Injector Performance Testing Implementation for Industrial

-- Cummins Confidential -- 23

Agenda

Background of IPT

Current Status and Ongoing Testing

Proposed path to implementation

Open Discussion

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-- Cummins Confidential -- 24

What is the Injector Performance Test?

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The Injector Performance Test (IPT) is a service event

approach where an unloaded engine is revved up

near hi-idle, the IMV is shut, and a full injector cutout

is enabled.

While the engine 'free' decelerates a single injector

fires a specified number of times and rail pressure

data is collected.

With a series of decelerations, all six injectors can be

evaluated at multiple fueling levels.

-- Cummins Confidential -- 25

Injector Performance Test –Motivation

Injector TNF

– We Presently Lack Robust In-Shop Injector Evaluations

IPT has demonstrated its importance to Injector

troubleshooting with ISX 12/15 2010, and recently

launched on ISX 12/15 2013, and ISL 2013.

The Matter Is Important To:

– The Customer: Repeat Service Events, $$$

– The Shop/Technician: Reduces Guesswork

– Cummins Inc.: Warranty $

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-- Cummins Confidential -- 26

Cummins Confidential Restricted 26

Data log of IPT Running 4 Points For 1 Cylinder

-- Cummins Confidential -- 27

Industrial Implementation

Wide array of Industrial applications poses a

challenge for ensuring we are capable of the test

Fully expect there may be some applications where it

isn’t possible to be able to complete this test

Need to protect for risk of causing damage to

machines by running the test

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-- Cummins Confidential -- 28

Proposed Path to Implementation

Generic Calibrations

– Any range of applications could use these

– For now, disable the test in these calibrations

Custom Calibration Development

– Team has assembled IQA test procedure to do initial testing

on IPT

Future

– Depending on testing – answer whether there is anything

more we can do to better automate when/whether the test

runs or not

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QSB6.7 Fuel Lines

Aaron Motz

24 March 2014

-- Cummins Confidential -- 68

At-Risk Engines

Check ESN against provided ESN list

If engine is on provided ESN list:

1. Replace all 8 high pressure fuel lines (see Fuel Line

Replacement Instruction)

2. Test engine for leaks (see Post Replacement Test

Instruction)

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-- Cummins Confidential -- 69

Replacement Instructions

Obtain (8) new fuel lines (see Affected Part

Numbers)

Remove (2) pump-to-rail lines (006-071 QSOL)

Remove (6) rail-to-injector lines (006-024 QSOL)

Install (8) new fuel lines with extra care to:

– Hand tighten prior to final torque

– Snug to 20 Nm prior to final torque

– Ensure lines are aligned (see Reference Pictures)

prior to final torque

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-- Cummins Confidential -- 70

Finishing Steps

Engine in Chassis

– Run engine until coolant reaches nominal temperature

– Perform INSITE Fuel System Leakage Test from the ECM

Diagnostic Tests screen.

– Shut engine off

– Inspect for fuel leak

Loose Engine

– Perform Engine in Chassis testing once engine is installed.

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-- Cummins Confidential -- 71

APPENDIX

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-- Cummins Confidential -- 72

Affected Part Numbers

Rail-to-HPC Lines

– 5306260

– 5306261

– 5306262

– 5306263

– 5306264

– 5306265

Cummins Confidential

Pump-to-Rail Lines

Fuel Plumbing Option FT 9473:

– 5306256

– 5306257

Fuel Plumbing Option FT 9474:

– 5306258

– 5306259

-- Cummins Confidential -- 73

Reference Pictures

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Above:

– Tube to be centered

in the tube nut hole

Right:

– Tube to be

perpendicular to the

fuel rail

LMFO Turbo Cal Mismatch

Richard Bodor, Parts & Service

25 March 2014

-- Cummins Confidential -- 75

Problem Statement

LMFO QSB6.7 engines built before 6 December

2013:

– Cal code was common for HMRO/LMFO

– When 32.11.11 released, cal split to separate HMRO/LMFO

– When updating, ensure correct cal is used for LMFO (slide 4)

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ER80010.04

HMRO/LMFO

ER80010.06

HMRO (CCW)

ER80037.03

LMFO (CW)

32.06 LP cals 32.11.11 LP Upfit cals

-- Cummins Confidential -- 76

Symptoms

No Fault Code!

Decreased power output

Decreased turbocharger boost pressure

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-- Cummins Confidential -- 77

Solution

When updating select correct code for HMRO/LMFO

If you already updated with the wrong cal:

– Reflash with correct cal

– Reflash VGTA with correct orientation

– Perform INSITE install/calibrate procedure in ECM

Diagnostic Tests

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Plant-Shipped SC Upfit LMFO Cal Upfit HMRO Cal

SC99712 ER80028.03 (12V)

ER80029.03 (24V)

ER80001.08 (12V)

ER80002.07 (24V)

SC99713 ER80030.03 (12V)

ER80031.03 (24V)

ER80005.08 (12V)

ER80006.06 (24V)

SC99764 ER80042.03 (12V)

ER80043.03 (24V)

ER80015.07 (12V)

Er80016.06 (24V)

SC99761 ER80054.02 (12V)

ER80055.02 (24V)

ER80056.02 (12V)

ER80057.02 (24V)

SC99716 ER80037.03 (24V) ER80010.06 (24V)