ISX15 Enhancements - Volvo - Cummins · PDF file5 History Rooted in Innovation Founded in 1919 by Clessie Cummins and W.G. Irwin Pioneered the development of diesel engines Promoted

The ISX15 is Better Than Ever

ISX15 Product Enhancements 2013 - 2016

Revised: February 2016

Contents

1. Introduction

2. Enhancements by Subsystem

a) Aftertreatment

b) Diagnostic Controls

c) Electronic Engine

Features

d) Fuel System

3. Fuel Economy Progress

4. Maintenance Progress

5. Conclusion

e) Lubrication & Cooling

f) Power Cylinder

g) Powertrain

h) Turbocharger &

Air Handling

INTRODUCTION

History of Cummins

5

History Rooted in Innovation

Founded in 1919 by Clessie Cummins and W.G. Irwin

Pioneered the development of diesel engines

Promoted diesels as a reliable source of power

Earned first profit in 1937

Focused on the long term and greater good

Cummins Internal Use Only

Legendary PerformanceDependable Partner

Loyal Customers

6Cummins Internal Use Only

7

ISX15: Your Leading Engine Choice

Fuel Economy Leadership

Lowest Cost of Operation

Superior Reliability & Durability

Unmatched Uptime & Support

Pioneer in Market Segment Optimization

Since 2004 ISX15 offers 2 optimized

distinctive solutions:

– Linehaul: Regional & Cross-country

• 400 – 475 HP / up to 1,750 Lb-ft

• Fuel Efficiency

• 18.9:1 Compression Ratio

– Heavy Haul and Severe Service

• 455 – 600 HP / up to 2,050 Lb-ft

• High Performance

• 17.2:1 Compression Ratio


9Insert Data Classification

1300

1400

1500

1600

1700

1800

1900

900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

Lb-f

t

RPM

Best In Class Low End Torque

ISX15 475 ISX15 525

VGT

XPI

• Adaptable performance

• Rapid response

• Enhanced braking

• Aftertreatment regen

• Highest injection pressure

• Optimized parasitics

• Efficient combustion

• Yields superior MPG

A Common Engine Across Truck Manufacturers

Solution for an entire fleet

Platform for efficiency or performance

Vast support network

Stop shop for engine subsystems

10

1

3500 authorized

service locations

Unmatched Support – Service Density

The ISX15 is Better Than Ever

Customer-focused innovation delivers:

• Uptime – profitability by keeping trucks on the road

• Efficiency – optimal fuel economy

• Maintenance – lower total cost of ownership

12Cummins Internal Use Only

ENHANCEMENTSBY SUBSYSTEM

AFTERTREATMENT

Maintenance Free Hydrocarbon Doser –January 2013

Self cleaning

design

– Previous design

required cleaning

at 150,000 miles

Compatible with

2007 ISX15 and

newer

15

Old New

Main

tenance


Improved SCR Catalyst Material –April 2013

New SCR catalyst material and corresponding

calibration

– 2013 received new SCR catalyst and calibration at

production

High NOx conversion efficiency

though the product life

Reduced lamps

16

Uptim

e


NOx Sensor Improvements –April 2014

Improved design for robust performance and moisture tolerance on

side-out SCR configurations

Hardware

– Shield to prevent moisture from penetrating the sensor probe

– Enhanced welding process for effective shielding

Software

– Revised controls logic to turn on sensor after

residual moisture is flushed

– Greater sensor accuracy by filtering signal

oscillation

Dependable performance17

Sensor Probe Shield

Uptim

e


ReCon DPF Exchange Program –July 2014

18

During normal operation, ash builds up in the Diesel Particulate Filter.

Eventually the DPF needs to be cleaned or replaced.

Faster than Cleaning

– Simply remove the DPF and install the Cummins ReCon DPF

– No need for DPF regeneration after installation

Dependable

– Cummins four-step remanufacturing process restores

the DPF to original condition

Better Value

– 1 year, unlimited mileage warranty

– Cummins gives full credit for undamaged cores

Available for 2010 ISX15 engines

Uptim

e


Extended DPF Ash Cleaning Interval- January 2016

* Most applications adhering to the operation and maintenance recommendations will exceed the

posted mileage before maintenance is due. When maintenance is due, it will be indicated to the driver

by a Check Engine Lamp (CEL) flashing for 30 seconds after the engine is put in operation. In some

vehicles a solid DPF lamp will also be lit.

Build DateCalibration

Revision

Maintenance

indicated by

lamp?

Fuel Economy

> 5.5 mpg < 5.5 mpg

Jan 2016

and afterAll Yes 400k – 500k miles* 250k – 400k miles*

Jan 2015 –

Dec 2015All Yes 400k miles 250k miles

Prior to

Jan 2015

Nov 2014

and afterYes 300k miles 200k miles

Prior to

Nov 2014No 200k miles

DPF ash loading is impacted by duty-cycle and engine health

At launch of EPA 2013 product, the cleaning interval was 200k miles

Main

tenance

Cummins Internal Use Only19

NH3 (Ammonia) Sensor Eliminated –January 2015

• NH3 sensor removed from SCR

• Reducing complexity of the system and enhancing reliability

• Enabled by enhanced engine after treatment diagnostics software

• 2015 SCR catalyst assemblies are not backward

compatible without a calibration update

• Likewise, 2014 and older engines uprated

to 2015 ratings will require new SCR

20

Uptim

e


DIAGNOSTIC CONTROLS

2015 Better Diagnostics

Improved customer experience

– Revised fault lamp strategy April 2015

• 66% fewer shop visits due to engine dash

lamp notifications

– Reduced engine derate instances

22

Uptim

e


Diagnostic Lamp Recap

Mal Function Lamp (MIL): Service when convenient

Check Engine Lamp (CEL): Arrange service at job shift’s end

– Also know as Amber Warning Lamp (AWL)

DEF Lamp (DEF): Arrange service at job shift’s end

Stop Engine Lamp (SEL): Vehicle must be stopped as soon

as is safe to do so

23

Uptim

e


DEF Level Notifications Simplified –November 2014

Simplified DEF Lamp strategy and more logical

interface

Allows operator more time to fill up the urea tank

before inducing torque derate

24

Uptim

e


DEF (Urea) Gauge Notification (audible OEM’s option) Inducement

(Each stage has a fault code

associated)10% reserve excluded in gauge Lamp

Stage 1

Minimum 10% full

(trimmable between 10-60% )

DEF Lamp solid None

Stage 2

From minimum of 2.5% to before

tank is empty

(trimmable between 2.5-50%)

DEF Lamp solid

Check Engine Lamp solid

25% torque derate

Stage 3

1% or (low level and fail to prime)

DEF Lamp flashing


40% torque derate and begin

search for severe

inducement

Stage 4

After engine has been

intentionally shut down or fuel re-

fill or idle continuously for > 1 hr.

DEF lamp flashing


Stop Engine Lamp solid

Torque derate & vehicle

speed limited to 5 mph after

one of the 3 possible triggers

are met.

DEF Level Notifications Simplified –November 2014

Uptim

e

Dash Lamp Quick Reference for Drivers –October 2015

Enabling effective operation

Bulletin # 4971518

26

Uptim

e


ELECTRONIC ENGINE FEATURES

ADEPT – April 2015

Enhances vehicle efficiency by managing torque

and leveraging momentum

– SmartTorque2 Feature

• Provides efficient torque management by varying torque

across all gears depending on transmission capability

and torque requirement

– SmartCoast Feature

• Enables better fuel economy by reducing fueling and

disengaging the driveline to take advantage of the

vehicle’s momentum in hilly terrain

Overview Video: https://www.youtube.com/watch?v=hoOFEHi7YlA

ADEPTTM

28

Effic

iency


https://www.youtube.com/watch?v=hoOFEHi7YlA

ADEPT – SmartTorque2 Feature

Torque is intelligently adjusted in real time for optimal fuel economy

SmartTorque2 is a feature within the SmartAdvantage ratings

This feature is now also available for all ratings paired with AMT

ISX15 450SA 1550/1750 Torque Curve 29

Effic

iency

ADEPT – SmartCoast Feature

Takes advantage of the vehicle’s momentum on moderate downhills.

Disengages the driveline and operates engine at idle

Makes every driver a Pro, providing a fuel economy benefit of up to 2%

Without SmartCoast

With SmartCoast

Fuel Command

Fuel Command

Requires Eaton

AMT built after

April 2015

30

Effic

iency

ADEPT – Maintains Driver in Control

When SmartCoast is enabled, it allows the driveline to disengage in conditions where little or no

power is required to sustain the set cruise speed within the cruise control operation limits

– Advanced controls logic determines instantaneous command fueling adjustments, dropping the engine to idle

or resuming required engine speed for preset vehicle speed

Driveline reengages in the appropriate gear under any of following conditions:

– Vehicle brakes are applied

– Driver presses accelerator pedal

– Cruise control is canceled

– Manual mode selected in transmission

– Road grade is greater than 4%

– Request by an adaptive cruise system

– Speed exceeds set cruise speed by 6mph (factory default)

31

Effic

iency


Vehicle Acceleration Management (VAM) –January 2013

Mimics acceleration of fully

loaded vehicle in lightly loaded

conditions such as:

– Bobtail

– Diminishing loads

Benefits

– Reduced driveline and tire wear

– Improved fuel economy

32

Effic

iency


TM

Over 150,000 trucks Connected!

Using telematics, your Cummins-

powered equipment wirelessly

connects your engine to Cummins

for real-time diagnosis

Enables maximum uptime for our

customers

No charge from Cummins

34

Uptim

e– April 2015


Connected Diagnostics – April 2015

Previously, the operator relied on lamps and gauges to make

operating decisions during an engine system fault

Now, Connected Diagnostics provides immediate, expert

recommendations in response to urgent faults

Telematics

Provider

Urgent Action

notification

sent

Fault Code

Data

Analysis

Fault Code

Generated

Process complete in seconds…

Customer

Notified

35

Uptim

e


Benefits of Connected Diagnostics

Instant Notification

– Saves time, saves money, and allows faults to be addressed

before mission is impacted

Effective Information

– Details on the fault code sent to fleet management for proactive

decision making

Expert Guidance

– Cummins provides recommendation based upon the

primary fault code and probable root cause

36

Uptim

e


Your Information. Your Way.

Data Integrator

• Third party system for

all telematics data

• Connected Diagnostics

reported through this

Fleet Maintenance

Software

• Single interface point

• Fleet operations or

maintenance

Telematics Service

Portal

• Data thru

telematics provider

• Integrated output

Email from

Cummins

• Simple

• Fast & complete

37

Uptim

e


Customer Notification – Email Example

Vehicle and Engine

information

Recommended

customer action

Fault code details

Suggested root

cause

Link to nearest

certified repair

locations

Cummins Care

contact information

Awareness of

possible impact on

performance

Connected

Diagnostics

Notification ID

38

Uptim

e


The Lifeline For Your Engine

Contact telematics provider for availability

Information that can be shared with customers:

– http://cumminsengines.com/connected-diagnostics

– Video

– Brochure

39

Uptim

e


http://cumminsengines.com/connected-diagnostics

https://youtu.be/n_Vfa4oY8kU

FUEL SYSTEM

XPI Fuel System with Steel Plunger –January 2013

Changed the fuel pump

plunger from ceramic to

steel

Improved robustness of

fuel pump

41

Uptim

e


Diamond Like Coated (DLC) Fuel Pump Tappets – December 2014

Changed the fuel pump tappet

roller pin from bronze to DLC Steel

– Part number: 4307152

Improved robustness of fuel pump

42

Tappet Body

Tappet Roller Pin

Tappet RollerUptim

e


Thermal Recirculation Valve (TRV) –December 2014

43

Fuel Gelling or Waxing (caused by extreme

cold weather) can result in:

– Difficulty starting engine or staying running

– DPF plugging

TRV combats fuel gelling

– Recirculates 90% of the fuel to the tank during idle

– Routes the warm returned fuel to the Stage 1 filter

when < 77°F (25°C)

– Capable of melting wax in filter down to around -9°F

(-23°C) below fuel cloud point

Retrofit TRV kit available for service – P/N 4376341Uptim

e


LUBRICATION & COOLING

Lubrication with Low Viscosity Oil –January 2013

ISX15 requires oil that meets Cummins Engineering Standard 20081

Low viscosity 10W30 oil is recommended

– This lower viscosity oil is recommended in applications, such as linehaul trucks,

where fuel efficiency is critical

Refer to the engine operator manual and lube oil service bulletin

for detailed oil requirements

Lower viscosity oil provides faster lubrication and less viscous drag

which reduces engine friction and enables

better fuel economy

45

Effic

iency


Coolant filter is optional, but requires proper coolant maintenance

– ‘No Filter’ is Jamestown Engine Plant standard option

– OEMs can specify filter based on operating region and conditions

Enabled by better controls, cleaner casting and

machining, and advanced coolant technology

Coolant is still a maintenance item

– Use coolant that meets CES14603

– Continue to monitor coolant level

Lower maintenance cost over engine life

– Total cost of ownership savings over a 500k mile lifetime is ~$550

Coolant Filter Maintenance Made Optional –January 2015

46

Main

tenance


ISX15 operates at higher temperatures and pressures while delivering class

leading fuel economy. This requires superior lubrication at all operating

conditions.

LF14000 NN with NanoNet media provides better filtration than stacked-disk

media (LF9080)

– Lower restriction and higher flow

– More effective lubrication

– Better engine protection on cold starts

– Superior dust and particulate collecting

capability; 99.9% efficiency at 30 micron

LF14000 NN is backward compatible to all ISX engines

NanoNet Lubricating Oil Filter –January 2015

Uptim

e


Cartridge

Cartridge

Stacked-DiscCartridge

* Note there is not a venturi Nozzle in LF14000 NN

* LF14000 NN design does not require the venturi to pull lube through the NanoNet combo section

Venturi Nozzle

LF9080LF14000 NN

48

Uptim

eNanoNet Lubricating Oil Filter –January 2015

Lubricating Oil Filter Bypass Valve –February 2015

The bypass relieves the pressure across the filter during conditions with high filter restriction such

as cold start, preventing damage to the filter and ensuring oil supply to the engine

49

Old BPV Design New BPV Design

Yellow – Stainless Steel Seat

Blue – 33% Glass Filled Nylon Seat

Red – Stainless Steel Stamped Cage

Black – Viton O-rings

Plug, Spring & Valve

Injection molded

polyetherimide

Uptim

e


Crankcase Ventilation System

Blow-by: the result of high pressure gases and oils escaping

around piston rings during normal engine operation

Function of CV system:

– To vent the positive pressure that can build

up in the crankcase as a result of blow-by

– To control crankcase emissions

• Separates oil from blow-by and returns

it to the oil pan

50

Main

tenance


Continuing to lower the total operating and increase

uptime for our customers

– New: Variable Impactor Filter

• Factory standard beginning

September 28, 2015

– Old: Coalescing Filter

• Remains available only as an

aftermarket retrofit option

Crankcase Ventilation System Enhancements – September 2015

51

Main

tenance


Maintenance Free Crankcase Ventilation Filter – September 2015

New CV Filtration technology for ISX15: Variable Impactor technology

– For ISX15 N. America

– Emissions and OBD transparent

No changes to external dimensions

Backwards compatible to 2007 ISX15

Maintenance free

– Lower TCO and more uptime

No calibration update required

– An illuminated Check Engine Lamp

may indicate need for engine inspection

Service P/N: 3691476

52

Maintenance

Free Insert

Base

Cover

Main

tenance


CV Coalescing Filter Extended Maintenance Interval – November 2014

CV coalescing filter media saturation is impacted by duty-cycle and engine health

Extended scheduled maintenance:

Engine software prior to Phase 9.40.0.24:

– Maintenance is due when the Check Engine Lamp is solid yellow

Engine software including and after Phase 9.40.0.24:

– Maintenance is recommended when the Check Engine Lamp flashes for 30 sec after key switch is set to ON

– Maintenance is due when the Check Engine Lamp is solid yellow

For detailed service requirements, consult operation and maintenance manuals.

53

Advertised Horsepower Filter Replacement Interval

400 to 450 175k miles

455 to 600 125k miles

Main

tenance


POWER CYLINDER

Cylinder Liner with Brass Shims –March 2012

Improved Cylinder Liner

– Brass shims adopted in production

– Blocks now have wider liner ledge for increased surface area

Less prone to fretting on liner seat

reduced liner recession

Ensures robust cylinder head gasket seal

55

Uptim

e


Power Cylinder Enhancements –December 2014

Reducing oil consumption and improving uptime for our customers

– Anti-polishing ring

• Overhangs liner bore

• Scrapes piston top land carbon deposits

• Maintains piston carbon deposit thickness

that will not contact the cylinder liner and

accelerate bore polish

– Smoother bore surface finish

• Liner crosshatch has been modified to reduce

residual oil in the combustion chamber

– Lower flow valve stem seal

Reduced oil consumption by ~40%56

Uptim

e


POWERTRAIN

Enhancing ISX15 SmartAdvantage – September 2014

• Leading the pack– Leveraging superior low-end torque

– Improved driver comfort

– 2-7% better mpg than competitors*

• 3rd party SAE-Type III

• Expanded portfolio of Small Step overdrive combinations

Effic

iency

* 2015 model year comparable powertrain and aerodynamic packages

Collaborative Improvements Implementation Schedule

ImplementationProduction : September 2014

Service: Available Now

Production: January 2015

Service: Available Now

EngineECM Code (Revision 11):

EF10078.11 (450ST2)

EF10079.11 (415ST2)

No Changes

Transmission No ChangesTransmission Electronic Control Unit (TECU)

Software: 5569944

Improvements• Prioritize full torque use in top gear over

downshift in moderate loads

• More precise vehicle mass estimate

• Downshift from 10th to 9th gear @ lower RPM

• Single downshift at engine brake interaction

• FAST Shift Mode set as default – quick shift response

Effic

iency

Cummins Internal Use Only 59

Enhancing ISX15 SmartAdvantage – September 2014

TURBOCHARGER & AIR HANDLING

EGR Cooler with Improved Thermal Fatigue Resistance – April 2012

Improved thermal fatigue resistance

– 3.5 years in production without any documented thermal fatigue failures

– More uniform coolant distribution

• Redirected coolant flow

• Better de-aeration capability

– Swaged tubes for robust front/endplate connection

– Confirmed substantial durability gain through extensive thermal cycle rig testing

61

2007 & 2010

ISX15

2013 ISX15

Swaged TubesUptim

e


Air intake throttle incorporated into intake manifold

system

– Assists with EGR flow reducing the air pumping losses which

improves fuel economy

Only available on ISX15 400-475HP

– Ideal for Linehaul: Regional & Cross-country

Air Intake Throttle – January 2013

62

Effic

iency


Naturally Aspirated Air Compressor –July 2013

Enhanced Fuel Efficiency

– On average 1.5% improvement for

line-haul applications

– Up to 2% improvement in regional

hauling with stop and go routes

“Boosted” configuration

– Suitable for applications requiring

enhanced air compressor performance

63

Effic

iency


Variable Geometry Turbocharger

64

Proven proprietary Cummins turbo technology

Widely recognized as highly effective

Enables:

– Swift and dynamic response

– EGR control / delivery

– Enhanced braking

– Aftertreatment regeneration

Effic

iency


Turbo Actuator Software Enhancement –October 2013

Actuator controls enhanced logic

– If actuator has difficulty moving to the

commanded position, the actuator will reverse

direction and then move quickly back to desired

position

– Allows actuator to overcome temporary sticking

conditions

Rapid and accurate response to modulate

Exhaust Gas Recirculation

65

Uptim

e


Turbocharger Hardware Improvements –October 2014

Actuator Motor Bearing

– Improved design keeps bearing and gear system firmly in place,

ensuring adequate actuator torque output

Overall improvement of VG

mechanism durability

– Reduced oil consumption which

reduced ash deposits on

VG mechanism

66

Uptim

e


FUEL ECONOMY PROGRESS

2.0%

3.5%

2.3%

0.5%

3.5%

4.0%

0.0%

1.0%

2.0%

3.0%

4.0%

5.0%

6.0%

7.0%

8.0%

9.0%

10.0%

11.0%

12.0%

13.0%

14.0%

15.0%

2010 2011 - 2012 2013 2014 - 2015 2016 SmartAdvantage ADEPT with PCC

Optimized use of SCR,

NAAC and reduced

parasitic losses

Reduced parasitic and

enhanced low end torque

for downspeeding

Combustion & System

Optimization

Reduced front gear train

parasitic loads and

optimized turbocharger

400 – 475 HP Fuel Economy Progress

Line-haul & Regional Applications

ST2 (1%)

MAINTENANCE PROGRESS

Total Cost Of Operation: Maintenance Breaking Away from the Pack!

Maintenance Item 2012 2013 2014 2015 2016 2017

Low Pressure Fuel Filter 25k 40k 40k 40k 40k

High Pressure Fuel Filter 25k 40k 40k 40k 40k

DPF Cleaning 200k 200k 300k400k

($800)

400k

($800)

Coolant Filter 50k 50k 50k 50kNo Cost

($550)

Oil Drain Interval 35k 40k 40k 40k 40k

Crankcase Breather 125k 125k 125k 175kNo Cost

($440)

($1,790)*All intevals in MilesTotal Cost of Operation

(over 500k mi)

$

CONCLUSION

72

ISX15: Your Leading Engine Choice

Fuel Economy Leadership Lowest Cost of OperationSuperior Reliability

and Durability Up to 13% since 2010

ADEPT

SmartAdvantage

Reduced Parasitic

Combustion Optimization

Calibration Optimization

Extended DPF Cleaning

Extended DEF Filter

Maintenance Free

Hydrocarbon Doser

Optional Coolant Filter

Maintenance Free Crankcase

Ventilation System Filter

EGR Swaged Tubes

Fault Lamp Logic

Turbo Actuator

Power Cylinder

Improvement

Unmatched Uptime

and Support

3500 Service Locations

24/7 Call Center

Expert Diagnostic Systems

Connected Diagnostics

QuickServe Online


Documents

ISX15 Enhancements - Volvo - Cummins · PDF file5 History Rooted in Innovation Founded in 1919 by Clessie Cummins and W.G. Irwin Pioneered the development of diesel engines Promoted