ISX15 CM2250SN surging whilst at speed/load

[Aj1189]

Hi,

Have been coming across a slight issue with the Australian ISX15 CM2250SN euro5 engine. Drivers are making complaints of a surging whilst travelling at speed and under load. Seems to be prevalent with the DS10001 & DS10003 cal files (600hp/2050ftlb-600hp/1850ftlb). May happen with other cals & hp ratings but due to size of loads quite uncommon to see other ratings so can’t comment if it does or not. Also does not seem to be calibration revision specific either.
Doesn’t seem to be OEM specific with the issue and has come up in both Kenworths & Weatern stars. Vehicles in question all run road train config pulling 3 x twin deck livestock crates, empty weights between 55-70 ton (150000-155000lb) and gross weight when loaded between 120-140 ton (265000-305000lb). No complaints of surging whilst empty only when loaded and travelling at speeds between 90-100km/h. Has been recorded on video monitoring the Murphy gauge & road relays that boost pressure & hp used drop for a split second then come back in like a silent derate is activating but no codes or faults present. Does not seem to be any uniform pattern when the surging happens and can come in any time/temps/road conditions.

Wastegates have been checked and happens at different levels of wastegate settings from 210kpa-220kpa-240kpa-260kpa. Fuel systems have been checked and verified rails holding pressure, no leaking of injectors, pass throughs, rail relief valve.

Wondering if anyone else has come across this before or if anyone might know where to look in calterm to prevent this happening.. Have got a video of it happening and have got a couple insite images & Xcal saved from vehicles where this is happening..

[hhow55]

I once had an issue like you describe. It turned out to be a fuel return splitter valve was bad.

[Rawze]

Anything much above abut 248kpa on that boost setting is going to shorten engine life over time. = running too lean and eventually cracked head or blown head gasket prematurely.

Below about 233kpa is under-boosting and is very hard on the turbo with excessive heat in the exhaust.

========

stop guessing blindly...
If the power is shifting, and its suspected that anything whatsoever in the programming at all is contributing towards it, then use Calterm to monitor what is happening in the engine. Monitor specially the the 'CBL_Fuel_state' parameter and others related to it. This will tell you exactly what is happening and why.
use this screen file + some desktop recording software (like OBS studio, etc.) to record what is going on on a test drive ...
ref: https://rawze.com/forums/showthread.php?...6#pid28636

Post a link to a desktop recording of when its running right .. and then transitioning to acting up or screen shots) again when its acting up via that CT session screen I linked to. I can translate the numbers into what its doing.

lastly.. are these engine deleted?.. (de-mandated)?. if so then copy the program out of the ecm and e-mail it to me for a review of what some yahoo did in there, as more than 90%+ of all delete programming out there is half-aarssed and harmful to the engine.

[tree98]

(09-17-2024 )Aj1189 Wrote:  loaded between 120-140 ton (265000-305000lb) and travelling at speeds between 90-100km/h.

All I can say is.... WOW!!!

And guys come on here claiming they need 800 hp to drive around pulling 20 tons lol.

[Aj1189]

(09-18-2024 )tree98 Wrote:  

(09-17-2024 )Aj1189 Wrote:  loaded between 120-140 ton (265000-305000lb) and travelling at speeds between 90-100km/h.

All I can say is.... WOW!!!

And guys come on here claiming they need 800 hp to drive around pulling 20 tons lol.

Pretty standard load for anyone who carts livestock, grain, freight as a road train config here in about 2/3 of Australia.. And majority of them are all running the standard 600/2050 cal file in them.

[tree98]

.....

[tree98]

(09-18-2024 )tree98 Wrote:  

(09-18-2024 )Aj1189 Wrote:  

(09-18-2024 )tree98 Wrote:  [quote='Aj1189' pid='81703' dateline='1726627404']
loaded between 120-140 ton (265000-305000lb) and travelling at speeds between 90-100km/h.

What's the average life span of one of these engines?
All I can say is.... WOW!!!

And guys come on here claiming they need 800 hp to drive around pulling 20 tons lol.

Pretty standard load for anyone who carts livestock, grain, freight as a road train config here in about 2/3 of Australia.. And majority of them are all running the standard 600/2050 cal file in them.

What's the average lifespan of one of these engines?