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Cummins Motorhome Engines
Operation and Maintenance
August 2014
Cummins Inc.
Sales of $17.3 billion in 2013
Over 950,000 engines built in 2013
48,000 global employees
Headquarters in Columbus, Indiana
Product Information
– Emissions history
– Technologies
Operation
– Pre-Trip checks
– Dash Lamps
– Fuel Economy
Maintenance
– Fluids – Fuel, Coolant, Oil, DEF
– Maintenance intervals
Support
– Cummins Care
– Cummins Power Club
– Q&A
Agenda
EPA Diesel Emissions Legislation
* Phase-In Average
NOx / NOx+HC Particulate
0
2
4
6
8
10
12
1988 1990 1995 2000 2005 2010 2015 2020
10.7g/HP-hr
6.0g/HP-hr
5.0g/HP-hr
4.0g/HP-hr
2.5g/HP-hr
1.2g/HP-hr* 0.2g/HP-hr
0
0.1
0.2
0.3
0.4
0.5
0.6
1988 1990 1995 2000 2005 2010 2015 2020
0.6g/HP-hr
0.25g/HP-hr
0.1g/HP-hr
0.01g/HP-hr Urban Bus 0.05g/HP-hr
Near Zero
Emissions
Evolution of Technology
CO2
Aftercooling (CAC)
Diesel Particulate
Filter (DPF)
Selective Catalytic
Reduction (SCR)
Cooled Exhaust Gas
Recirculation (EGR)
Electronic Fuel Systems
(HPCR, XPI)
1990 2000 2010 2020
NOx, PM
Combustion
Technology
Variable Geometry
Turbo (VGT)
Fuel Systems
(XPI, HPCR)
SCR catalyst
and DPF
Filters and fluids
Integrating Critical Subsystems
Electronic Controls
Operation
Pre Trip Inspection
Crankcase Breather Tube
– Plugged (ice or snow)
Fuel-Water Separator
– WIF lamps on most coaches; drain with engine off
Lubricating Oil Level
– Level surface, 15 minute wait, 1 gallon between add and full (2 quarts on ISB)
Fan, Cooling
– Cracks or bent blades?
Coolant Level
– Never open hot (above 120 deg F); most have a poly bottle; sensor
Air Intake Piping
– Clamps tight?
Aftertreatment Exhaust Piping
– No white smoke from connections when warming up (on 2007 and later)
Air Tanks and Reservoirs
– Air system holding pressure? Unusual noises?
Diesel Exhaust Fluid (DEF) Level
– Poly bottle; sensor
Operation – Dash Lamps
DPF (Diesel Particulate Filter) lamp - Normally OFF. Increase Duty Cycle or Perform Stationary Regeneration.
HEST (High Exhaust System Temperature) lamp
Elevated exhaust temperature. Information Only.
Check Engine Lamp – used with DPF Lamp to indicate need for Service Action – Can be coupled with De-Rate
Stop Engine Lamp – used with DPF Lamp to indicate need for Immediate Service Action – Can be Coupled with Severe De-Rate Must be taken to a repair location.
Diesel Exhaust Fluid (DEF) lamp – indicates when DEF level in tank is low. Correct with refilling DEF tank.
Malfunction Indicator Lamp (MIL) – OBD and emissions control system related.
Starting with 2007 – DPF regeneration
Soot accumulates in the DPF
Without regeneration, DPF can
plug
We oxidize the soot by
regeneration
Two methods of regeneration
– Passive – occurs with normal engine
operation
– Active – fuel is added to exhaust to
generate heat
All that is left is ash (minerals)
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Normal Operation
•Passive Regen
•Stationary Regen
Disabled
Indication
None
Desired Response
None
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Normal Operation
•Passive Regen
•Active Regen As
Conditions Permit
Indication
None
Desired Response
None
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Normal Operation
•Aftertreatment outlet
temperatures higher
than normal operation
Indication
HEST Lamp On Solid
Desired Response
None
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Regen Needed – Low
Priority
•Passive Regen
•Active Regen As
Conditions Permit
•Stationary Regen
Available
Indication
DPF Lamp On Solid
Desired Response
Provide Regen
Opportunity
•Highway Speed Driving
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Regen Needed –
Medium Priority
•Passive Regen
•Active Regen as
Conditions Permit
•Stationary Regen
Available
Indication
DPF Lamp Flashing
Desired Response
Require Regen
•Highway Speed Driving
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Regen Needed –
High Priority
•Passive Regen
•Active Regen Disabled
•Stationary Regen
Available
Indication
DPF Lamp Flashing
Check Engine Lamp
On Solid
Desired Response
Require Regen
•Seek Service
Empty Auto Low Medium High Stop
Increasing Soot Load
Situation
Regen Needed - Stop
•Passive Regen
•Active Regen Disabled
•Stationary Regen
Disabled
Indication
Stop Engine Lamp
On Solid
Desired Response
Stop Engine at
Earliest Opportunity
•Seek Service
2010 - SCR
SCR – Selective Catalytic Reduction
DEF (urea) is injected to make ammonia
Ammonia + NOx react to form nitrogen and water
Provided up to a 6% fuel economy improvement
Response to Low Level in DEF Tank
Situation
DEF@ 10%
DEF Lamp
Indication DEF Indicator Lamp is
Illuminated
Inducement /
Performance
Penalty
None
Corrective
Action
Fill the DEF Tank to at least
20%
Response to Low Level in DEF Tank
DEF@ 5%
Situation
DEF Lamp
Indication DEF Indicator Lamp is
Flashing
Inducement /
Performance
Penalty
None
Corrective
Action
Fill the DEF Tank to at least
15%
Response to Low Level in DEF Tank
DEF@ 2.5%
DEF Lamp
Situation
Check Engine Lamp
Indication
DEF Indicator Lamp is
Flashing AND Check Engine
Lamp is Illuminated
Inducement /
Performance
Penalty
Torque Derate of 25%
Corrective
Action
Fill the DEF Tank to at least
12.5%
Response to Low Level in DEF Tank
DEF Tank at 0%
AND
Truck is in motion
Situation
DEF Lamp Check Engine Lamp MIL
Indication
DEF Indicator Lamp is
Flashing AND Check Engine
Lamp is Illuminated
Inducement /
Performance
Penalty
Torque Derate of 40%
Ramped in at 1% per Minute
Corrective
Action
Fill the DEF Tank to at least
10%
Response to Low Level in DEF Tank
DEF Tank at 0%
AND
Engine has been
shutdown
OR
Idled for 1 Hour
OR
Vehicle has been
refueled
Situation
DEF Lamp Check Engine Lamp MIL Stop Engine
Lamp
Indication
DEF Indicator Lamp is
Flashing AND Check Engine
Lamp is Illuminated AND
Stop Engine Lamp is
Illuminated
Inducement /
Performance
Penalty
Torque Derate of 40%
Speed Limited to 5 MPH
Corrective
Action
Fill the DEF Tank to at least
10%
Fuel Economy
More power = more fuel
– Aerodynamics
• Air drag – largest power demand
• Function of speed
– Rolling Resistance
• Tires/pressure
• road surface
• weight
– Accessory Losses
• cooling fan
• engine parasitics
Fuel Economy = Money in your pocket
Reduce vehicle speed … #1 factor affecting MPG is speed … ‘Rule of Thumb’ 1 mpg per 10 mph above 55 mph
Maintain proper tire pressure
– Rolling resistance increases as pressure drops
– 1% loss in MPG per 5-10 PSI
Avoid excessive manual fan usage
– cooling fans draw 20-40 hp.
Limit unnecessary engine idling
Reduce weight when possible
Other operating tips
If Motorhome is equipped with an exhaust brake (“Jake brake”) turn off on slick roads
Engine may automatically increase idle speed to warm up or reduce soot in DPF
Warm-up – operate with light throttle until coolant termpature reaches 150 degrees
Cooldown – idle for 3-5 minutes
Do NOT use ether
Maintenance
Fluids – Fuel
ULSD – Ultra Low Sulfur Diesel (<15 ppm)
No fuel additives are required or recommended
EPA2002 and later engines up to B20 Biodiesel
– Suggest not storing long term with Biodiesel
Avoid black “slime” in fuel filter
– Keep tank full when storing
– Fill at high volume fuel stations
– Biocide and fuel filters
Fluids - Oil
API Classification
– Preferred: CJ-4 – Cummins CES 20081
• Example – Valvoline Premium Blue
– Optional: CI-4 – Cummins CES20078 – more ash in DPF
Synthetic Oils
– Do NOT extend oil drain intervals
– Can be used after first oil drain
– Useful below -13 degrees F
Oil analysis
– Can be useful to detect contaminants
– Should not be used to extend drain intervals
Fluids – Coolant/Antifreeze
Consult chassis manufacturer recommendation
Test Freeze point – 2 times per year – detect dilution
– Refractometer (C2806)
– Test Strips – single (CC2602B), 4 pack (CC2602A)
Fully Formulated Coolant – Green
– Examples: Fleetcool™
– Requires SCA testing & maintenance (each oil change)
OAT – Organic Acid Technology – Red
– Examples: Final Charge®, ES Compleat ™ OAT, Shell Rotella® ELC
– Be careful mixing brands – not all OAT Coolants are the same chemistry
Fill For Life – Pink
– example: Fleetcharge®
– Does have a recommended change interval
Fluids - DEF
Used with SCR to reduce NOx
Freezes at 11°F (does not degrade)
ISO spec 22241-1 – 32% Urea, 68% deionized water
Avoid direct sunlight and temperature above 78°F
– Shelf life 18 months – 2 years
No Special Handling
– Non-toxic, non-polluting, non-flammable
2-5 gallons DEF for 100 gallons of diesel
– Most motorhome DEF tanks are 10-13 gallons
– Sized for about 2-3 complete fuel tank fills
Maintenance Intervals
ISB6.7 (200-360hp)
ISC8.3/ISL9 (330-450hp)
ISX12 (450-500hp)
ISX15 (550-600hp)
Coolant testing 6 months 6 months 6 months 6 months
Oil and oil filter 12 months
15,000 miles
12 months
20,000 miles
6 months
25,000 miles
6 months
30,000 miles
Fuel filter 12 months
15,000 miles
12 months
15,000 miles
6 months
30,000 miles
6 months
30,000 miles
Coolant Filter n/a n/a (optional) 12 months
50,000 miles
12 months
50,000 miles
Overhead
Adjustment
48 months
150,000 miles
48 months
150,000 miles
24 months
250,000 miles
60 months
500,000 miles
Crankcase Breather
Element
Every 3rd or
4th oil change
Every 3rd or
4th oil change
150,000 miles
125,000 miles
DEF filter 200,000 miles 200,000 miles 300,000 miles 300,000 miles
DPF cleaning 200,000 miles 200,000 miles 200,000 miles 200,000 miles
Long term storage (6 months) suggestions
Better to change oil/filters before storage than after
Fill fuel tank (prevent condensation)
Do NOT store with Biodiesel
A monthly exercise program is good
– Start the engine, lubricate parts, charge batteries
Tighten DEF cap
Check coolant freeze protection (northern states)
RV Maintenance and Operation
Quick Reference Guides
ISB6.7 all years bulletin 4971286
ISL9 all years bulletin 4971288
ISX12 all years bulletin 4971384
ISX15 all years bulletin 4971289
Customer Support
Cummins Care
Enhanced customer assistance program (24/7/365)
Operates from Customer Support Center
1-800-DIESELSTM
Service Locator and information
– Can also use service locator on www.cummins.com
Finding a Cummins Service Location
Enhanced service location support
– Assist customers by providing “Best Fit”
location for diagnosis
– Provide support when additional repair
management needs are required
175 distributor service centers
– 3500 dealer locations
8/15/2
014 Cummins Confidential 38
Process
Customer places call to 1-800-DIESELSTM
Cummins Care representative
– Gathers information
– Locates closest authorized repair location
– Assists customer with scheduling the unit into the
repair location
Cummins Power Club
Receive newsletters
Website access with reference information
– Online literature
– Access to QuickServe Online
– FAQs
Engines and Generators
– Parts and Service Support
– Cummins distributor discount
Annual Fee
Stop by the Cummins exhibit for more information
– www.cumminspowerclub.com
Questions?
Thank you!