tier 4 qsk60 ss oem impact presentation - · pdf file(2 per bank) new piston with new rings 4x...

Tier 4 QSK60 SS OEM Impact Presentation

Cummins Confidential – Restricted *All information in this document is preliminary and subject to change

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Cummins Confidential-Restricted

Introduction This purpose of this presentation is to highlight major

product differences between the QSK60 SS Tier 4 Industrial and Locomotive engine and today’s QSK60 SS MOH Tier 2 and Loco Tier 3/SIIIa engine (D593007CX03) – MOH Tier 2 and Loco Tier 3/SIIIa will be referenced as

‘previous emission certified product’ throughout the remainder of this presentation

These changes will likely affect how this engine is integrated into your equipment This presentation, along with the OEM Design Guide,

will help best integrate this Cummins Tier 4 product into your equipment and deliver a world-class product to your customers

NOTE: All references are made with respect to previous emission certified MCRS product


QSK60 Base Engine Architecture - Single Stage

‘4 No More’ turbocharger solution 4x HE800 ‘Low Flow’

New turbocharger support bracket

Revised Turbocharger coolant and oil plumbing

New Exhaust Manifold

Proprietary Fuel Filter Interface

4x CM2350 ECMs (2 per bank)

New Piston with new rings

4x External Wastegates

Revised fuel plumbing

Q60 Style Aftercooler Covers and Air Cross-overs

2200 Bar Bosch Fuel Injector

2200 Bar Bosch Fuel Pump

New Impactor Breather

Revised LTA Plumbing


Cummins Confidential-Restricted Cummins Confidential

Figures in parentheses relate to Q60 previous emission certified product

Base Engine Sub Systems Single Stage initial packaging dimensions

1260mm 50”

(1180mm 46.5”)

1215mm 48”

(1135mm 45”)

2615mm 103”

1560mm/ 61.5”(1510mm/ 59.5mm) Across Aftercoolers

1590mm/ 62.6” Across ECM Guards

800mm 31.5”


QSK60 Tier 4 Loco Design/ Development plan

Unique Loco Options •Unique Loco hardware design integration with MOH engine hardware •Specific Loco Analytical tasks •Specific Loco QAP verification

Tier 4 Required Hardware •Base MOH Design Tier 4 unique components •MOH CPE Pre Alpha engine used for Rating development (Both MOH & Loco) •MOH Unique Tier 4 Analytical tasks •MOH Mech Dev engine QAP Validation testing to verify Tier 4 hardware robustness. •MERGE MOH & LOCO

+


Locomotive Tailored Components: Loco Tier 3 options shown

Reinforced Flywheel housing – FH 6102

Similar to FH 6082 modified brackets to accommodate oil pan

Grade 10.9 capscrews

support, engine (10) 3641779 – E phase support, engine (10) 3641780 – E phase

Eliminator – New LF option required – unique eliminator bracket 3642349 filter,lubricating oil (21-1) - e phase 3642350 bracket,filter (13) - e phase 3642351 piece (10) - e phase 3642352 piece (10) - e phase Prelube PL 6771 off

engine

Oil heaters - OH 6003

Released into config on QGD1611

Unique Architecture QSK60 Loco


Locomotive Fuel System Schematic Loco Tier 3 Config

Locomotive Fuel tanks

Fuel pre filter (FS 6042)

Lift pump (FS 6731)

Deaeration reservoir (FS 6731)

MCRS fuel pump

Stage 1 fuel filters

MCRS fuel system

Customer supplied Customer mounted Cummins Supplied Cummins mounted Cummins remote mounted

Deaeration tank overflow drain to main locomotive fuel tank

Inje

ctor

dr

ain

Unique Architecture QSK60 Loco


Overview – Tier 4 certified QSK60 production start date is 2014 – Will integrate Selective Catalyst Reduction (SCR) exhaust

aftertreatment hardware to meet U.S.EPA Tier 4 Final regulations

Base Engine / Performance – Base engine and MCRS fuel system architecture remains the same – Will continue with existing ratings from 1875 – 3000hp – The engine will continue with 2 pump 2 loop aftercooling – Turbochargers will be external wastegate architecture – Turbos will increase in size over previous emission certified product.

Single stage turbos will be HE 800. – Altitude derate schedule is planned to remain the same as previous

emission certified product levels – Transient response will be the same or better than previous emission

certified product

Fuel Economy – Fuel economy target is to be better than previous emission certified

product – Combined fuel + DEF consumption will be comparable to previous

emission certified product fuel consumption

Platform Overview

Tier 4 Wastegate Valve


Packaging – Engine weight will increase by approximately 100 kg plus

the weight of aftertreatment hardware. – Engine height will increase by approximately 3 inches

and engine width will increase by approximately 2 inches over previous emission certified product.

– SCR will target the muffler space claim and also serve as the silencer.

New customer options will be released with the Tier 4 engine

– Heat shields are being considered for offering as an option at start of production

– An air shut off valve is planned to be provided as a factory option

– To meet Tier 4 regulations non-burn Centinel options will be provided

Service and Durability Impact – Fuel filter change interval targeted at 500 hrs

(improvement over 250 hr previous emission certified product filters)

– The design life of the aftertreatment module is equal to that of the engine

Platform Overview (cont’d)

T4 Aftertreatment


Mechanical Interface Impact

OEM will need to integrate SCR aftertreatment hardware into chassis.

Water inlet and outlet connections remain the same

Fuel inlet and drain connections will remain on intake manifold and fuel pump respectively, although the fuel pump envelope has changed.

Turbocharger inlet and exhaust outlet connections will move vertically upwards by approximately 3-4 inches.

Exhaust collector centerline moved up vertically 75 mm will point inwards at a 45 degree angle from vertical rather than the side and top out arrangement of the existing options

Inlet and exhaust plumbing – Exhaust plumbing sizes are still being evaluated – Exhaust plumbing must be of stainless steel construction

Fuel cooler may be required (depends on tank size and duty cycle)



Fuel Cooler Requirement

Fuel return heat rejection is estimated to be increased for Tier 4 when compared to current product MCRS fuel systems

Refer to the fuel rating datasheet for heat rejection to fuel values

Due to the increased heat rejection, engines operating with a high load factor and small fuel tanks will likely require a fuel cooler

This includes applications such as underground mine trucks, drills, and excavators

AEB 24.07 provides detailed guidelines for fuel cooler design and testing


Five Primary OEM Interface Connectors Base Engine Connectors (Same as previous emission

certified product)

– Signal Connector #1 (Deutsch 31-pin) – Signal Connector #2 (Deutsch 23-pin) – Power Connector (Deutsch 16-pin)

OEM Electrical Interface Connectors Left Bank Rear Base Engine Connectors

(same as T2/ LocoT3/S IIIa)

Right Bank Rear Aftertreatment Connectors

(New for T4)

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New Aftertreatment Connectors for Tier 4

− Signal Connector #3 (Deutsch 47-pin) − Signal Connector #4 (Deutsch 31-pin)

To be connected to these two connections: −Urea quality sensor, ambient air sensor, line heater relay, DEF supply module, SCR temperature sensors, coolant control valve electric heater (if applicable), etc…


Electrical Interface Impact Same as previous emission certified product

– Three OEM chassis connectors and location will remain the same • 16 pin power connector • 23 pin signal connector • 31 pin signal connector

Different from previous emission certified product

– Harness from aftertreatment components to the ECM will be the responsibility of the OEM. • DEF tank heaters • DEF line heaters • DEF temperature sensors • DEF level sensor • NOx sensor • Dosing module

*more details will be provided in the Aftertreatment Requirements AEB


Selective Catalyst Reduction (SCR) Key Features

Exhaust enters SCR module

Integrated DEF doser

SCR Module will replace muffler (sound attenuation target approximately 25 dB)

Exhaust exits SCR module


SCR Aftertreatment

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Preliminary packaging details Model 6000

– 17” x 25” x 70” overall dimensions – 8” inlet & outlet pipe – 470 lbs

Packaging Models are available

All QSK60 ratings will be Tier 4F certified with an SCR catalyst with integrated DEF dosing system (1 / bank).

Preliminary packaging details Model 8000

– 17” x 25” x 85” overall dimensions – 10” inlet & outlet pipe – 660 lbs

Packaging Models are available


Inlet / Outlet Configurations (Under Investigation)

Model 6000 – End-In and End-Out is the only configuration

need identified at this time. – Side-In and End-Out with Inlet currently being

evaluated and designed • 9 O’Clock Inlet position currently being evaluated

– Looking for further input from specific applications

– Development of alternatives would be based on requirement and business case

– Inlet designation described viewing the SCR canister from the exhaust inlet end with dosing module placed at the top.

3 O’Clock Inlet Position

9 O’Clock Inlet Position

Dosing Module location

End in End Out Configuration

Side in End Out Configuration

View Direction


SCR System Component Responsibilities CMI Supplied

SCR Catalyst Assembly SCR inlet and outlet connections DEF (Urea) pump & dosing injector DEF Line Heater Controls NOx Sensors NOx ECUs SCR Temperature Sensors

OEM Supplied Exhaust Piping: Turbo to SCR Tailpipe Assembly DEF Tank Assembly

Tank vent, tank filter, tank drain DEF Heating Related

DEF tank heater DEF line heaters DEF line heater relays Coolant lines to/from DEF tank from engine Coolant lines to/from dosing pump Coolant flow valve

DEF Sensors DEF level, temperature, and quality sensors

Ambient Air Sensor DEF Lines

DEF line from DEF tank to dosing pump DEF line from dosing pump to dosing injector DEF line from dosing injector to DEF tank

DEF Electrical System Wiring Vehicle to Aftertreatment Wiring DEF indicator lamps and gauges SCR and Dosing Pump Mounting

Brackets/Fasteners Insulation of Exhaust Piping (if necessary)


Investigating SCR Canister Mounting Requirements Primary direction is OEM supplied mounting components OEM will have to design mounting system for SCR catalyst and

Dosing Supply Module (DSM) to limit maximum transmitted shock and vibration (May require vibration isolated mounting in some applications)

Studies in progress: – ‘End in-end out’ 6000 Unit adding a mounting bracket to facilitate mounting in

OEM equipment – 8,000 Unit mounting still not decided, most likely a bolted hardware configuration

which will be embedded into the SCR assembly to enable OEM mounting

Allowable canister orientation is a function of the doser orientation (the doser cannot be mounted in a vertically upward orientation)

Dosing Injector

Supply Pump


DEF Issue Detection Requirements Based on preliminary U.S. EPA provided guidance

Three DEF related issues require a machine response to effect operator behavior 1. Empty DEF tank

• DEF tank level sensor broadcasting fault via engine/AT integrated control system

2. Poor Quality DEF • Expected direction is: DEF quality sensor broadcasting fault

via engine/AT integrated control system

3. DEF system tampering • Affected AT system component broadcasting fault via

engine/AT integrated control system


Required Machine Response to DEF Issues Based on preliminary U.S. EPA provided guidance

Operator Warnings – Mandatory to alert operator visually and/or audibly

Operator Inducements – Reduction in engine torque output and/or speed to negatively

influence the vehicle’s operating characteristics – 3 available levels

• Mild Inducement (Optional) – Supplement to Operator Warnings, reduced machine functionality

• Severe Inducement (Mandatory) – Disable primary functionality of machine, but not prohibit mobility

• Proposed – Ultra-Severe Inducement (Optional) – Disable all machine functionality except “limp home” type mobility

Engine Shutdown – Engine stop (Mandatory)

• Also classified as “final inducement”

tier 4 qsk60 ss oem impact presentation - · pdf file(2 per bank) new piston with new rings 4x...

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