Kerlin Service Training

3 March 2015

Michael HodgeCummins CrosspointField Service Engineer

Agenda

� Aftertreatment

– Components

– Theory of Operation

– SCR Layout

� Driver Indicators – dash lamps

� Maintenance

– Filter Intervals

– Biodiesel and DEF

� Service

– In-warranty

– Out of warranty2

Agenda (cont)

� Common Issues

� Idle/Warm-up

� Aftertreatment Overview

• DPF

• Selective Catalytic Reduction (SCR)

3

Emissions Targets History – Past, Present and Future

Target for

2010

4

Aftertreatment

2010 & 2013 Emission Level Engines

5

Selective Catalytic Reduction

DEF Tank

Diesel Exhaust Fluid Dosing

Unit

ECM

SCR Catalyst Particulate Filter

Diesel Exhaust

Fluid Dosing Controller

Diesel Exhaust Fluid Dosing Control Valve

Aftertreatment Components

Diesel Oxidation Catalyst

Diesel Particulate Filter

SCR Fundamentals

11 22 33

DEF Injection• Small quantity of DEF

injected

• Proportional to NOx rate

• 32.5% solution in water,

freezing point = -11°C

• Stored in heated tanks

• (NH2)2CO

Hydrolysis• DEF breaks down

by hydrolysis to

form ammonia

• NH3

NOx Catalysis• NO and NO2 react

with ammonia over a

catalyst to form

nitrogen and water

vapor

DEF

Injector

SCR

Catalyst

9

Diesel Exhaust Fluid System Layout

Tank

Pressure Line

Level Sensor

Dosing

Module

Return LineSuction Line

Tank Heater Valve Tank

Valve

Pressure SensorPump

Main Filter

SCR System Component Responsibilities

CES Supplied

� Standard Cummins Particulate Filter

assembly

• Catalyzed filter, DOC elements

• V-band clamps on 3 modular sections

• ¼” insulated housing

� Standard SCR Catalyst Assembly

• SCR, AMOX catalyst elements

• ¼” insulated housing

� Inlet / Outlet Subassembly

� Decomposition Pipe w/ 2 Gasketed Marmon Flanges

� Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM)

� Aftertreatment DEF Dosing Valve

� Delta Pressure Sensor, Mounting, Tube

� NOx Sensor

� Temperature Sensors (DPF and SCR)

� Wiring harness with Common Vehicle Connection

� Insulated Platform for Sensor Mounting

� Aftertreatment DEF Dosing Unit

OEM Supplied

� Turbo to CPF Assembly Downpipe

� DEF Tank

� DEF Tank Filter

� DEF Level Sensor

� DEF Temperature Sensor

� DEF Tank Heater (CES to integrate w/OEM)

� DEF Tank Heater Relay/Valve

� DEF Line Heaters

� DEF Lines to/from DEF tank to Aftertreatment DEF Dosing Unit

� DEF Line from Aftertreatment DEF Dosing Unit to Aftertreatment DEF Dosing Valve

� Coolant Lines to/from DEF Tank

� Coolant Lines to/from Doser Nozzle

� Vehicle to Aftertreatment Wiring

� Tailpipe Assembly

� Mounting Brackets/Fasteners

10

Driver Indicators

Dash lamps depicted are for representation – Actual lamps may have different

depictions

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Normal Operation

• Passive Regeneration

• Stationary Regeneration with

vehicle mounted switch disabled

Indication

None

Desired Response

None

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Normal Operation

• Passive Regeneration

• Mobile Active Regeneration As

Conditions Permit

• Stationary Regeneration with

vehicle mounted switch disabled

Indication

None

Desired Response

None

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Normal Operation

• Aftertreatment outlet temperatures (ie,

tailpipe) higher than normal operation

• This lamp is for information only; it does not indicate a

failure

Indication

HEST Lamp On Solid

Desired Response

None

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Regeneration Needed – Low Priority

• Passive Regeneration available

• Mobile Active Regeneration As Conditions

Permit

• Stationary Regeneration using vehicle mounted

switch available

Indication

DPF Lamp On Solid

Fault code 2639

Desired Response

Provide Regeneration Opportunity

• Alter Duty Cycle

• Perform Stationary Regeneration

• Seek Service

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Regeneration Needed – Medium Priority

• Passive Regeneration available

• Mobile Active Regeneration as Conditions

Permit

• Stationary Regeneration using vehicle mounted

switch available

Desired Response

Suggest Regen

• Alter Duty Cycle

• Perform a Stationary Regeneration

• Seek Service

Indication

DPF Lamp Flashing

Fault code 2639

Moderate Engine Derate

• No derate in emergency vehicles

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Regeneration Needed – High

Priority

• Passive Regeneration available

• Mobile Active Regeneration Disabled

•Stationary Regeneration via vehicle mounted switch

available

Desired Response

Require Regeneration

• Perform a Stationary Regen

• Seek Service

Indication

DPF Lamp Flashing

Check Engine Lamp on Solid

Fault code 1921

Severe Engine Derate

• No derate in emergency vehicles

Empty Auto Low Medium High Stop

Increasing Soot Load

Situation

Regeneration Needed - Stop

• Mobile Active Regeneration Disabled

• Stationary Regen Disabled

Desired Response

Stop Engine at Earliest Opportunity

• Seek Service

Indication

Stop Engine Lamp on Solid

Fault code 1922

Severe Engine Derate

• No derate in emergency vehicles

19

Malfunction Indicator Lamp (MIL)2013 engines

20

Maintenance

21

Maintenance

� Filters

– Lube oil filter - 500 hrs, 15000 miles

– Pressure Side Fuel Filter – 500 hrs, 15000 miles

• Do NOT prefill unless clean side block-off plug used

• Use priming pump

– Coalescing Crankcase Filter – 2500 hrs, 75000 miles

• Housing on top of valve cover

• Separates oil vapor from crankcase gas

• Oil drains back to pan

Maintenance (cont)

� Filters (cont)

– Diesel Particulate Filter (DPF) – 6500 hrs, 200k mile

• Ash cleaning or replacement

• Interval will depend on … duty cycle, oil consumption, and type of oil being

used

– Diesel Exhaust Fluid Dosing Unit Filter – 6500 hrs, 200k

miles

• Located in the DEF dosing unit (pump)

23

Maintenance (cont)

� Other filters – OEM– Primary engine fuel filter

– DEF tank filter

� Overhead set – 5000 hrs, 150,000 miles

24

Maintenance (cont)

� Fluids

� Biodiesel

– B20 approved for use on ISB engines built 2002 – present

– Shelf life

• Used within six months of manufacture

• Should not be stored in equipment longer than three months

25

Diesel Exhaust Fluid (DEF)

� Diesel Exhaust Fluid (DEF) is an urea based liquid

– Is widely used as an agricultural fertilizer, in food, cosmetics, and pharmaceuticals and is perfectly safe to handle

– Is not harmful to handle, however corrosive to certain materials overtime (buna-n, neoprene, silicon, tygon, non-alloyed steels, copper, copper-containing alloys and zinc-coated steels).

� 32.5% aqueous solution

� Diesel Exhaust Fluid (DEF) is non-toxic, non-polluting, non-explosive and non-flammable

– With proper dispensing and storage equipment there will be no inconveniences for the users

� Reference Diesel Exhaust Fluid Specifications for Cummins Selective Catalytic Reduction Systems Service Bulletin 4021566

Diesel Exhaust Fluid

� Temperature at which Diesel Exhaust Fluid freezes is 11°F (-11.5°C)

� Diesel Exhaust Fluid shelf life at normal conditions is approximately 12 months

– optimum storage temp between 12 °F to 77 °F

� Sensitive to UV radiation

� Concentration measured with specific refractometer

– Available from Cummins

27

Service Options

How to address service over life of product

28

Warranty Period

� Warranty details - Cummins Bulletin 3381329– Kerlin Sales Group

– Local Cummins Distributor Sales

� 5 year – 100,000 mile base engine warranty– Begins with date of delivery to first user

– Covers Cummins supplied aftertreatment components

� Optional 3 year – 300,000 mile extended coverage– Begins with expiration of base warranty

29

Warranty Period

� Automotive application

– In-shop repairs

– Towing to closest authorized warranty repair location

– Crosspoint Field Service –

• Travel isn’t covered by warranty

• Providing fault codes or ECM image can speed repairs

30

Outside of Warranty

� Training

� Service Literature

� Diagnostic hardware

31

Training

� Cummins Virtual College

– DVD based factory training

– Same material Cummins Techs use

– Taylor to specific products

– Onsite classroom not available

– Cummins warranty repairs not available

– Purchase/pricing information - Cummins Crosspoint

• 800-345-001232

Service Literature

� Quickserve Online (QSOL)

– Service Manuals, fault code troubleshooting, service

bulletins, owners & operation manuals

– All engines – Latest information – updated real time

– Subscription

– Purchase/pricing information - Cummins Crosspoint

• 800-345-0012

33

Diagnostic Hardware

� Insite

– Insite Basic, Lite, Pro

– Datalink adapter – Inline,

Nexiq or equivalent

– 5 year expiration on

Insite Basic

– Requires computer to be

connected to internet

every 90 days34

Diagnostic Hardware

� Insite

– Purchase/pricing

information - Cummins

Crosspoint

• 800-345-0012

35

Insite Functionality Capability

36

Diagnostic Hardware (cont)

� Quickcheck 5600

– Stand alone – requires

no datalink adapter

– Read/reset fault codes

– Adjust features

– Review trip informaiton

37

Current Common Issues

38

FC 285/286 – J1939 Multiplexing PGN Timeout Error

– Communication error between engine ECM and other

multiplexed components…ABS controller, body controller

– Often too much traffic on datalink or other controllers not

communicating fast enough for ECM to detect

– Most often found in an inactive state

39

DEF Doser Gasket Leaks

� Most frequently encountered on ISB CM2250 (2010)

� Gasket material changed

– Steel carrier

– Like 2013 design

40

FC 3243 – Cooling System -Below Normal Operating Range

� Engine didn’t get reach 162 deg F in a specified amount of time

� Only see in school buses

– Theorized that additional components in cooling system

contributes

� Led to improper thermostat replacements

� Viscous fan can contribute

41

FC 3243 – Cooling System -Below Normal Operating Range (cont)

� Calibration – 28 February 2014

� Winter front

42

Idle Time� Question – What is Cummins recommended practice on

idle time?

� Answer – Minimum amount required to accomplish desired

goal.

43

Idle Time (cont)

Fast Idle Warm-up

44

Idle Time (cont)

� Fast idle warm-up

– Cuts fueling to 3 cylinders and raises engine speed when temp

thresholds are met

– Coolant and Intake manifold temp inputs

– Default = enabled

– Valid when engine operated in PTO – Raised idle speed

• PTO Load Threshold Likely Must be Raised

45

Appendices

46

Detailed regeneration and SCR dosing cycle description

47

Aftertreatment Definitions� Soot

– Exhaust particles composed of partially burned fuel and oil

from engine operation (ie, black smoke)

� Ash

– Material from the oil additive package that cannot be

oxidized, and is collected in the DPF. Ash is what requires

the DPF to be removed and cleaned at specified intervals.

� Aftertreatment Injection

– Injection of fuel into the exhaust to increase exhaust

temperatures. The injected fuel is oxidized across the DOC

to create heat.

Aftertreatment Definitions� Regeneration

– The process of converting the soot collected in the DPF into carbon dioxide

– This process requires heat to occur

– There are two types of regeneration

• Passive regeneration – the engine exhaust temperatures are high enough during normal operation to oxidize the soot faster than it’s collected

• Active regeneration – the engine exhaust temperatures during normal operation are not sufficient enough to oxidize the soot (soot is collected faster than it is oxidized). The engine then uses aftertreatment injection to increase the exhaust temperature. Active regeneration can be either “mobile” (while the vehicle is moving) or “stationary” (while the vehicle is not moving).

• Both kinds of regeneration can occur during normal operation and are transparent to the vehicle operator

Aftertreatment Definitions� Regeneration

– Stationary Regeneration

• Stationary regeneration is performed while the vehicle is not moving

• Only available via dash switch when DPF lamp is illuminated

• Requires elevated idle speed (ie, 1050 to 1100 RPM)

• Can be initiated with either a vehicle mounted switch or with Insite

• Note that stationary regeneration is a form of active regeneration since it requires aftertreatment injection

Filtration Points inDEF Circuit

• Tank Filter: 100 micron

• Supply Module Main Filter: 10 micron

• Injector Inlet Filter: 40 micron

• Supply Module Inlet Filter: 100 micron

• Supply Module Backflow Filter: 100 micron

Tank filter

DEF Dosing System Operation� The SCR system is comprised of many components but

requires a minimal amount of servicing or driver intervention. The SCR system is comprised of four main states: Priming, Dosing, Purging and Heating.

� Priming state:

– Once the SCR catalyst reaches a temperature of 480°F (250°C) the aftertreatment DEF controller will command the aftertreatment DEF dosing unit to start its priming process. The aftertreatment DEF dosing unit will draw DEF from the DEF tank, filter the DEF, and then pressurize the DEF to the aftertreatment DEF dosing valve. The aftertreatment DEF dosing valve will open and close to purge any air out of the system. Once the system is able to build up pressure and has removed most of the air bubbles from the DEF lines the aftertreatment DEF dosing system is capable of dosing.

DEF Dosing System Operation

� Dosing state:

– The aftertreatment DEF dosing valve will open and spray DEF in

the exhaust stream when the engine’s ECM commands it. As

long as the dosing system is in the dosing state the aftertreatment

DEF dosing unit will continue to run regardless of whether the

aftertreatment DEF dosing valve is spraying DEF or not. DEF

dosing rates are dependent on vehicle duty cycle. The dosing

rates are not necessarily constant under most duty cycles. The

aftertreatment DEF dosing valve will pulse the demanded amount

of DEF into the exhaust stream. Any DEF that is not used by the

aftertreatment DEF dosing valve is returned to the DEF tank.

DEF Dosing System Operation

� Purging state:

– When a driver keys off, the dosing system will shut down with a purge cycle to prevent DEF from being left in the system. This is done to prevent freezing in cold climates. An audible click and pumping sound will be heard from the DEF dosing unit when it is in a purge cycle. The DEF dosing unit will actuate the return valve and cause a change in the flow direction of the DEF. The DEF dosing unit will pull all of the DEF out of the aftertreatmentDEF dosing valve and pressure line and return it to the DEF tank. During this process, the aftertreatment DEF dosing valve will open eliminating the vacuum created in the lines for a more complete purge process. After a complete purge the majority of the system will be free of any remaining DEF. If the main power to the aftertreatment DEF controller is removed, via a battery cut off or other means, before the purging is competed, an internal fault will be logged in the ECM. The incomplete purge counter can be viewed in INSITE.

DEF Dosing System Operation

� Heating state:

– DEF freezes at 11°F (-11°C). If the ambient air temperature

sensor reads ambient conditions are below 25°F (-4°C) the

aftertreatment DEF controller will command the dosing system to

go into the defrost state. The aftertreatment dosing unit will turn

on its internal heater to defrost any remaining DEF that still may

be inside it. The heated DEF lines will also be commanded on. If

the DEF tank temperature drops below 23°F (-5°C) the DEF tank

coolant valve will be commanded open by the aftertreatment DEF

controller. Engine coolant will flow though the tank to defrost the

frozen DEF. The DEF dosing system will not prime until every

component is completely defrosted. If ambient conditions

continue to be cold after the system primes, the aftertreatment

DEF controller will command a maintenance heating feature to

prevent the DEF dosing unit from refreezing. This feature will

cycle the heating on and off to the DEF lines, DEF tank, and

aftertreatment DEF dosing unit.

Insite – Image Export

56

57

Highlight desired image

58

• Export to external file = .csv

format can be viewed with

Excel

• Export Image - .eif format

can only be viewed with

Insite

59

Save file location