Cummins Transit Maintenance Forum: Best Practices · Cummins Transit PM Schedule Kilometers x 1000 6 11 22 45 112 146 Miles x 1000 3.5 7 14 28 70 91 Hours 250 500 1000 2000 5000 6500

Cummins Confidential

Cummins Transit

Maintenance Forum:

Best PracticesKyle McDonald

Ryan Vaughn

2

Objectives

At the end of this training we will be

able to:

• In depth look at the Cummins aftertreatment system(s)

• Review maintenance and service best practices

• Review technical service bulletins

• Review active diesel powered transit bus campaigns

Cummins Transit Engine Review

4

Objective

At the end of this section the we will

be able to:

• Understand years of transit technology and innovation

• Understand the specifications, ratings, and warranty

• Understand engine changes between 2013 and 2017

• Identify key components on the L9 engine

5

ONE CENTURY

OF POWERTRAIN

FOCUS

1919 1932

Model H diesel set a transcontinental

bus record time from New York to Los

Angeles in just over 91 hours.

1946 1967

Cummins 220 hp 14-liter flat engine

installed mid-bus to free up space for

increased capacity of up to 97 seats.

1999 20061989

Cummins founded by Clessie

Cummins and W.G. Irwin in a

small garage in Columbus, IN.

First diesel engine design was

the 1.5 to 8 hp HVID.

1000 diesel-electric hybrid transit

buses enter service with Cummins

ISB and ISL hybrid engines.

Beijing Public Transit launches a

fleet of 300 buses with B5.9 natural

gas engines to improve air quality

with positive results.

A Cummins H Series engine powers

the Kaiser Coach with its unique

articulated midsection allowing for a

60ft length and 63 seat capacity.

The Cummins Turbo Diesel releases in

the Dodge Ram 250 and 350 models

transforming the pick-up truck market.

1955

A 300 hp Cummins HRBS-600

pushes the first double decker luxury

coach across US, Mexico, and Cuba.

6

History of Cummins Diesel in Transit

L10

< 1998

M11

2002

ISM

C8.3 ISC

ISL

2007

ISM

ISC

ISL

2010 2013 to Present

ISC8.3

ISL9

ISL9 to L9

Cummins has been the only

powertrain supplier to remain and

provide traditional solutions for the

transit market since 2010.

7ISB ISB ISB6.7 B6.7ISB

ISL ISL9ISL L9

History of Cummins Hybrid in Transit

2001 2004 2007-2010 2010-2017 Present

8

History of Natural Gas in Transit

L10G

< 1998 2002

L Gas Plus

C Gas Plus

2007-2013

ISL G

ISL G

2015

ISL G Near Zero

Present

L9N

9

▪ 2 Years / Unlimited Miles

▪ 100% Coverage for:

– Parts and labor on warrantable failures

– Aftertreatment

– Consumables used in the repair

▪ Limitations:

– Failures of belt(s) and hoses supplied by Cummins are covered

for the first year of the warranty.

– Failures resulting in excessive oil consumption for B series

engines are covered for the duration of the coverage, 100,000

miles (160,935 kilometers) or 7,000 hours, whichever occurs

first.

▪ Extended coverages available

– Check with warranty administrator before starting job / repair

Base Transit Engine Warranty

10

11

▪ Released to fill the gap of the L10 and ISM11

▪ Architecture based of C8.3 / ISC

▪ 20+ Years of Heavy Duty Features

– Wet liner

– Roller followers

– Targeted piston nozzles

▪ 15 Years:

– Variable Geometry Turbocharge (VGT)

– Exhaust Gas Recirculation (EGR)

– High Pressure Common Rail (HPCR)

▪ 10+ Years of Aftertreatment

▪ American designed and globally embraced

Stable Architectural Design

12

Transit Bus Specifications & Ratings

Engine

Model

Power

HP (kW)

Peak Torque

lb-ft (Nm) @ rpm

Diesel Ratings

L9 330 330 (246)1100 (1439)

@ 1300

L9 280 280 (209)900 (1221)

@ 1300

Hybrid Diesel Ratings*

L9 330 330 (246)1100 (1439)

@ 1300

Displacement 543 in3 (8.9 liters)

Number of Cylinders 6

Aspiration Turbocharged CAC

Governed Speed 2600 rpm

Max. Altitude 12000 ft (3658 m)

Engine (Wet) 1770 lb (803 kg)

Engine (Dry) 1695 lb (769 kg)

13

L9 Engine Familiarization1. NOx Sensor

2. VGT Actuator

3. Turbocharger oil supply line

4. Exhaust gas pressure sensor

5. Exhaust gas pressure sensor tube

6. Rocker lever housing

7. Coolant outlet connection

8. Lubricating oil thermostat

9. Coolant temperature sensor

10. EGR cooler coolant

11. Coolant inlet connection

12. Lubricating oil cooler

13. Coolant drain petcock

14. Lubricating oil pressure regulator

15. Lubricating oil filter

16. Lubricating oil pan

17. Engine barring port

18. Flywheel housing

19. Turbocharger oil drain line

20. Exhaust manifold

9

3

11

1317 15

19

18

5

16 14

1

12

4

6

7

8

20

10

2

14

L9 Engine Familiarization1. EGR Valve

2. EGR delta pressure sensor / ports

3. Intake manifold temperature and pressure sensor

4. Fuel rail

5. Fuel rail high-pressure relief valve

6. Fuel drain manifold

7. Crankcase breather oil drain tubes

8. Fuel filter

9. Crankshaft speed sensor

10. Lubricating oil pressure sensor

11. Lubricating dipstick location

12. Fuel lift pump (behind engine control module (ECM))

13. Engine control module

14. Air compressor

15. Gear housing

16. Camshaft speed sensor

17. Engine dataplate

18. Fuel pump

19. Valve cover

7

1 2

12 11

5

3

4

8

19

9

101314

15

16

17

18

6

7

15

L9 Engine Familiarization

1. Coolant outlet connection/Thermostat housing

2. Exhaust gas recirculation (EGR) connection tube

3. Intake throttle actuator

4. Oil fill location

5. Fan hub mounting locations

6. Front gear cover

7. Front engine mount

8. Vibration damper (rubber ot viscous)

9. Automatic belt tensioner

10. Alternator / refrigerant compressor mounting

11. Water pump

12. Turbocharger compressor inlet

13. Turbocharger compressor outlet

14. 1st Stage Fuel Filter

1

5

2

3

4

7

8

9

10

11

13

12

14

6

Cummins AftertreatmentSystem Review

17

Objective

At the end of this section the we will

be able to:

• Understand the 2013 - 2016 aftertreatment architecture

• Identify the components of the aftertreatment.

• Identify PM sensors within the aftertreatment system

• Identify the aftertreatment diesel exhaust fluid systems

18

▪ 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

19

Aftertreatment Video

20

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

21

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)

S

M

Air Throttle

NO

x

DOC DPF

SCR Catalyst

SC

R 1

SC

R 2

AMOX

2013 MR System Architecture

22

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

23

Particulate Matter (PM) Sensor

24

2010 - 2016 DEF System Architecture

24

Tank

Pressure Line

Level Sensor

Dosing Module

Return LineSuction Line

Tank Heater Valve Tank

Valve

Pressure SensorPump

Main Filter

25

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

26

• 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

Service and Maintenance Best Practices

28

Objective

At the end of this section the we will

be able to:

• Understand general routine maintenance schedule

• Understand DPF service maintenance

• Understand DEF dosing pump filter maintenance

• Review potential clean inventory best practice

• Review programmable parameters transit best practice

• Understand best practice to starting troubleshooting

29

Cummins Transit PM ScheduleKilometers x 1000 6 11 22 45 112 146

Miles x 1000 3.5 7 14 28 70 91

Hours 250 500 1000 2000 5000 6500Procedure Step

Air Cleaner Restriction Check X

Charge Air System Check X

Fuel Filter Change X

Batteries* Check X

Lube Oil and Oil Filter Change X

Battery Cables* Check X

Coolant Filter Change X

Coolant Concentration Check X

Radiator Pressure Cap Check X

Cooling System Flush X

Drive Belts Check X

Belt Tensioner Check X

Crankcase Breather Change X

Overall Engine Clean X

Vibration Damper Check X

Radiator Hoses Check X

Air Compressor Lines Check X

Overhead Valve Set Adjust X

Engine Brake Adjust X

Diesel Particulate Filter Clean X

EGR Diff. Pressure Ports Clean X

DEF Dosing Unit Filter Change X

*See equipment manufacturer service information.

30

DPF and EGR Diff Sensor & Port Cleaning

▪ Inspect all INTAKE and EXHAUST CONNECTIONS for LEAKS AT EVERY CHANCE.

▪ Cleaning DPFs:

• Look at hours not miles to maximize uptime due to idle: 5,000 hours

• Requires “Maintenance Reset” in ECM using Insite Software.

• ALWAYS use new exhaust gaskets in DPF and exhaust connections.

• Remove old gasket materials completely from connections.

• Inspect Aftertreatment Inlet for Oil, Coolant, Fuel Contamination.

▪ Cleaning EGR differential sensor and ports:

• Packed or dirty EGR diff sensor and ports can create downstream issues in aftertreatments

• Look at intake air connection for EGR diff port cleaning

31

DEF Pump Filter Maintenance

• DEF dosing unit filter replacement is the second maintenance item for

aftertreatment system.

• DEF dosing unit filter replacement occurs at 6500 hours.

• DEF system both Cummins and OEM require proper clean care

32

Proactive Cleaning & Maintenance Routine

• Aftertreatment issues can be related to upstream component impacts (i.e. excessive carbon packing / soot)

• Proactive exhaust and EGR system component cleaning can support optimal aftertreatment performance

• Establishing a cleaning maintenance routine can support quick maintenance intervals with increased uptime*

• A bus comes in for scheduled aftertreatment service: Dirty parts are removed and clean parts installed in one stop

• Dirty parts then are sent to cleaning stations where they are added back to clean inventory for next service event

Clean Parts Inventory

and InstallDirty Parts Inspection

and Cleaning

SERVICE

*Follow Cummins service requirements and guidelines when inspecting, cleaning, and installing components

For more information, refer to service manual or contact your local Cummins branch representative

33

Aftertreatment Programmable Parameters• Aftertreatment Diesel Particulate Filter programming should be setup to support urban transit bus cycles

• OEM can establish and programming prior to delivery to support bus fleet operations

• Two parameters that should always be ENABLED:

• Automotive Mobile Regeneration at 0 MPH vehicle speed

• Active Regeneration in PTO and Remote Modes

• A feature that was added in 2010 is DPF Temperature Stabilization or “Stay Warm”

• Keeps the DPF “warm” so that the regeneration will not have to completely start over

• Currently up to agency for review, as 0 MPH mobile regeneration will allow low speed idle regeneration

34

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

35

Cummins Care – Message

Cummins Care is not a typical call center. We are a solutions center helping to prevent issues and provide answers quickly.

36

Cummins Care – Strategy

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 and

reimburse fairly.

Self Service

“I found it on my own”

Level 1

Answer is published

Solution in ~5 minutes or escalate

Level 2

Answer is available

Solution in ~24 hours or escalate

Level 3

Answer is a mystery

Solution in <7 days

Technical Service Bulletins Transit BusNOTE: TSBs listed are for reference, please read full TSB in QSOL for all technical information and images prior to starting repairs.

38

2019 Technical Service BulletinsTSB190014 - Damaged Flywheel Housing: Nova Bus ™ Chassis

• Engine(s) – ISL9 CM2350; L9 CM2350; ISLG CM2180; L9N CM2380

• Symptom - Visible crack and/or damage of the flywheel housing

• Root Cause - Overloading of the flywheel housing.

• Verification - Visible crack and/or damage of the flywheel housing at or near the flywheel housing mounting pad location.

• Resolution - Replace existing flywheel housing with new Part Number 5477583.

TSB190040 - Coolant Level Sensors Discontinued on New Production Engines for Transit Bus Applications

• As of 01 January 2019, Cummins Inc. no longer supplies coolant level sensors on new production engines for transit bus applications

• Cummins Inc. will continue to troubleshoot and repair any Cummins® coolant level sensor if the vehicle and or coolant level sensor is still within the specified warranty period.

• Transit bus original equipment manufacturers (OEM) are required to supply their own coolant level sensor for production after 01 January 2019.

• As of 01 January 2019, a single OEM supplied coolant level sensor is monitored with a diagnostic using 30 second slosh delay verses previous diagnostic using two coolant level sensors and 255 second slosh delay.

• Any transit bus engine, excluding natural gas-powered engines, manufactured prior to 01 January 2019, should be equipped with Cummins® supplied coolant level sensors.

• Before troubleshooting coolant level sensor fault codes, such as, but not limited to FC 195, 196, 197, and 2448: Verify coolant level sensor is a genuine Cummins® part See Figures 1 and 2 below.

• If coolant level sensor does not look like coolant level sensor in either Figures 1 and 2, and does not have a Cummins® part number: Contact customer and/or OEM for repair direction and authorization.

TSB190042 - New Vented Coolant Drain Line Kit to Reduce Variable Geometry Turbocharger Actuator Overheating: FC2636 and FC1894

• Engine(s) – ISL9 CM2350; L9 CM2350

• Symptom – STOP ENGINE light with FC2636; Amber lamp with FC1894

• Root Cause – Turbocharger actuator overheating.

• Verification – Active or logged occurrences of fault codes 2636 or 1894; See Table in TSB.

• Resolution – Replace turbocharger actuator vented coolant drain line with corresponding kit.

39

2018 Technical Service BulletinsTSB180042 - Heat Exchanger Mounting Bracket Installation

• Engine(s) – ISL9 CM2350; L9 CM2350; ISLG CM2180; L9N CM2380

• Symptom - Heat exchanger mounting bracket, Part Number 5289017, has gaps when mounted to engine.

• Root Cause - Incorrect initial assembly procedure.

• Verification - Inspect for gaps at heat exchanger mounting bracket mounting points as indicated by Figure 1.

• Resolution - If gaps are identified loosen all mounting cap screws and follow the torque procedure below:

• Torque bottom two mounting screws to 43 N•m [ 32 ft-lb ], working from front to rear of engine.

• Torque top mounting screws to 43 N•m [ 32 ft-lb ], working from front to rear of engine.

TSB180112 - New Rear Crankshaft Seal Service Tools

• Reusable required service tools to be used for rear crankshaft seal service events have been released.

• Existing service practices can damage adjoining components which can lead to repeat malfunctions.

• Advise self-servicing customers that new required re-usable rear crankshaft seal service tools must be used to failsafe installation and removal of rear crankshaft seals in event of leaks moving forward.

• New required service tools are reusable and meant to replace existing disposable service kits. Associated service literature is being published in affected service manuals.

• Centering guide tool must be used with front gear train engines.

TSB180172 - Extended Lubricating Oil Drain Interval

• This document announces an optional 1000 hour lubricating oil drain interval which requires lubricating oil filter, Part Number LF14009.

• Cummins® distributors and dealers are to inform customers of the option to extend lubricating oil drain intervals from 500 hours to 1000 hours.

• Part Number LF14009 and the use of a high quality heavy duty engine lubricating oil, such as Valvoline Premium Blue™, which meets or exceeds Cummins Engineering Standard (CES) 20086 is required for the lubricating oil drain interval extension.

• 1000 hour lubricating oil drain intervals apply only when using ultra low sulfur diesel (ULSD) fuel.

• Adjustments are required for biodiesel or other alternative fuels. Lubricating oil drain intervals for biodiesel blends of B5 and greater are not to exceed 500 hours.

TSB180174 - Fault Code 2375, 2376 or 1867 Caused by Wiring Damage at Exhaust Gas Recirculation (EGR) Temperature Sensor Connector

• Engine(s) – ISL9 CM2350; L9 CM2350

• Symptom - Active or inactive counts of Fault Code 2375, 2376 and/or 1867

• Root Cause - Damaged wiring at EGR temperature sensor connector.

• Verification - If Troubleshooting directs replacement of EGR temperature sensor or engine wiring harness, perform thorough inspection of wiring going in to EGR temperature sensor connector.

• Resolution - If damage to EGR temperature sensor wiring is found, repair with electrical repair connector or electrical repair connector terminal.

Active Diesel Transit Bus CampaignsNOTE: Highly recommended to contact local Cummins branch or Area Manager for Campaign support

41

Campaign 1941ISL CM2350 Product Improvement Campaign for Transit

Applications

▪ Engine recalibration and improved SCR (w/o NH3 sensor) on certain ISL CM2350 L101 engines.

▪ Retroactive coverage approved for repairs made on or after June 15, 2017.

▪ Actions:

• Please refer to Attachment B. A matrix of ECM base codes and CPLs are provided for your consideration.

• New SCRs delete the NH3 Sensor and move from a three (3) wire harness to a NEW two (2) wire harness assembly. Install the appropriate SCR and a new two (2) wire harness assembly.

- Note : Where available, RX parts are to be used to replace the SCR.

• Download the latest calibration available on QuickServe® Online. Recalibrate the ECM as described in Procedure 019-032 in Service Manual 4310787.

• Complete "Label, Authorized Change," Cummins Part Number 5297400. Clearly print or type "ECM Calibration Update" in the center box. Fill in the Campaign Number, Distributor or Dealer Code and Date information. Peel off the backing material and install the label on the engine valve cover near the engine data plate. There is a clear protective cover on this label. Peel the backing off of this cover and push the clear cover over the printed material.

• File one claim for all labor and travel associated with this repair. Provide documentation of the ECM calibration revision codes from before and after the recalibration in the claim narrative.

42

Campaigns 1983 & 1984L9 CM2350 MY2017 & ISL9 CM2350 MY2015-2016

Transit Calibration Campaign

▪ New engine calibration to improve multiple systems to reduce fault occurrences

• EGR fouling

• DEF deposits and O2 sensors diagnostics

• J1939 communication

• Coolant temperature diagnostics

▪ Retroactive coverage approved for repairs made on or after release of campaign (March 28, 2018).

▪ Actions:

• will be covered Regardless of coverage status, and must show as OPEN on QuickServe® Online for this field action.

- Note : See ESN list attached in QSOL for reference.

• After verifying that the engine meets the above requirements, perform the following actions:

• Recalibrate the ECM as described in Procedure 019-032 in Service Bulletin 5411465 ISL9 CM2350. Download the latest

calibration available on Quickserve® Online.

• File claim for labor associated with this repair. Provide documentation of the ECM revision codes from before and after the

recalibration in the claim narrative.

43

Campaigns 2108ISC and ISL CM2250 Transit Emission Recall Campaign▪ This field action authorizes certified repair locations to upfit certain ISC and ISL CM2250 engines with an

improved SCR Catalyst, if the engine meets the criteria listed below.

▪ This field action provides for retroactive coverage of repairs, including customer billable repairs, completed by

Cummins authorized repair locations prior to the release date of this field action.

• Previous repairs may be eligible for reimbursement of ONLY the work defined in this publication.

• Service providers should have invoice documentation of original repair ready for support of the retroactive claim.

• All Service Providers attempting to file claims for retroactive repairs should reference Warranty Memo M1825 for instructions.

▪ Actions:

• will be covered Regardless of coverage status, and

• must show an OPEN status for this field action on QuickServe® Online, and

• For ISC and ISL CM2250 (Model Year 2010 thru 2012 Product) the SCR Part Number must be compared with Attachment B.

- As required, complete "Label, Authorized Change," Cummins Part Number 5297400. Clearly print or type "SCR Catalyst Update" in the

center box.

- As required, an "Emissions Campaign - Proof of Correction" form, Bulletin #4310621, must be filled out and provided to the customer.

Inform the customer to retain this certificate as proof that the Emissions Campaign has been performed.

- File one claim for only the applicable parts and labor listed in this document.

• Any SCR Part Number found in the Affected Part Number Column should be replaced. If the SCR Part Number is not found

in the Affected Part Number Column, the engine is not eligible for this action.

4444

45