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!