1. Off-Highway Diagnostic Improvement Project
Rev. 1 – Revised slides are marked
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2. Agenda Background of the Diagnostic Improvement Project
Major Classifications for Changes
OEM / Customer Impact Overview
Improvement Schedule
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3. Diagnostic Improvement Group (DIG) Team Deliverables
Objective:
Re-design diagnostics to provide meaningful operator communication of needed repair action
Maximize customer uptime
Drive appropriate customer response
Ensures correct repair action
Meet legislative requirements
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4. Major Classifications of Changes
Lamp Changes
Tuning Changes
Accommodation Changes
DEF Lamp Changes
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5. Lamp Definition Strategy
Amber Warning Lamp: Equipment can be used to the end of shift. Arrange service.
Red Warning Lamp: Stop equipment now
Flashing AWL: Operator able maintenance Operator can perform some action without
special tools to fix the issue
Flashing
DEF Lamp Solid: DEF tank level is low or DEF quality is low or DEF/SCR system related malfunction occurred.
Leads to 25% or 50% torque derates over time (3.5 hrs)
Flashing DEF lamp: Final Inducement after 30 minutes (Engine locks to idle or shutdown depending on OEM desired response)
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6. Lamp Changes
Change the definition of what lamp to turn on when the ECM detects an issue.
Amber Warning Lamp (AWL) to No Lamp
Amber Warning Lamp (AWL) to Maintenance Lamp
Red Lamp to Amber Warning Lamp
These changes will cause a new fault code number to be used (but maybe the same SPN/FMI)
Lamp, J1939 SPN/FMI make up a unique Cummins fault code
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7. Impact of Lamp Changes
When a fault is moved to a no lamp condition, the fault’s SPN/FMI no longer shows up in the DM1 message on J1939.
The fault is still recorded in the ECM and is available upon request via the DM53 message on J1939
So the fault code is still available for servicing events but does not interrupt the operator. It is still available on the J1939 datalink but under a different message (DM53).
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8. Accommodation Change
Definition: Accommodation means the ECM turns off the EGR or SCR or HC dosing. Turning off EGR or SCR means the engine will go to a 25% derate. This is required by law because an emissions control device is being modified.
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9. Accommodation Change
Minimizing the number of diagnostics that force the system into an accommodation is an improvement for the customer because torque is not reduced as often.
Insert Data Classification

10. Tuning Changes
Tuning changes include actions to make sure the fault condition is actually occurring and not intermittent before indicating we have an issue.
We may take more time to determine that a system or component is truly in error.
These changes lead to less false faults
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11. Tampering Improvement
When a fault is considered tampering, the engine will eventually lock itself on idle (or shutdown if specified by the OEM) after 4 hours.
Moving a Fault Diagnostic out of the tampering list means the engine does not get locked on idle or shutdown.
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12. DEF Lamp Changes
Improve consistency of lamp activity with the meaning to the operator.
When the DEF lamp flashes, you are 30 minutes away from entering final inducement (lock to idle or shutdown).
Allows operator to take appropriate action for the given job, machine, etc..
When the AWL (Yellow) lamp is on and the DEF lamp is on solid, you have a problem with your aftertreatment subsystem and you will experience derates in power.
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13. Low DEF Warning and Inducement 10% reserve not shown on gauge
Off-Highway, Tank Level Inducement - Current
DEF (Urea) Gauge
Notification*
Inducement
Deactivate
Warning or
10% reserve not shown on gauge
Lamp
Fault
>10% full
None
Stage 1
Minimum 10% full
DEF lamp solid
FC 3497
Fill DEF tank to a minimum of 2.5% above stage 1
Stage 2
Minimum 5% full
DEF lamp flashing
FC 3498
Fill DEF tank to a minimum of 2.5% above stage 2
Stage 3
From minimum of 2.5% to before tank is empty
Amber warning lamp solid
FC 1673 and 3714 / 4863 (optional)
25% torque derate and optional speed derate
Fill DEF tank to a minimum of 2.5% above stage 3
Stage 4 0%
FC3547 and 3714 / 4863 (optional)
50% torque derate and optional speed derate
Fill DEF tank to a minimum of 2.5% above 2% level and system is able to prime
Stage 5
Stage 4 detection + 30 mins
Red lamp solid
FC 3547 and FC 3712
Final inducement
Fill DEF tank to a minimum of 2.5% above stage 4 and system is able to prime
Do we need to include SPN 5246 which tells the inducement level
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14. Low DEF Warning and Inducement 10% reserve not shown on gauge
Off-Highway, Tank Level Inducement - Proposed
DEF (Urea) Gauge
Notification*
Inducement
Deactivate
Warning or
10% reserve not shown on gauge
Lamp
Fault
>10% full
None
Stage 1
Minimum 10% full
DEF lamp solid
Maintenance
FC 3497
Fill DEF tank to a minimum of 2.5% above stage 1
Stage 3
From minimum of 2.5% to before tank is empty
Amber warning lamp solid
FC 3498 and 3714 /
4863 (optional)
25% torque derate and optional speed derate
Fill DEF tank to a minimum of 2.5% above stage 3
Stage 4 0%
DEF lamp flashing
FC1673, FC3547 and 3714 / (optional)
50% torque derate and optional speed derate
Fill DEF tank to a minimum of 2.5% above 2% level and system is able to prime
Stage 5
Stage 4 detection + 30 mins
Red lamp solid
FC 3547 and FC 3712
Final inducement
Fill DEF tank to a minimum of 2.5% above stage 4 and system is able to prime
Do we need to include SPN 5246 which tells the inducement level
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15. Industrial Tier4 Final -Tampering/Malfunction Inducement Strategy
Off-Highway, Tampering Inducement - Current
AECD #13-4
Industrial Tier4 Final -Tampering/Malfunction Inducement Strategy
Inducement
None
Warning1
Warning2 1
Initial2
Secondary2
Final2
X1 hrs
X2 hrs
X3 hrs
X4 hrs
Red Stop On
FC 3712
Amber Warning
Off
Solid
FC for failure leading to Tampering/Malfunction
FC 3714
FC 3714
4 hours
3x30mins override allowed
Engine Start
Detected
FC = Fault Code
Notes
1 The signal can be used for visual or audible alarm by OEM
2 Derate is ramped in 5 minutes.
*Warning/FC will be turned on at least 2 minutes before the inducement
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16. Off-Highway, Tampering Inducement - Proposed
AECD #13-4
UPDATED SLIDE
Cummins Internal Use Only

17. Off-Highway, Quality Inducement - Current
AECD #13-4
ADDED SLIDE
Cummins Internal Use Only

18. Off-Highway, Quality Inducement - Proposed
AECD #13-4
UPDATED SLIDE
Cummins Internal Use Only

19. Roll out strategy
New DOs will be created which will have the new software / tuning / improvements.
This allows AEs and OEMs to work together to control when the improvements are rolled out to their product line.
Recommend OEMs have new PN to help manage integration.
This is only really critical if the machine is impacted by the calibration change and the OEM pulls engines randomly from stock.
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20. Checkout procedure
DEF Lamp Strategy – Level test only (AEB Attachment D) – Required
Line Heater Tampering – line heater “failure” in warm ambient should not be considered tampering
Provided but not required
One fault that changes from AWL to no lamp
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21. Software Phases Impacted
PXX.XX.XX.XX numbers are software phases as they would show up in Calterm or Field Calterm
The HEX number is shown in Insite
QSF3.8: P , 20020F00 (HEX)
QSB4.5/QSB6.7/QSL9: Ph , 20000F01 (HEX)
QSG12: Ph , 20030B02 (HEX)
QSX 15: Ph , 20010E01 (HEX)
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22. Impact of this release on Quality
This software release improves ~27% of all occurrences of fault conditions reported within the warranty period through lamps, tuning, or accommodations modifications.
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23. Impact of this release on Quality
The top 25 fault codes account for about half the total warranty occurrences.
This release improves over 50% of the top 25 warranty issues through lamps, tuning, or accommodations modifications.
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24. Impact of this release on Quality
This release improves critical communications to the operator
When you see the DEF lamp by itself go check your DEF system. It is either low or contaminated.
When you see the DEF lamp and the Yellow (AWL) lamp you are or will soon experience a reduction in power.
When the DEF lamp is blinking you will see a further reduction in power and have 30 minutes before you will be locked to idle or shutdown.
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