Better EveryTM. Time. Engine Reference Guide For EPA 2010 Engines

Transcription

1 Better EveryTM Time. Engine Reference Guide For EPA 2010 Engines

2 EnginE REfEREncE guide 2010

3 2010 Table Of Contents Page Heavy-Duty Features 1 ISX15 3 Medium-Duty Features 12 ISC ISB Cummins Westport Inc. 25 ISL G 26 Electronic Tools And Software PowerSpec 32 RoadRelay 4 35 QuickCheck 37 INSITE 39 Special Features Jacobs Brake Systems 41 Rear Engine Power Take-Off 41 Warranty Heavy-Duty Truck Engines 42 Medium-Duty Truck Engines 43 Alternative Fuel Engines 44 Fire Apparatus/Crash Truck Engines 45 Motorhome Engines 46 Extended Coverage Heavy-Duty ISX15 Truck Engines 47 Vocational ISX15 Engines 50 Medium-Duty ISC8.3/ISB6.7 Truck Engines 51 Alternative Fuel ISL G Engines 53 Fire Apparatus/Crash Truck And Motorhome ISX15/ ISC8.3/ISB6.7 Engines 56 Encore Coverage 58 National Overhaul Warranty (NOW ) 61 iii Cummins is a pioneer in product improvement. Thus specifications may change without notice.

4 Parts, Service And Support Page Genuine Cummins Parts 66 ReCon Parts And Engines 67 CUMPAS 69 RapidServe 70 Virtual College 71 QuickServe Online 72 Parts Professional 74 Sales Information freightliner.cummins.com 75 cumminsengines.com 75 cummins.com 75 Customer Assistance Center 75 Vehicle Mission Simulation (VMS) 76 Diesel Exhaust Fluid, Fuels And Lubricants 77 Premium Blue 79 Premium Blue Extreme 79 Formulas Formulas And Conversions Inside Back Cover iv

5 1 Heavy-Duty Features And Benefits Every Challenge. Met. n System Integration Cummins is the only engine manufacturer to design and develop, manufacture and support every component from the air intake to the exhaust aftertreatment in a totally integrated system. n Cummins is able to optimize critical systems to deliver the right technology to our customers in a way that other engine manufacturers using outside suppliers can t match. n XPI Fuel System Cummins is the only North American manufacturer with the in-house capability to design and develop this critical element. The XPI fuel system is capable of the highest injection pressures in the industry consistent at every rpm for stronger performance with multiple injection events for cleaner, quieter and more complete combustion. n Single Overhead Cam Our improved XPI fuel system eliminates the need for a second camshaft. This provides weight savings and simplifies operation. n VGT TM Turbocharger Custom-built by Cummins Turbo Technologies; this proven technology has set the industry standard for precision performance, dependability and durability since Lower Operating Costs. n Fuel Economy The ISX15 integrated engine package delivers up to 6% better fuel economy (versus EPA 2007 ISX). n Selective Catalytic Reduction (SCR) A key factor in this fuel economy improvement is the use of proprietary SCR technology, which allows Cummins to lower the amount of cooled EGR in the power cylinder and recalibrate the engine for more efficient combustion and increased fuel economy. In 2010, the proven Cummins Particulate Filter, which reduces particulate matter by over 90% is combined with Cummins Selective Catalytic

6 Reduction (SCR) to meet emissions standards while maintaining best-in-class performance, reliability and durability. Cummins SCR technology has been proven in over 350,000 European vehicles and uses Diesel Exhaust Fluid (DEF) to achieve NOx emissions at near-zero levels. DEF is readily available; reference Cummins Filtration flyer LT15618 for more information. n Larger Sweet Spot Fleets with less experienced drivers will see even bigger fuel economy gains from the three-times larger sweet spot with the ISX15. n Less Regenerations The fully integrated technology of the ISX15 requires fewer regeneration events (none at all for over-the-road truckers). n Maintenance Intervals Maintenance intervals and costs remain virtually unchanged with the only additional items being a cleaning of the hydrocarbon doser injector every 150,000 miles (240,000 km) and replacement of the DEF filter at 200,000-mile (320,000 km) intervals. n Big Bore ISX15 will deliver a higher resale value at trade-in than smaller displacement engines. Driver Satisfaction. n Power and Performance The ISX15 delivers the features that drivers want and need 600-bhp Intebrake TM system, Load-Based Speed Control (LBSC), Gear-Down Protection (GDP). n Ratings SmartTorque ratings continue to be offered, adding up to 200 lb-ft of extra torque in the top two gears so drivers can maintain road speed going up steep grades with fewer downshifts and better fuel economy. Plus, vocational ratings are also available, delivering extra torque in lower gears for dump trucks, mixers and refuse vehicles. Service. n Largest Service Network Cummins Service Network is the largest in North America with over 3,500 locations. 2

7 ISX15 EPA 2010 Engines hp ( kw) Every Advantage Cummins ISX15 is meeting the 2010 EPA standards with a solution that does more than achieve lower emissions. Our totally integrated, driver-friendly engine package delivers better fuel economy with better performance and exceptional reliability. How much better? The ISX15 for EPA 2010 delivers up to 6% better fuel economy and near-zero emissions (versus EPA 2007 ISX). ISX15 Specifications Advertised hp kw Horsepower Maximum 600 bhp 447 kw Braking Horsepower Peak Torque lb-ft N m Governed Speed rpm Number of Cylinders 6 Oil System Capacity 14 U.S. gallons 52.9 liters Coolant Capacity, 35 U.S. quarts 33.1 liters Engine Only Clutch Engagement 1000 lb-ft 1356 N m Torque System Weight 3,186 lb 1,445 kg Engine (Dry) 2,964 lb 1,344 kg Aftertreatment* 222 lb 101 kg * Increase over standard muffler and does not include chassis OEM-supplied components. 3

8 ISX15 Truck Applications Maintenance Intervals Duty Cycles* Light Normal Severe Oil and Filter 35,000 mi 25,000 mi 15,000 mi 56,000 km 40,000 km 24,000 km Fuel Filter 25,000 mi 25,000 mi 25,000 mi 40,000 km 40,000 km 40,000 km Coolant 50,000 mi 50,000 mi 50,000 mi Filter** 80,000 km 80,000 km 80,000 km Valve 500,000 mi 500,000 mi 500,000 mi Adjustment 800,000 km 800,000 km 800,000 km Coalescing 125,000 mi (200,000 km) or Filter*** Every 5th to 6th Oil Change Interval DEF Filter 200,000 mi (320,000 km) Hydrocarbon Doser Injector Cleaning 150,000 mi (241,000 km) Particulate Filter Cleaning 300,000 mi (482,803 km) *Light Duty = > 7 mpg Normal Duty = 6 to 7 mpg Severe Duty = < 6 mpg **With appropriate filter. ***For blowby <12 in. H 2 O See Owners Manual for complete details. The Cummins Particulate Filter is designed to last the life of your engine. Passive and active regeneration are transparent to the operator. ISX Vocational Maintenance Intervals Miles Hours Months Kilometers Oil and Filter 15, ,000 Fuel Filter 25, ,000 Coolant Filter* 50,000 1, ,000 Valve 500,000 10,

9 Adjustment 800,000 Coalescing 125,000 3, Filter 200,000 ISX15 Fire And Emergency Vehicle Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Fuel Filter 25, ,000 Coolant Filter** 50,000 1, ,000 Valve 500,000 10, Adjustment 800,000 Coalescing 125,000 3,000 Filter*** 200,000 DEF Filter 200,000 4, ,000 Hydrocarbon Doser 150,000 4,500 Injector Cleaning 241,000 Particulate 300,000 6,750 Filter Cleaning 482,803 *Assuming severe duty cycle for fire and emergency vehicle applications. **With appropriate filter. ***For blowby <12 in. H 2 O See Owners Manual for complete details. 5

10 ISX15 Motorhome Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Fuel Filter 25, ,000 Coolant Filter** 50,000 1, ,000 Valve 500,000 10, Adjustment 800,000 Coalescing 125,000 3, Filter*** 200,000 DEF Filter 200,000 4, ,000 Hydrocarbon Doser 150,000 4,500 Injector Cleaning 241,000 Particulate 300,000 6,750 Filter Cleaning 482,803 *Assuming normal duty cycle for recreational vehicle applications. **With appropriate filter. ***For blowby <12 in. H 2 O See Owners Manual for complete details. 6

11 SmartTorque Putting Technology In High Gear SmartTorque technology is a torque enhancement system that gives fleets and owner/operators massive hill-pulling torque. And, at the same time, delivers up to 3% savings on fuel costs. Here s how it works: The electronic control module monitors engine speed, load and gear position. When the driver shifts into the top two gears, SmartTorque automatically kicks it up, unleashing as much as 200 extra lb-ft of torque. Though SmartTorque increases power significantly, that s not a consideration when spec ing the transmission. For example, if SmartTorque boosts engine torque to 1850 lb-ft, the transmission can be spec d for a lower torque rating. Saving both the weight and expense of a beefier transmission. Yet with SmartTorque s extra power, drivers get up steeper hills with fewer downshifts, saving fuel, decreasing trip times and reducing driver fatigue. So destinations are reached more economically, faster and safer. 7

12 Load-Based Speed Control Cummins Load-Based Speed Control (LBSC) is a patented electronic feature on ISX15 engines that helps drivers achieve higher fuel economy without compromising performance. This Cummins exclusive feature automatically adjusts the engine operating range to match the load on board and the route. It optimizes engine rpm during normal driving conditions by governing the engine speed to encourage shifting in the most fuel-efficient ranges. At the same time, it continuously monitors vehicle operating conditions and allows access to an extended engine operating range every time it senses the need. For example: n On a grade exceeding 2% n During sharp turns when tire scrub may occur n When carrying a load in excess of 80,000 lb LBSC also does not limit engine speed during gear changes or when operating in the top two gears. Load-Based Speed Control lowers the average engine revs/mile (kilometer). This has many benefits: n Improved fuel economy n Reduced parasitic losses due to cycling of engine accessories (such as the fan) n Lower engine noise in parking lots and residential areas n Improved engine durability 8

13 ISX15 Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N rpm ISX (447) ISX15 600* 600 (447) ISX (447) ISX (410) ISX (410) ISX (392) ISX (373) ISX (373) ISX (362) ISX (362) ISX (336) ISX (336) ISX (317) ISX (298) *Restricted to Recreational Vehicle applications. For additional information, see: ISX15 EPA 2010 Truck Applications Spec Sheet, Bulletin ISX15 For Fire And Emergency Applications Spec Sheet, Bulletin Motorhome Engines For EPA 2010 Brochure, Bulletin ISX15 Gearing Recommendations A major factor in optimizing performance and fuel economy is vehicle gearing. Log on to for gearing recommendations specific to your application. 9

14 ISX15 SmartTorque (ST) Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N rpm ISX ST 500 (373) 1650/ ISX ST 485 (362) 1650/ ISX ST 450 (336) 1550/ ISX ST 450 (336) 1450/ ISX ST 425 (317) 1550/ ISX ST 425 (317) 1450/ ISX ST 400 (298) 1550/ ISX ST 400 (298) 1450/

15 ISX15 Special Vocational Engines Cummins has developed special ratings for vocational applications like mixers, refuse and dump trucks. Vocational ratings are designated by a V in the model name. ISX15 Vocational Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N rpm ISX15 500V 500 (373) ISX15 500V 500 (373) ISX15 455V 455 (339) ISX15 435V 435 (325) Additional ratings may be available. 11

16 Medium-Duty Features And Benefits n Improved Base Engine Very few changes have been made to the ISC8.3 and ISB6.7 base engines for EPA You can expect the same high level of performance, reliability and dependability that you currently get from Cummins Medium-Duty engines. n Better Fuel Economy The combination of SCR, XPI or High Pressure Common Rail (HPCR) fuel injection and the total integration of all elements controlled under a single system results in up to 3% better fuel economy for ISC8.3 and ISB6.7 engines (versus EPA 2007 ISC and ISB). n Every System. Integrated. Cummins designs and develops, manufactures and supports nearly every component from the air intake to the exhaust aftertreatment in a totally integrated system. Cummins is able to optimize critical systems to deliver the right technology to our customers in a way that other engine manufacturers using outside suppliers can t match. Cummins Aftertreatment System The Cummins Aftertreatment System combines the Cummins Particulate Filter with proven Selective Catalytic Reduction (SCR) technology and has been fully integrated with the engine to deliver near-zero emissions. Adding SCR does more than clean up the exhaust. It enables us to lower cooled-egr levels and recalibrate the engine for stronger performance and better fuel efficiency. 12

17 Diesel Exhaust Fluid (DEF) is sprayed at a rate of approximately 2-3% of fuel consumption and will need to be refilled periodically. Simply check the DEF gauge on your dashboard at each refueling. XPI Fuel System The ISC8.3 features the XPI fuel system. Cummins is the only North American manufacturer with the in-house capability to design and develop this critical element. The XPI fuel system is capable of the highest injection pressures in the industry, consistent at every rpm for stronger performance with multiple injection events for cleaner, quieter and more complete combustion. High Pressure Common Rail (HPCR) Fuel System The ISB6.7 features the HPCR fuel system which delivers a precise mixture of fuel and air at a constant pressure, regardless of engine rpm. This flexibility in injection timing allows multiple injection events per cycle, which maximizes fuel economy and performance while decreasing noise and exhaust emissions. VGT TM Turbocharger Custom-built by Cummins Turbo Technologies; this proven technology has set the industry standard for precision performance, dependability and durability since

18 Exhaust Gas Recirculation (EGR) Cummins Medium-Duty engines also include a next-generation EGR cooler designed for better flow control. Electronic Control Module The same Electronic Control Module (ECM) and engine software is featured on all Cummins on-highway diesel engines and has been enhanced in 2010 with more precise control for better combustion. n Maintenance Intervals Maintenance intervals and costs remain virtually unchanged for the Medium-Duty engines. The only additional item is the replacement of the DEF Filter every 200,000 miles (320,000 km). n Largest Service Network Cummins Service Network is the largest in North America with over 3,500 locations. 14

19 ISC8.3 EPA 2010 Engines hp ( kw) Better Performance Year after year, in every type of vehicle from buses to dump trucks, Cummins ISC has earned the trust of operators and owners alike. That s the reason very few changes have been made to the base engine for You can expect the same great reliability with even better performance from the ISC8.3 EPA 2010 than you currently get from ISC-powered vehicles. With heavy-duty features like replaceable wet liners, the ISC8.3 has one of the highest powerto-weight ratios in its class. ISC8.3 Specifications Advertised hp kw Horsepower Peak Torque lb-ft N m Governed Speed 2200 rpm Number of Cylinders 6 Oil System Capacity 6.3 U.S. gallons 23.8 liters Clutch Engagement 500 lb-ft 678 N m Torque System Weight 1,895 lb 859 kg Engine (Dry) 1,695 lb 769 kg Aftertreatment* 200 lb 90 kg * Increase over standard muffler and does not include chassis OEM-supplied components. 15

20 ISC8.3 Medium-Duty And Vocational Truck Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Primary 15, Fuel Filter** 24,000 Secondary 15, Fuel Filter 24,000 Coolant Filter None*** None*** None*** Overhead 150,000 5, Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing Filter Every 3rd to 4th Oil Change Interval DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming normal duty cycle. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. Regardless if the engine is or is not equipped with a coolant filter, SCA/DCA additive levels must be checked according to the interval listed in the Owners Manual. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 16

21 ISC8.3 Fire And Emergency Vehicle Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 9, ,500 Primary 9, Fuel Filter** 14,500 Secondary 9, Fuel Filter 14,500 Coolant Filter None*** None*** None*** Overhead 150,000 5, Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing 60,000 2,000 Filter 96,000 DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming severe duty cycle for fire and emergency vehicle applications. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. Regardless if the engine is or is not equipped with a coolant filter, SCA/DCA additive levels must be checked according to the interval listed in the Owners Manual. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 17

22 ISC8.3 Motorhome Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Primary 15, Fuel Filter** 24,000 Secondary 15, Fuel Filter 24,000 Coolant Filter None*** None*** None*** Overhead 150,000 5,000 Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing Filter Every 3rd to 4th Oil Change Interval DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming normal duty cycle for recreational vehicle applications. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. Regardless if the engine is or is not equipped with a coolant filter, SCA/DCA additive levels must be checked according to the interval listed in the Owners Manual. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 18

23 ISC8.3 Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N rpm ISC * 380 (283) ISC (260) ISC (246) ISC (224) ISC (201) ISC (194) * Restricted to RV, Fire and Emergency applications. Additional ratings may be available. For additional information, see: ISC8.3 EPA 2010 For Truck Applications Spec Sheet, Bulletin ISC8.3 EPA 2010 For Fire and Emergency Applications Spec Sheet, Bulletin ISC For RV Applications Spec Sheet, Bulletin ISC8.3 Gearing Recommendations A major factor in optimizing performance and fuel economy is vehicle gearing. Log on to for gearing recommendations specific to your application. 19

24 ISB6.7 EPA 2010 Engines hp ( kw) Every Advantage For superior performance with the lowest cost of operation and maximum uptime, Cummins ISB6.7 EPA 2010 is best in class. Low operating costs and big results are what you ve come to expect from a Cummins B Series engine, and the ISB6.7 delivers in every kind of job, from dump trucks to P&D vehicles and more. ISB6.7 Specifications Advertised hp kw Horsepower Peak Torque lb-ft N m Governed Speed rpm Clutch Engagement 400 lb-ft 542 N m Torque Number of Cylinders 6 Oil System 4 U.S. gallons 15.1 liters Capacity System Weight 1,340 lb 608 kg Engine (Dry) 1,150 lb 522 kg Aftertreatment* 190 lb 86 kg * Increase over standard muffler and does not include chassis OEM-supplied components. 20

25 ISB6.7 Medium-Duty Truck Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Primary 15, Fuel Filter** 24,000 Secondary 15, Fuel Filter 24,000 Coolant Filter None*** None*** None*** Overhead 150,000 5, Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing Filter Every 3rd to 4th Oil Change Interval DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming normal duty cycle. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 21

26 ISB6.7 Fire And Emergency Vehicle Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Primary 15, Fuel Filter** 24,000 Secondary 15, Fuel Filter 24,000 Coolant Filter None*** None*** None*** Overhead 150,000 5, Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing 75,000 2,500 Filter 120,000 DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming severe duty cycle for fire and emergency vehicle applications and 14.2-liter (15 qt) capacity lubricating oil pan. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 22

27 ISB6.7 Motorhome Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15, ,000 Primary 15, Fuel Filter** 24,000 Secondary 15, Fuel Filter 24,000 Coolant Filter None*** None*** None*** Overhead 150,000 5,000 Adjustment 241,500 Standard Coolant 60,000 2, Change**** 96,000 Coalescing Filter Every 3rd to 4th Oil Change Interval DEF Filter 200,000 mi (320,000 km) or 6,500 Hours Particulate 200,000 mi (320,000 km) Filter Cleaning or 6,500 Hours *Assuming normal duty cycle for recreational vehicle applications and 14.2-liter (15 qt) capacity lubricating oil pan. **OEM-supplied; intervals may vary. ***If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. ****Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to the Cummins Coolant Requirements and Maintenance Service, Bulletin See Owners Manual for complete details. 23

28 ISB6.7 Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N rpm ISB * 360 (269) ISB * 340 (254) ISB AD** 340 (254) ISB ** 325 (243) ISB (243) ISB (224) ISB AD** 300 (224) ISB (209) ISB (194) ISB (187) ISB (179) ISB (164) ISB (149) *Restricted to Fire and Emergency Vehicle and RV applications. **Restricted to RV applications. Additional ratings may be available. For additional information, see: ISB6.7 EPA 2010 For Truck Applications Spec Sheet, Bulletin ISB6.7 EPA 2010 For Fire and Emergency Applications Spec Sheet, Bulletin ISB6.7 XT for RV Applications Spec Sheet, Bulletin ISB for RV Applications Spec Sheet, Bulletin ISB for RV Applications Spec Sheet, Bulletin ISB6.7 Gearing Recommendations A major factor in optimizing performance and fuel economy is vehicle gearing. Log on to for gearing recommendations specific to your application. 24

29 Cummins Westport Inc. Every Alternative Cummins Westport Inc. is a 50/50 joint venture between Cummins Inc. and Westport Innovations, created to develop, manufacture and market low-emissions high-performance alternative fuel engines worldwide. The vision of Cummins Westport Inc. is to be the world s leading provider of clean gaseous-fueled engines that deliver an economic solution to bus and truck customers. Cummins Westport alternative fuel engines are manufactured by Cummins and sold and serviced by the global Cummins network with Cummins Parts and Service and Warranty support. Optional extended warranty plans are also available. The ISL G natural gas engine operates on both liquid (LNG) and compressed (CNG) natural gas with a minimum methane rating of 75. The ISL G will also operate on renewable natural gas, or biomethane that meets fuel quality specifications. The ISL G has met the EPA 2010 emissions regulations since launch in The new combustion technology and Three-Way Catalyst exhaust aftertreatment creates low emissions without the use of Diesel Particulate Filters (DPF) or Selective Catalytic Reduction (SCR) systems. The ISL G is available from leading truck, urban transit, and school bus OEMs in a variety of applications, with four ratings in the following power range: ISL G hp ( kw) 25

30 ISL G Engines hp ( kw) Every Alternative The ISL G is the leading evolution of alternative fuel engine technology, combining all the advantages of clean-burning natural gas with no compromise power and torque for shuttle and school bus, urban transit, refuse, vocational and medium and heavy-duty truck and tractor applications. It combines high displacement and superior horsepower with proven wastegate turbocharger technology for impressive low-end torque and transient response, with an increase in fuel efficiency. The ISL G has met 2010 U.S. EPA and CARB emissions standards since Key Features And Benefits n Stoichiometric Cooled EGR Improves power density as well as fuel economy. Uses high EGR rates in the combustion process, in place of excess air, creating an oxygen-free exhaust. This allows for the use of the Three-Way Catalyst n Electronic Control Module Full drive-bywire. Constantly monitors and controls engine sensors, fuel system and ignition system. Provides OEM and end users with the ability to tailor performance of the engine to fit the vehicle mission. Full interface capability to Cummins INSITE and QuickCheck diagnostic service tools n Accessory Belt Drive System Self-tensioning serpentine polyvee belt accessory drive system for water pump, engine-mounted fan hub and most alternators 26

31 n Wastegated Turbocharger Electronically controlled wastegated turbocharger for superior engine response to changing conditions n Air Intake System Charge air cooling reduces emissions by lowering intake manifold air temperatures n High-Energy Ignition System Provides better performance and longer service intervals, improved spark plug and coil durability, plus self-diagnostics n High-Efficiency Lube Cooler Lowers oil temperatures for longer engine life n Crankshaft Eight counterweight, fully balanced, high-tensile-strength steel forging with induction-hardened fillets and journals for outstanding durability Low Maintenance Costs: n Oil Filter The combination full-flow and bypass oil filter improves filtration while minimizing oil filter replacement and disposal costs n Three-Way Catalyst Simple passive device that requires no maintenance 27

32 ISL G Specifications Advertised hp kw Horsepower Peak Torque lb-ft N m Governed Speed 2200 rpm Type 4 cycle, spark-ignited inline 6 cylinder, turbocharged, CAC Engine 540 cu in 8.9 liters Displacement Clutch Engagement 550 lb-ft 746 N m Torque Operating Cycles 4 Oil System 7.3 U.S. gallons 27.6 liters Capacity Coolant 13.1 U.S. quarts 12.4 liters Capacity System Voltage 12 V System 1,625 lb 737 kg Weight (Dry) For additional information on specifications and gearing recommendations, in addition to the specific charts on the following pages, log on to cumminswestport.com and download the following: ISL G Next Generation Natural Gas Engines For Truck And Bus, Bulletin

33 ISL G Truck Applications Maintenance Intervals* Miles Hours Months Kilometers Oil and Filter** 15, ,000 Fuel Filter 15,000 1, ,000 Coolant Filter 7, ,000 Spark 22,500 1, Plugs 36,000 Coolant 30,000 2, Change*** 48,000 Valve 30,000 2, Adjustment**** 48,000 *Assuming normal duty cycle. **Requires Natural Gas Engine Oil (CES20074). ***Do not change if SCA above 3. ****Initial Overhead Adjustment at 1,000 hours. For complete maintenance interval and service information refer to the ISL G Owners Manual, or to QuickServe Online. 29

34 ISL G Ratings Advertised Engine Horsepower Peak Torque Model rpm lb-ft (N rpm ISL G ISL G ISL G ISL G Note: Three-Way Catalyst required for all ratings. 30

35 Notes 31

36 Electronic Tools And Software Cummins PowerSpec Every Engine Customized No two people operate a truck, van or motorhome the exact same way. They all have different routes, different loads, different driving habits and different preferences. Cummins PowerSpec makes it possible to tailor the operation of Cummins engines to fit every customer s needs and desires, exactly. Plus, PowerSpec can read fault codes, collect trip information and even provide gearing recommendations. PowerSpec works on every Cummins engine from the ISB to the ISX. This includes full functionality support for 2010 engine platforms (ISX15, ISC8.3, ISB6.7) and earlier engine models. What s more, PowerSpec provides recommendations based on your application, in every type of vehicle from refuse to line-haul. For complete electronic feature descriptions, download PowerSpec for free from 32

37 Electronic Features: n Road Speed Governor Accelerator Max Road Speed Accelerator Upper/Lower Droop n Gear Down Protection n Idle Speed Control n Idle Shutdown n Driver Reward n Fan Control Minimum Fan On Timer Fan On During Engine Braking Manual Fan Switch n Load Based Speed Control (ISX15) n Cruise Control Maximum Cruise Control Speed Cruise Control Upper/Lower Droop Cruise Control save Set Speed Cruise Control Auto-Resume n Engine Brakes (ISX15, ISC8.3) Engine Brake Minimum Vehicle Speed Engine Brake Cruise Control Activation Engine Brake Service Brake Activation n Accelerator Control n Adaptive Cruise Control n Reserve Speed 33

38 Electronic Features (Cont d): n PTO/Remote PTO PTO Maximum Vehicle Speed PTO Max/Min Engine Speed PTO Service Brake Override PTO Accelerator Override PTO Remote Enable Ignore Vehicle Speed Sensor (VSS) in PTO n Trip Information n Engine Protection n Anti-Tampering Measures Maximum Engine Speed without VSS VSS Tamper Detection n Password Security Configure Engine Passwords n Aftertreatment High Soot Load Shutdown n Driveline Configuration n Switched Maximum Engine Speed n Cruise Control Switch n OEM Ambient Air Temperature Sensor n Crankcase Ventilator Heater Visit contact your local Cummins distributor or call us toll-free at DIESELS TM ( ) Customer Assistance Center. 34

39 RoadRelay 4 RoadRelay has helped improve the productivity of thousands of fleets and owner/operators, becoming the most popular in-cab display of driver information in the trucking industry. RoadRelay 4 helps drivers increase mpg, reduce idle time and improve delivery performance by providing the feedback they need on the road, while driving. Plus, there are many additional features to improve driving habits and save money: n Displays and records fuel, miles and engine hours spent in idle, PTO and other operating modes n Allows analysis of specific user-definable routes (i.e., from the loading dock to a customer location) with the route recorder feature n Stores the number of sudden decels, as well as seventy-five seconds of detailed vehicle data rpm, mph, and brake and clutch activity for the last three sudden decels n Records exact time of events with a real-time clock n Informs the driver and gives instructions on how to minimize potential damage if an unexpected event happens n Provides extended descriptions of vehicle fault codes 35

40 n Tracks customizable service intervals for fluid changes, filter changes and tire rotations, notifying drivers when it s time for scheduled preventive maintenance n Easy-to-read four-line display that automatically dims when the vehicle headlights are turned on for night driving with adjustable brightness control n Gives drivers data entry option with backlit 12-key numeric keypad n Helps keep track of fuel tax deductions n Provides ETA feature with alarm clock n Password protects engine ECM with antitheft option n Displays Driver Reward status n Compatible with any electronic engine, regardless of make or age n Records service history of maintenance events n Records information for up to four drivers with driver ID feature n Provides real-time coaching pop-ups that can help make a good driver even better For additional information, see: RoadRelay 4 Flyer, Bulletin RoadRelay 4 For Motorhome Owners Flyer, Bulletin

41 QuickCheck With the QuickCheck handheld computer you get everything you need to capture and monitor engine data quickly and conveniently. Powered by the Windows * CE operating system, the QuickCheck device features an integrated adapter that s built in for connecting to any electronic engine with a J1587 or J1939 industrystandard data link. Easy To Use The QuickCheck is simple to learn and to operate: n Simple push-button and touch-screen navigation n 3.8" monochrome or 3.5 color LCD screen n Long-lasting rechargeable lithium-ion battery for up to 10 hours of usage n Multiple recharging capability using USB cable, AC power supply/recharger or vehicle service connector The QuickCheck handheld comes with powerful QuickCheck CE and PowerSpec CE applications pre-installed. QuickCheck CE allows you to monitor a range of data from any manufacturer s engine with electronic controls, transmission, braking and vehicle systems. For more information, go to: quickcheck.cummins.com. *Windows is a registered trademark of Microsoft Corporation. 37

42 PowerSpec CE reads and resets trip and fault code information from Cummins on-highway engines. The summary screen displays the ten most requested trip parameters: n Average mpg n Average mpg driving n Percent idle time n Percent PTO time non-moving n Percent top gear distance n Maximum vehicle speed n Number of sudden decelerations n Distance n Total engine hours n Trip time QuickCheck and PowerSpec allow you to read current engine parameter settings and transfer a custom setting from your PC to your engine. Trip information captured on the QuickCheck can then be uploaded to a PC for viewing with PowerSpec PC. 38

43 INSITE INSITE is a PC-based software application that provides quick and easy access to your engine s electronic performance information, which enables faster service turnaround times. INSITE helps to ensure accurate procedures and diagnosis and limit downtime, while increasing productivity and profits. Cummins INSITE software supplies engine information quickly, getting the inside details you need. Delivering Every Detail INSITE can provide you with: n Trip and vehicle information n Parameter and feature adjustment n Accurate problem diagnosis n Complete wiring diagrams and sensor location maps n Step-by-step troubleshooting information n Fault tree information n Fault code and symptom-based diagnostics n Engine diagnostic tests n Tools to create templates for a group of vehicles n Fleet management/driver reward programs n Audit trail information n Enhanced ECM security 39

44 A Version To Meet Every Need INSITE is offered in four functional levels: Basic, Lite, RSGR and Pro, ranging from a read only access level for the do-it-yourselfer to fullfunction access and capability for the service professional. INSITE Lite, INSITE RSGR and INSITE Pro are subscription programs, with automatic shipment of software updates as they are released. This provides you with the latest in features, functions and new engine support. INSITE Basic is offered as a one-time purchase without updates. INSITE requires one of our INLINE adapters to communicate with an engine. This adapter translates communications between the INSITE software on your PC and the engine s ECM. Additional information is available online at 40

45 Jacobs * Brake Systems Cummins engines use Jacobs brake systems. For additional information on engine compatibility and performance data, log on to jakebrake.com. * Jacobs is a registered trademark of Jacobs Vehicle Systems. Rear Engine Power Take-Off (REPTO) Available on Cummins ISC8.3 engines: n Provides continuous live power n Allows up to 1,500 lb more payload under the Bridge Law n Eliminates extended frames and bumpers of front PTOs, improving visibility and maneuverability n Does not require radiator clearance for a raised PTO shaft, so engine cooling is not compromised 41

46 Warranty Base Warranty For Heavy-Duty Truck Engines ISX15 2-Year/250,000-Mile (402,336 km), Whichever Occurs First 100% parts and labor on warrantable failures* Travel or towing when engine is disabled by a warrantable failure Consumables not reusable due to covered failure Cooled-EGR components, Variable Geometry Turbocharger and aftertreatment components, including the SCR system Limited progressive damage, including aftertreatment X X X X X Additional information See Bulletin See North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin *Warrantable failures are those due to defects in Cummins material or factory workmanship. No deductible. Belts and hoses are not covered beyond the first year from the date of delivery of the engine to the first user or duration of the warranty, whichever occurs first. 42

47 Base Warranty For Medium-Duty Truck Engines 100% parts and labor on warrantable failures* Travel or towing when engine is disabled by a warrantable failure (from date of delivery through first year) Consumables not reusable due to covered failure Cooled-EGR components, Variable Geometry Turbocharger and aftertreatment components, including the SCR system Limited progressive damage, including aftertreatment ISC8.3 2-Year/250,000-Mile (402,336 km), Whichever Occurs First X X ISB6.7 2-Year/Unlimited-Mile No deductible X X Additional information See Bulletin See Bulletin X X X X X X X X See North American Truck Coverages for ISL9, ISC8.3 And ISB6.7 Engines Brochure, Bulletin *Warrantable failures are those due to defects in Cummins material or factory workmanship. Belts and hoses are covered for the first year of warranty or duration of coverage, whichever occurs first. 43

48 Base Warranty For Alternative Fuel Automotive Engines ISL G 2-Year/250,000-Mile (402,336 km), Whichever Occurs First 100% parts and labor on X warrantable failures* Travel or towing when X engine is disabled by a warrantable failure (from date of delivery through first year) Consumables not X reusable due to covered failure Limited progressive X damage, including aftertreatment No deductible X Additional information See Bulletin *Warrantable failures are those due to defects in Cummins material or factory workmanship. Belts and hoses are covered for the first year of warranty or duration of coverage, whichever occurs first. 44

49 Base Warranty For Fire Apparatus/ Crash Truck Engines ISX15, ISC8.3, ISB6.7 5-Year*/100,000-Mile (160,935 km), Whichever Occurs First 100% parts and labor on warrantable failures** Travel or towing when engine is disabled by a warrantable failure or further operation would cause damage Consumables not reusable due to covered failure Cooled-EGR components, Variable Geometry Turbocharger and aftertreatment components, including the SCR system X X X X Additional information See Bulletin *$100 deductible per service event in years 3, 4 and 5. **Warrantable failures are those due to defects in Cummins material or factory workmanship. Cummins-branded starters are good for 2 years/100,000 mi (160,935 km). Belts and hoses are covered for the first year of warranty or duration of coverage, whichever occurs first. 45

50 Base Warranty For Motorhome Engines ISX15, ISC8.3, ISB6.7 5-Year*/100,000-Mile (160,935 km), Whichever Occurs First 100% parts and labor on warrantable failures** Travel or towing when engine is disabled by a warrantable failure or further operation would cause damage (from date of delivery through first year) Consumables not reusable due to covered failure X X X Additional information See Bulletin *$100 deductible per service event in years 3, 4 and 5. **Warrantable failures are those due to defects in Cummins material or factory workmanship. ISB6.7 AD ratings begin with sale and end 3 years/75,000 miles, whichever occurs first, after the date of delivery of the engine to the first user. Belts and hoses are covered for the first year of warranty or duration of coverage, whichever occurs first. 46

51 Extended Coverage Extended Coverage For Heavy-Duty ISX15 EPA 2010 Truck Engines Protection Plan 1: Options ranging from 3 to 5 years/300,000 to 500,000 miles (482, ,672 km) n Internal components and major engine systems covered, including turbocharger, water pump and fuel injectors* n 100% parts and labor on covered failures n Limited progressive damage, including aftertreatment n See chart on page 50 for covered components * Does not include hydrocarbon doser injector. For additional information, see: Bulletin North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin

52 Protection Plan 2: Options ranging from 3 to 5 years/300,000 to 500,000 miles (482, ,672 km) n Internal components and major engine systems covered n 100% parts and labor on covered failures n Limited progressive damage, including aftertreatment n See chart on page 50 for covered components For additional information, see: Bulletin North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin Aftertreatment Extended Coverage.* Extended coverage is also available for your Cummins Aftertreatment System. Options range from 3 to 5 years and 300,000 to 500,000 miles (482, ,672 km). The coverage includes Cummins-supplied aftertreatment components, including: n Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and SCR assemblies n Hydrocarbon dosing system n Diesel Exhaust Fluid (DEF) dosing system n Aftertreatment controls *Protection Plan 1 EPA 2010 of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage. For additional information, see: Bulletin North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin

53 Major Components Coverage: Options ranging from 5 to 7 years/500,000 to 700,000 miles (804,672-1,126,541 km) n 100% parts and labor on covered failures n Limited progressive damage n Consumables not reusable due to covered failure n Major castings and forgings n See chart on page 50 for covered components For additional information, see: Bulletin North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin

54 Extended Coverage For ISX15 EPA 2010 Vocational Engines Options available up to 7 years/250,000 miles (402,336 km) n Internal components and major engine systems covered n 100% parts and labor on covered failures n Limited progressive damage, including aftertreatment n See following chart for covered components For additional information, see: Bulletin North American Truck Coverages For ISX15 And ISX11.9 Engines Brochure, Bulletin ISX15 Extended Coverage Terms* SCR Assembly Aftertreatment Injector Decomposition Reactor DPF Assembly Hydrocarbon Doser System Water Pump Turbo Fuel Injectors EGR Cooler, EGR Valve, EGR Mixer Cylinder Head Assembly Rocker Lever Assembly ECM Pistons, Rings and Liners Lube Oil Cooler Assembly Cylinder Block Assembly Crankshaft Assemblies Front Gear Cover Oil Pan Connecting Rod Assembly Lube Pump Assembly Cam and Bushings Brake Housing, Rocker Lever Bushings, Roller Pin, Roller, Crosshead Pin, Crosshead, Including Mounting Hardware and Gaskets Engine Cylinder Block Casting Engine Main Bearing Bolts Engine Cylinder Head Casting Engine Cylinder Head Capscrews Engine Crankshaft Forging Engine Camshaft Forging Cam Follower Housing Cam Follower Assemblies Engine Connecting Rods and Caps Engine Connecting Rod Bolts Intake Manifold Castings Rocker Lever Housings Gear Train Gears Aftertreatment Extended Coverage** Protection Plan 1 Options are available up to 5 years/ 500,000 miles (804,672 km) Protection Plan 2 available up to 5 years/ 500,000 miles (804,672 km) Vocational Coverage available up to 7 years/ 250,000 miles (402,336 km) Major Components Coverage Options are available up to 7 years/ 700,000 miles (1,126,541 km) * Terms and conditions are subject to change. ** Protection Plan 1 EPA 2010 of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage. 50

55 Extended Coverage For Medium-Duty ISC8.3 And ISB6.7 EPA 2010 Truck Engines Protection Plan 1: Options ranging from 3 to 5 years/100,000 to 300,000 miles (160, ,804 km) n Internal components and major engine systems covered, including turbocharger, water pump and fuel injectors* n 100% parts and labor on covered failures n Limited progressive damage, including aftertreatment n See chart on page 52 for covered components * Does not include hydrocarbon doser injector. For additional information, see: Bulletin North American Truck Coverages For ISL9, ISC8.3 And ISB6.7 Engines Brochure, Bulletin Protection Plan 2: Options ranging from 3 to 7 years/100,000 to 300,000 miles (160, ,804 km) n Internal components and major engine systems covered n 100% parts and labor on covered failures n Limited progressive damage, including aftertreatment n See chart on page 52 for covered components For additional information, see: Bulletin North American Truck Coverages For ISL9, ISC8.3 And ISB6.7 Engines Brochure, Bulletin

56 Aftertreatment Extended Coverage.* Extended coverage is also available for your Cummins Aftertreatment System. Options range from 3 to 5 years and 100,000 to 300,000 miles (160, ,804 km). The coverage includes Cummins-supplied aftertreatment components, including: n Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and SCR assemblies n Diesel Exhaust Fluid (DEF) dosing system n Aftertreatment controls * Protection Plan 1 EPA 2010 of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage ISC8.3 And ISB6.7 Extended Coverage Terms* SCR Assembly Aftertreatment Injector Decomposition Reactor DPF Assembly Water Pump Turbo Fuel Injectors EGR Cooler, EGR Valve, EGR Mixer Cylinder Head Assembly Rocker Lever Assembly ECM Pistons, Rings and Liners Lube Oil Cooler Assembly Cylinder Block Assembly Crankshaft Assemblies Front Gear Cover Oil Pan Connecting Rod Assembly Lube Pump Assembly Cam and Bushings Brake Housing, Bushings, Rocker Levers, Roller Pin, Roller, Crosshead Pin, Crosshead, Including Mounting Hardware and Gaskets Engine Cylinder Block Casting Engine Main Bearing Bolts Engine Cylinder Head Casting Engine Cylinder Head Capscrews Engine Crankshaft Forging Engine Camshaft Forging Cam Follower Housing Cam Follower Assemblies Engine Connecting Rods and Caps Engine Connecting Rod Bolts Intake Manifold Castings Rocker Lever Housings Gear Train Gears Aftertreatment Extended Coverage** Protection Plan 1 Options are available up to 5 years/ 300,000 miles (482,804 km) Protection Plan 2 Options are available up to 7 years/ 300,000 miles (482,804 km) * Terms and conditions are subject to change. ** Protection Plan 1 EPA 2010 of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage. 52