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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
Agenda
 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
EPA Diesel Emissions Legislation
NOx / NOx+HC
Particulate
0.6g/HP-hr
0.6
12
10.7g/HP-hr
0.5
10
0.4
8
6.0g/HP-hr
6
0.3
5.0g/HP-hr
0.25g/HP-hr
4.0g/HP-hr
0.2
4
2.5g/HP-hr
0
1988 1990
0.1g/HP-hr
1.2g/HP-hr*
0.2g/HP-hr
2
1995
2000
2005
2010
2015
2020
0.1
0.01g/HP-hr
Urban Bus 0.05g/HP-hr
0
1988 1990
1995
2000
* Phase-In Average
Near Zero
Emissions
2005
2010
2015
2020
Evolution of Technology
CO2
NOx, PM
Selective Catalytic
Reduction (SCR)
Diesel Particulate
Filter (DPF)
Cooled Exhaust Gas
Recirculation (EGR)
Electronic Fuel Systems
(HPCR, XPI)
Aftercooling (CAC)
1990
2000
2010
2020
Integrating Critical Subsystems
Filters and
fluids
Electronic
Controls
Combustion
SCR catalyst
Technology
and DPF
Variable
Geometry
Turbo (VGT)
Fuel
Systems
(XPI, HPCR)
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
HEST (High Exhaust System Temperature) lamp
Elevated exhaust temperature. Information Only.
DPF (Diesel Particulate Filter) lamp - Normally OFF.
Increase Duty Cycle or Perform Stationary Regeneration.
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)
Situation
Normal Operation
Indication
None
Desired Response
None
•Passive Regen
•Stationary Regen
Disabled
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Normal Operation
Indication
None
Desired Response
None
•Passive Regen
•Active Regen As
Conditions Permit
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Normal Operation
Indication
HEST Lamp On Solid
Desired Response
None
•Aftertreatment outlet
temperatures higher
than normal operation
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Regen Needed – Low
Priority
Indication
DPF Lamp On Solid
•Passive Regen
Desired Response
Provide Regen
Opportunity
•Highway Speed Driving
•Active Regen As
Conditions Permit
•Stationary Regen
Available
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Regen Needed –
Medium Priority
Indication
DPF Lamp Flashing
Desired Response
Require Regen
•Highway Speed Driving
•Passive Regen
•Active Regen as
Conditions Permit
•Stationary Regen
Available
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Regen Needed –
High Priority
•Passive Regen
•Active Regen Disabled
Indication
DPF Lamp Flashing
Desired Response
Require Regen
•Seek Service
Check Engine Lamp
On Solid
•Stationary Regen
Available
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
Situation
Regen Needed - Stop
•Passive Regen
Indication
Stop Engine Lamp
On Solid
Desired Response
Stop Engine at
Earliest Opportunity
•Seek Service
•Active Regen Disabled
•Stationary Regen
Disabled
Empty
Auto
Increasing Soot Load
Low
Medium High Stop
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
DEF Lamp
Situation
DEF@ 10%
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 Lamp
Situation
DEF@ 5%
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 Lamp
Situation
DEF@ 2.5%
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 Lamp
Situation
DEF Tank at 0%
AND
Truck is in motion
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 Lamp
Check Engine Lamp
Indication
Inducement /
Performance
Penalty
Torque Derate of 40%
Speed Limited to 5 MPH
Corrective
Action
Fill the DEF Tank to at least
10%
DEF Tank at 0%
AND
OR
Idled for 1 Hour
OR
Vehicle has been
refueled
Stop Engine
Lamp
DEF Indicator Lamp is
Flashing AND Check Engine
Lamp is Illuminated AND
Stop Engine Lamp is
Illuminated
Situation
Engine has been
shutdown
MIL
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
ISC8.3/ISL9
ISX12
ISX15
(200-360hp)
(330-450hp)
(450-500hp)
(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
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
8/15/2
38
014
Cummins Confidential
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!

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