High Horsepower Tier 4 OEM Design Guide for QSKV Engines · – DEF Line Layout, ......

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High Horsepower Tier 4 OEM Design Guide for QSK60 Locomotive Engine

Cummins

May 20th-2013

Cummins Confidential – Restricted

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Table of Contents

5/21/2013 Cummins Confidential - Restricted 2

Architecture & Block Diagrams

Component Responsibilities

Decomposition Reactor Tube (DRT)

– Overview

– Model Details (Size & Weight)

– Mounting Requirements

• Vibration & Bending Moment Requirements

• Mounting Zones & Support

• Mounting Orientation

– Shielding & Insulation

SCR Unit

– Overview

– Model Details (Size & Weight)

– Inlet / Outlet Configurations


• Vibration & Bending Moment Requirements

• Mounting Zones & Support

• Mounting Orientation

– Shielding & Insulation

– Water Drain

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Table of Contents (Cont.)

DRT and SCR Unit Fluid, Electrical Interfaces

NOx Sensor ECU


– Mounting Dimensions

– Shielding

– Electrical Interface

– Mating Connector

SCR Exhaust Gas Temperature Sensor ECU


– Mounting Dimensions

– Shielding


– Mating Connector

DEF Supply Module

– Overview

– Installation Requirements

• Environmental Constraints

• Vibration Requirements

• Shielding & Insulation

– Mechanical, Fluid, Electrical Interfaces

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Heated DEF Line

– Overview and Requirements

– Installation Requirements

– DEF Line Layout, Pressure Drop Requirements

DEF Tank

– Overview

– DEF Tank Sizing

– Construction Criteria

Coolant Utilized Heating System

– Coolant Line Schematics

– Coolant Pressure Drop thru DEF Supply Module

– Coolant Line Installation Requirements

Exhaust Tubing

– Overview

– DRT and SCR unit inlet/outlet bolted flange details

– Temperature Drop, Leakage Rate

– Exhaust Restriction Proposal

Exhaust Aspirator

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Tier4 Base Engine NUD components


• Connector Layout and Matting Connectors

– Added 47 and 35 pin connectors for Aftertreatment

– Revised 16 pin power connector

– 9 pin Service Diagnostic Connector

• Compressor Inlet Temperature Sensor

• Ambient Air Temperature Sensor

• J1939 Message added for Tier4

Appendices

– Appendix A : Example of Electrical Demand Projection

– Appendix B : DEF Tank Design and Validation

– Appendix C : HHP Engine Data

– Appendix D : DEF Facts

– Appendix E : Component Thermal Limits

– Appendix F : Mounting zone locations and recommended mounting cap screws for SCR unit

– Appendix G : Lifting Requirements and Best Practices for SCR unit

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5/21/2013 Cummins Confidential – Restricted 6

HHP LOCOMOTIVE TIER 4 QSK60 ARCHITECTURE

Option 1 : Coolant-based DEF Tank Heating

SCR

Catalyst

Urea (DEF) Tank

Base Engine

Urea

(DEF)

Line

Heaters

Tank Heater

Coolant Circuit

Urea (DEF) Pump

Turbocharger

with Wastegate

Aftertreatment

NOx NOx

2200bar HPCR

Temp

Temp

Fluid Level

Aft

erc

oo

ler

Air Filter

Urea (DEF) Dosers

DRT

DRT : Decomposition Reactor Tube

SCR : Selective Catalytic Reduction

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SCR System Schematic – Option 1 (Coolant-based DEF Tank Heating)


Red = CMI Supplied

Others = OEM Supplied

DEF Line

Coolant Line

Electrical/Electronic Signal

DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve

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SCR DEF Line Schematic – Option 1 (Coolant-based DEF Tank Heating)

5/21/2013 8

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve


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SCR Coolant Schematic – Option 1 (Coolant-based DEF Tank Heating)

5/21/2013 9

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve


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SCR Wiring Schematic – Option 1 (Coolant-based DEF Tank Heating)

5/21/2013 10

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve


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HHP LOCOMOTIVE TIER 4 QSK60 ARCHITECTURE

Option 2 : Electric-based DEF Tank Heating

SCR

Catalyst

Urea (DEF) Tank

Base Engine

Urea

(DEF)

Line

Heaters

Electrical Tank Heater

Coolant Circuit

Turbocharger

with Wastegate

Aftertreatment

NOx NOx

2200bar HPCR

Temp

Temp

Fluid Level

Aft

erc

oo

ler

Air Filter

DRT

DRT : Decomposition Reactor Tube

SCR : Selective Catalytic Reduction

(+)

(-)

Urea (DEF) Pump

Urea (DEF) Dosers

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SCR System Schematic – Option 2 (Electric-based DEF Tank Heating)

12

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve

Cummins Confidential – Restricted 5/21/2013

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SCR DEF Line Schematic – Option 2 (Electric-based DEF Tank Heating)

5/21/2013 13

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve


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SCR Coolant Schematic – Option 2 (Electric-based DEF Tank Heating)

5/21/2013 14

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve


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SCR Wiring Schematic – Option 2 (Electric-based DEF Tank Heating)

Red = CMI Supplied


DEF Line

Coolant Line


DEF supply module

DEF doser

DEF line heater

Smart sensor

Analog sensor

Control Relay

Control Valve

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SCR System Component Responsibilities

CMI Supplied

SCR Units

DRT Units

DEF (Urea) Supply Modules

DEF (Urea) Dosing Modules

SCR Unit Outlet NOx Sensors

NOx Sensor Electronic Control Units (ECU)

SCR Unit Exhaust Gas Temperature Sensors (EGTS)

EGTS ECUs

OEM Supplied

Exhaust Piping: Exhaust Outlet Collectors to DRTs

Tailpipe Assembly

DEF (Urea) Tank Assembly

Tank Vent, Tank Filter, Tank Drain

DEF (Urea) Sensors

DEF (Urea) Level Sensor

DEF (Urea) Temperature Sensor

DEF (Urea) Quality Sensor

DEF (Urea) Heating Related

DEF (Urea) Tank Heaters

DEF (Urea) Line Heaters

DEF (Urea) Line Heater Relays

DEF(Urea) PTC Dosing module heater relay

Coolant Lines between DEF (Urea) Tank and engine

Coolant Lines to/from DEF Supply Modules

Coolant Flow Control Valves or Relays for DEF tank heaters

DEF (Urea) Lines

DEF (Urea) Line from DEF tank to DEF Supply Modules

DEF (Urea) Line from DEF Supply Module to Dosing Modules

DEF (Urea) Line from Dosing Modules to DEF tank

DEF (Urea) Electrical System Wiring

Vehicle to Aftertreatment Wiring

DEF indicator Lamps and Gauges

DEF Supply Module Mounting Brackets & Fasteners

SCR and DRT Unit Mounting Brackets & Fasteners

Ambient Air Temperature Sensor

Insulation (if necessary)

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DRT (Decomposition Reactor Tube)


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DRT – Overview

The locomotive aftertreatment design will consist of one

decomposition reactor tube (DRT) per engine bank, mounted

directly at SCR inlet

DRT include:

– DEF dosing module (1 per engine bank)

• Unique hydraulic connections

• Unique electrical connections

– 10” inlet and outlet tube, 12-bolt flange at DRT inlet and outlet

– Designated mounting zones

– Mounting bolts and gaskets can be provided as option

The following pages include details of each system described above


DRT

SCR

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Outlet Flange

DRT Model Details

DEF Dosing Module

Inlet Flange

12 Bolt Inlet & Outlet End Flanges

Dimensions : 1193.8 X 254 X 254 (mm)

Estimated weight: 29.5 kg (65 lbs)

Inlet and Outlet Tube Diameter: 10” OD

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DRT Mounting Requirements

Maximum acceptable shock and vibration levels

– Shock : 10.2 G, in all directions at 20 – 2000 Hz frequency

– Vibration : 3.4 gRMS, in all directions at 20 – 2000 Hz frequency

Maximum Bending Moment limits at DRT Inlet and Outlet Tube

– The maximum bending moment exerted on DRT device inlet and outlet tube @ 1 G acceleration

without additional exhaust tube support is 60 N-m. Maximum distance from the inlet or outlet

tube of the DRT device to the nearest exhaust tube support bracket or hanger is 1 m (39.37 in.).

– If the specified limit is exceeded, the bending moments can be reduced by adding additional

tube supports.

Mounting clearance

– The mounting must prevent the DRT from contacting adjacent equipment components during its

entire useful life. The DRT must be mounted such that all outer surfaces on the DRT are at least

25.4 mm (1.0 in) from adjacent chassis components.

– It is recommended that the DRT must be mounted such that the dosing module has a minimum

radial clearance of 41mm (1.6 in.) to permit access for replacement without removal of the

assembly from the chassis.


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DRT Mounting Requirements (cont.)

The DRT outlet flange must be mounted directly to the SCR inlet connection.

The DRT must be mounted using mounting straps around it’s body.

Mounting straps must only be located on the area indicated as “mounting area” as shown in the

diagram below.

– The mounting area must not be covered by thermal insulation wrap or blanket before installation of the

mounting straps.

Clamp pressure from mounting straps must be adequate to retain the DRT without causing visible

deformation of the tube.

The DRT lifting brackets must not be used to mount the DRT to the equipment frame.


813.8 mm

1193.8 mm

194 mm

From Engine

Turbocharger To SCR

63.5 mm

Mounting Zone 1 Mounting Zone 2

lifting bracket

63.5 mm

lifting bracket

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900 900

DRT Mounting Orientation

– DRT mounting orientation must be clocked so that the DEF dosing module is not pointing

upward, as shown in the snapshot below.

– The DRT must be also oriented in a way that the DEF lines and Wiring Harnesses connecting to

the dosing module are routed away from external heat sources, sharp corners and moving parts.

DRT Horizontally Mounted, seen from inlet

DEF Dosing Module

Vertical Position

Maximum Allowable Clocking

(Doser 900 from Vertical)

DRT

Gravity direction

DRT Mounting Requirements (cont.)

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Shielding

– The DRT components require protection from debris

– DRT should be located in spaces that will minimize their vulnerability for damage from debris

and mishandling. Depend on installation, shielding maybe required to protect the dosing

module

Insulation

– Thermal insulation can be added to the external surfaces of the DRT.

– Insulation materials must be able to withstand surface temperatures up to 550 °C (1022 °F).

– Maximum weight of insulation should not exceed xx lbs (xx kg) , xx : TBD

– Components which cannot be covered with thermal insulation:

• DEF dosing module and its wiring harness

• DEF lines

• DRT mounting zones before installation of the mounting straps

– Minimum recommended clearances between insulation and critical component(s) on DRT are

shown in the table below :

DEF Dosing Module

DRT – Shielding and Insulation


Component Min. Recommended Insulation Cutout Size (mm)

DEF Dosing Module TBD

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Selective Catalytic Reduction (SCR)


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The locomotive aftertreatment design will consist of one selective catalytic

reduction (SCR) unit per engine bank.

SCR unit include:

– DEF dosing module (one per SCR)

• Unique hydraulic connections

• Unique electrical connections

– Exhaust Gas Temperature and NOX sensors with J1939 data link message output.

– 10” inlet and outlet tube, 12-bolt flange at exhaust inlet and outlet.

– The SCR unit will have integrated mounting points.



SCR unit - Overview

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SCR Model Details, without Outlet Bolted Flange


• 12 Bolt Inlet Flange

• Side In End Out Configuration

• Dimensions: 1507.9 mm x 784.23 mm x 653.5 mm

• Estimated weight: 302 kg (665.8 lbs)

• Inlet and Outlet Tube Diameter: 10” OD

EGTS ECU

DEF Dosing Module

NOX Sensor ECU

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SCR Model Details, with Outlet Bolted Flange


• 12 Bolt Inlet & Outlet Flange

• Side In End Out configuration

• Dimensions: 1562.7 mm x 784.23 mm x 653.5 mm

• Estimated weight: 311 kg (685 lbs)

• Inlet and Outlet Tube Diameter: 10” OD

NOX Sensor ECU

DEF Dosing Module

EGTS ECU

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The table below shows the different inlet/outlet configurations for the 8000 SCR unit.

SCR Model Inlet Inlet Diameter & Flange Outlet Outlet Diameter & Flange

1 8000 Right Side In 10”, 12-Bolt End Out 10”, 12-Bolt

2 8000 Left Side In 10”, 12-Bolt End Out 10”, 12-Bolt

3 8000 Right Side In 10”, 12-Bolt End Out 10”, N/A

4 8000 Left Side In 10”, 12-Bolt End Out 10”, NA

Inlet / Outlet Configurations


Side In End Out Configuration

Left Side Inlet (9’O Clock)


Right Side Inlet (3’O Clock)


Left Side Inlet (9’O Clock)


Right Side Inlet (3’O Clock)

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SCR unit Mounting Requirements

Maximum acceptable shock and vibration levels in all directions at 20 – 2000 Hz frequency

– Shock : 10.2 G

– Vibration : 3.4 gRMS

Mounting isolation will be required if shock and vibration levels exceed the limitations define above

Maximum Bending Moment limits at SCR Unit Inlet and Outlet Tube

– The following table shown below indicates the maximum bending moment exerted on SCR inlet

and outlet tube @ 1 G acceleration) without additional exhaust tube support is 60 N-m.

Maximum distance from the inlet or outlet tube of the SCR device to the nearest exhaust tube

support bracket or hanger is 1 m (39.37 in.)

The assembly must be mounted to rigid equipment frame members using designated mounting

zones highlighted below on a Side In End Out configuration. Zone dimension is 75 mm X 375 mm.

Please refer Appendix F for details of zone locations

Back Left Right Front

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Constraints at 6 mounting zones on the SCR

SCR unit Mounting Requirements – cont.

Thermal expansion of SCR unit needs to be considered in

designing the mounting features.

– Estimated thermal expansion rate :

X = max TBD mm, Y = max TBD mm

For vertically mounted Side In – End Out SCR, it is

recommended to apply constraints at 6 mounting zones.

The mounting system must prevent the entire exhaust system

from contacting adjacent vehicle components during its entire

useful life. The assembly must be mounted such that all outer

surfaces of the exhaust system are at least 25 mm (1.0 in)

away from adjacent components.

The SCR unit is not designed to be a load-bearing structural

member of the vehicle chassis and must not be used as a

transmission path for static or dynamic loads other than loads

due to components installed as part of the original assembly

delivered from CES.

It is recommended that the SCR unit must be mounted such that the dosing module has a

minimum radial clearance of 41mm (1.6 in.) to permit access for replacement without

removal of the assembly from the chassis.

Lifting requirements are shown in Appendix G

5/21/2013 30 Cummins Confidential – Restricted

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SCR unit Mounting Orientations

Figure-1

Horizontally mounted SIEO

Doser oriented downwards

Figure-3

Vertically Mounted SIEO

Doser oriented sideways

Figure-4

Unacceptable Horizontally mounted SIEO

Doser oriented upwards

Acceptable orientations: Figs 1, 2 & 3

Unacceptable orientations: Fig 4

Figure-2

Vertically Mounted SIEO

Doser oriented sideways

DEF Dosing Module


SCR unit Mounting Requirements – cont.

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Shielding

– The SCR unit components shown below require protection from debris.

– Sensors should be located in spaces that will minimize their vulnerability for damage from debris

and mishandling. Shielding maybe required to prevent damage to the sensors and doser.

– Thermal requirements of components assembled on SCR unit must be considered when designing

protective shielding.

SCR unit Shielding and Insulation

NOX Sensor ECU

DEF Dosing Module

NOx Sensor Outlet temperature

sensor port

NOX Sensor Wiring

SCR EGTS Sensor ECU

SCR EGTS Sensor Wiring

Inlet temperature

sensor probe (900)

Outlet temperature

sensor probe (straight)

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Insulation

– Thermal insulation can be added to the external surfaces of the SCR unit.

– Insulation materials must be able to withstand surface temperatures up to 550 °C (1022 °F).

– Maximum weight of insulation should not exceed 80 lbs (36 kgs)

– Components which cannot be covered with thermal insulation:

• DEF dosing module and its wiring harness

• DEF lines

• Sensors and their wiring harness

• mounting zones before installation of the mounting brackets

– Insulation wrap must have cut-outs around NOX and Temp sensor bosses, Water drain holes

and the used SCR mounting. Minimum recommended clearances between insulation and

critical component(s) on SCR unit are shown in the table.


Component Min. Recommended Insulation Cutout Size (mm)

NOX Sensor Boss 33 mm (1.3 in Diameter)

Temp Sensor Bosses 25.4 mm (1 in Diameter)

Dosing Module TBD

Water Drain Hole TBD

SCR unit Shielding and Insulation – cont.

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SCR unit Water Drain Requirements

Water Drain

– Drain holes are equipped on the SCR unit to assist in draining the rain water and/or the water

ingress during power wash. SCR unit is delivered with all holes plugged.

• Four Drain holes (size 1/8 NPT) are located on outlet side (top and bottom surface) where water or treated

exhaust gas exits the package.

• Depending on installation orientations, two bottom holes can be unplugged and used as drains (See

Figures 1, 2 and 3 on next slide).

– It is recommended to use tubing to connect to the drain holes. All tubing must be properly

supported, routed and connected to the drain holes without interfering with any SCR sub

system components.

• The material used for the drain tubing must be resistant to power wash fluid.

• The drain tubing must be mounted, supported and routed such that all outer surfaces are at least 25.4 mm

(1.0 in) from the SCR unit and adjacent OEM chassis components.

– In addition to drain hole provisions, it is also recommended to the OEM to install rain caps at

the SCR exhaust outlet to prevent any additional water and or/power wash fluid ingress during

normal operation and service events.

– There may be installation cases where tubing may not be used, hence water and/or treated

exhaust gas may escape the drain holes . The SCR unit should be located in such a way that

water and hot exhaust moisture exiting the drain holes do not impinge on heat sensitive

materials.


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SCR unit Water Drain Requirements (cont.)

Fig. 1

Open Drain Holes

Plugged Drain Holes

Fig. 2

Fig. 3


Vertical SIEO installation

Horizontal SIEO installation

Horizontal SIEO installation

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Shown below are interfaces on the dosing module for DEF pressure and return line connectors.

All electrical and hydraulic connectors at the dosing module interface must withstand a direct

connected force of 200N in all directions.

DEF Pressure line (from DEF supply unit to dosing unit) SAE J 2044 1/4"

DEF Return line (from dosing unit to tank) SAE J 2044 5/16“

DRT and SCR unit Fluid Interface

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Dosing Injector OEM Interface Connector

Pin Details

Electrical connector at supply unit Tyco HDSC, 8 Pin, 1.5mm MCP, coding A acc. Tyco number C-114-18740-1, rev. C

Pin 1 Injector

Pin 2 Injector

Pin 3 Heating

Pin 4 Heating

Pin 5 Sensor Supply (5V)

Pin 6 Temperature Signal

Pin 7 Sensor Ground

Pin 8 Pressure Signal

DRT and SCR unit Electrical Interface

Connector Manufacturer Part Number Wire Gauge Quantity

Doser Mating Connector (8-pin) Tyco Connector - 1-1418479-1 16-20 AWG

16AWG

20 AWG

1

Terminal - AMP MCP 1.5K

Contact System 1418885-1

8

Contact System 1241381-3

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NOx Sensor ECU Assembly Mounting • Mounting Requirements for NOx sensor ECU

– The sensor ECU must be remotely mounted by the OEM away from the SCR surface and must be

accessible for replacement without removal of the SCR assembly from the chassis

– The maximum surface temperature at the NOx sensor ECU and the sensor’s electrical connection point

must not exceed 115 ºC (239 ºF).

– The maximum cable temperature of the ECU must not exceed 200 ºC (392 ºF)

– The sensor mount must be able to withstand the limits specified below. The maximum transmitted shock

and vibration levels in all direction at 20 – 2000 Hz frequency are:

• Shock : 10.2 G

• Vibration : 3.4 gRMS

– ECU must be located in spaces that will minimize their vulnerability for damage from debris and

mishandling. Shielding may be required to prevent damage to the sensors. The OEM must follow the

maximum surface and cable temperature requirements for the ECU when designing shielding.

NOx Sensor AssemblyNOx Sensor Assembly

NOX Sensor ECU – The mounting details for the NOx sensor ECU is

shown in figure below

– Torque limits for the NOx Sensor installation is

50 Nm +/- 10 Nm (37 lbs-ft +/- 7.3 lbs-ft)

– NOx sensor ECU must be shielded from debris

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NOx Sensor ECU Electrical Interface

Wiring harness that provides power and ground and J 1939 connections from this ECU to the

ECM will be required.

NOx sensor harness length and voltage:

– Available length : 915 mm (36 in)

– Voltage : 24 VDC

The outgoing cable from the NOx sensor must exit at an angle of 0º ±15 degrees. The permitted

twisting angle of the cable is 180 degrees. The minimum bending radius for the cable must be

greater than 20 mm (0.79 in). The cable must be fixed in a distance 100 mm (3.9 in) from the ECU

or needs some other channeling to provide cable support. An example is shown below.

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NOx Sensor ECU Mating Connector

Connector Pin Signal

Pin 1 Power

Pin 2 CAN low

Pin 3 CAN high

Pin 4 Ground

Connector Manufacturer Part Number Wire

Gauge Quantity

NOx ECU Mating Connector (4-pin)

Tyco

Connector : 1-1418390-1, Coding A

16-20

AWG

1

4

Terminal : AMP MCP 2.8 Contact

System 1-968875-2

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SCR Exhaust Gas Temperature Sensor (EGTS) ECU Assembly Mounting Mounting Requirements for SCR EGTS ECU:

– The ECU must be remotely mounted by the OEM away from the SCR unit surface and must be

accessible for replacement without removal of the SCR unit from the chassis.

– The maximum surface temperature at the SCR EGTS ECU and the sensor’s electrical connection point

must not exceed 140 ºC (284 ºF).

– The maximum cable temperature of the ECU must not exceed 200 ºC (392 ºF).

– The sensor mount must be able to withstand the shock and vibration limits specified below. The

maximum transmitted shock and vibration levels in all direction at 20 – 2000 Hz frequency are:

• Shock : 10.2 G

• Vibration : 3.4 gRMS

ECU must be located in spaces that will minimize their vulnerability for damage from

road debris and mishandling. Shielding may be required to prevent damage to the

sensors. Maximum surface and cable temperature requirements must be considered

when designing shielding.

EGTS ECU

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Recommended installation angle for the temperature sensor ECU is shown in Figure A below.

Mounting details of the temperature sensor ECU is shown in the Figure B below.

Torque limits for the Temperature Sensor installation are 30 Nm +/- 6 Nm (22.1 lbs-ft +/- 4.4 lbs-ft).

The inlet and outlet probes of the sensor must be connected on the designated probes indicated on the

SCR unit.


Fig A. Installation Recommendation Fig B. Mounting Details

SCR Exhaust Gas Temperature Sensor (EGTS) ECU Assembly Mounting, cont.

Outlet Temperature Sensor

Probe (Straight)

Inlet Temperature Sensor

Probe (90-deg)

Sensor Leads

Sensor ECU

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SCR EGTS ECU Electrical Interface

Wiring harness that provides power and ground and J 1939 connections from this ECU

to the ECM will be required.

SCR Temperature sensor harness length and voltage :

– Available length : 1000 mm ( 39.3 in.)

– Voltage : 24 VDC


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Connector Pin Signal

Pin 1 Ground

Pin 2 CAN low

Pin 3 CAN high

Pin 4 Power


SCR Exhaust Gas

Temperature Sensor ECU

Mating Connector (4-pin)

Tyco

Connector : 3-1418390-1, Coding C

16-20 AWG

1

Terminal : AMP MCP 2.8

Contact System 1-968875-2

4

SCR EGTS ECU Mating Connector

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DEF Supply Module


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As part of the certified Tier 4 final system DEF must be supplied to the dosing modules

located on the DRT and SCR units

Each DRT and SCR unit requires a separate DEF Supply Module

DEF supply modules

– Unique hydraulic connections

– Unique electrical connections

– Unique mounting requirements

DEF supply modules require engine coolant to be supplied in cold weather

operation

– Coolant flow must be controlled using a electronically controlled valve

– DEF supply module has a maximum coolant flow rate that must not be exceeded



DEF Supply Module - Overview

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Operating Ambient Temperature : -40C ~ 85C

Vibration

– The supply module is designed to be chassis mounted

– The supply module is capable of meeting the vibration

profile defined in ISO 16750-3 (test VII). The OEM

must demonstrate these levels are vibration are not

exceeded during the normal operation of the vehicle.

For the optimum performance and serviceability the

supply module must be mounted with filter cap in

the downward position within +/- 45° from the

vertical as shown in Figure above

DEF Supply Module Installation Requirements

Installation Clearance for Service

– It is strongly recommended that the supply module has a minimum of 130 mm (5 in) clearance for

filter removal and replacement as shown in the figure above

Protection / Shielding

– Supply module must be located in spaces that will minimize their vulnerability for damage from

road debris and mishandling. Shielding may be required to prevent damage to the following

components on supply module : Electrical connections, Hydraulic Connections, Ventilation diaphragms

– The OEM must follow the maximum ambient and operating temperature requirements for the

supply module when designing shielding provisions

– The supply module must not be covered with thermal insulation

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Mounting Interface

– The Supply Module must be mounted using all mounting locations

provided as shown below

– Use two M8 fasteners, Strength category 8.8 or A2 70

• Tightening torque 14-28 Nm (10-21 lbs-ft)

• Thread engagement limits: 17-21 mm (0.669 to 0.827 in)

The Supply Module must be mounted directly to the vehicle frame

or suitable rigid bracket

The Supply Module should not be used for a handle or foot step

Integrated serviceable filter with a 4500 hour change interval

DEF Supply Module Mechanical Interface M8

Threaded

Mounting

Boss

M8

Threaded

Mounting

Boss

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Shown in the figure below are the DEF Line connector and coolant connector interfaces on the supply

module.

All electrical and hydraulic connectors at the supply module interface must withstand a direct

connected force of 200N in all directions.

Either left side or right side coolant port can be used as the coolant inlet/outlet from the engine to the

supply module.

Engine coolant mating connectors are Norma NQPS3 NW8-0 (straight) or NQPS3 NW8-90 (900

elbow).

DEF Supply Module Fluid Interface

DEF Suction line (from DEF tank to supply module)

SAE J 2044 3/8“

DEF pressure line (from DEF supply module to dosing module)

SAE J 2044 5/16"

Engine Coolant Connectors

Norma NQ PS3, NW8

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Electrical connector at

supply unit

Tyco HDSC, 4 Pin, 2.8mm MCP, coding A acc.

Tyco number C-114-18739-1, rev. D

Pin 1 Pump_Rpm_Feedback

Pin 2 Pump_Supply

Pin 3 Pump_Rpm_Control

Pin 4 Pump_GND

DEF Supply Module Electrical Interface

Connector Manufacturer Part Number Wire

Gauge Quantity

DEF Supply Module Mating

Connector (4-pin)

Tyco

Connector : 2-1418390-1, Coding B

16-20 AWG

1

Terminal : AMP MCP 2.8

Contact System 1-968875-1

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The integrated DRT and SCR unit consists of 3 types of DEF lines

– DEF Suction Line : DEF Tank to Supply Module (SM)

– DEF Pressure Line: Supply Module (SM) to Dosing Module (DM)

– DEF Return Line: Dosing Module (DM) to DEF Tank

The DEF lines and connectors must be electrically heated and the lines must be capable to

accommodate repeated freeze and thaw cycles. All DEF lines require an elasticity of greater than 8%

volume expansion.

All connectors must be SAE J-2044 quick connect fittings. The DEF lines must be purchased with the

quick-connect fittings pre-installed.

DEF line inner diameter to be 5.5 mm to 6.5 mm.

DEF line operating pressure must be capable of 11 bar.

Other DEF line requirements are shown in the table below.

EPDM: Ethylene Propylene Diene Monomer


Heated DEF Line – Overview and Requirements

DEF

Line

Material Connection

Type

Connection

Type

Max.

Connector

Temp Limits

Max. Fluid

Temp Limits

ISO 16232-10 Cleanliness

Specification

Suction EPDM 3/8” (SM) 3/8” (Tank) 1200C (2480F)

130°C Spike

65°C (1490F)

CCC = G7/H6/I5/J4/K00

Pressure EPDM 5/16” (SM) 1/4” (DM) 1200C (2480F)

130°C Spikes

65°C (1490F)

CCC =

D10/E9/F8/G7/H6/I5/J4/K00

Return EPDM 5/16” (DM)

5/16” (Tank) 1200C (2480F)

130°C Spikes

65°C (1490F)

CCC =

D10/E9/F8/G7/H6/I5/J4/K00

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Do not use materials that react chemically with DEF.

For example : Do not use Buna-N, Nylon, Neoprene, Silicon or Tygon

The DEF lines must be shipped with shipping caps in place to protect against the ingress of debris

during shipping.

The shipping caps must remain in place until final installation on the equipment.

During any service events, shipping caps must be used to prevent debris from getting into the DEF

lines.

The DEF lines must be internally clean when assembled and meet the cleanliness specifications

as outlined in the requirements table in the previous slide.

All DEF lines must have adequate slack so not to allow undue stress on the connectors. All DEF

lines must be supported so not to allow the weight of the lines to cause undue stress on the

connectors.

Dips and loops in the line must be avoided to prevent trapped air/gas in the system.

Supplier Reference Information

– Hutchinson

– Parker

– Conti Tech

– Voss

See Appendix A – for a sample of electrical demand calculation


Heated DEF Line – Installation Requirements

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DEF Line Flow Rate Maximum

(l/min)

Max. Pressure Drop

(millibar)

Line Size - ID

(mm)

Suction 0.38 (**) 5.5 – 6.5 (*)

Pressure 0.38 600 5.5 – 6.5 (*)

Return 0.14 200 5.5 – 6.5 (*)

Suction

Line

Pressure

Line

Return

Line

Heated DEF line - DEF System Line Layout, Pressure Drop Requirement

(*) Approximate recommended DEF hose inner diameter

(**) Maximum height from Suction Inlet (in DEF tank) to Supply Module Inlet to be one (1) meter

DEF Tank

Ma

x 1

m

Dosing Module

Supply Module

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DEF Tank


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DEF Tank Design

– Minimum DEF volume considerations

• EPA Requirement

• Volume required for heat rejection provided by dosing module

• Freeze expansion volume

– Construction

• Material must be compatible with DEF

– (See Appendix D)

– Contour

• Factors depend on volume required or requested

• Available machine space constraints

• Agreed upon heater design

– Design needs to be coordinated between physical tank supplier and head supplier

• Engine coolant ramp rate for HHP engines

– (See Appendix C)

• Available Flow versus restriction

• DEF tank required to include

– DEF Temperature Sensor

– DEF Level Sensor

– DEF Quality Sensor

See Appendix – B – for specific DEF tank Design and Validation Criteria


DEF Tank - Overview

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DEF Tank Sizing

– DEF usage calculated by % of fuel consumption (BSFC) based on volume

• DEF usage depends on engine power rating, notch setting, duty cycle, ambient conditions. Higher Duty

Cycle, Higher Ambient Temperature, Lower Ambient Humidity would require higher DEF usage.

• Please work closely with Cummins AE on specific DEF usage for your application.

– 15% usable DEF volume required for cooling on dosing injector tip, can not be consumed

Minimum 2 gallons per doing module (doser)

– 10% required expansion volume for freeze protection

DEF Tank Sizing

DEF usage calculated by % of fuel consumption based on volume

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DEF Tank Construction Options

– Tank Material must be Medium-High Density Polyethylene or 300 Series Stainless Steel.

– Below is a picture showing the manufacturing processes used for DEF tanks.

DEF Tank Heating

– The current recommended process is to utilize engine coolant to thaw the DEF tank during cold weather

operation. Refer to Appendix X for designated coolant line connections to the supply and return ports on the

engine.

– The OEM must incorporate a heater system to support cold weather operations. The OEM’s tank design must

be capable of complying with the DEF tank thaw procedure outlined in Appendix B.

– If the OEM deviates from coolant based DEF tank thawing system, then the OEM must demonstrate that the

tank heating system comply with the DEF tank thawing test procedure as listed in Appendix B .

DEF tank to include:

– DEF Level Sensor

– DEF Temperature Sensor

– DEF Quality Sensor


DEF Tank Construction Criteria

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The current system design requires engine coolant to be used to provide heat to the

DEF supply module(s).

DEF tank can be heated by engine coolant or dedicated electrical heaters.

In case engine coolant is used to heat both DEF supply module and DEF tank :

– This circuit to be controlled by two coolant valves (OEM Supplied) with a normal open/close

signal from the engine ECM, providing coolant to DEF supply module and DEF tank separately.

In case engine coolant is used only to heat DEF supply module, and DEF tank is heated

by dedicated electrical heaters :

– Coolant valve is controlled by ECM to provide coolant to DEF supply module

– Heater relay is controlled by ECM to turn on/off the electrical heaters for DEF tank

Depending on the DEF tank heating (Coolant/Electric) strategy selected, the coolant line

schematics are outlined on the next slides.

Coolant Utilized Heating System

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In case engine coolant is used to heat both DEF supply module and DEF tank, two (2)

coolant valves to be supplied based on the following criteria:

– DEF supply module required flow

• 1.3 GPM max

• Total circuit restriction component

• Compatible with engine coolant

• Compatible with engine coolant operating temperatures

• Normally closed valves

• Example: Parker 321K1533 SCRCV-12 24VDC

– DEF tank supply coolant valve

• Flow requirements need to be coordinated with DEF tank supplier

• Total circuit restriction component

• Compatible with engine coolant

• Compatible with engine coolant operating temperatures

• Normally closed valves

• Example: Parker 73218BN64E000N0BZ01C2

–

Coolant Utilized Heating System, cont.

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QSK-60

Engine

Diesel Exhaust

Fluid Tank

Coolant Heater

Water Pump Inlet

60

SCR System - Coolant Line Schematic Coolant used for heating both DEF Supply Module and DEF Tank

Coolant Valve-

DEF Tank

Max Flow to Each DEF Supply Module must not exceed 300 L/hr (1.3 GPM)

DEF

Supply

Module

DEF

Supply

Module

Coolant Outlet

Coolant Valve-

Supply Modules

DEF

Supply

Module

DEF

Supply

Module NORMA NQ PS3 NW8 DEF

Supply Module Coolant

Inlet Connections

NORMA NQ PS3 NW8

DEF Supply Module

Coolant Outlet

Connections

Return Manifold Supply Manifold

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QSK-60

Engine

Water

Pump Inlet

61

Coolant Valve-

Supply Modules

DEF

Supply

Module

DEF

Supply

Module

Coolant Outlet

DEF

Supply

Module

DEF

Supply

Module NORMA NQ PS3 NW8 DEF

Supply Module Coolant

Inlet Connections

NORMA NQ PS3 NW8

DEF Supply Module

Coolant Outlet

Connections

Supply Manifold Return Manifold

SCR System - Coolant Line Schematic Coolant used for only heating DEF Supply Module

Max Flow to Each DEF Supply Module must not exceed 300 L/hr (1.3 GPM)

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5/21/2013 Cummins Confidential - Restricted 62 62

SCR System – Supply Module Pressure Drop vs. Flow

0

200

400

600

800

1000

1200

1400

0 100 200 300 400 500 600 700 800 900 1000 1100

Pre

ssu

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rop

mb

ar

Flow liters/hour

Pressure Drop vs. Flow for different temperatures

-5 deg C

20 deg C

90 deg C

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SCR System - Coolant Lines Installation Requirements Coolant line material must meet the SAE J20 R3 Class D-2. In installations where coolant line

temperatures will exceed limits of the class D2 material then it is recommended that class D3

material, class A material or heat shielding will be required.

Coolant lines must have adequate slack so not to allow undue stress on the connectors.

Coolant lines must be supported so not to allow the weight of the lines to cause undue stress on

the connectors.

The coolant lines must be properly routed, supported and protected from heat, moving parts and

potential debris impact.

Coolant lines must not have sharp bends or abrasion points.

In case of using metal coolant lines :

– Insulation to prevent heat loss must be installed on all metal lines used as part of the coolant supply line to the

DEF system.

– The insulation material should provide thermal properties equivalent or better than coolant hose material (SAE

J20 R3 Class D-2)


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Due to the Tier4 total system approach, the exhaust tubing material specification is

unique

– Tubing material between engine exhaust collector outlet to the bellows inlet, and between bellows

outlet to the DRT inlet must be made out of 439, 409, 304L, or 316L stainless steel

• Cast parts should be made of ferrite ductile iron ASTM A536 grade 60-40-18 with a minimum of 2.6% silicon.

• Materials that contain brass, zinc, copper and mild steel must not be used in the internal surface of the

exhaust system. This includes items such as fittings and plugs.

– Bellows material to be 321 or 304L Stainless Steel, or Inconel 625

Inner Diameter of Bellows to be at least 9.8”

Maximum total exhaust restriction (back pressure) for OEM designed exhaust tubing to

be 1.5 in-Hg or less


Exhaust Tubing - Overview

Installation Example

Exhaust Aspirator / Dust Injector must

be located downstream of the SCR

unit (after SCR outlet)

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Exhaust gas flow must pass from the engine to the Aftertreatment system. Diverting

exhaust gas flow prior to the Aftertreatment system is not allowed.

DRT and SCR unit inlet/outlet bolted flange details :

Flange of OEM exhaust pipe connected to DRT and SCR unit inlet/outlet bolted flange


Exhaust Tubing

Engine Model

SCR Model

No. of DRT units per

engine

No. of SCR units per

Engine

DRT Inlet/Outlet

Tube Dia.

SCR Inlet/Outlet

Tube Dia.

DRT Inlet/Outlet Connection

Design

SCR Inlet/Outlet Connection

Design

QSK60 8000 2 2 254 mm

(10”) 254mm

(10”) 12 Bolt Flange 12 Bolt Flange

254 mm ID

(10 in.)

12x 25.4 mm

Dia. Hole

12.7 mm thick

(0.5 in.)

300

406.4 mm OD

(16 in.)

361.95 mm (14.25 in.)

BCD

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Temperature Drop (Between Turbocharger Exhaust Outlet and SCR Inlet)

– To be determined based on rating.

Leakage Rate

– A gasket must be used between the flanges to prevent any exhaust leakage. The OEM is

recommended to use the following gaskets

• At the SCR inlet and outlet connection, the gasket material must be Type 409/430 stainless steel wire

with graphite or equivalent. Do not reuse old gasket or use multiple gaskets.

• At other locations at the downpipe, the gasket material can be any other stainless steel material. For

example 304/316 SS or equivalent. Do not reuse old gasket or use multiple gaskets.

• Gasket thickness 1.6 mm. The gasket must be replaced with new each time the flange connection is

disassembled.

• Fastener material at the SCR inlet and outlet connection should be Type 316 stainless steel or

equivalent

– An assembled leak check between the turbo outlet and SCR outlet may be required for all

installations. This test should be carried out with the system mounted to the vehicle. Drain

connections will need sealed with rubber caps and plugs.

– Total leakage specification - TBD.

Bellows

– Due to thermal expansion, misalignment, bending forces, etc., flexible connections (bellows)

must be used with the exhaust tubing length between the turbo out connection and

DRT/SCR unit

Exhaust Tubing (Cont.)

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Turbocharger

After-Treatment

Measurement & Spec Location

AT Pressure Drop

Pre-AT

Pressure Drop

Post-AT

Pressure Drop

Min Exhaust Restriction = AT Pressure Drop (Protect Turbo)

Max Exhaust Restriction = AT Pressure Drop + 1.5 in-hg

Assumption: Pre-AT + Post-AT ≤ 1.5 in-hg

Diameter D: Define and add per AEB24.14 (or new AEB)

D

Exhaust Restriction Proposal

Exhaust Tubing (Cont.)

Maximum allowable exhaust

restriction for OEM exhaust

tubing : 1.5 in-Hg

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Exhaust Aspirator / Dust Ejector

Aspirators must be installed downstream of the aftertreatment device to prevent

contamination

Aspirator restriction must be included in the design budget when evaluating

exhaust back pressure

An example is shown below

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Five Primary OEM Interface Connectors

Base Engine Connectors (Same as Tier 2 MCRS for 23-pin & 31-pin connectors)

– Signal Connector #1 (Deutsch 31-pin)


– Revised Power Connector (Deutsch 16-pin)

New Aftertreatment Connectors for Tier 4


– Signal Connector #4 (Deutsch 35-pin, Socket)

OEM Electrical Interface Connectors

Right Bank Rear

Aftertreatment Connectors


Left Bank Rear

Base Engine Connectors

35 Pin AFT Connector

47 Pin AFT Connector

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47-Pin Aftertreatment Connector Layout (Main AFT – QSK60)

* NOTE: Pins 1 & 4

require size 16 sockets 5/21/2013 Cummins Confidential - Restricted 70

For DRT

For SCR

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35-Pin Aftertreatment Connector Layout (Auxiliary AFT – QSK60)


For DRT

For SCR

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16-Pin Power Connector Layout

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9-Pin Service Connector Layout

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31-Pin OEM Connector Layout


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75

Electrical - Base Engine Connectors

Power Connector Signal Connector #1 Signal Connector #2

Connector Manufacturer Part Number Wire Gauge Power Connector (16-pin) Deutsch Connector - HD36-24-16SE-059 12-14 AWG

Contact (size 12 socket) – 0462-203-12141

HD36-24-16SE-059 Seal Plug – 114017

Signal Connector #1 (23-pin) Deutsch Connector - HD36-24-23PE-059 14-20 AWG

Contact (size 16 pin) – 0460-215-16141 (14-16 AWG Wire) OR

HD36-24-23PE-059 Contact (size 16 pin) – 0460-202-16141 (16-20 AWG Wire)

Seal Plug – 114017

Signal Connector #2 (31-pin) Deutsch Connector - HD36-24-31SE-059 14-20 AWG

Contact (size 16 socket) – 0462-209-16141 (14 AWG Wire) OR

HD36-24-31SE-059 Contact (size 16 socket) – 0462-201-16141 (16-20 AWG Wire)

Seal Plug – 114017

5/21/2013 Cummins Confidential - Restricted

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Cummins Confidential - Restricted 76

Electrical – Aftertreatment Connectors – QSK60

Connector Manufacturer Part Number Wire Gauge Quantity Signal Connector #3 (47-pin) Deutsch Connector - HD36-24-47SE-059 16-20 AWG 1

Contact (size 20 socket) – 0462-201-2031 (20 AWG Wire) OR 25

HD36-24-47SE-059 Contact (size 20 socket) – 0462-005-2031 (16-18 AWG Wire) 25

Contact (size 16 socket) – 0462-201-1631 (16-18 AWG Wire) 2

Seal Plug (size 20) – 0413-204-2005 17

Seal Plug (size 16) – 114017 3

Signal Connector #4 (35-pin) Deutsch Connector - HD36-24-35PE-059 16-20 AWG 1

Contact (size 16 pin) – 0460-202-16141 (16-20 AWG Wire) 3

HD36-24-35PE-059 Seal Plug (size 16) – 114017 0

Seal Plug (size 20) – 0413-204-2005 1

Contact (size 20) – 0460-202-20141 (20 AWG Wire) 31

Signal Connector #4 (QSK60) Signal Connector #3

5/21/2013

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Compressor Inlet Temperature Sensor

OEM installed sensor supplied in kit with engine

OEM interface connection on engine harness at engine left bank

(near to the Wastegate Connector Harness)


Compressor Inlet Temperature Sensor Connector Wastegate Connectors

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Sensor to be ideally installed in a straight section of the air inlet pipe

close to the turbocharger compressor inlet, but no closer than two

pipe diameters.


Compressor Inlet Temperature Sensor, cont.

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Compressor Inlet Temp. Connector (2-pin) Deutsch Connector - DT04-2P (NOTE: Comes with engine harness.) 16-20 AWG 1 Contact (size 16 pin) – 0460-202-16141 (16-20 AWG Wire) 2

DT04-2P Wedgelock - W2P 1


Sensor Mating Connector (2-pin) Metri-Pack Connector - 12162197 16-20 AWG 1 Terminal - 12124075 2 150-2 Female Metri-Pack 150 Gold Plated Terminal, Cable Range 1.00 - 0.80 mm2,

Cable Insulation Range 2.40 - 2.03 mm

Engine Harness Stub Mating Connector for Compressor Inlet Temperature

Compressor Inlet Temperature Sensor Mating Connector


Compressor Inlet Temperature Sensor Connector

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Ambient Air Temperature Sensor

Ambient air temperature sensor is used for the SCR system heating

control

OEM must source and install the temperature sensor per the

guidelines defined below.

– Mount close to the DEF line that is placed in cooler ambient air temperature, in a

location shaded from direct sunlight

– Keep away from radiant heat sources such as engine, transmission, exhaust, etc.

– Place sensor in a location that prohibits tampering

Wiring interface at the 47-pin Main Aftertreatment interface connector

on engine


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81

Cummins Sensor Part #: 4088832

Metric sensor contains M14 x 1.5-6 threads


Ambient Air Temperature Sensor, cont.

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J1939 Message added for Tier4


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Revision History Revision Description Page Revised by Date

00 Initial Release (specifically for QSK60 locomotive) --- MIG May 20th - 2013


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Appendices


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APPENDIX A – Example of Electrical Demand Projection


DEF line has the heated coils inside to warm DEF in cold weather. Current draw

(typically, 18W~25W/meter) should be considered in DEF line layout.

- An example of calculating additional current draw for AT system.

Aftertreatment Component Quantity Unit

Current

(amps)

Total Current

(amps) Notes

NOx Sensor 2 pcs 2 4.0 Includes an additional 1.4 amp draw per sensor when heating.

Relay - NOx Sensor 1 pcs 1 1.0

Coolant Valve (Tank) 1 pcs 2.5 2.5 Not counted twice for a two leg system.

Coolant Valve (Supply Module) 1 pcs 2.5 2.5 Not counted twice for a two leg system.

DEF Doser 1 pcs 3.5 3.5 Includes an additional 2 amp draw when the heating.

DEF Supply Pump 1 pcs 5 5.0

Relay - Line Heater 1 pcs 1 1.0

DEF Line Length (Suction) 3.5 meter 1.04 3.6 25 W/m -- Current demand defined by line lengths needed for machine.

DEF Line Length (Pressure) 10 meter 1.04 10.4 25 W/m -- Current demand defined by line lengths needed for machine.

DEF Line Length(Return) 13 meter 1.04 13.5 25 W/m -- Current demand defined by line lengths needed for machine.

DEF Line Connector (2/line) 6 pcs 0.25 1.5 6 W/fitting

DEF Lamp, DEF Temp & Level Sensor 1 pcs 2.5 2.5 Not counted twice for a two leg system.

51.1

94.6 Valves, DEF lamp, DEF temperature and DEF level sensors do not double.Total Additional Aftertreatment System Current Demand (two legs) =

Total Additional Aftertreatment System Current Demand (per leg) =

Change values depends on desired DEF line lengths

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APPENDIX B – DEF Tank Design and Validation


• DEF Thaw Specifications

• DEF Tank Design Criteria

• DEF Tank Design and Validation

• EPA Thaw Cycle Test Procedure for Non-Road application

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DEF Thaw specifications

DEF supply module heating

– Require engine coolant to be supplied to DEF supply module (pump)

– Maximum flow to be delivered to DEF supply module is 300 Liters/hour

– This must be calculated or measured at rated speed with coolant flow directed to the supply

module circuit only

The heated DEF tank design is typically controlled by a tank supplier with key input

from the customer

DEF tank heating

– Using engine coolant powered heaters

• Coolant ramp rate supplied in this document should be used in conjunction with the DEF tank and heater

designers to obtain a thawing strategy that will meet the individual customer needs

• Minimum coolant flow requirements to be determined based on engine operational speed and application

specific DEF tank and heater system design

– Using electrical heaters

• DEF tank’s electrical heaters are turned ON/OFF by heater relays controlled by ECM

• ECM’s driver for DEF tank heater relay is capable of driving up to 2 amp


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Tank Contour

– The tank must have a shape such that depth and volume have a linear relationship, or the level sensor

needs to be designed and calibrated to match a particular tank design.

– The tank body or the tank cap must be clearly identified as being for “DIESEL EXHAUST FLUID ONLY”

or “DEF and Logo”.

– The tank must be constructed using suitable material.

• Suitable tank materials are 300 series stainless steel or medium-high density polyethylene.

Tank Features

– Ventilation

• The supply tank must be vented at low pressure both to and from atmosphere to allow free flow from

the supply module connections and to vent any vapour or expansion in the tank.

– The vent must be designed such that it is not susceptible to blockage and with a filter to prevent

contamination.

– Tank ventilation systems are subject to tank slosh, and tank evaporation. This slosh and evaporation

may cause urea crystals to form on and near the tank vent. Precaution should be taken to prevent urea

crystals from forming in the vent or adjacent components.

– Filtration

• 40 micron or better. The filter specifications are shown below

– The filter must be made out of Gradient Depth Media.

– The filter must be rated at an efficiency of 98% (tolerance of +2% / -3%) @ 40 microns per SAE J 1985

(Single Pass Efficiency, ISO A2 Fine Dust, Flow Rate of 120 LPH).

– The filter must have a minimum dirt retained capacity of 9 grams per SAE J 905 (Flow rate of 10 LPH,

ISO A2 Fine Dust, Termination Pressure of 20 KPa, dust addition of 0.5 grams/5 minutes).

– The filter must have affinity to diesel and urea. The filter must be capable of withstanding temperatures

between -40 °C to 80 °C.

– The surface area of the tank filter must be adequate to allow for dosing system flow rate requirement of

1.2 L/min


DEF Tank Design Criteria

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Tank Features (cont.)

– The tank design must be capable of freeze/ thaw cycling.

• The tank heater assembly should be robust enough that it cannot be deformed or damaged by repeated freezing

and thawing of the DEF or by impact from ice chunks due to fluid sloshing.

– It is strongly recommended that the tank has a drain for periodic servicing.

‒ Fill Neck

• The tank fill neck must be designed to prevent spillage when tank is being filled (Ref draft ISO 22241-4).

• The fill neck should be sized such that a standard gasoline or diesel pump will not fit into it.

• The tank fill neck design must prevent overfill of the tank into the required expansion space.

Tank Heating

– Tank heater design is the responsibility of the OEM.

– The tank heater location must be close to the tank suction line inlet such that the thawed solution is available

for use as early as possible to ensure thawing requirements are met.

– Heating may be provided by means of engine coolant.

• Specific coolant supply and return ports on the engine must be used by the OEM for this cooling circuit so that the

coolant flow is regulated and the correct coolant balance across engine components is maintained.

• The OEM is responsible for providing suitable coolant lines to ensure proper coolant flow to the diesel exhaust fluid

tank heater is maintained.

• Coolant-based tank heater design must include a flow control valve in the coolant supply line that is controlled by the

ECM

• The connection point on the DEF tank for the DEF lines and coolant lines should be designed with sufficient

assembly clearance for the connector fitting used.

Coolant Circuit For Tank Heating Refer to system coolant line schematics in this document.

Electrical Heater Option

– Electrical heater may be used for thawing and freeze prevention.

– Current draw from the battery needs to be considered in electrical heater selection.


DEF Tank Design Criteria (cont.)

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Cleanliness Specifications

– The diesel exhaust fluid tank must be free from contamination visible to the unaided eye.

– All connections and lines to and from the dosing supply module must be internally clean when assembled and

meet cleanliness specification below.

– A sample collection method and particle sizing method relevant to the particles being collected should be used

to determine component cleanliness. ISO standard 16232 contains acceptable practices for this process.



The filter assembly and DEF suction inlet port must be level with or

above the lowest part of the tank heater. Refer to the figure on the

right for an example

The tank must be designed to provide uninterrupted flow of DEF to the dosing system (supply

module and dosing module) during maximum equipment operation angularity in all directions.

The tank filter must not come in contact with the bottom of the tank to prevent suction of debris that

has settled on the bottom.

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The vehicle manufacturer must provide a fluid

level sensor in the diesel exhaust fluid tank.

– Fluid level sensor specifications and their role in

SCR system function and diagnostics are

designed in forthcoming AEB.

The temperature sensor is a resistive analog

device that provides a temperature

representative signal through an A/D converter

to the ECM.

– The tank temperature is used to monitor

temperature within the tank and control tank

heater activation.

– The sensor is located at the end of the suction

tube. The ECM is designed for a thermistor

sensor with the following characteristics


DEF Tank Sensors – DEF Temperature

Diesel Exhaust Fluid Tank Temperature Sensor Input Table

Temperature in deg C

Resistance (Min) Ohms

Resistance (Nominal) Ohms

Resistance (Max) Ohms

-55 25716.50 27070.00 28423.50

-50 18757.75 19745.00 20732.25

-45 13827.25 14555.00 15282.75

-40 10298.00 10840.00 11382.00

-35 7747.25 8155.00 8562.75

-30 5880.50 6190.00 6499.50

-25 4505.85 4743.00 4980.15

-20 3481.75 3665.00 3848.25

-15 2712.25 2855.00 2997.75

-10 2128.95 2241.00 2353.05

-5 1684.35 1773.00 1861.65

0 1342.35 1413.00 1483.65

5 1076.35 1133.00 1189.65

10 869.25 915.00 960.75

15 706.33 743.50 780.68

20 577.60 608.00 638.40

25 475.00 500.00 525.00

30 392.83 413.50 434.18

35 326.61 343.80 360.99

40 273.03 287.40 301.77

45 229.33 241.40 253.47

50 193.52 203.70 213.89

55 164.07 172.70 181.34

60 139.75 147.10 154.46


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The DEF level sensor provides a volume representative signal through an A/D converter in the

ECM.

The Sensor can be an active or passive/resistive device.

The tank level sensor is used to monitor remaining usable volume of DEF in terms of percent of

total usable volume and provides the information for warning and inducements.

Cummins requires vehicles to be equipped with a DEF tank sensor for indicating percent remaining

usable DEF in order to meet EPA requirements associated with driver warning and inducement.

The DEF level sensor shall provide a signal proportional to the percentage of total usable volume of

DEF remaining in the tank.

– The linearization table and out-of-range (OOR) values are shown in the table below.

– A simplified schematic of the input circuit shown in the figure below is for design purposes.

– Rsense represents a passive resistance sensor that would typically be a potentiometer or ladder network connected to a float.

– An active sensor would inject its signal here with reference to ground and Rsense would not be present.


DEF Tank Sensors – DEF Level

DEF Tank Level Sensing

Simplified Analog Input Circuit

DEF Tank

Level Voltage

% DCV

OORH >4.50

0.00 4.00

100.00 0.50

OORL <0.25

Diesel Exhaust Fluid Level

Sensor Linearization Table


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10% Expansion Volume

• 15% Trapped Heat Rejection Volume

• 0% Tank Level is Broadcast via J1939

message (PGN 65110)

• 100% Tank Level is Broadcast via J1939

message (PGN 65110)

15% Heat Rejection Volume

Useable DEF Tank Volume

NOTE: The DEF level sensor must be capable of sensing the entire DEF volume.


DEF Tank Sensors – DEF Level Logic


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Usable

DEF

with no

de-rate

but,

indicator

Usable

DEF

with no

de-rate

or

indicator

Usable

DEF with

possible

de-rate and

indicators

Torque and Speed de-rate could be

applied

Torque de-rate could be applied

DEF Tank Design Criteria (cont.) DEF Tank Sensors – DEF Level Best Practices

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Power Consumption Criteria

– The power required to heat the mixture from a frozen state to liquid can be calculated from the

following properties:

• Specific heat of liquid state diesel exhaust fluid is 3.4 kJ/kg.K

• Melting enthalpy (specific heat for melting frozen diesel exhaust fluid) is 307 kJ/kg.

• The specific heat of frozen diesel exhaust fluid is approximately 2.0 kJ/kg.K

DEF Tank Design Criteria (Cont.)

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DEF Tank Design and Validation


In case of applying engine coolant powered heaters, the following items must be

provided to the tank supplier to support the design of a new tank.

1. Engine coolant flow and allowable pressure drop in heater system (tank plumbing)

• The allowable pressure drop that’s provided must take the entire DEF coolant circuit into account. The

coolant flow vs. restriction curves contained herein defines the entire DEF coolant circuit restriction.

2. Engine coolant temperature ramp rate

3. Desired tank volume based on:

• Expected DEF consumption based on BSFC

• 10% volume added for DEF expansion

• 15% usable DEF volume required for cooling on dosing injector tip

– Minimum 2 Gallons of DEF required per dosing module

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DEF Tank Design Validation

The OEMs has overall design responsibility of the DEF tank and must ensure that it’s

capable of meeting the EPA’s requirements for DEF thawing.

– For reference, EPA’s 70 minute thaw cycle requirement for Non-Road application

Validation data must be submitted as part of the IQA process.

– Tank supplier conducts thaw cycle test and provides validation test data

– Customer conducts thaw cycle test and provides validation test data

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APPENDIX C HHP Engine Data


• HHP Coolant Ramp Rates For EPA Thaw Cycle Test

• QSK60 Coolant Supply and Return Port Detail

• QSK50 Coolant Flow Versus DEF Restriction Curves

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Engine Coolant Temperature Ramp Rate

– This is a generic ramp rate that’s representative of all HHP engines

– This ramp rate supports the EPAs 70 minute thaw cycle test procedure contained in the

Appendix of this document

– HHP engines may operate below the red curve. Development under way.

– Worst case design ramp rate would be at low idle of green – blue curve

Engine

Speed and

Load

Increased

at 20 min


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DEF System Coolant Supply Ports QSK60 engine

Circuit Supply

M27 X 2 -6H STOR Port

Circuit Return

See GCE for detail per

specific water inlet


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Coolant Flow vs. DEF Coolant Circuit Restriction

(Tier 4 QSK50 Engine for reference only)

The coolant flow vs. DEF circuit restriction charts are

contained on the next four slides.

– Chart 1 – Low idle with thermostat open

– Chart 2 – Low idle with thermostat closed

– Chart 3 – High idle with thermostat open

– Chart 4 – High idle with thermostat closed

Chart reference data shown below

– Low Idle = 600 rpm

– High Idle = 1900 rpm

– Radiator circuit restriction set to 12 psi with open thermostat


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DEF Coolant Circuit Flow – Chart 1

3.62, 2

3.41, 5

2.96, 10

0

2

4

6

8

10

12

0 0.5 1 1.5 2 2.5 3 3.5 4

Co

ola

nt

Flo

w (

gp

m)

DEF Circuit Restriction (psi)

Restriction vs. Flow for QSK50 DEF Coolant Circuit Low Idle (T'stat Open)

5/8" Outlet Port


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4.67, 2.26

4.41, 5.66

3.89, 11.4

0

2

4

6

8

10

12

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Co

ola

nt

Flo

w (

gp

m)


Restriction vs. Flow for QSK50 DEF Coolant Circuit Low Idle (T'stat Closed)

5/8" Outlet Port

Key chart for defining DEF coolant circuit and tank design to meet

thaw cycle requirements based on low idle flow characteristics.


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35.9, 6.39

33.84, 15.98

29.47, 32

0

5

10

15

20

25

30

35

0 5 10 15 20 25 30 35 40

Co

ola

nt

Flo

w (

gp

m)


Restriction vs. Flow for QSK50 DEF Coolant Circuit High Idle (T'stat Open)

5/8" Outlet Port


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45.07, 7.1

42.61, 17.76

34.75, 35.76

0

5

10

15

20

25

30

35

40

0 5 10 15 20 25 30 35 40 45 50

Co

ola

nt

Flo

w (

gp

m)


Restriction vs. Flow for QSK50 DEF Coolant Circuit High Idle (T'stat Closed)

5/8" Outlet Port

Key chart for defining DEF coolant circuit design so that the

maximum flow rate to the Hilite pump is limited to 300 l/hr.


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5/21/2013 106

Diesel Exhaust Fluid is the reactant required for the SCR system

– Urea is a solid at room temperature

– DEF is prepared by dissolving solid Urea in purified water to create 32.5% solution

Primary reactants for DEF production

– Ammonia (NH3)

– Carbon Dioxide (CO2)

Solution will freeze at 12° F (-11° C)

– Thaw rates are equal so concentration will remain constant

– Equipment tanks and lines will be heated

– Cummins systems are designed to operate in cold climates

Shelf life of DEF is a function of ambient storage temperature

– For maximum shelf life Cummins recommends DEF be stored at under 86° F (30° C)

– Not a concern even in the harshest climates (evidence of DEF at 95° F for 6 months)

DEF has high purity requirements defined by

– German Institute of Standardization DIN 70700

– International Organization for Standardization ISO 22241-1

– There is also an American Petroleum Institute (API) certification

www.cumminsfiltration.com

DEF Facts

APPENDIX D


http://www.cumminsfiltration.com/

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APPENDIX E Component Thermal Limits


Requirement Temperature Label Location

115 °C (239 °F ) System Out NOx ECU 200 °C (392 °F) System Out NOx ECU Cable 140 °C (284 °F ) SCR Sensor Table (Delegated Ass'y Connector) 130 °C (266 °F) Doser Electrical Connector 85 °C (185 °F) DEF Supply Moduels (Pumps)

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APPENDIX F Mounting zone locations and recommended mounting capscrews for SCR unit


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Interface Points (in millimeters)


Front

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Left


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Back


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653.5

186.75

196.75

90

90

90

721.3

40.6

640.2

Right


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Recommended Mounting Capsrew

M14 - 2

ASTM A193 grade B16 (SS)

Thread engagement

– 14mm Minimum

– 30mm Maximum

Final Applied Torque

– T = 176 ± 5 Nm

113

OEM mounting bracket

cross-section

SCR threaded internal mounting bracket


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APPENDIX G Lifting Requirements and Best Practices for SCR unit


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SCR Unit Lifting Requirements

• The OEM must supply all lifting components used to lift the SCR unit

• The assembly can be lifted using eye-bolts (regular (non-shoulder)/shoulder) or hoist rings threaded

into lifting zones highlighted below on a Side In End Out configuration

• Depending on the way the aftertreatment is oriented and mounted, the OEM can choose to use the

lifting zones that are required below.


Left Back

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Use threaded eye bolts or swivel hoist rings for lifting

– Eye bolt/hoist ring size: M14 X 2

– Load Rating for Shoulder Pattern Eyebolt: 1840 lbf (8185 N)

• Reference ASME B18.15

Common examples of lifting equipment are shown below

– Eye Nuts

– Eye Bolts including shoulder nut, non shoulder nut, non shoulder machinery and shoulder machinery types

– Swivel hoist rings

The OEM must always ensure full thread engagement when installing lifting hardware onto the

SCR unit’s lifting surface.

Eyebolts not shouldered to the load shall only be used for in-line loads

When using regular eye bolts without shoulder or eye nuts, it is recommended to lift the SCR unit

using a lift angle of 900 to utilize the eye bolt’s maximum lifting capacity. This can be done with the

use of a spreader bar.

Only shoulder eye bolts shall be used for angular loading. When used for angular loading, the

shoulder shall be flush and must be securely tightened against the load.

When using eye bolts with shoulder, it is recommended that the eye bolts be used at a horizontal

angle greater than 450

When using eye bolts for angular loading, the plane of the eye-bolt shall be aligned with the

direction of the pull

Shock loading must be avoided during lifting of the SCR unit.

The following slides outline the lifting requirements on the SCR unit.


SCR Unit Lifting Requirements (cont.)

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Lifting Option # 1


Regular Eye Bolts

Primary Lifting Surface

Using Non-Shoulder Eye Bolts and Spreader Bar

Lifting

Direction

Lifting

Chains

Spreader Bar

900

900

Lift

Angle

CASE-1

DO

To maximize the eye bolt and spreader bar’s lifting capacity, it is

recommended to use eye bolts in the lifting holes highlighted by the

locations above in Case-1.

With regular (non shoulder) eye bolts, use a spreader bar as shown

in Case-1 to keep the lifting angle at 900 to the horizontal.

In this case, a minimum of 2 eye bolts shown above must be used

for lifting.

It is not recommended to use eye bolts and spreader bars for lifting

in the location shown in Case-2.

If the OEM plans to utilize the remaining lift holes for lifting the SCR

unit other than the holes prescribed above, they need to consult

with the lift hook manufacturer and Cummins Application Engineer

for approval.

900

900

Lifting

Direction

CASE-2

DON’T

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Lifting Option # 2

5/21/2013 118

Using Shoulder Eye Bolt/ Swivel Hoist Rings

Lifting Direction

450 450

Lifting

Chains

CASE-1

DO

DON’T

CASE-2

It is recommended to use eye bolts with shoulder or hoist rings in the lifting

holes highlighted by the locations listed above in Case-1.

For this case-1, two eye bolts or swivel hoist rings must be used and the

lifting angle from horizontal must be greater than 450

It is not recommended to follow Case-2 for lifting the SCR unit.

If the OEM plans to utilize the remaining lift holes for lifting the SCR unit

other than the holes prescribed above, they need to consult with the lift hook

manufacturer and Cummins Application Engineer for approval.

Lifting Direction

Primary Lifting Surface

Shoulder Eye

Bolts/Swivel hoist

Rings


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Lifting Option # 3

5/21/2013 119

Using regular eye bolt and spreader bar

DO

To maximize the eye bolt and spreader bar’s lifting capacity, it is recommended to use eye bolts in the

farthest lifting holes highlighted by the locations above.

With regular (non shoulder) eye bolts, use spreader bar to keep the lifting angle at 900 to the horizontal.

If the OEM plans to utilize the remaining lift holes for lifting the SCR unit other than the holes prescribed

above, they need to consult with the lift hook manufacturer and Cummins Application Engineer for approval.

900

Lifting Direction

Primary Lifting

Surface

Spreader Bar

900


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Lifting Option # 4

5/21/2013 120

Using Shoulder Eye Bolt/ Swivel Hoist Rings

It is recommended to use eye bolts with shoulder or hoist rings in the farthest lifting holes highlighted by the

locations listed above.

Two shoulder eye bolts or swivel hoist rings must be used and the lifting angle from horizontal must be

greater than 450 for the eye bolts.

If the OEM plans to utilize the remaining lift holes for lifting the SCR unit other than the holes prescribed

above, they need to consult with the lift hook manufacturer and Cummins Application Engineer for approval.

450

Lifting Direction

Primary Lifting

Surface

450

DO


High Horsepower Tier 4 OEM Design Guide for QSKV Engines · – DEF Line Layout, ......

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