diesel aftertreatment systems · 2019-12-10 · aftertreatment def controller and line heater...
TRANSCRIPT
![Page 1: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/1.jpg)
Diesel Aftertreatment Systems
D e c e m b e r 0 3 2 0 1 9
![Page 2: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/2.jpg)
Moderator
Obed Mejia, Senior Bus Equipment Maintenance Instructor, LA Metro and Vice Chair-Webinars, APTA Bus Technical Maintenance Committee
TITLE OF PRESENTATION I 2
![Page 3: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/3.jpg)
Presenters
Zigmund (Ziggy) MeluskeyRegional Support ManagerCummins Inc.
TITLE OF PRESENTATION I 3
Ricky MaresManager of Maintenance TrainingMetropolitan Transit Authority of Harris County TX
Tim WallaceTechnical Training InstructorRegional Transportation District Denver, CO
![Page 4: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/4.jpg)
Objectives
At the completion of this this webinar, you can expect to come away with:
1. Knowledge of system operation
2. Preventive maintenance practices
3. System troubleshooting and diagnosis tips
TITLE OF PRESENTATION I 4
![Page 5: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/5.jpg)
TITLE OF PRESENTATION I 5
Cummins Inc
![Page 6: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/6.jpg)
Your Trusted Partner in Transit
Public
11/21/2019
![Page 7: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/7.jpg)
Agenda
Innovation: Our Electrification Story
Questions
Cummins Transit Market Overview01
02
03
04
The Power Of Choice
![Page 8: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/8.jpg)
Where We’ve Come From
0.6g/HP-hr
0.25g/HP-hr
0.1g/HP-hr
0.01g/HP-hr
Particulate
1988 1990 1995 2000 2005 2010 2015 2020
10.7g/HP-hr
6.0g/HP-hr
4.0g/HP-hr
2.5g/HP-hr
1.2g/HP-hr
0.2g/HP-hr
NOx
5.0g/HP-hr
Charge Air Cooling
Electronic Fuel System
EGR & VG Turbo
SCR & XPI Fuel System
OBD
HPI Fuel System
Particulate Filter500 PPM
SulfurDiesel Fuel
500 PPMSulfur
Diesel Fuel
15 PPMULSD
Diesel Fuel
15 PPMULSD
Diesel Fuel
![Page 9: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/9.jpg)
Coming in 2019
Cummins Portfolio:
![Page 10: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/10.jpg)
Cummins AftertreatmentSystem Review
![Page 11: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/11.jpg)
▪ Reduces oxides of nitrogen (NOx) and particulate matter (PM)▪ Achieves near-zero emissions; maintains industry-leading fuel economy ▪ Diesel Exhaust Fluid (DEF) usage approximately 3-4% of fuel usage
▪ Cummins Selective Catalytic Reduction (SCR) Catalyst Converts NOx into harmless nitrogen gas and water vapor.
▪ Diesel Exhaust Fluid (DEF) Dosing Valve Allows a fine mist of DEF to be sprayed into the exhaust stream of the Decomposition Reactor.
▪ Electronic Controls Single Electronic Control Module (ECM) constantly adjusts engine and aftertreatmentoperations for peak performance and emissions control.
▪ Cummins Particulate Filter Collects and oxidizes carbon to remove PM from the exhaust.
▪ Decomposition Reactor converts DEF into ammonia (NH3) through hydrolysis.
2013 Multi-Module Aftertreatment
![Page 12: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/12.jpg)
Aftertreatment Video
![Page 13: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/13.jpg)
System Component Responsibilities
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
Cummins 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
![Page 14: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/14.jpg)
DEF
Doser
EGR-COOLER
CH
AR
GE
AIR
CO
OL
ER
DEF TankDEF
Mixer
dP+P
CM 2350 with AT Controls
+
DEF Doser Controls
NH
3
= Change from 2010
NO
x
Cyclone Mixer
(end inlet
SCR)
SM
Air Throttle
NO
x
DOC DPF
SCR Catalyst
SC
R 1
SC
R 2
AMOX
2013 MR System Architecture
![Page 15: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/15.jpg)
2016 MR System Architecture
DEF Quality Sensor• New component added to the DEF
Tank Header Assembly• Supplied by OEM• Smart component (datalink)
NH
3
TSB150203 & TSB150152 for reference
Particulate Matter Sensor• Supplied by Cummins• SCR sensor table changes as part of
this additional component
![Page 16: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/16.jpg)
Particulate Matter (PM) Sensor
![Page 17: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/17.jpg)
2010 - 2016 DEF System Architecture
17
Tank
Pressure Line
Level Sensor
Dosing Module
Return LineSuction Line
Tank Heater Valve Tank
Valve
Pressure SensorPump
Main Filter
![Page 18: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/18.jpg)
Filter
Cap
Supply Port (to DEF
Dosing Valve)
1. Fitting, Connector
2. O-ring (serviceable)
DEF Filter Kit
1. O-ring
2. Filter
3. O-ring
4. Equalizing Element
Return Port (To Tank)
1. Fitting, Connector
2. O-ring (serviceable)
Inlet Port (From Tank)
1. Fitting, Connector
2. O-ring (serviceable)
Electrical
Connector
2010 - 2016 Bosch DEF Dosing Unit
![Page 19: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/19.jpg)
• Tank Filter: 40 or 100 micron depending on equipment year
• 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
Filtration Points in DEF Circuit
![Page 20: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/20.jpg)
Troubleshooting Steps
DO NOT use INSITE for troubleshooting steps
• Troubleshooting steps within INSITE are not updated as regularly as other sources
DO use QSOL for troubleshooting steps
• Campaign notifications
• Fault Code Analyzer
•Updated regularly
![Page 21: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/21.jpg)
Service and Support
![Page 22: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/22.jpg)
Unmatched Service
& Support NetworkWith 24/7 support in over 225 locations across North America, the Cummins service network is the most extensive in the industry.
![Page 23: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/23.jpg)
Cummins Care
Self Service “I found it on my own”
Level 1 Answer is published
Level 2 Answer is available
Level 3 Answer is a
mystery
Cummins Care is not a typical call center. We are a solutions
center helping to prevent issues and provide answers quickly.
Phone
Text
Text
Cumminsengines.com/urban-bus-shuttleCumminsengines.com is your one stop-shop
for high lever service, product, literature and
support information. The On-Highway, Urban
Bus & Shuttle section provides more specific
information for transit and shuttle bus
applications.
We are here to make the lives of our customers easier by providing
a seamless support experience.
We help prevent issues, answer quickly, provide solutions
![Page 24: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/24.jpg)
24
CAPABILITIES ACROSS
APPLICATIONS
ONE CENTURYOF POWERTRAIN
FOCUS
POWERTRAINOF
CHOICE
The Cummins difference
![Page 25: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/25.jpg)
TITLE OF PRESENTATION I 25
Houston Metro
![Page 26: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/26.jpg)
Metro Facts
Houston METRO currently operates 1,236 buses. METRO is currently purchasing compressed natural gas (CNG) and clean diesel buses.
Currently, Houston METRO operates 930 Clean Diesel buses.
26
![Page 27: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/27.jpg)
System Preventive Maintenance Cummins Clean Diesel Preventive Maintenance:
ISBo DPF replacement with swing unit – 5000 hourso EGR components and port cleaning – 5000 hourso Replace Differential Pressure Sensor – 5000 hourso Minor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)
ISLo DPF replacement with swing unit – 5000 hourso EGR components and port cleaning – 5000 hourso Replace Differential Pressure Sensor – 5000 hourso Minor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)
ISXo DPF replacement with swing unit – 5000 hourso EGR components and port cleaning – 5000 hourso Replace Differential Pressure Sensor – 5000 hourso Minor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)
27
![Page 28: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/28.jpg)
Current Common Issues
Dosing valve plugging when battery switch is turned off too quickly
Picture of plugged dosing valve
![Page 29: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/29.jpg)
Resolved Common Issues
Dirty EGR components and ports have been remedied with 5k hour cleaning
Frequent DPF soot loading has been remedied with 5k hour replacement of DPF with cleaned swing units
Frequent DPF soot loading has been addressed with programmed “0” mph regens on non-SCR aftertreatment systems
29
![Page 30: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/30.jpg)
Service Procedures
5k hour DPF replacement
5K hour EGR component / port cleaning
5k hour dosing unit filter replacement
5k / 10K hour Tune Up
30
![Page 31: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/31.jpg)
Steps of the DPF pneumatic cleaning, vacuum testing, and/or baking and retesting (with pictures)
Service ProceduresDPF Cleaning Procedures:
![Page 32: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/32.jpg)
TITLE OF PRESENTATION I 32
RTD Denver
![Page 33: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/33.jpg)
33
• Cold Side EGR Valve
• Very poor duty cycle
• Frequent Plugging of EGR and DPF
• 96000 mile EGR CCO
• Hot Side EGR valve
• Highway duty cycle
• Less plugging of EGR & DPF, causes intermittent problems
• 150000 mile EGR CCO
RTD Facts
![Page 34: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/34.jpg)
Common Failures
34EGR related components on both a ISL9 and ISX12
![Page 35: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/35.jpg)
Typical Repairs
35
ISL9 Intake Horn
ISX12 EGR Valve
![Page 36: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/36.jpg)
Logical Troubleshooting Steps
36
Light
ISL 9 EGR Valve and Intake Horn Bottom View
![Page 37: Diesel Aftertreatment Systems · 2019-12-10 · Aftertreatment DEF Controller and Line Heater Controls (CES to integrate w/ OEM) Aftertreatment DEF Dosing Valve Delta Pressure Sensor,](https://reader030.vdocuments.site/reader030/viewer/2022040303/5e9268bf9aaa5e6691450340/html5/thumbnails/37.jpg)
TITLE OF PRESENTATION I 37
Summary