)
Ye
Fuel tank design incorporates sediment space and drain No
s
Correctly vented Yes No

Expansion space in line with AEB requirements Yes No

Supply & Return fittings correctly located in tank Yes No

Fuel Lines and Filtration

Main Filter supplied with engine Yes No

Pre filter supplied with engine Yes No

If no, does the OEM supplied pre filter meet AEB requirements Yes No

If OEM supplied manufacturer

Part No
Filtration
Fuel supply line length (meters)
Fuel supply line diameter (mm Inside diameter)
Fuel return line length (meters)
Fuel return line diameter (mm Inside diameter)
Fuel return location (above / below) fuel level
Fuel supply line is routed such that it will not cause air
Yes No
locks during normal operation

Fuel return is free from fuel shut offs Yes No

In No provide explanation of operation below

Water in Fuel (WIF) Sensor fiitted? Yes No

Measurement Result Limit

Fuel inlet restriction at rated power (kPa)
Fuel return restriction at rated power (kPa)

Fuel system compliance Yes No

Explanation of fuels shut off solenoids

Photographs of Fuel system components
Air intake system AEB's 21.10 & 24.21
Fill in only yellow cells
Light
Air Filter Duty Medium

Heavy

Make
Model

Material Diameter (mm) Qty / Length (mm) Type

Air intake pipework Straights
(filter to engine) 90-deg bends
45-deg bends
Other

Engine Compartment
Location of air inlet Outside
Other

Restriction indicator fitted Yes No

Location
Setting
Yes No
Is filter incorporated to restriction indicator fitting

Filter dirt holding capacity Gram / CFM

Clamps used meet Cummins recommendations Yes No

Measurement Result Limit

Restriction with clean air filter at rated power kPa
Air intake rise over ambient at rated power deg C

Air intake compliance Yes No

Photograph of Air filter arrangement
Exhaust system
Fill in only yellow cells
Silencer manufacturer
Silencer model

Diameter (mm) Qty / Length (mm)

Exhaust System Layout,
Note for SCR systems: Stainless steel exhaust pipework is
required from 200mm upstream of the AdBlue spray nozzle,
to the EGP

Is the exhaust pipe work supported such that it does Ye

not impose bending or thermal stress on the turbo? s o

If 'No', corrective actions will be required

Ye N
Is an exhaust retarder part of the exhaust system?
s o

If 'Yes' give details of Make, Model, & Location

Enigine speed at which back pressure was measured rpm

Max pressure imposed when activated kPa

Measurement Result
Engine back pressure at rated power kPa

Ye N
Exhaust system compliance s o
Photographs of Exhaust system
 AEB 21.32

Type
Straights
90-deg bends
45-deg bends
Other / Flexible

N
o

Limit

N
o
ographs of Exhaust system
Cranking and Charging systems AEB 111.15 & 24.53
Fill in only yellow cells
Cranking system
Starter Motor make and model
Ye
Supplied by Cummins No
s

Starter Lockout (Required for Cummins supplied starter) Yes No

Details of lockout system used

Starter lockout meets requirements and functions correctly Yes No

Signal returned directly to ECM general return pin Yes No

System Voltage Volts

Number of Batteries
Battery capacity (Cold Cranking Amps) Amps
Battery cable size mm2
Battery cables total length mm
Ye
Is vehicle frame part of the starter circuit s No
Ye N
Is a battery isolator incorporated in the starter circuit s o
The starter is sized to be capable of cranking the engine Ye
No
and the accessories connected during cranking s

Starter relay
Ye
No
s
Ground wire connection
Ye N
Direct to battery s o
Ye N
Engine Block Ground Stud s o

Starter Negative Terminal Yes No

Other (please explain)

Wire Size
mm2
Alternator grounding meets the AEB requirements Yes No

OEM Wiring

Accelerator Position Sensors #1 and #2 twisted pair Yes No

Remote Accelerator Position Sensor twisted pair Yes No

Ye
Vehicle Speed Sensor twisted pair No
s
Ye
Tachometer Output twisted pair s No

ECM Wiring
Switch Ground Returns To ECM Are Isolated from Cab/Chassis
Ground Yes No

Switch Ground Returns To ECM Are Returned To The ECM N

Yes
Common Switch Return Pin o
Sensor Ground Returns To ECM Are Isolated from Cab/Chassis
Yes No
Ground
 Yes

Sensor Ground Returns To ECM Are Returned To The ECM

Yes No
Common Sensor Return Pin
ECM Output Drivers Are Returned Through The ECM General
Return Pins Or Through The Engine Block Ground Stud Yes No

ECM Ground wire connection

Ye N
Engine Block Ground Stud connected to Starter (-) s o

Battery (-) Connected to vehicle frame/chassis in only one location Yes No

Ye
Connected to engine block ground stud No
s

Braided Ground Strap Between Engine Block And Frame/Chassis Yes No

Voltage Differential Between ECM Engine Block Ground Stud and

Battery (-) Meets Requirements.
ECM Power Connections
Connected directly to batteries Yes No
Circuit Protection Type:
Circuit Protection Rating Amps
Circuit Protection Confguration (single 30A, two 15A etc)
OEM Connector
Dirt and moisture intrusion protection is provided, including the
fitting of all unused connector cavities with sealing plugs or Yes No
equivalent sealing mechanism.
ECM Connector
Adequate Pin Stress Relief at ECM Connector Yes No
Connector Backshell Used

Intake Air Heater (ISBe/ISLe)

Circuit protection type (describe)
Circuit protection rating Amps

OEM Supplied Components

Yes No
Battery disconnect standard
Yes No
Battery dissconnect installed on barrety (+)
Yes No
All battery connections go through battery dissconnect

if no, details
Key Switch (engine ignition switch)

Independantly fused circuit Yes No

Circuit protection type

Circuit protection rating Amps

Switch excluded from accessory position Yes No

Service Brake Switch Yes No

Switch installed Yes No

Switch meets requirements and functions correctly Yes No

Clutch Switch

Switch installed Yes No

 Yes No

Switch meets requirements and functions correctly Yes No

Venicle Speed Source

Magnetic pickup Yes No

Digitsal Sensor Yes No

Digital Signal form ECU in pulses /rev Yes No

source

J1939 Datalink Tailshaft Speed Yes No

source
Water In Fuel Sensor (WIF)
WIF sensor installed and meets electrical interface requirements Yes No

Sensor manufacturer and part number

Coolant Level Sensor

Coolant level sensor meets requirements

Coolant level sensor installed at correct level Yes No

Sensor manufacturer and part number

Idle Shutdown

Idle shutdown set up or availabel as an option Yes No

Fault / Information Lamps

Stop

Type (lamp, LED, Digital display)

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

Warning

Type (lamp, LED, Digital display)

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

Wait to Start

Type (lamp, LED, Digital display)

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

Malfunction Indication Lamp (MIL)

Type (lamp, LED, Digital display) Yes No

 Yes No

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

Diesel Particulate Filter (if applicable)

Type (lamp, LED, Digital display)

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

High Exhaust Temperature (if applicable)

Type (lamp, LED, Digital display)

Visibility Acceptable Yes No

SAE J1939 Data link controlled Yes No

Symbol/label ISO Number

Maximum current draw

Auxiliary OEM Monitor/Control Systems

Auxiliary systems installed or available as an option Yes No

Details

Systems operate and function correctly Yes No

Measurements Result Limit

Alternator output voltage at high idle - full electrical load Volts
Cranking RPM RPM
Starter voltage during cranking Volts
Starter current during cranking Amps
Battery voltage while cranking Volts
Cranking circuit resistance Ohms

Cranking and charging system compliance Yes No

Details of electrical components

Sketch Or Attach A Drawing Of All Wire Segments From Battery (+) and (-) To ECM. Include All
Connections, Disconnect, Fuses, intake heaters Etc. Include details for all auxiliary systems installed.
Attaching the OEM Schematic and Harness Diagrams are preferred.
Comments
 1

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0

1 0
Drive Line
Fill in only yellow cells

Manual Gearbox

Automated Manual

Automatic Gearbox
Type of transmission
Hydraulic

Other - Please specify

Make
Model

For vehicles using Road Speed Governing

Gear ratio
Axle ratio
Tyre size, rev/mile
Vehicle speed sensor type

Checks required

Maximum thrust load on flywheel is within limits Yes No

Crankshaft end play checked on prototype installation Yes No

Torsional analysis of the system conducted Yes No

Measurement or calculation
Torque converter stall speed (RPM)
Hydrostatic Stall speed (RPM)
Combined stall speed (RPM)
Time to achieve stall speed (Sec)
Result
Bending moment at the rear face of the cylinder block (Nm)

Engine drive line compliance Yes

Photograhs of drive line
 AEB 21.37

Limit
No

No

No

Limit

Yes No
Aftertreatment system AEB21.90
Fill in only yellow cells
Visual Inspection

AdBlue lines protected from heat, chafing, squashing (see note ) Yes

Doser / Nozzle is mounted in a position free from potential damage Yes

All SCR Components are accessible for maintenance Yes

EGP is mounted using stainless steel straps Yes

Exhaust pipe work is fully supported & not under stress Yes

Are there any signs of possible urea leakage in the exhaust pipe work? Yes

Back shells are present on the Dosing Unit electrical connections Yes
Vehicle is wired to prevent incomplete purge Yes
(power maintained to doser for 30 sec after key off)

EGP Part Number

EGP Serial Number

AdBlue

Volume of AdBlue above the 100% gauge level is less than 1.5 Litres Yes

The AdBlue tank provides adequate expansion space in line with AEB Yes

The tank is correctly vented Yes

Distance of tank from Dosing unit is less than 8 metres Yes

The AdBlue tank is located such that AdBlue temperature does not exceed the Yes
temperature quoted in the AEB

AdBlue line lengths (Supply / Return) (m)

AdBlue line diameters (Supply / Return) (mm)

AdBlue tank is heated Yes

AdBlue lines are heated Yes

No brass, mild steel or zinc used as part of the AdBlue system Yes

AdBlue supply line is correctly filtered Yes

The AdBlue level sensor is mounted and calibrated correctly Yes

Dosing pump & spray nozzle

Doser is mounted in line with the AEB Yes

Doser is oriented as shown in the AEB Yes

Doser to Nozzle supply line length meets requirements of AEB Yes

AdBlue injector nozzle correctly installed >440mm from face of EGP Yes

Result

Distance of AdBlue nozzle from nearest upstream bend (mm)

Distance of AdBlue nozzle from nearest downstream bend (mm)

Urea spray nozzle part no.

The air supply to the doser is correctly filtered Yes

A 20 Amp fuse is incorporated in the doser supply line Yes

All connections to the Doser are of the correct type Yes

NOx sensing system

The NOx sensor is located as per AEB Yes

The electronic module is correctly mounted Yes

Cabin Display

An AdBlue gauge is fitted, working and fully visible Yes

MIL warning lamps are correctly installed Yes

Controls

Features and Parameters have been set (Tank Volume) Yes No

Details of Active Faults (if any)

Details of Inactive Faults (if any)

Measurement Result

Surface temperature on doser unit deg C

Urea temperature at doser inlet deg C

NOx sensor control unit temperature deg C
LAT
Urea temperature LAT (Limiting Ambient Temperature) calculated deg C
0.0
AdBlue lines pressure/restriction measurements tested Yes

Doser over ride test completed Yes

Thermistor temperature checks completed Yes

Aftertreatment compliance Yes No

Note: AdBlue lines - If the answer is no, provide further details in the summary section & Capture with Photograph

Photographs relevant to the aftertreatment system

Location of Thermistors
Location of NOx sensor

Location of NOx Module

 Photographs relevant to the aftertreatment system
Location of doser pump

Location of AdBlue tank

Location of spray nozzle

EGP Mounting straps

 AEB 21.60

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Limit
 Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

Yes No

No N/A

Limit

Ambient

Yes ● No

Yes No

Yes No

No N/A

& Capture with Photograph

he aftertreatment system
he aftertreatment system
Comments
 N/A

● N/A

Photograph

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 no

1
0

0 0

0 0 1 0 0 1

0 1 1 0 1 0

0 0 0
yes

0
Engine mounting AEB 21.36
Fill in only yellow cells

Front

Side of block
Location of mounting on engine
Flywheel Housing

Transmission

Make & Model Soft

Semi-soft ●

Solid

Operate engine at 100rpm intervals. N

Are there any observed points of significant vibration? Yes ●
o

rpm
If unacceptable, at what engine speeds did the rpm
significant vibration occur? rpm
rpm

N
Engine mounting compliance Yes
o
Photograph of Front mount

Photograph of Rear Mount

Lubrication system AEB 20.17
Fill in only yellow cells
Oil pan
Engine installation angle (degrees)
Engine tilt angle (degrees)
Oil pan option number
Oil pan sump location (Front / Rear)

Oil pan / vehicle angularity limits Engine Vehicle

Front of engine up (degrees) nnnn nnnn
Front of engine down (degrees)
Engine tilted right (viewed from front of (degrees)
Engine tilted left (viewed from front of en (degrees)

Dipstick (Oil level gauge)

Supplied with engine Yes No

If "no" has the dipstick calibration been completed? Yes No

Location of dipstick in the engine

Front / center / rear

Is the engine fitted with an Electronic dipstick? Yes No

Oil Filter
Mounted on engine or remote? (on/remote)

Auxiliary oil feeds

※ If Auxiliaries are fed with engine oil, please supply the following data:
Oil flow required in litres/sec Idle Rated
Auxiliary 1
Auxiliary 2
Auxiliary 3

Is the auxiliary flow within the limits given on the data sheet? Yes No

Lubrication system compliance Yes No

Photographs of Lube System

Turbocharger Refer to Cummins Turbo Technologies Guidelines
Fill in only yellow cells
Enclosure Design

Turbo modified (differences from supplied installation) ● Yes No

Turbo is susceptible to road spray, debris, chemicals contaminants or a pressure washer ● Yes No

Minimum 34mm clearance between the turbo and its surroundings Yes No

Induction, Charge Air and Exhaust System

Minimum gap of 38mm between all end to end connecting pipe work Yes No

Filter standards, maintenance and drainage/cleaning procedures included in service documents Yes ● No

Distance of the first bend from the turbine outlet (mm)

Minimum air gap of 15mm maintained between turbine housing and heat shield Yes No

Heat shield fitted to any part of the turbo (if yes provide photo) ● Yes No

Does the application have a downstream exhaust brake which is supported? (if yes provide photo) Yes No

Oil circuit design

Oil Drain pipe insulated against heat soak, where it runs close to the exhaust pipe Yes No

Based on your visual inspection of the vehicle & turbo installation do you have any further points to add and
do you believe a further in-depth installation review by CTT is required and why?

Turbocharger cont…
 Photographs
Turbo Installation Overview Photographs including:
Top, Side, Compressor end, Turbine end and any other area's of interest/concern

Turbo Pipework routing to 1st supporting bracket for: For Water Cooled turbo add photographs of:
Compressor Inlet, Compressor Outlet and Exhaust Pipe. Water cooling pipework arrangement to turbo and turbo
Turbine Housing Vent.
Front End Accessory Drive (FEAD)
Fill in only yellow cells
Main Belt Drive
Warrantable Front End Accessory Drive? If yes complete
this section ● Yes No

FEAD incorporates a Fan? ● Yes No

Fan mounting Location
Description of Fan (if applicable)

FEAD incorporates alternator/s? Yes No

Supplied by Cummins? ● Yes No

Alternator, Make, Model and Power

FEAD incorporates a Refigerant Compressor? ● Yes No

Supplied by Cummins? ● Yes No

Compressor Make and Model

Secondary Drive

FEAD includes second drive? Yes No

Supplied by Cummins? Yes No

Warrantable by Cummins? Yes No

Driving Pulley
Description of Accessories on 2nd Drive

Mounting - FEAD

All brackets supplied by Cummins? Yes No

Dimensional Variation Analysis Complete? Yes No

If "No" has belt alignment check been completed? Yes No

Operation FEAD
Belt chirp heard on normal operating conditions
Yes No
Belt squeal heard on start up and shut down
Yes No

Excessive belt tensioner movement seen Yes No

Reliability - FEAD
Photographs of FEAD
 Comments

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Compressed air system AEB's 20.11 & 21.71
Fill in only yellow cells
☞ Note: This section is only to be completed if the engine is fitted with an air compressor

Compressor
Option Number
Manufacturer
Model
Air or Water cooled
Turbocharged or NA
Compressor function ( Tick those applicable )

Air brakes

Suspension ●

Auto-lub

Aftertreatment supply

Other - Please Specify

Compressor installation checks

Compressor is sized correctly for the application Yes ● No

Measured compressor load Factor (%)
Compressor discharge line size (mm)
Length of cooling coil (mm) and material

Cooling coil follows a steady downward path Yes No

Unloader valve is correctly connected Yes No

Is a ping tank fitted? Yes No

Torque absorption of pumps mounted on the compressor

Bending moment on the compressor through drive flange (Nm)

Yes No
Tail support bracket fitted to OEM supplied hydraulic pumps
Components requiring an air supply are on the Yes No
"DRY" side of the system
Test results
Compresssed air temperature at air drier inlet Deg C
Ambient air temperature

Compressed air system LAT (based on 66Deg C inlet to air drier)

Air compressor compliance Yes No Not Applicable

Photograph of Compressed air system
Control System (Complete only for Electronic Engines) refer to GCE for all related AEB's
Fill in only yellow cells
Customer Interfaces
ECM Code (Calibration File Name)
Type of calibration tested
Generic
Custom ●

N
The calibration is released Yes ●
o
N
ECM is provided with an unswitched power supply ● Yes
o
N
ECM power is retained for a minimum of 30 Seconds after "Key off" ● Yes
o
N
Instrument panel is equipped with warning lamps in line with the AEB ● Yes
o
N
"Insite" features have been set and verified ● Yes
o
OEM's wiring harness and its routing meets Cummins N
recommendations Yes
o
N
OEM's grounding practices comply with Cummins recommendations Yes
o
N
The engine ECM is clear of all active fault codes Yes
o
Engine protection shutdown override switch installed
N
switch function tested Yes
o
N
Powertrain protection used Yes
o
N
Instrument cluster hardwired Yes
o
N
Instrument cluster CANBus controlled Yes
o
If yes is it direct to engine or through a gateway
N
Ambient air temperature sensor fitted Yes
o
N
Sensor isolated from chassis grounds Yes
o
N
Sensor return direct to ECM Yes
o
N
Sensor accuracy tested Yes
o
Real time clock setting (Tacho / Battery Back up )

Type of throttle used (Ref AEB 15.59 & 15.67)

If Custom throttle table is used please provide details in the Remot
None
comments section below Primary
e
Remot
Switched Primary
e
Remot
J1939 Multiplexed Primary
e
Remot
Dual Pot Throttle Primary
e
Remot
Frequency Throttle Primary
e
Remot
Custom Throttle Primary
e
Manufacturer
Model/Type

For Industrial complete the following

p
r
o
d
u
cIf a "Custom" calibration is being used, has the calibration sign off process been
tcompleted? (ETIF)
s N
If YES - please provide the date of completion in the comments section Yes
o
o If NO - please provide a scheduled completion date in the comments
n
l
y
Complete for Mid Range products only

The 3 pin diagnostic connector on the engine harness is available and N

accessible for service connection Yes
o

Engine Performance

N
Engine is stable under all operating conditions Yes
o
N
Feature set-up meets all of the customer requirements Yes
o
N
Engine rating meets the certified curve (AEB 15.49) Yes
o

Yes No Not
Controls and Monitoring compliance applicable
Photographs of Control system components
Create a work order of the engine, export to excel and paste onto this sheet
CAN bus (Complete only for CAN enabled installations) refer to GCE for all related AEB's
Fill in only yellow cells
CAN Layout

Number of controllers on the CAN of this machine being reviewed

Maximum number of controllers possible on this CAN for this machine range
Maximum CAN bus loading measured (%)

Resistance between CAN High /Low is approximately 60 Ohms Yes No

CAN Topology Diagram attached and reviewed? Yes ● No

Full CAN trace is attached Yes ● No

Pictures taken of CAN installation? Yes ● No

Insite image attached and reviewed Yes ● No

Reference Documentation

CAN installation is compliant with J1939-11 & J1939-15? ● Yes No

CAN installation and operation is compliant with AEB15.45? Yes No

Photographs of CAN bus components

Accessories driven from engine
Fill in only yellow cells
Provide the following data on engine driven accessories
Function Model Power Req'd
Accessory 1
Accessory 2
Accessory 3
Accessory 4
☞ Note: Accessories do not include components supplied as part of the engine specification,
e.g. Alternators, Air compressors and Fans

Accessories (driven off engine) compliance ● Yes No Not applicable

Service access routine checks

Comments
Has the Accessibility rating study
been carried out inline with AEBs? Yes No
(AEB 21.19)
Accessibility rating information
submitted to QSOL (Add ticket Yes No
number in comments section)

Daily checks Acceptable? Comments

Check engine oil Yes No

Check coolant level Yes No

Check Air filter Yes No

Empty air filter dust pan Yes No

Check drive belts Yes No

Check AdBlue level Yes No

☞ The above checks should take less than 5 Minutes and require no other item to be removed from the engine

Routine checks Acceptable? Comments

Remove & install Air filter elements Yes No

Remove & install Oil filter Yes No

Remove & Install Primary fuel filter Yes No
element
Remove & install Fuel Pre filter Yes No
assembly

Remove & Install oil pan drain plug Yes No

Clean radiator core Yes No

Remove & Install coolant drain Yes No

Check & Adjust drive belts Yes No

Check cooling fan Yes No

 Yes No

Adjust Injectors and valves Yes No

Tighten engine mounts Yes No

Access 9 Pin ECM connector Yes No

Ye
Service Accessibility compliance No
s
Photographs of Engine Driven Accessories

Photographs of Service Access

 Comments

pecification,

Not applicable

Comments

o be removed from the engine

Comments
No
hs of Engine Driven Accessories

Photographs of Service Access

Service Accessibility Rating Checklist – AEB 21.19 Attachment II
Use the following checklist and the Guidelines for Establishing Service Accessibility to establish a Service Accessibility Rating.

ACCESSIBILITY RATING
OPERATION OR PROCEDURE
A B C D Comments
Air Compressor - Replace x
Cam Followers / Tappets - Replace v
Camshaft - Replace b
Crankcase Breather Element/Filter b
Crankshaft Oil Seal, Front - Replace
Crankshaft Oil Seal, Rear - Replace
Cylinder Head - Replace
EGR Cooler
EGR Valve
Electronic Control Module - Replace
Engine Harness - Replace
Engine - Remove & Install
Engine Oil Cooler / Filter Head - Replace
Flywheel Housing - Replace
Fuel Injectors - Replace
Fuel Pump - Replace
Fuel Pump / Assy Drive Support - Replace
Gear Cover - Replace
Gear Housing / Cover Plate - Replace
Intake Mfd / Aftercooler Assy - Replace
Lubrication Oil Pump - Replace
Oil Pan - Replace
Pistons, Liners, & Rings - Replace
Rocker Lever Assy / Housing - Replace
Thermostat - Replace
Turbocharger - Replace
Vibration Damper / Pulley - Replace
Water Manifold / Header Plate - Replace
Water Pump - Replace
DPF Remove and Install for Cleaning
Nox sensor - Replace
Urea Doser pump - Replace
EGP - Replace
Urea spray nozzle - Replace
Thermistors - Replace
Alternator - Replace
Starter motor - Replace
OVERALL ACCESSIBILITY RATING OF THIS EQUIPMENT
CNG Engines - Fuel Supply
Fill in only yellow cells
Fuel Supply
Fuel pressure meets datasheet requirements under all operating
conditions (+/- 10 psi) Yes No

Electric fuel shut-off solenoid, controlled by the key switch, is installed

before the low-pressure filter. Yes No

Low-pressure gas filter (Cummins supplied) is located where it may be

easily serviced. Yes No

Low-pressure gas filter is mounted as close to the engine fuel

connection as possible, but away from the exhaust. Yes No

The drain for the low pressure gas filter is not located directly above
electrical components. Yes No

Fuel lines are properly supported and carefully routed. Yes No

Gas tank has pressure relief device and manual quarter turn shutoff
valve Yes No

Coolant supply lines to high pressure regulator are free from any valves,
which could shut-off supply ● Yes No

☞ Note: Stainless steel lines and fittings MUST be used for gas supply lines
☞ Note: Fuel lines & fittings MUST meet size requirements, as outlined in AEB 21.25

Drivers display

A low-pressure fuel Lamp is located in the dash. Yes ● No

Photographs of fuels supply components
Comments
To Insert the photograph into this Worksheet open the photo in Windows picture and Fax Viewer, click right
mouse button, select Edit and Copy/Paste the picture into this document. Photograph will be automatically
inserted on the top of this page. Drag the picture to the correct location.
Always use photographs in .JPG format

Reduce the file size of your pictures:

Select one or more pictures in a file.
On the Picture toolbar, click the Compress Pictures Icon .
Note: If you do not see the Picture toolbar, click View, then point to Toolbars, and then click Picture.
Select the options you want and click OK:
CNG Engines - Exhaust system
Fill in only yellow cells
Fuel Supply
Exhaust system meets minimum and maximum backpressure limits as
listed on the data sheet. Yes No

Exhaust system meets maximum turbo to catalyst temperature drop limit

as listed AEB 21.48. Yes No

Exhaust adapter is orientated so the HOS (Heated Oxygen Sensor) is at

the top of the exhaust, per AEB 21.48 or AEB 21.58 Yes No

Catalyst is placed within required length from the engine (per engine
datasheet). Yes No

The oxygen sensor, catalyst, or turbo is not wrapped or painted. Yes No

Any heat sensitive component, located within 12” of the catalyst, turbo,
or exhaust manifold, is protected with heat shielding. Yes No

An 1/8” NPT port is located on the catalyst assembly, upstream of the

core, or on the piping between the engine and catalyst, in an accessible Yes No
location.
The exhaust system has a flex section between turbo outlet and catalyst
(required). Yes No

If a vertically mounted exhaust outlet is used, is a provision for water

draining present. Yes No

HOS cap temperature does not exceed 390 degrees F (199 C) on the
NTK sensor, or 350 degrees F (177 C) on the Bosch sensor. Yes No

The catalyst assembly must have an accessible location to visually

inspection the catalyst core. Yes No

Engine compartment temperature does not exceed 220 degrees F, when

measured at the ECM Yes No

☞ Note: Exhaust adapter used MUST be Cummins supplied (except L gas plus).
☞ Note: Tubing between the engine and catalyst MUST be 409 stainless or equivalent, to provide
adequate life.
☞ Note: The catalyst mounts MUST be capable of supporting the weight of a catalyst and piping.
☞ Note: Exhaust brakes or compression brakes can NOT be used.

Muffler
Make
Model
Inlet size mm
Outlet size mm
Describe any changes in piping size, below
Photographs of Exhaust components
COLS Specification
Document Revision Information

Revision version Date Name Section

v8.5 11-Oct-11 John Green All

v8.4 9-Mar-11 John Green Sign Off

Summary page
Cooling
Cooling & CAC Test

Fuel

Exhaust
Crank charge and wiring

Aftertreatment

Turbocharger
FEAD
Compressed Air

Insite Job Image

v8.3 2-Jun-10 Carl Jenkins

v8.2 2-Feb-10 Carl Jenkins

v8.1 27-Aug-09 Carl Jenkins Sign Off

Summary & Results

Cooling

Fuel
Exhaust

Cranking and Charging systems

Aftertreatment system

Driveline

Lubrication
Turbo
Compressed air system

Controls
Accessories & Service
CNG-exhaust
All/general

Summary & Results

Cooling
Cooling Test
Charge air
Checklist
Details
Reformatted sheet to make easier to use

Names changed for sign off

Copy details from Title page
remove individual system results
Fan Mass bending moment rewording
Added LAT ambient correction comment and checkbox
Added Charge air LAT & ambient correction comment and checkbox
Added log file required for road testing
Added details for OEM supplied pre filter
Added fuel shut off solenoid operation
Added speed of engine for exhaust brake pressure test
Reference AEB 24.53 for starter lockout test
Multiple lines added covering wiring and starter lock out
Add calculation for urea temperature LAT
Added urea nozzle part No
Remove turbo shaft angle question
Added complete TAB sheet
Added section for test results
Added measures compressor duty cycle
Added hydraulic pump details
Added tail support section
Added compressed air LAT section
Tab sheet added

Never published all changes put into 8.4

Never published all changes put into 8.4

Add Customer Support to sign off list

Add Gas Engine Specialist to sign off list
Results decimal places aligned with general results sheets

Add check box for WIF sensor

Modify note for SCR systems, specify stainless steel sections
Add qty/length column to exhaust system table
Add check box and comment for starter lockout
Reword question regarding urea leakage
Add check box for AdBlue line pressure test
Add check box for Automated manual transmission
Add comment box to specify Other transmission
Remove electronic dipstick (ISBe4+ only) comment
Remove controlled turbine section - not relevant to application IQA
Add 'Other' check box to Compressor function
Add check box for ping tank
Modify throttle type list,
Add throttle manufacturer, make/model comment
Add photos section
Engine torque curve - reference to AEB 15.49
Add service access questions, reformat page layout
Reword exhaust components wrapped or covered
Revised instructions to insert photographs, to reduce file size
Minor revisions to spelling and layout

Update links to new cooling section

Test measurements section removed to new tab
New tab for cooling trial and fill D/D results
Link CAC measurements to cooling test sheet
New tab for Service Accessibility Rating
Service Accessibility Rating Checklist – AEB 21.19 Attachment II