Better EveryTM Time. Engine Reference Guide For 2013 Engines
Engine Reference Guide 2013
2013 Table Of Contents Page Heavy-Duty Features 1 ISX15 4 ISX12 11 Cummins Westport Inc. 16 ISX12 G 19 ISL G 22 Electronic Tools And Software PowerSpec 26 RoadRelay 5 28 QuickCheck 30 INSITE 32 Expert Diagnostic System (EDS) 34 Special Features Jacobs Brake Systems 35 Rear Engine Power Take-Off 35 Warranty Heavy-Duty Truck Engines 36 MidRange Truck Engines 37 Fire Apparatus/Crash Truck Engines 38 Extended Coverage Heavy-Duty ISX15/ISX12 Truck Engines 39 Natural Gas ISX12 G Truck Engines 42 Natural Gas ISL G Truck Engines 45 Fire Apparatus/Crash Truck ISX15/ISX12 Engines 48 Encore Coverage 51 iii Cummins is a pioneer in product improvement. Thus, specifications may change without notice. Please contact your local Cummins representative for the most current information.
Page Parts, Service And Support Genuine Cummins Parts 54 ReCon Parts And Engines 55 CUMPAS 57 RapidServe 58 Virtual College 59 QuickServe Online 60 Parts Professional 62 Sales Information peterbilt.cummins.com 63 cumminsengines.com 63 cummins.com 63 Customer Care 63 Vehicle Mission Simulation (VMS) 64 Diesel Exhaust Fluid, Fuels And Lubricants 65 Premium Blue 67 Premium Blue NextGen 67 Premium Blue Extreme 5W-40 67 Formulas Formulas And Conversions Inside Back Cover iv
Heavy-Duty Features And Benefits Better. Where It Counts. n Continuous Improvement In 2013 we have refined our technology and our complete on-highway line-up, including the Heavy-Duty ISX15 and ISX12. Our 2013 engines meet 2014 Environmental Protection Agency (EPA) and United States Department of Transportation (DOT) regulations for fuel economy and greenhouse gas (GHG) reduction, a year ahead of schedule. Our Cummins 2013 engines are also equipped with the required On-Board Diagnostics (OBD) system that monitors and ensures optimal performance of the emissions system. If the system detects any emissions related malfunctions, it will alert the operator to these detected malfunctions through a dash lamp known as the Malfunction Indicator Lamp (MIL). n Better Fuel Economy Cummins has taken our industry-leading fuel economy and improved it by up to 2% in 2013, versus 2010 engines, by reducing parasitic losses, optimizing combustion, improving component efficiencies and needing fewer active aftertreatment regenerations. Better fuel economy means lower operating cost and maximized profits. n Better Reliability And Durability Cummins designs, develops and supports every critical component from air handling to exhaust aftertreatment as a totally integrated system. Only Cummins has the ability to optimize every function better than any other engine manufacturer. n Better Customer Care Cummins-powered vehicles are backed by the largest and most capable parts and service network in North America, with over 3,500 locations. Call Cummins Care at 1-800-DIESELS (1-800-343-7357), and you will get 24/7/365 assistance from a Cummins Care representative. If you need service, your Cummins Care representative will locate the nearest available and authorized facility. 1
Systems Integration n VGT Turbocharger Built by Cummins Turbo Technologies; this proven technology has set the industry standard for precision performance, dependability and durability since 2002. The VGT Turbocharger increases fuel economy and braking horsepower and electric actuation improves precision and responsiveness. n Cummins Aftertreatment System from Cummins Emission Solutions A proprietary system that consists of a Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) technology for near-zero emissions. n Cummins Filtration Fleetguard filters protect against corrosion and contaminants that can cause performance issues. High quality Diesel Exhaust Fluid (DEF) is widely available at authorized Cummins and Fleetguard locations as well as in bulk delivery. n Cummins Fuel Systems The ISX15 and ISX12 feature 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. Our improved XPI fuel system eliminates the need for a second camshaft, which provides weight savings and simplifies operation on the ISX15. n Electronic Control Module The same ECM and engine software is featured on all Cummins on-highway diesel engines. Now, in 2013, a single ECM manages the engine and aftertreatment system for optimum performance and fuel efficiency. 2
Driver Satisfaction And Ratings n Power and Performance The ISX15 delivers the features that drivers want and need 600-bhp Intebrake system, Load-Based Speed Control (LBSC) and Gear-Down Protection (GDP). n Compact Design Cummins ISX12 is making a huge impact in work trucks of all types, from mixers and dump trucks to day cabs and lessthan-truckload (LTL) operations. It combines the strength and reliability of proven technology from the ISX15 the industry s most popular heavy-duty diesel with a high power-to-weight ratio and over 800 lb-ft (1085 N m) clutch engagement torque. n ISX15 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 available, delivering extra torque in lower gears for dump trucks, mixers and refuse vehicles. n ISX12 Ratings The ISX12 is ideal in operations calling for a compact heavy-duty engine. The ISX12 Vocational ratings are engineered to provide additional torque in the lower gear ranges, where it s needed most. We offer multiple options, including both Front- and Rear Engine Power Take- Off (FEPTO and REPTO) units and a selection of hydraulic drive options. This versatility makes the ISX12 an ideal choice for rear- and front-pouring mixers as well as dump trucks and refuse haulers. We also offer standard ratings, with engine software configurations designed to deliver the precise combination of fuel economy and performance to meet the needs of regional and LTL fleets. Maintenance n Maintenance Intervals We have increased our maintenance intervals for both fuel and oil. Oil-change intervals for the 2013 ISX15 and ISX12 can be extended by 5,000 miles (8,000 km) with the use of Valvoline Premium Blue oil in normal-duty and light-duty cycle operation, helping to maximize uptime while reducing maintenance costs. 3
2013 ISX15 Engines 400-600 hp (298-447 kw) ISX15 Specifications Advertised 400-600 hp 298-447 kw Horsepower Maximum 600 bhp 447 kw Braking Horsepower Peak Torque 1450-2050 lb-ft 1966-2779 N m Governed Speed* 1800-2100 rpm Number of Cylinders 6 Clutch Engagement 1000 lb-ft 1356 N m Torque System Weight 3,204 lb 1,453 kg Engine (Dry) 2,964 lb 1,344 kg Aftertreatment** 240 lb 109 kg *Fire and emergency vehicles and motorhomes have a governed speed of 2100 rpm. **Increase over standard muffler; does not include chassis OEM-supplied components. 4
ISX15 Truck Applications Maintenance Intervals Duty Cycles Light Normal Severe Fuel Filter 40,000 mi 30,000 mi 30,000 mi 64,000 km 48,000 km 48,000 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 Filter DEF Filter Particulate Filter Cleaning *With appropriate filter. Oil Drain Intervals* 125,000 mi (200,000 km) 300,000 mi (480,000 km) 200,000 mi (320,000 km) Linehaul Trucks Duty Cycles Miles/Kilometers Hours Months Severe < 5.5 mpg 20,000 mi 1,000 6 32,000 km Normal = 6.5-5.5 mpg 30,000 mi 1,000 6 48,000 km Light > 6.5 mpg 40,000 mi 1,000 6 64,000 km Vocational Trucks** Miles/Kilometers Hours Months 20,000 mi 500 6 32,000 km * Using CJ-4 oil. When using Valvoline Premium Blue, add 5,000 miles (8,000 km) to normal-duty and light-duty cycle intervals. **Includes refuse, mixer, dump and delivery trucks See Owners Manual for complete details. 5
ISX15 Fire And Emergency Vehicle Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 20,000 500 6 32,000 Fuel Filter 20,000 500 6 32,000 Coolant Filter** 50,000 1,500 12 80,000 Valve 500,000 10,000 60 Adjustment 800,000 Coalescing 125,000 3,000 Filter*** 200,000 DEF Filter 300,000 6,750 480,000 Particulate 200,000 4,500 Filter Cleaning 320,000 *Assuming severe duty cycle for fire and emergency vehicle applications. **With appropriate filter. ***CJ-4 oils meeting CES 20081 See Owners Manual for complete details. 6
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
Load-Based Speed Control Cummins Load-Based Speed Control (LBSC) is a patented electronic feature on ISX15 and ISX12 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: On a grade exceeding 2% During sharp turns when tire scrub may occur 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: Improved fuel economy Reduced parasitic losses due to cycling of engine accessories (such as the fan) Lower engine noise in parking lots and residential areas Improved engine durability 8
ISX15 Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N m) @ rpm Linehaul Truck Applications Ratings ISX15 600 600 (447) 2050 (2779) @ 1200 ISX15 600 600 (447) 1850 (2508) @ 1200 ISX15 550 550 (410) 2050 (2779) @ 1200 ISX15 550 550 (410) 1850 (2508) @ 1200 ISX15 525 525 (392) 1850 (2508) @ 1200 ISX15 500 500 (373) 1850 (2508) @ 1200 ISX15 500 500 (373) 1650 (2237) @ 1200 ISX15 485 485 (362) 1850 (2508) @ 1200 ISX15 485 485 (362) 1650 (2237) @ 1200 ISX15 450 450 (336) 1650 (2237) @ 1000 ISX15 450 450 (336) 1550 (2102) @ 1000 ISX15 425 425 (317) 1650 (2237) @ 1000 ISX15 400 400 (298) 1450 (1966) @ 1000 SmartTorque Ratings ISX15 500ST 500 (373) 1650/1850 (2237/2508) @ 1200 ISX15 485ST 485 (362) 1650/1850 (2237/2508) @ 1200 ISX15 450ST 450 (336) 1550/1750 (2102/2373) @ 1000 ISX15 450ST 450 (336) 1450/1650 (1966/2237) @ 1000 ISX15 425ST 425 (317) 1550/1750 (2102/2373) @ 1000 ISX15 425ST 425 (317) 1450/1650 (1966/2237) @ 1000 ISX15 400ST 400 (298) 1550/1750 (2102/2373) @ 1000 ISX15 400ST 400 (298) 1450/1650 (1966/2237) @ 1000 9
ISX15 Ratings (Cont d) Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N m) @ rpm Vocational Ratings ISX15 500V 500 (373) 1850 (2508) @ 1200 ISX15 500V 500 (373) 1650 (2237) @ 1200 ISX15 455V 455 (339) 1650 (2237) @ 1200 Fire And Emergency Vehicle Ratings ISX15 600 600 (447) 1850 (2508) @ 1200 ISX15 550 550 (410) 1850 (2508) @ 1200 ISX15 500 500 (373) 1850 (2508) @ 1200 ISX15 455 455 (339) 1750 (2373) @ 1200 For additional information, visit cumminsengines.com. ISX15 Gearing Recommendations A major factor in optimizing performance and fuel economy is vehicle gearing. Log on to www.powerspec.cummins.com for gearing recommendations specific to your application. 10
2013 ISX12 Engines 310-500 hp (231-373 kw) ISX12 Specifications Advertised 310-500 hp 231-373 kw Horsepower Peak Torque 1150-1650 lb-ft 1559-2237 N m Governed Speed 2100 rpm Number of Cylinders 6 Clutch Engagement 800 lb-ft 1085 N m Torque System Weight 2,880 lb 1,306 kg Engine (Dry) 2,640 lb 1,197 kg Aftertreatment* 240 lb 109 kg * Increase over standard muffler; does not include chassis OEM-supplied components. 11
ISX12 Work Truck Applications Maintenance Intervals Miles Hours Months Kilometers Fuel Filter 30,000 1,000 6 48,000 Coolant Filter* 50,000 1,500 12 80,000 Valve 250,000 6,000 24 Adjustment 400,000 Coalescing 150,000 4,000 Filter 240,000 DEF Filter Particulate Filter Cleaning 300,000 mi (480,000 km) 200,000 mi (320,000 km) *With appropriate filter. Oil Drain Intervals* Linehaul Trucks Duty Cycles Miles/Kilometers Hours Months Severe < 6 mpg 15,000 mi 400 6 24,000 km Normal = 6-7 mpg 25,000 mi 400 6 40,000 km Light > 7 mpg 35,000 mi 400 6 56,000 km Vocational Trucks** Miles/Kilometers Hours Months 15,000 mi 400 6 24,000 km * Using CJ-4 oil. When using Valvoline Premium Blue, add 5,000 miles (8,000 km) to normal-duty and light-duty cycle intervals. **Includes refuse, mixer, dump and delivery trucks See Owners Manual for complete details. 12
ISX12 Fire And Emergency Vehicle Maintenance Intervals Miles Hours Months Kilometers Oil and Filter* 15,000 400 6 24,000 Fuel Filter 30,000 1,000 6 48,000 Coolant Filter** 50,000 1,500 12 80,000 Valve 250,000 6,000 24 Adjustment 400,000 Coalescing 150,000 4,000 Filter 240,000 DEF Filter 300,000 6,750 480,000 Particulate 200,000 4,500 Filter Cleaning 320,000 Assuming severe duty cycle for fire and emergency vehicle applications. *Using CJ-4 oil. **With appropriate filter. See Owners Manual for complete details. 13
ISX12 Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N m) @ rpm Linehaul Truck Applications Ratings ISX12 425 425 (317) 1650 (2237) @ 1100 ISX12 400 400 (298) 1650 (2237) @ 1100 ISX12 370 370 (276) 1450 (1966) @ 1100 ISX12 370 370 (276) 1350 (1830) @ 1100 ISX12 350 350 (261) 1350 (1830) @ 1100 ISX12 330 330 (246) 1350 (1830) @ 1100 ISX12 330 330 (246) 1250 (1695) @ 1100 ISX12 310 310 (231) 1150 (1559) @ 1100 SmartTorque Ratings ISX12 425ST 425 (317) 1450/1650 (1966/2237) @ 1100 ISX12 400ST 400 (298) 1450/1650 (1966/2237) @ 1100 ISX12 350ST 350 (261) 1350/1450 (1830/1966) @ 1100 ISX12 330ST 330 (246) 1250/1350 (1695/1830) @ 1100 Vocational Ratings ISX12 425V 425 (317) 1650 (2237) @ 1100 ISX12 425V 425 (317) 1550 (2103) @ 1100 ISX12 400V 400 (298) 1650 (2240) @ 1100 ISX12 385V 385 (287) 1450 (1968) @ 1100 ISX12 385V 385 (287) 1350 (1832) @ 1100 ISX12 350V 350 (261) 1450 (1968) @ 1100 ISX12 350V 350 (261) 1350 (1832) @ 1100 ISX12 320V 320 (239) 1150 (1560) @ 1100 Refuse Ratings ISX12 385R 385 (287) 1450 (1966) @ 1100 ISX12 385R 385 (287) 1350 (1830) @ 1100 ISX12 350R 350 (261) 1450 (1966) @ 1100 ISX12 350R 350 (261) 1350 (1830) @ 1100 ISX12 330R 330 (246) 1250 (1965) @ 1100 ISX12 320R 320 (239) 1150 (1559) @ 1100 14
ISX12 Ratings (Cont d) Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N m) @ rpm Fire And Emergency Vehicle Ratings ISX12 500* 500 (373) 1645 (2232) @ 1100 ISX12 450* 450 (336) 1550 (2103) @ 1100 ISX12 425 425 (317) 1550 (2103) @ 1100 ISX12 400 400 (298) 1550 (2103) @ 1100 ISX12 400 400 (298) 1450 (1968) @ 1100 ISX12 370 370 (276) 1450 (1968) @ 1100 *Restricted rating. For additional information, visit cumminsengines.com. ISX12 Gearing Recommendations A major factor in optimizing performance and fuel economy is vehicle gearing. Log on to www.powerspec.cummins.com for gearing recommendations specific to your application. 15
Cummins Westport Inc. The Natural Choice 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 natural gas 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 and ISX12 G share major engine components with their diesel counterparts, ensuring parts durability and availability. The ISL G and ISX12 G operate on 100% clean burning natural gas, which can be carried on the vehicle in either compressed natural gas (CNG) or liquefied natural gas (LNG) form. They can also operate on renewable natural gas or biomethane that meets fuel quality specifications. Both engines meet current U.S. Environmental Protection Agency (EPA) and California Air Resource Board (ARB) emission standards and 2014 EPA and U.S. Department of Transportation (DOT) fuel efficiency and greenhouse gas (GHG) regulations. The use of stoichiometric combustion technology and a Three-Way Catalyst exhaust aftertreatment creates low emissions without the need for Diesel Particulate Filters (DPF) or Selective Catalytic Reduction (SCR) systems. The ISX12 G and ISL G are available from leading truck, urban transit, and school bus OEMs in a variety of applications. 16
Natural Gas Features And Benefits n Lower Operating Costs In high fuel use applications, the combination of lower alternative fuel costs, improved fuel economy and lower incremental maintenance costs make it possible to save valuable dollars with a natural gas-powered fleet. n Performance The high torque and broad power band of the ISL G, with ratings from 250-320 hp provide excellent performance when matched to various automatic transmissions in vocational, medium-duty and heavy-duty trucks up to 66,000 lb GVW, as well as urban transit, shuttle and school bus applications. The ISX12 G, with ratings from 320-400 hp, is designed for a wide variety of vehicles, including regional-haul trucks/tractors up to 80,000 lb GVW, vocational trucks and refuse applications. The ISX12 G will offer optional engine braking, plus automatic and manual transmission options. n Maintenance-Free Aftertreatment Stoichiometric combustion with cooled Exhaust Gas Recirculation (EGR) provides the ideal combustion process in which fuel and oxygen are completely consumed, leaving no unburned fuel or oxygen in the exhaust stream. This advanced combustion technology enables the use of a Three-Way Catalyst (TWC), which is a passive device packaged as a muffler that is maintenance free. It does not require a particulate filter or Selective Catalytic Reduction (SCR) system using Diesel Exhaust Fluid (DEF). n Cooled Exhaust Gas Recirculation (EGR) Combustion Technology Takes a measured quantity of exhaust gas and passes it through a cooler to reduce the temperature before mixing it with fuel and the incoming air charge to the cylinder. The use of cooled EGR in combination with stoichiometric combustion improves power density and fuel economy versus lean-burn or traditional stoichiometric natural gas engines. 17
n Electronic Control Module - The ECM constantly monitors and controls the engine actuators, sensors, fuel system and ignition system. It provides OEM and end users with the ability to tailor performance of the engine to fit the vehicle mission. It also has full interface capability to Cummins INSITE and QuickCheck diagnostic service tools. For additional information, visit cumminswestport.com. 18
2013 ISX12 G Engines 320-400 hp (239-298 kw) ISX12 G Specifications Maximum 320-400 hp 239-298 kw Horsepower Peak Torque 1450 lb-ft 1966 N m Governed Speed 2100 rpm Clutch Engagement 700 lb-ft 949 N m Torque Type 4 cycle, spark-ignited inline 6 cylinder, turbocharged, CAC Engine 726.2 cu in 11.9 liters Displacement Bore and Stroke 5.11 in x 5.91 in 130 mm x 150 mm Operating Cycles 4 Coolant 26.5 U.S. quarts 25.1 liters Capacity Net Weight (Dry) 2,650 lb 1,202 kg Fuel Type CNG/LNG/biomethane Aftertreatment Three-Way Catalyst (TWC) Number of Cylinders 6 For additional information, visit cumminswestport.com. 19
ISX12 G Maintenance Intervals Note: Miles Hours Months Normal Duty Truck, Kilometers 45 mph Avg Speed Spin-on Fuel Daily Check Filter Oil and Filter* 18,000 400 6 30,000 Coolant Filter** 67,500 1,500 12 108,500 Spin-on Fuel 45,000 1,000 9 Filter* 72,000 Spark 67,500 1,500 12 Plugs* 108,500 Valve 67,500 1,500 12 Adjustment* 108,500 Engine Brake 270,000 6,000 24 (Adjust) 435,000 Standard 270,000 6,000 24 Coolant 435,000 Air Cleaner/ Element Follow vehicle manufacturers published recommendations *Assuming normal duty cycle/based on 45 mph average speed. Spark plug interval/valve adjustment must be reduced for slower speed applications. Requires Natural Gas Engine Oil (CES20074). **Do not change if SCA above 3. Intervals for normal duty must be reduced for lower average speeds/duty cycles. Default interval is the hours stated. Interval is whichever comes first hours, miles or time. Refer to Owners Manual for complete details on Maintenance Intervals. 20
ISX12 G Ratings Engine Advertised Peak Torque Model Horsepower (kw) lb-ft (N m) @ rpm Linehaul Truck Applications Ratings ISX12 G 400 400 (298) 1450 (1966) @ 1200 ISX12 G 385 385 (287) 1350 (1830) @ 1200 ISX12 G 350 350 (261) 1450 (1966) @ 1200 ISX12 G 330 330 (246) 1250 (1695) @ 1200 ISX12 G 320 320 (239) 1150 (1559) @ 1200 Refuse Truck Applications Ratings ISX12 G 350R 350 (261) 1350 (1830) @ 1200 ISX12 G 350R 350 (261) 1450 (1966) @ 1200 ISX12 G 330R 330 (246) 1250 (1695) @ 1200 ISX12 G 320R 320 (239) 1150 (1559) @ 1200 ISX12 G Gearing Recommendations For best reliability and durability, the recommended maximum GVW in line haul applications is 80,000 lb GVW. Cummins PowerSpec makes it possible to tailor the operation of Cummins Westport engines to fit every customer s needs and desires. Log on to www.powerspec.cummins.com for gearing recommendations specific to your application. 21
2013 ISL G Engines 250-320 hp (186-239 kw) ISL G Specifications Advertised 250-320 hp 186-239 kw Horsepower Peak Torque 660-1000 lb-ft 895-1356 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 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, visit cumminswestport.com. 22
ISL G Medium-Duty, Vocational And Delivery Truck Maintenance Intervals* Miles Hours Months Kilometers Check CAC 7,500 250 8 Cooler, Piping, 12,000 and Air Cleaner Oil and Filter** 15,000 500 6 24,000 Fuel Filter 30,000 1,000 12 48,000 Coolant Filter 15,000 500 6 24,000 Spark 45,000 1,500 18 Plugs 72,000 Coolant 60,000 2,000 24 Change 96,000 Valve 60,000 2,000 24 Adjustment*** 96,000 *Assuming normal duty cycle. **Requires Natural Gas Engine Oil (CES20074). ***Initial Valve Adjustment at 1,000 hours. The ISL G is not approved for motorhome or fire and emergency vehicle applications. For complete maintenance interval and service information refer to the ISL G Owners Manual, or to QuickServe Online. 23
ISL G Refuse Maintenance Intervals Refuse Truck Miles Hours Months Kilometers Check CAC 3,000 250 3 Cooler, Piping, 5,000 and Air Cleaner Oil and Filter* 6,000 500 6 10,000 Coolant Filter** 15,000 500 6 24,000 Spin-on Fuel 12,000 1,000 12 Filter 20,000 Spark 18,000 1,500 18 Plugs 30,000 Standard 24,000 2,000 24 Coolant 40,000 Valve 24,000 2,000 24 Adjustment*** 40,000 Air Cleaner/ Follow vehicle manufacturers Element published recommendations *Assuming normal duty cycle/based on 12 mph average speed. **Do not change if SCA above 3. ***Initial Valve Adjustment at 1,000 hours. Distance intervals will increase or decrease based on average speeds. The default interval is the hours shown. Perform maintenance at hours, distance, or months indicated, whichever comes first. Refer to Owners Manual for complete details on Maintenance Intervals. 24
ISL G Ratings Advertised Engine Horsepower Peak Torque Model (kw) @ rpm lb-ft (N m) @ rpm ISL G 320 320 (239) @ 2000 1000 (1356) @ 1300 ISL G 300 300 (224) @ 2100 860 (1166) @ 1300 ISL G 280 280 (209) @ 2000 900 (1220) @ 1300 ISL G 260 260 (194) @ 2200 660 (895) @ 1300 ISL G 250 250 (186) @ 2200 730 (990) @ 1300 Three-Way Catalyst required for all ratings. ISL G Gearing Recommendations Gearing guidelines are similar to the ISL9 diesel product. Automatic Transmissions only and no engine braking capability. Vocational applications require application specific gearing recommendations. Consult your Cummins / Cummins Westport representative for specific gearing guidelines on the ISL G. Log on to www.powerspec.cummins.com for gearing recommendations specific to your application. 25
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. PowerSpec s full functionality is available to support all Cummins North American 2013 on-highway diesel engine products, 2010 diesel engines, 2007 diesel engines, and the natural gas on-highway products. Euro 3/4/4.5/5, ISBe, N14+ and M11+ CELECT Plus engines are supported by PowerSpec for fault codes and trip information only. 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 www.powerspec.cummins.com. 26
Electronic Features: Road Speed Governor Gear Down Protection Idle Speed Control Driver Reward Fan Control Load Based Speed Control (Heavy Duty engines only) Cruise Control Engine Brakes (Standard in all on-highway engines) Accelerator Control Adaptive Cruise Control Reserve Speed Power Take Off (PTO) / Remote PTO Trip Information Engine Protection Anti-Tampering Measures Aftertreatment High Soot Load Shutdown Maintenance Monitor Automatic Downloads Demo Mode For additional information, visit www.powerspec.cummins.com, contact your local Cummins distributor or call Cummins Care at 1-800-DIESELS (1-800-343-7357). 27
RoadRelay 5 RoadRelay has helped improve the productivity of thousands of fleets and owner/operators, becoming one of the most popular in-cab display of driver information in the trucking industry. RoadRelay 5 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: Displays and records fuel, miles and engine hours spent in idle, PTO and other operating modes Tracks trip information and performance data for up to 16 different drivers in a single vehicle with the Driver ID feature Stores the number of sudden deceleration events, as well as seventy-five seconds of detailed vehicle data rpm, mph, and brake and clutch activity for the last three sudden decelerations Records exact time of events with a real-time clock Informs the driver and gives instructions on how to minimize potential damage if an unexpected event happens Provides extended descriptions of Cummins engine fault codes and SAE descriptions of Non-Cummins vehicle faults 28
Tracks customizable service intervals for fluid changes, filter changes, tire rotations, and many other common serviceable components, notifying drivers when it s time for scheduled preventive maintenance Easy-to-read graphical liquid crystal display (LCD) automatically dims when the vehicle headlights are turned on for night driving with adjustable brightness control The navigational arrow keypad and an icon menu driven display make it easy to find the information you need Incorporates a lithium rechargeable/ replaceable backup battery, reducing the risk of data loss Provides an Estimated Time of Arrival (ETA) feature Password protects the engine ECM and vehicle with the Cummins Antitheft feature Compatible with any electronic diesel engine, regardless of make or age Records service history of maintenance events Provides real-time coaching pop-ups that can help make a good driver even better The front panel USB port makes it easy to tailor the functionality of the RoadRelay or to download data using Cummins PowerSpec Supports English, Spanish, French and Portuguese languages For additional information, visit www.roadrelay.com. 29
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 The QuickCheck CE application allows you to monitor a range of data from any manufacturer s engine with electronic controls, transmission, braking and vehicle systems. *Windows is a registered trademark of Microsoft Corporation. 30
PowerSpec CE The PowerSpec CE application 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. For additional information, visit quickcheck.cummins.com. 31
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 Engine diagnostic tests n Fault tree information n Fault code and symptom-based diagnostics n Step-by-step troubleshooting information n Complete wiring diagrams and sensor location maps n Audit trail information n Enhanced ECM security n Calibration downloads n Built-in Help n Work orders n Tools to create templates for a group of vehicles n Real-time monitoring n Trip and vehicle information n Parameter and feature adjustment n Fleet management/driver reward programs 32
A Version To Meet Every Need INSITE is offered in four functional levels: Basic, Lite, Road Speed Governor Restriction (RSGR) and Pro, ranging from a read only access level for the do-it-yourselfer to full-function 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 insite.cummins.com. FEATURES INSITE BASIC LITE/RSGR PRO Read Only Adjustment Load Cal. View Trip Information View Fault Trees View Trouble Shooting Steps View Fault Codes View Parameter Settings View Feature Settings View Wiring Diagrams View Engine Dataplate Driver Rewards Data Monitor / Logger Reflash INLINE Adapters Create Work Orders / Jobs Reset Trip Information Reset & Clear Fault Codes Set Engine Features (on/off) * Set / Adjust Parameters * Set / Change ECM Passwords Create/Apply Settings Templates ZAP-IT Functionality***Check Req ECM Diagnostic Tests / Advanced ECM Data Read INCAL Calibrations Load Engine Calibrations - Install New Features - Horsepower Upgrades View non-engine faults 33 *Except RSGR features in INSITE RSGR version
Expert Diagnostic System (EDS) An innovative engine diagnostic tool, Expert Diagnostic System (EDS) uses historical trends and advises in the simplest terms the most likely steps needed to resolve engine problems. This helps the technician get to the problem quickly, reducing vehicle downtime and saving money for everyone. When entering required data and answering some questions, EDS will recommend to the technician the most likely solution for the repair. EDS is the Next Generation troubleshooting system that continually learns from any repair made. Each service event will be tracked using a Diagnostic Session Identification (DSID) which will then record all service history for a given Cummins Engine Serial Number (ESN). Warranty administrators will also benefit from this tool since EDS is designed to simplify the warranty claim process. You can upload the diagnostic Standard Repair Times (SRTs) to RAPIDSERVE Web by entering the DSID into the first page of the RAPIDSERVE Web Claim. EDS is a web-based system and can be found at insite.cummins.com under Related Tools. Training courses cover a variety of roles so it will help guide everyone to mastering the full benefits of this great tool. The EDS user guide, FAQs and other related information can be found on the EDS page. For more information, visit insite.cummins.com/insite/eds/, contact your local Cummins distributor or call us toll-free at 1-800-DIESELS (1-800-343-7357). 34
Special Features Jacobs * Brake Systems Cummins Intebrake Integrated on the ISX15 with best-in-class braking horsepower (up to 600 bhp) for greater vehicle control and reduced service brake wear. Compression Brakes An option, available for the ISX12 and ISL9 engines, that provides additional control, as it minimizes service brake wear and replacement costs. VGT TM Turbocharger An option, available for ISB engines, that provides exhaust braking without additional add-on hardware in the exhaust system and eliminates exhaust brake maintenance. * Jacobs is a registered trademark of Jacobs Vehicle Systems. For additional information on engine compatibility and performance data visit jakebrake.com. Rear Engine Power Take-Off (REPTO) Available on Cummins ISX12 and ISL9 engines: Provides continuous live power Allows up to 1,500 lb more payload under the Bridge Law Eliminates extended frames and bumpers of front PTOs, improving visibility and maneuverability Does not require radiator clearance for a raised PTO shaft, so engine cooling is not compromised 35
Warranty Base Warranty For Heavy-Duty Truck Engines ISX15 ISX12 ISX12 G 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, turbocharger and aftertreatment components, including the SCR system X X X X X X X X X X X N/A No deductible X X X Additional information See Bulletin 3381437 or visit cumminsengines.com *Warrantable failures are those due to defects in Cummins material or factory workmanship. 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. 36
Base Warranty For MidRange Truck Engines ISL G 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 (from date of delivery through first year) Consumables not reusable due to covered failure Cooled-EGR components, turbocharger, and aftertreatment components, including the SCR system No deductible X X X N/A X Additional information See Bulletin 3381342 Visit cumminsengines.com *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. 37
Base Warranty For Fire Apparatus/Crash Truck Engines 2 5-Year*/100,000-Mile (160,934 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 X X X Cooled-EGR components, Variable Geometry Turbocharger and X aftertreatment components, including the SCR system Additional information See Bulletin 3381161 *$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 alternators and starters are covered for the first 2 years from the date of delivery of the engine to the first user, or the expiration of the Base Engine Warranty, whichever occurs first. Belts and hoses are covered for the first year of warranty or duration of coverage, whichever occurs first. 38
Extended Coverage Extended Coverage For Heavy-Duty 2013 ISX15 And ISX12 Truck Engines Protection Plan 1: Options range from 3 to 5 years/100,000 to 500,000 miles (160,934-804,672 km) n Internal components and major engine systems, covered, including turbocharger, water pump and fuel injectors*, air compressor, fuel pump and select engine sensors n Registered parts and labor on covered failures n See chart on page 41 for covered components * Does not include hydrocarbon doser injector. For additional information, see Bulletin 3381455 or visit cumminsengines.com. 39
Protection Plan 2: Options range from 3 to 7 years/100,000 to 500,000 miles (160,934-804,672 km) n Internal components and major engine systems covered n Registered parts and labor on covered failures n See chart on page 41 for covered components For additional information, see Bulletin 3381439 or visit cumminsengines.com. Aftertreatment Extended Coverage* Extended coverage is also available for your Cummins Aftertreatment System. Options range from 3 to 5 years and 100,000 to 500,000 miles (160,934-804,672 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 Ammonia Sensor *Protection Plan 1 for 2013 engines of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage. For additional information, see Bulletin 3381454 or visit cumminsengines.com. Major Components Coverage: Options range from 5 to 7 years/500,000 to 700,000 miles (804,672-1,126,541 km) n Registered parts and labor on covered failures n Consumables not reusable due to covered failure n Major castings and forgings n See chart on page 41 for covered components For additional information, see Bulletin 3381410 or visit cumminsengines.com. 40
2013 ISX15 And ISX12 Extended Coverage Terms* SCR Assembly Aftertreatment Injector Decomposition Reactor Mid-Bed Ammonia Sensor DPF Assembly Hydrocarbon Doser System Fuel Pump Air Compressor Select Engine Sensors Water Pump Turbo Fuel Injectors EGR Cooler, EGR Valve, EGR Mixer Cylinder Head 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 Camshaft Assembly 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 Rocker Lever Assembly 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 Options are available up to 7 years/ 500,000 miles (804,672 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 2013 of equal duration is required prior to the purchase of the Aftertreatment Extended Coverage. 41
Extended Coverage For Natural Gas 2013 ISX12 G Truck Engines Protection Plan 1: Options range from 3 to 5 years/150,000 to 500,000 miles (241,402-804,672 km) Registered parts and labor Covers internal components and major engine systems Covers all these components, including listed parts below and their mounting hardware and gaskets: Cylinder head assembly Rocker lever assembly ECM Piston, rings and liners Lube oil cooler assembly Front gear cover Oil pan Connecting rod assembly Lube pump assembly Camshaft and bushings Cam follower assemblies EGR cooler, valve and mixer Turbo Water pump Air compressor Select engine sensors Low fuel pressure regulator Throttle plate actuator For additional information, see Bulletin 3381455 or visit cumminsengines.com. 42
Protection Plan 2: Options range from 3 to 5 years/150,000 to 500,000 miles (241,402-804,672 km) Registered parts and labor Covers internal components and major engine systems Covers all these components, including listed parts below and their mounting hardware and gaskets: Cylinder head assembly Rocker lever assembly ECM Piston, rings and liners Lube oil cooler assembly Cylinder block assembly Front gear cover Oil pan Connecting rod assembly Lube pump assembly Camshaft and bushings Cam follower assemblies EGR cooler, valve and mixer For additional information, see Bulletin 3381439 or visit cumminsengines.com. 43
Major Components: Options range from 5 to 7 years/500,000 to 700,000 miles (804,672-1,126,541 km) Covers any failure of a registered part which results, under normal use and service, from defects in material or factory workmanship Registered parts and labor Registered parts include: Cylinder block casting Crankshaft forging Camshaft forging Valve covers Flywheel housing Oil cooler cover/filter heads Intake manifold castings Gear cover and housing Connecting rods Oil pan Cylinder head casting and capscrews Gear train gears: Crankshaft gear Camshaft idler gear Accessory drive gear Fuel pump drive gear For additional information, see Bulletin 3381346 or visit cumminsengines.com. 44
Extended Coverage For Natural Gas 2013 ISL G Truck Engines Protection Plan 1: Options range from 3 to 5 years/100,000 to 300,000 miles (160,934-482,803 km) Registered parts and labor Covers internal components and major engine systems Covers all these components, including mounting hardware and gaskets: Air compressor Select engine sensors Cylinder head assembly Rocker lever assembly ECM Piston, rings and liners Lube oil cooler assembly Cylinder block assembly Front gear cover Oil pan Connecting rod assembly Lube pump assembly Camshaft and bushings Cam follower assemblies EGR cooler, valve and mixer Water pump Throttle Plate Actuator Turbocharger Crankshaft assemblies Low fuel pressure regulator For additional information, see Bulletin 3381455 45
Protection Plan 2: Options range from 3 to 7 years/100,000 to 300,000 miles (160,934-482,803 km), Whichever Occurs First Internal components and major engine systems covered Registered parts and labor Covers all these components, including mounting hardware and gaskets: Cylinder head assembly Rocker lever assembly ECM Pistons, rings and liners Lube oil cooler assembly Cylinder block assembly Front gear cover Oil pan Connecting rod assembly Lube pump assembly Camshaft and bushings Cam follower assemblies EGR cooler, valve and mixer For additional information, see Bulletin 3381439 46
Major Components: 6-Year/300,000-Mile (482,803 km), Whichever Occurs First Covers any failure of a registered part which results, under normal use and service, from defects in material or factory workmanship Registered parts and labor Registered parts include: Cylinder block casting Crankshaft forging Camshaft forging Valve covers Flywheel housing Oil cooler cover/filter heads Intake manifold castings Gear cover and housing Connecting rods Oil pan Cylinder head casting and capscrews Gear train gears: Crankshaft gear Camshaft idler gear Accessory drive gear Fuel pump drive gear For additional information, see Bulletin 3381346 47
Extended Full Engine Coverage For 2013 ISX15 And ISX12 Fire Apparatus/Crash Truck Engines 5-Year/150,000-Mile (241,402 km), Whichever Occurs First 5-Year/200,000-Mile (321,869 km), Whichever Occurs First Covers any failure of the engine resulting from defects in material or factory workmanship Registered parts and labor Includes EGR components Coverage does not apply to non-cummins accessories $100 deductible* after base warranty * $100 deductible applies per service visit after expiration of the base warranty. For additional information, see Bulletin 3385468 48
Extended Coverage For 2013 ISX15 And ISX12 Fire Apparatus/Crash Truck Engines 5-Year/150,000-Mile (241,402 km), Whichever Occurs First 5-Year/200,000-Mile (321,869 km), Whichever Occurs First Covers any failure of the engine resulting from defects in material or factory workmanship Registered parts and labor Includes EGR components Coverage does not apply to maintenance components Coverage does not apply to non-cummins accessories $100 deductible* after base warranty * $100 deductible applies per service visit after expiration of the base warranty. For additional information, see Bulletin 3381368 49
Major Components Coverage For 2013 ISX15 And ISX12 Fire Apparatus/Crash Truck Engines 7-Year/150,000-Mile (241,402 km), Whichever Occurs First 10-Year/200,000-Mile (321,869 km), Whichever Occurs First Registered parts and labor $100 deductible* after base warranty Covers damage resulting from failures of the following major components: Cylinder block casting Cylinder head castings Cylinder head capscrews Crankshaft forging Camshaft forging Connecting rods Flywheel housing Intake manifold castings Valve covers Oil cooler cover/filter heads Oil pan Gear cover and housing Gear train gears: Crankshaft gear Camshaft idler gear Accessory drive gear Fuel pump drive gear * $100 deductible applies per service visit after expiration of the base warranty. For additional information, see Bulletin 3381367 50
Encore Pre-Owned Protection Plan Extra Confidence Only engines that pass every one of our strict quality tests can receive the Encore pre-owned engine coverage, which protects your customer from repair bills down the road. Encore Availability Terms*: ISX and ISM engines with in-service date within 6 years/650,000 miles (1,046,074 km) ISL, ISC and ISB engines with in-service date within 6 years/400,000 miles (643,738 km) Encore coverage is not available to original engine owners or on Cummins ReCon engines. To qualify for the program, engines must pass a full inspection which includes a Dyno Check performed by an authorized Cummins dealer or distributor. *Excludes EPA 2010 and newer engines. 51
Encore ISX And ISM Engines 1-Year/100,000-Mile (160,934 km) ISL, ISC And ISB Engines 1-Year/50,000-Mile (80,468 km), Whichever Occurs First Cummins will pay for a covered failure of any pre-owned engine that results, under normal use and service, from a defect in Cummins material or factory workmanship.* Internal components and major engine systems are covered, including the cooled- EGR major components $150 deductible** Registered parts and labor Encore covers every one of these components, including mounting hardware and gaskets: Cylinder head assembly Rocker lever assembly ECM Pistons, rings and liners Lube oil cooler assembly Cylinder block assembly Front gear cover Oil pan Connecting rod assembly Lube pump assembly Crankshaft assembly Camshaft and bushings Cam follower assemblies EGR cooler, valve and mixer * Program excludes all wear, tear, abuse and normal operational expenses. ** Deductible applies per service visit. 52
Encore Plus ISX And ISM Engines 2-Year/200,000-Mile (321,869 km) Whichever Occurs First Option 1: For extra insurance against major repair bills, consider Encore Plus major components coverage. The first year of Encore Plus major components includes basic encore coverage and the second year includes major components only. Option 2: Encore Plus Major Components* Injectors Turbo Water pump Major components parts Major castings and forgings $150 deductible** *Only available for replaced injector, turbo and water pump during inspection. **Deductible applies per service visit. 53