Objectives Overview of ISX15 engine emissions strategies Identification of system components Operation of system components Diesel Particulate Filter.

CUMMINS ISX15 ENGINE EMISSIONS TRAINING

Objectives

Overview of ISX15 engine emissions strategies

Identification of system components Operation of system components Diesel Particulate Filter (DPF) functions Selective Catalyst Reduction (SCR)

functions Items the driver/operator will notice with

these installed emission control devices Summary

Overview

The new Rosenbauer 2012 pumpers have the latest 2010 EPA Emission standards Cummins ISX15 14.9 liter 500HP big Block engines. With meeting the current EPA standard, it employs two systems. The first being a Diesel Particulate Filter or DPF. The second system is called Selective Catalytic Reduction or SCR. Both of the systems are addressed on the exhaust side of the engine called after treatment devices or ATD. Why? EPA required over the last several years to reduce Diesel Particulate (DP) matter and nitrogen oxide (NOx) to almost zero, these items are a leading cause of greenhouse gasses.

Identification of System Components

View Cummins Emissions video on Hendersonfireonline.com

DPF Functions

Regeneration Types:

Passive Regeneration-

Active Regeneration-

Passive Regeneration

Occurs when the vehicle’s duty cycle and exhaust temperature drive the continuous oxidation of carbon.

No incremental actions are required by the engine or operator to keep the DPF clean.

This typically occurs when the vehicle is driven at high speeds (i.e., highway speeds) and/or under heavy loads.

Active Regeneration

Required when the duty cycle does not generate enough heat to convert all the carbon being collected in the DPF.

In this case, the Engine Control Module (ECM) initiates an active regeneration by injecting a small amount of Diesel Fuel into the exhaust stream, which generates heat as it enters the DOC.

The additional heat ensures that the excess carbon is oxidized without any operator intervention.

Active regeneration will occur more frequently in vehicles with low speed, low load, or stop and go duty cycles.

Active Regeneration

Active regeneration only occurs if the engine ECM has detected that the after treatment DPF restriction has reached a specified limit, and may only occur if the vehicle is moving above the speed threshold or in pump mode.

The engine ECM will activate and de-activate active regeneration as needed.

The speed threshold for active regeneration to occur is 20 mph.

Note: The Cummins engines are set up to allow an active regeneration while in pump mode.

Active Regeneration

Active regeneration is largely transparent to the vehicle operator.

The operator might notice an increase in turbocharger noise during an active regeneration event, and may notice the high exhaust temperature lamp is illuminated, if the exhaust temp is greater than the high exhaust temperature set threshold.

The high exhaust temperature lamp will illuminate at a speed less than 45 mph at an exhaust temperature between 662 F to 1472 F.

DPF Dash Lamps/Indicators

Indicator Light Bar

Graphic Multifunction

Message Center

Note: Some Indicator Light lamps descriptions may also display in the Graphic Multifunction Message Center. These will have the “Check Message” Lamp illuminated in the Indicator Light Bar to alert operator more information is available in the Message Center.

 High Exhaust System

Temperature (HEST) Lamp

The HEST Lamp illuminates to indicate that high exhaust temperatures may exist due to after-treatment regeneration.

This is normal and does not signify the need for any kind of vehicle or engine service.

When this lamp is illuminated, ensure that the exhaust pipe outlet is not directed at any combustible surface or material.

Illuminated

 After treatment Diesel

Particulate Filter (DPF) Lamp

The After treatment DPF Lamp indicates, when illuminated or flashing, that the after treatment DPF requires regeneration. This is accomplished by the following:

1. Our apparatus is equipped with a Regeneration Inhibit Switch; ensure that the switch is not in the Inhibit position.

2. Perform DPF regeneration by one of the following methods:a. Change to a more challenging duty cycle, such as

highway driving, for at least 20 minutes.ORb. Perform a parked regeneration.

Illuminated

 After treatment Diesel Particulate Filter (DPF) Lamp

If regeneration is not performed in a timely manner after the DPF Lamp is illuminated, the DPF Lamp will begin to flash. This indicates a higher level of soot in the DPF.

a. Change to a more challenging duty cycle, such as highway driving, for at least 20 minutes.

OR

b. Perform a parked regeneration.

Flashing

After treatment Diesel Particulate Filter (DPF) Lamp

Flashing with Warning or Check Engine Lamp

A flashing DPF Lamp combined with an illuminated Warning or Check Engine Lamp indicates that the after treatment DPF needs regeneration immediately.

A parked regeneration is required.

After treatment Diesel Particulate Filter (DPF) Lamp

If a parked regeneration is not performed, the red Stop Engine Lamp will illuminate. The vehicle should be stopped as soon as it is practical and safe to do so. Contact the Fire Shop so they can arrange a tow for repair at an authorized Cummins repair location.

Note: Cummins engines calibrated for emergency vehicle use are programmed to not reduce power or speed due to soot load. However, excessive soot load may impact engine performance and or damage to DPF and engine components.

Stop Engine Lamp

DPF Manual Inhibit Switch

The purpose of this switch is to prevent or disable after treatment DPF regeneration.

Can be used at a scene or in a situation that would cause damage or harm by High Exhaust Temperatures

(Note: when parking be aware of exhaust outlet location proximity to combustible items).

CAUTION: Unnecessary or excessive use of the Regeneration Inhibit Switch will result in an increased need for parked regeneration or may result in the need to service or replace the Cummins Particulate Filter.

How to Perform a Parked (Stationary) Regeneration

Ensure the DPF Lamp is illuminated or flashing: Park the vehicle in an appropriate location.

Preferably on a surface that will NOT burn or melt under high exhaust temperatures (such as clean concrete or gavel, NOT grass or asphalt)

Set the parking brake. Place transmission in Neutral, and allow at least 40

minutes for the regeneration. Set up a safe exhaust area (minimum 2 feet clear of

exhaust outlet). Items that can burn, melt or explode MUST be kept a minimum of 5 feet away from exhaust. Confirm that nothing is on or near the exhaust system surfaces. Ensure that there are no gases or vapors nearby that could burn, explode or contribute to a fire.

How to Perform a Parked (Stationary) Regeneration

Confirm that Compartment #8 Safe Step is in the up (closed) position away from exhaust.

If the Safe Step is

left down during the regeneration process or pump mode, paint damage will occur.

How to Perform a Parked (Stationary) Regeneration

Ensure that your High-idle switch is off before starting regeneration.

How to Perform a Parked (Stationary) Regeneration

Push the red Manual Regeneration switch located below the pump panel shifter assembly to begin a parked regeneration.

Note: Engine speed will increase, and there may be a noticeable change to the sound of the turbocharger during the regeneration process.

How to Perform a Parked (Stationary) Regeneration

Once the Diesel Particulate Filter (DPF) is regenerated, the engine will automatically return to the normal idle speed.

Monitor the vehicle and surrounding area during regeneration. If any unsafe condition occurs, shut off the engine immediately.

To stop a parked regeneration, depress the brake or throttle pedal. Drive away as normal. If after driving the DPF Light is still illuminated, start the parked regeneration procedures again.

Once regeneration is complete, exhaust gas and exhaust surface temperatures will remain elevated for 3 to 5 minutes.

WARNING:

During regeneration, exhaust gas temperature could reach 1500 degrees, and exhaust system surface temperature could exceed 1300 degrees, which is hot enough to ignite or melt common materials, and to burn people.

How to Perform a Parked (Stationary) Regeneration

Note:In vehicle, Cummins DPF placard is located on the underside of the center dash electrical access panel.

Selective Catalytic Reduction (SCR)

Diesel exhaust fluid (DEF) is required for an engine equipped with a SCR system.

Diesel Exhaust Fluid

67.5% de-ionized water and 32.5% urea

May have a slight ammonia smell Is colorless Is non-toxic and non-polluting Is non-flammable Urea is naturally occurring and is

biodegradable.

Diesel Exhaust Fluid

Is corrosive for some metals such as carbon steel, aluminum, copper and zinc.

Do not get the substance in your eyes. In case of contact, flush with large amounts of water for a minimum of 15 minutes. SEE MSDS for additional information.

Avoid prolonged contact with skin. In case of contact, wash immediately with soap and water.

If not washed immediately, when the DEF dries, a white film will be left that can be more difficult to wash off.

If spilled, rinse and clean immediately with water.

Diesel Exhaust Fluid

Has a shelf life of two years. However, this can be reduced if the fluid is exposed to direct sunlight for a long time or if the temperature of the DEF remains above 77°F (25°C) for sustained periods. All DEF packaging should be labeled with the expiration date.

Note: DEF fluid is made mostly of de-ionized water, just a small amount of regular tap water introduced into the DEF tank can cause contamination and malfunctions to the emissions systems. If cleaning funnel prior to filling tank, wash thoroughly to remove any contaminants and then rise with distilled water. If distilled water is unavailable, ensure the funnel is completely dry before using it.

DEF Tank Supplied with the Rosenbauer engine

and is 6 gallons. Located on driver’s side crew cab step-

well behind access door. Should last about two-50 gallon diesel

fuel ups.

DEF Lamps and Gauges

 DEF Lamp

An illuminated DEF is an indication that the DEF level is low (15% remaining). This can be corrected by refilling the DEF tank.

Illuminated

 DEF Lamp

A flashing DEF lamp indicates that the DEF level has fallen below a critical level (10% remaining). This can be corrected by refilling the DEF tank.

Flashing

 DEF Lamp

A flashing DEF Lamp combined with an illuminated Warning or Check Engine Lamp indicates that the DEF level is critically low (5%).

A speed inducement of 55 mph will be enacted the first time the ignition switch is cycled off then back on.

The speed limit of 55 mph will be suspended during pumping operations.

Normal engine power and vehicle speed will be restored after the DEF tank is refilled.

Flashing with Check Engine Light

 DEF Lamp

If the engine has been shut down after the DEF tank has run dry, the Stop Engine lamp will also be illuminated, along with the flashing DEF Lamp and illuminated Warning or Check Engine Lamp.

A speed inducement of 25 mph will be enacted the first time the ignition switch is cycled off then back on.

The speed limit of 25 mph will be suspended during pumping operations.

Normal engine power and vehicle speed will be restored after the DEF tank is refilled.

Stop Engine Lamp, MIL Lamp with flashing DEF and warning Check Engine Lamp

Malfunction Indicator Lamp (MIL)

Used on engines that are equipped with On-board Diagnostics (OBD), the emission control system monitors and reports malfunctions that impact the emission control devices.

If the OBD detects such a malfunction, the on-board diagnostic system illuminates the MIL to indicate that the engine needs to be serviced at the first available opportunity.

The MIL can be illuminated along with any of the engine indicator lamps.

Illuminated

Spartan DEF Level Gauge and Info Center

DEF Level Chart

DEF Supplies and Refilling

The city shop will provide the required amount of DEF after each PM.

If at some point you run low of DEF then call the warehouse to get the required fluid.

Due to the shelf life of DEF, the city shop will give you the minimum amount to get you thru until the next PM.

Refilling of the DEF tank will not be any different than the policy of refueling the diesel tank, when you reach ¾ tank then refill.

Items the Driver Will Notice

After treatment System Under certain conditions (Cold or very

dry), condensation in the form of water vapor can be seen coming from the vehicle tailpipe.

This is normal. It will clear within a few minutes of normal vehicle operation.

Items the Driver Will Notice

Selective Catalytic Reduction (SCR) Specific:

After turning the ignition switch off, A pumping sound may be heard from

underneath the vehicle (can last up to 60 seconds).

This sound is the after treatment DEF dosing unit purging any unused DEF from the system and returning it to the tank.

This is normal.

Items the Driver Will Notice

Engine Sounds

The ISX15 engine is equipped with a feature to warm up the after treatment system under various conditions.

This “Warm Up” feature can cause slight sound changes during idle. These sounds are normal.

The electric-actuated VGT Turbocharger causes the engine sound to vary at different times. This is normal.

A slight turbo whistle may also be observed at idle conditions.

Compression brakes are quieter on engines with after treatment.

Items the Driver Will Notice

Exhaust

After prolonged idle, you may notice momentary white vapor and an odor. This is normal.

When the High Exhaust System Temperature Lamp is illuminated, you may notice an odor.

If the odor is excessive and you also notice white vapor, have the exhaust system inspected for leaks.

Summary

Do not ignore any check engine, DPF, or DEF warning lights.

Regenerate or refill based upon indicator lights to avoid engine damage, power or speed inducements.

For further info, see the manufacturer’s owner’s manual and the following links:

Resource Links

Diesel Particulate Filter for Emergency Vehicleshttp://cumminsengines.com/uploads/docs/4971356.pdf

Driver Tips for Fire & Emergency Vehicles (shows the different DEF derates based on when your engine was built)http://cumminsengines.com/uploads/docs/4971316.pdf

VIDEO: 2010 Cummins Aftertreatment System Overview For Fire Truckshttp://www.youtube.com/playlist?list=PL82D6C0E1AEECBFDB&feature=plcp

Cummins Diesel Particulate Filter Regeneration User InterfaceEmergency Vehicle Calibrated Engineshttp://www.fdsoa.org/2012_apparatus_symposium/cummins_dpf_regens.pdf