The ISX15 is Better Than Ever ISX15 Product Enhancements 2013 - 2016 Revised: February 2016
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
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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
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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
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tenance
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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
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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
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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
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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
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tenance
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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
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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
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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
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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
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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
Check Engine Lamp solid
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
Check Engine Lamp solid
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
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Dash Lamp Quick Reference for Drivers –October 2015
Enabling effective operation
Bulletin # 4971518
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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
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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
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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
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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
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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
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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
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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
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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
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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
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FUEL SYSTEM
XPI Fuel System with Steel Plunger –January 2013
Changed the fuel pump
plunger from ceramic to
steel
Improved robustness of
fuel pump
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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
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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
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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
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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
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tenance
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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
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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
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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
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tenance
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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
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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
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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
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tenance
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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
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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
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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
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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
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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
Cummins Internal Use Only
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
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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
Cummins Internal Use Only
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
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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
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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
Cummins Internal Use Only