Diesel Aftertreatment Systems

Diesel AftertreatmentSystemsDecember 03 2019

ModeratorObed Mejia, Senior Bus EquipmentMaintenance Instructor, LA Metro andVice Chair-Webinars, APTA Bus TechnicalMaintenance CommitteeTITLE OF PRESENTATIONI2

PresentersZigmund (Ziggy) MeluskeyRegional Support ManagerCummins Inc.Ricky MaresManager of MaintenanceTrainingMetropolitan Transit Authorityof Harris County TXTim WallaceTechnical Training InstructorRegional Transportation DistrictDenver, COTITLE OF PRESENTATIONI3

ObjectivesAt the completion of this this webinar, you can expect to come away with:1. Knowledge of system operation2. Preventive maintenance practices3. System troubleshooting and diagnosis tipsTITLE OF PRESENTATIONI4

Cummins IncTITLE OF PRESENTATIONI5

Your TrustedPartner inTransit11/21/2019Public

Agenda0102Cummins Transit Market OverviewThe Power Of Choice03Innovation: Our Electrification Story04Questions

Where We’ve Come FromCharge Air CoolingElectronic Fuel System500 PPMSulfurDiesel Fuel10.7g/HP-hrHPI Fuel SystemEGR & VG TurboParticulate FilterSCR & XPI Fuel SystemOBD0.6g/HP-hr15 PPMULSDDiesel 98819901995200020052010201520200.01g/HP-hr

Cummins Portfolio:Coming in 2019

CumminsAftertreatmentSystem Review

2013 Multi-Module AftertreatmentReduces oxides of nitrogen (NOx) and particulate matter (PM)Achieves near-zero emissions; maintains industry-leading fuel economyDiesel Exhaust Fluid (DEF) usage approximately 3-4% of fuel usage Cummins Selective Catalytic Reduction (SCR)Catalyst Converts NOx into harmless nitrogengas and water vapor. Decomposition Reactor converts DEF intoammonia (NH3) through hydrolysis. Electronic Controls Single Electronic ControlModule (ECM) constantly adjusts engine andaftertreatmentoperations for peakperformance and emissions control. Diesel Exhaust Fluid (DEF) Dosing ValveAllows a fine mist of DEF to be sprayed intothe exhaust stream of the DecompositionReactor.Cummins Particulate Filter Collects andoxidizes carbon to remove PM from theexhaust.

Aftertreatment Video

System Component ResponsibilitiesCummins SuppliedOEM Supplied Standard Cummins Particulate Filter assembly Turbo to CPF Assembly Downpipe Catalyzed filter, DOC elements DEF Tank V-band clamps on 3 modular sections DEF Tank Filter ¼” insulated housing DEF Level Sensor Standard SCR Catalyst Assembly DEF Temperature Sensor SCR, AMOX catalyst elements DEF Tank Heater (CES to integrate w/OEM) ¼” insulated housing DEF Tank Heater Relay/Valve Inlet / Outlet Subassembly DEF Line Heaters Decomposition Pipe w/ 2 Gasketed Marmon Flanges DEF Lines to/from DEF tank to Aftertreatment DEF Dosing Unit Aftertreatment DEF Controller and Line Heater Controls (CES tointegrate w/ OEM) DEF Line from Aftertreatment DEF Dosing Unit to Aftertreatment DEF Dosing Valve 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 Coolant Lines to/from DEF Tank Coolant Lines to/from Doser Nozzle Vehicle to Aftertreatment Wiring Tailpipe Assembly Mounting Brackets/Fasteners

2013 MR System ArchitectureCyclone Mixer(end inletSCR)AMOXCHARGE AIR COOLERDOCDPFEGR-COOLERDEFDoserSCR CatalystSMAir ThrottleCM 2350 with AT Controls DEF Doser ControlsDEFDEF Tank Change from 2010NOxSCR 1NOxMixerSCR 2NH3dP P

NH32016 MR System ArchitectureParticulate Matter Sensor Supplied by Cummins SCR sensor table changes as part ofthis additional componentDEF Quality Sensor New component added to the DEFTank Header Assembly Supplied by OEM Smart component (datalink)TSB150203 & TSB150152 for reference

Particulate Matter (PM) Sensor

2010 - 2016 DEF System ArchitecturePressure LineMain FilterPressure SensorPumpValveSuction LineReturn LineLevel SensorDosingModuleTank Heater Valve17TankTank

2010 - 2016 Bosch DEF Dosing UnitInlet Port (From Tank)1. Fitting, Connector2. O-ring (serviceable)Return Port (To Tank)1. Fitting, Connector2. O-ring (serviceable)ElectricalConnectorFilterCapDEF Filter Kit1. O-ring2. Filter3. O-ring4. Equalizing ElementSupply Port (to DEFDosing Valve)1. Fitting, Connector2. O-ring (serviceable)

Filtration Points in DEF CircuitTank filter 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

Troubleshooting StepsDO NOT use INSITE for troubleshooting steps Troubleshooting steps within INSITE are notupdated as regularly as other sourcesDO use QSOL for troubleshooting steps Campaign notifications Fault Code Analyzer Updated regularly

Service andSupport

Unmatched Service& Support NetworkWith 24/7 support in over 225 locations across North America,the Cummins service network is the most extensive in theindustry.

Cummins CareWe are here to make the lives ofour customers easier by providinga seamless support experience.Cumminsengines.com/urban-bus-shuttleWe help prevent issues, answerquickly, provide solutionsLevel 3Answer is amysteryCumminsengines.com is your one stop-shopfor high lever service, product, literature andsupport information. The On-Highway, UrbanBus & Shuttle section provides more specificinformation for transit and shuttle busapplications.Level 2Answer is availableEmailTextLevel 1Answer is publishedSelf Service“I found it on my own”Cummins Care is not a typical call center. We are a solutionscenter helping to prevent issues and provide answers quickly.PhoneText

The Cummins differenceONE CENTURYOF SAPPLICATIONS24

Houston MetroTITLE OF PRESENTATIONI25

Metro FactsHouston METRO currently operates 1,236 buses. METRO is currently purchasingcompressed natural gas (CNG) and clean diesel buses.Currently, Houston METRO operates 930 Clean Diesel buses.26

System Preventive MaintenanceCummins Clean Diesel Preventive Maintenance:ISBooooDPF replacement with swing unit – 5000 hoursEGR components and port cleaning – 5000 hoursReplace Differential Pressure Sensor – 5000 hoursMinor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)ISLooooDPF replacement with swing unit – 5000 hoursEGR components and port cleaning – 5000 hoursReplace Differential Pressure Sensor – 5000 hoursMinor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)ISXooooDPF replacement with swing unit – 5000 hoursEGR components and port cleaning – 5000 hoursReplace Differential Pressure Sensor – 5000 hoursMinor Tune Up – 5000 hours / Major Tune Up – 10000 hours (turbo/SCR inspection, & injector replacement)27

Current Common IssuesDosing valve plugging when battery switch is turned off too quicklyPicture of plugged dosingvalve

Resolved Common IssuesDirty EGR components and ports have been remedied with 5k hour cleaningFrequent DPF soot loading has been remedied with 5k hour replacement of DPF withcleaned swing unitsFrequent DPF soot loading has been addressed with programmed “0” mph regens on nonSCR aftertreatment systems29

Service Procedures5k hour DPFreplacement5K hour EGRcomponent / portcleaning5k hour dosing unitfilter replacement5k / 10K hour Tune Up30

Service ProceduresDPF Cleaning Procedures:Steps of the DPF pneumatic cleaning, vacuum testing, and/or baking and retesting (withpictures)

RTD DenverTITLE OF PRESENTATIONI32

RTD Facts Cold SideEGR ValveVery poorduty cycleFrequentPlugging ofEGR and DPF96000 mileEGR CCO Hot Side EGRvalveHighway dutycycleLess pluggingof EGR & DPF,causesintermittentproblems150000 mileEGR CCO33

Common FailuresEGR related components on both a ISL9 and ISX1234

Typical RepairsISX12 EGR ValveISL9 Intake Horn35

Logical Troubleshooting StepsISL 9 EGR Valve and Intake Horn Bottom ViewLight36

SummaryTITLE OF PRESENTATIONI37

o Replace Differential Pressure Sensor –5000 hours o Minor Tune Up –5000 hours / Major Tune Up –10000 hours (turbo/SCR inspection, & injector replacement) ISX o DPF replacement with swing unit –5000 hours o EGR components and port cleaning –5000 hours o Replace Differential Pressure Sensor –5000 hours