Tier 4 Maintenance & Troubleshooting Workshop 

 

The Rental Show 

February 20, 2016

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ARA: Tier 4 Final Workshop

Andy Dick

Abhishek Manekar

Logan Fleeharty

Paul Hartstirn

February 20, 2016 – Atlanta, GeorgiaPublic

Power Generation

Engines

Agenda Tier 4 background Maintenance

– Issues– Best practices

DEF (Diesel Exhaust Fluid)– Lamps– Exhaust system cleaning– Operator interface

Fault Codes Resources

– Apps– Websites

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US EPA Mobile Off Highway Regulations

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• Engine systems

• Fuel

• Cooling

• Exhaust

• Lubrication

• Electronic wiring

• Machine dashboard

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Maintenance Follow the maintenance guidelines for the engine!

– Tier 4 Final maintenance may not be the same as earlier “tiered” equipment

– Refer to your• Operation and Maintenance Manuals

• QuickServe Online website

• Local certified repair facility

Don’t forget the basics– Drain water from fuel/water separator

– Change oil on time, with the correct grade4Public

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Maintenance (Continued)

A special note on air filter maintenance– Helpful hints

• Don’t over-service – wait for maintenance minder

• Square air filters - wipe out the housing with a damp rag

Best practice is to use genuine Cummins filters/parts– Some filters are only available through Cummins

Filtration/Fleetguard

– Not all aftermarket filters meet the specifications for the engine!

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DEF System How do I know if the DEF system is contaminated?

– Fault code(s)– Visual – dirt/debris, discolored, oil floating on top

Cleanup of DEF system (coolant, hydraulic oil, fuel, windshield washer fluid, dirt, etc)

– Recommend to contact your nearby Cummins service location

Common issues– Running out of DEF– Dirt in DEF – E-stops– Inhibit switch– Battery disconnect switches

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DEF System Best Practices

Refill DEF before 10% level

Follow DEF system procedures

Exhaust system cleaning inhibit switch

– Make sure it is not inhibiting system cleaning

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Wiring Issues Simple checks you can make

– Continuity

– Wiggle test

– Sensor swap

– Parallel gauge test

Common issues– Corrosion

– Broken wires

– Ground circuit

– Wrong (too big) electrical connector test kits/leads8Public

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Lamps Yellow lamp means take action now

– There may be a derate or impending shutdown• Can be avoided by taking action

Red lamp means it may be too late– A derate will be severe– May include a shutdown or idle only– May require a field service visit with electronic tools

Is there another lamp on?– Exhaust system cleaning– DEF lamp– Other lamps

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Operator Interface

Start SCR Cleaning

HEST Lamp

STOP Engine

Check Engine

Inhibit SCR Cleaning

DEF Level Lamp

Cleaning inhibited, most severe

Cleaning inhibited, least severe

Information Only–no action required unless operating in heat sensitive area

Activates a manual SCR Cleaning when pushed

Inhibits SCR Cleaning when manually selected by operator Provides notification when DEF needs to be added.

AFT Lamp SCR System Cleaning required

(Solid- Action needed, blinking –action taken)

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Exhaust System Cleaning Manual

– Active non-mission (activated by operator)

Automatic– Passive or active (activated by the engine’s electronic

control module – ECM)

Inhibit – Inhibit does not improve anything

• May cause problems

• Only used where higher exhaust temperatures pose a risk

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Exhaust System Cleaning (Continued)

When should cleaning be performed?– ECM calculates appropriate time to clean based on the length of time engine has

been operating and its duty cycle

– Not needed before unit goes on rent

– After some service events a manual cleaning may be required

How does the engine perform cleaning?– Increases exhaust temperature (less than with DPF cleaning) with

• Intake air throttle (Cummins Power Generation)

• Variable geometry turbo

• Fuel dosing on exhaust stroke

What is being cleaned?– Residual deposits (if any) left from normal machine operation

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Fault Codes Fault codes

– Electronic control module detection

– How to figure out what they mean• SPN/FMI → Cummins fault code

– Suspect Parameter Number/Failure Mode Identifier

• Cummins Power Generation units will have a fault code manual

– Where to get help• Cummins QuickServe OnLine (service info website)

• Cummins dealer or distributor

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Two Key Mobile Device Apps

Tier 4 Operator Guide Quickserve Online Mobile

• Both apps are available free of charge

• Apps require no passwords

• Many functions within the apps require internet access

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Mobile App Features Tier 4 Operator Guide contains the below information for Cummins Tier 4 engines

– Exhaust system cleaning lamps

– DEF lamps

– Exhaust system cleaning switch

– Tier 4 Final service Info

Contains specific information for each individual engine

– Tier 4 Final product details

Contains specific information for each individual engine

– DEF calculator

– DEF locator

Quickserve Online Mobile provides– Engine dataplate

– Cummins Fault Code Analyzer (not SPN/FMI → Cummins fault code translator)

– ESN specific parts manual

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Why Use Mobile Device Apps?

Provide access points to Cummins Tier 4 Final Information

Apps can be downloaded by employees and customers

Material will help individuals be more effective in assisting employees and customers with Cummins Tier 4 Final questions

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The Tier 4 Operator Guide and Quickserve Online Mobile are both available on Apple I Tunes App Store

– Cummins Tier 4 Resource App

– Quickservemobile

Both apps are ready to be used once downloaded onto your device

– No Passwords required to access these apps

Download & Installation (Apple)

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The Tier 4 Operator Guide and Quickserve Online Mobile are both available on the Google Play App Store

– Cummins Tier 4 Resource App

– Quickservemobile

Both apps are ready to be used once downloaded onto your device

– No Passwords required to access these apps

Download & Installation (Android)

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Customer Resources QuickServe Online (QSOL) - repair resources and

manuals1,2

– https://quickserve.cummins.com/

General customer questions – Engine: 1-800-DIESELS

– Power Generation: 1-800-888-6626

Generator set application and specification sheets1

– https://powersuite.cummins.com

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1Registration required2Limited access to service information for end users

Wrap-Up

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Follow published maintenance guidelines

Start troubleshooting with the basics

Use available resources

Stop by booth 4517– See Tier 4 Final products on display

– Learn more details about Tier 4 products

– Learn about Cummins telematics

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Appendix – More Information

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Cummins Booth Location

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Come say “hey” to us at booth 4517

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Appendix – Telematics

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Cummins Connected Solutions

Solutions which

–Connect a Cummins electronic engine through telematics

• to Cummins expertise

• for remote data and information sharing between the engine system, Cummins and the customer

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Connected Diagnostics

Software-only application which

– Uses engine system data transmitted through a connected telematics device

– Instantly diagnoses and sends detailed information and expert recommendations about urgent fault codes

• Sent to the operator, fleet management or anywhere

Operators and Fleet Managers are now

empowered to make in mission decisions

on what to do during a fault

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Appendix – DPF Regeneration

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DPF Regeneration Basics When should a regeneration be performed?

– ECM calculates appropriate time to regenerate based on the soot load of the DPF (back pressure in the DPF)

How does the engine perform a regeneration?– Increases exhaust temperature with:

• Intake air throttle (Cummins Power Generation)

• Variable geometry turbo

• Fuel dosing on exhaust stroke

• Increased exhaust flow

What is a regen doing?– Remove the soot build up in the DPF

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Appendix – Website Registrations

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Registrationfor additionalresources

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Power Suite: https://powersuite.cummins.com

QSOL: https://quickserve.cummins.com/

Appendix – How to Find Cummins

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How to Find a Cummins Distributor http://www.cummins.com

• Then, select “Service Locator”

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Click the Support drop down menu

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How to Find a Cummins Distributor

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1 - Check the box Cummins Distributor Locations

2 - Enter your location 3 – Click on Search button at bottom of page

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How to Find a Cummins Distributor Distributor locations are flagged

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