Retrofitted Cummins ISX with E

Discussion in 'Peterbilt Forum' started by Andy the mover, May 15, 2016.

  1. Andy the mover

    Andy the mover Bobtail Member

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    May 14, 2016
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    Hi everybody. I have problem with my Volvo powered with Cummins ISX EGR. I bough it in 06' model 07' unfortunatelly enigmę 06'. Not good for CARB rules. In 13' just before I retrofitted my rig I needed to overhaul the engine (600k miles only) due to broken valve and destroyed cylinder head. DPF filters been installed. They need to be serviced every 60k miles or every year whichever comes first. First service (vacuuming and baking them) I did after 57k and they were super clean!!! On the middle of next cycle I had problem with fuel system, loosing power on low RPM's and jumping. I went to cummins service and they figured I need new EGR plus all fuel pump selenoids. Had no way out so I paid for. On top they found broken fuel line (it was the main problem of course but aa always they start with big things not small ones). Problem resolved but I start smelling smoke in my cab trough vents and decreased fuel economy so I went back and they decided to calibrate ECU. Uploading, downloading and erasing data. Let's say I was satisfied. But next cycle for DPF shortened to 42k. Next one was only 21k miles. Shop manager said my engine is bad. They took filters down and performed opacity test. Results been great, only 3.6%. So they decided I need to go and do DYNO test. My truck runs great, turbo works smooth and silent (only noise I hear is pleasurable to ears "weeeez") does not take oil and only quarter of a gallon of coolant every 12-15k miles. Takes diesel:)
    Results of the DYNO:
    DYNO test truck, perform snap idle test before DYNO run and 5.6 percent opacity observed. Under load the smoke was so minimal that we could not get a reading on the opacity meter. Blow-by is at minimum no signs of smoking out of exhaust, did find that the turbo hot housing is glowing red under full load. Turbo is not working correctly and needs to be replaced. Also found exhaust leaking at manifold. Engine runs good.
    I am not sure if the test was done the right way. How come on idling they were able to get reading on the meter and under full load-not? Where the smoke/hot air went? What can cause building up the sood in the filters if no smoke been observed?
    Replacing turbo is easy, "only" 3-3.5k $'s but is this the problem of the sood buildup? How come turbo needs to be replaced if it runs great, silent, no weird noises and turbo boost gauge shows quick respond to releasing or decreasing on accelerate pedal.
    Any ideas, advices or similar experiences? I am lost between shop mechanics directions.
    Help.
    Thank you
     
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  3. Snailexpress

    Snailexpress Road Train Member

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    First what you need is to change shop. They want to drain your wallet.
    If turbo is glowing red EXHAUST GAS PRESSURE is too high. You mention about coolant loss. Probably EGR gases cooler is leaking and coolant will plug DPF in short time what cause high exhaust pressure. Is your truck has aftertreatment injector for DPF regeneration?
    Don't waste money. Just buy good ISX CM-871 and be happy.
     
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  4. HopeOverMope

    HopeOverMope Road Train Member

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    Sounds like you could use a good AMSOIL oil bypass filter part number BMK-30 I think. That will greatly assist in reducing soot. Make sure your exhaust back pressure sensor is new, they go bad around 500/600k. The sensor has a long life span but is often over looked. If it can't correctly read how much back pressure is going on, the EGR system won't work as efficient, to much pressure could be built up, and sorts of (not) good stuff revolving around excess pressure.
     
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  5. Andy the mover

    Andy the mover Bobtail Member

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    May 14, 2016
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    Thank you for advice. I will stop in friendly shop. They never ripped me of money so I trust them. I will ask them to check the EGR cooler. But do you really think small amount of coolant can cause so quick sood buildup in DPF? It's "passive" DPF system- it's uses hot air/smoke produced by engine to burn the sood in filters. Also my pyro gouge is not working since I stopped I cummins service last year. Can it give wrong/false info to ECU and cause it to mess with my turbo/exhaust system? According to DYNO test shop there is not enough of smoke to be tested under full load run so are they stupid or the smoke goes somewhere else? (????)
    Last question, if high exhaust gas pressure will be corrected will it help to burn/clean the filters under normal duty?
    Thank you in advance for help.
     
  6. Snailexpress

    Snailexpress Road Train Member

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    Ok Andy. I dont have much time today will try to be short how it works. EPA requirement for pollution create next situation in engines design to lower NOx the combustion temperature should be not so hot. For this we have EGR valve. Valve opens under ECM control and some exhaust gases get in the intake instead of air (oxygen) but cooler combustion produces more soot. Soot if system is well balanced should be trapped by DPF and burned during regeneration. If any of many elements in this system is fail as a result we have excessive soot.
    What can cause excessive soot
    Bad turbo or turbo actuator
    Leaking CAC
    Bad or not working sensors
    Electrical system
    Bad fuel injectors
    Bad fuel actuators
    Low fuel pressure
    Air in fuel
    Bad overhead set
    Bad EGR
    Bad ECM calibration
    and many other
    DPF designed to "digest" certain amount of soot. If engine produces over of this it will plug DPF and trigger self destruction process.
    Engine can't breath, exhaust gases pressure extremely high. It cause EGR cooler cracks and as a result leaks what is plugging DPF even more.
    High heat will destroy turbo and exhaust valves cause cracks in head liners and melted pistons.
    If i get some time i will post pictures for you how it looks.
    Again I will NOT recommend you to play this game with your engine. Engine was designed to work with open exhaust. DPF equipped engine has difference in camshaft, fuel settings, turbo. Are you reach as a Cummins to do research?
     
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