1. Off-Highway Diagnostic Improvement Project
Rev. 7 – Revised slides are marked.
Cummins Internal Use Only

2. 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.
Cummins Internal Use Only

3. 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
Cummins Internal Use Only

4. 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)
Cummins Internal Use Only

5. Background Information and Reasoning for Change
Cummins Internal Use Only

6. Agenda Background of the Diagnostic Improvement Project
Major Classifications for Changes
OEM / Customer Impact Overview
Improvement Schedule
Cummins Internal Use Only

7. Diagnostic Improvement Group (DIG team)
Group of “experts” assembled to review all the fault codes across the off-highway HMLD product line (QSF2.8 through QSX15) and determine if we are taking the appropriate level of lamp activity, torque/speed derate, and proper tuning level based on the various architectures used across the off-highway product line and legal requirements.
Cummins Internal Use Only

8. 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
Cummins Internal Use Only

9. Summary of the Fault Codes Covered by the Off-Highway DIG team
Each recommendation
was evaluated for
how long to implement
Reviewed all
700+ fault codes
Cummins Internal Use Only

10. Summary of Diagnostic Recommendations
Cummins Internal Use Only

11. Diagnostic Recommendations were reviewed in
detail as part of the implementation planning
DIG team
Recommendation
Individual Fault Code
Design Team Review
Accept DIG
Recommendation
Modify DIG
Recommendation
Implement
Recommendation
And Provide
Timing
Cummins Internal Use Only

12. Recommended vs Actual Changes
Of the 123 Fault Codes that had short term lamp recommendations only 66 Fault Codes Effected
61 AWL to No Lamp
3 RSL to AWL
2 Removed
11 NC
~10% reduction in fault lamp severity with ~92% of those changes resulting in no lamp at all
Cummins Internal Use Only

13. Major Classifications of Changes
Lamp Changes
Tuning Changes
Accommodation Changes
DEF Lamp Changes
Cummins Internal Use Only

14. Lamp - Definitions Red – Need to stop work immediately
Yellow – Run to the end of the shift
Maintenance – Operator can perform some action without special tools to fix the issue
No Lamp – Fault is used for problem identification and fault isolation by the technician at service interval
Cummins Internal Use Only

15. 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)
Cummins Internal Use Only

16. 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
Cummins Internal Use Only

17. 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).
Cummins Internal Use Only

18. Lamp Changes Recommended vs Actual
Of the 123 Fault Codes that had short term lamp recommendations only 66 Fault Codes Effected
61 AWL to No Lamp
3 RSL to AWL
2 Removed
~10% reduction in overall fault lamp severity with ~92% of those changes resulting in no lamp at all
Cummins Internal Use Only

19. 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.
Cummins Internal Use Only

20. 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.
Cummins Internal Use Only

21. 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.
Cummins Internal Use Only

22. Disable Diagnostic 19 Diagnostics were recommended to be turned off.
These were most often diagnostics required for OBD products that we inherited from the on-highway programs but are not required for off-highway.
Less faults… less possibility of false indications which lead to stopped work.
Cummins Internal Use Only

23. 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
Cummins Internal Use Only

24. 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.
Cummins Internal Use Only

25. Low DEF Warning and Inducement 10% reserve not shown on gauge
Off-Highway, Tank Level Inducement - Current
UPDATED SLIDE
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%
FC1673, 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 1673, FC 3547, FC 3714 and FC 3712/ 4863 (optional)
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
Cummins Internal Use Only

26. Low DEF Warning and Inducement 10% reserve not shown on gauge
Off-Highway, Tank Level Inducement - Proposed
UPDATED SLIDE
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 1673, 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 1673, FC 3547, FC 3714 and FC 3712/ (optional)
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
Cummins Internal Use Only

27. 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
Cummins Confidential

28. Off-Highway, Tampering Inducement - Proposed
AECD #13-4
Cummins Internal Use Only

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

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

31. Inducement Strategy Summary Off-Highway
Cummins Internal Use Only

32. 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.
Cummins Internal Use Only

33. 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.
Cummins Internal Use Only

34. 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.
Cummins Internal Use Only

35. CEAF
The file excel file provided with the CEAF provides the details of specific improvements for each fault code.
Cummins Internal Use Only

36. Task or Milestone Definition
Item
Target End Date ##
Task or Milestone Definition D
Nov. 7
Create Initial communication package for the Application Engineering Community 1
Dec.20
Initial communication of upcoming change to World Wide Application Engineering Community 2
Jan. 30
Create Detailed Communication of Actual Changes and Schedule of Availability 3
Feb. 28
Communicate Detailed Changes to the World Wide Application Engineering Community 4
April 15
OEM Communications 5
OEM Impact Assessment 6
May 15
Create CEAF 7
June 1
Publish CEAF to World Wide Application Engineering Community 8
OEM Planning 9
May 30
Update Test Plans in AEB 27.10 10
Update other AEBs (15.151, , etc…) 11
Declare when OEM test calibration is required to support change 12
May 11
Test Calibrations Available to Support OEM Verification (feedback comments to controls ASAP) 13
Jul. 10
Interface Modification Verification(Controls DR is 6/2) 14
Jun. 30
OEM Change Request Submission 15
New OEM Part Numbers Assigned 16
Jul.10
OEM Change Request Approvals 17
Engine Specification Change 18
Jul. 30
Auditor Communications 19
1-Sep
Ready to Support the Customer's Launch
Cummins Internal Use Only