kerlin service training - kerlin bus sales service training 3 march 2015 michael hodge cummins...
TRANSCRIPT
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