Truck Heading to the Shop

[lovoltage]

Taking the truck to Mr. Hagg's later this week to correct some things I was not able to correct at home. In addition to what I know needs t be done, what else should we be looking at?

2014 KW T660
516K miles
ISX15 CM2350 (ISX15 450ST)
Was a team truck, bought in 2016 May used for household goods, limited OTR miles running 1/2 to 2/3 GVW. Rarely gross 80k lbs

Issues began at the start of the year, has been in and out of shops since. Found this website, studied the issues and corrected many at home. Shops did some work first, and I did some after spending way too much time and money and still having issues. Found many issues with the shop work.

Fixed so far
- Fuel pump campaign (ceramic plungers issue) (Shop under warranty)
- Aftertreatment system repair of aftertreatment wiring harness (shop)
- Overhead adjustment (shop)
- Aftertreatment system DEF doser injector (shop)
- Aftertreatment system DPF (Shop) (Sept 2015 new installed)
- Turbo and aftertreatment diesel injector (shop) (March 2016, Cummins reman turbo and new VGT actuator. New updated diesel aftreatment injector)
- EGR Tune Up with sensor & small diameter pipe replacement (Self)
- NOX outlet sensor (Self)

Known outstanding issues
- TSB notification from Cummins on a conflict between the engine and aftertreatment calibration files (after 1st shop updated the calibration) (Can post details of the TSB)
- Fault code for regen too often
- Usually 5 regens in under 40 hrs of engine operation
- Regens last for about 20 mins (incomplete regen)
- Intake throttle actuator fails self calibration intermittently at engine start; becomming more frequent and unit has become noisy during operation; Ongoing issue since purchase of truck
- EGR cooler down pipe is leaking small amounts of coolant at block junction seal externally
- Ghost fault code. According to Cummins the fault code does not apply to my ESN

Need to check
- Verify fuel pump warranty work
- Verify overhead setting was done right
- Verify/correct calibration files

The EGR tune up went smoothly, seemed that the ERG plumbing was in better shape than expected. Deposits were evenly coated and no signs of leaking coolant or oil. MPG after last shop went way down. After EGR tune Up, went way up.

- Before issues started 6.5 MPG all day 55 mph or 75 mph
- After shops 5.7 MPG
- After EGR Tune Up, over 7.1 MPG, not usually over 70 mph

Opinions and suggestions on what else we should look at?

[lovoltage]

TSB130099
Technical Service Bulletin

Subject

Engine Control Module (ECM) Calibration and Aftertreatment Selective Catalytic Reduction (SCR) Catalyst Compatibility
Issue

Engine control module (ECM) calibrations released after June 21, 2013 are only compatible with specific aftertreatment selective catalytic reduction (SCR) catalyst part numbers. Downloading newer versions of an ECM calibration may require the aftertreatment SCR catalyst to be replaced. To determine the appropriate repair direction, use the ISX12/15 CM2350 Calibration Selection Tool. See link provided below.

Verification

Product Affected

ISX12 CM2350 X102
ISX15 CM2350 X101
Use the ISX12/15 CM2350 Calibration Selection Tool below to determine if a replacement SCR catalyst is required following an ECM calibration download or if an alternate ECM calibration is available to address the issue on the subject engine. An alternate ECM calibration that does not require an SCR catalyst replacement may be available.

NOTE: https://quickserve.cummins.com/qs3/porta...index.html

In addition, check the ECM calibration revisions history on QuickServe Online under My Applications section for the specified ECM base code. See link below.

NOTE: https://quickserve.cummins.com/qs3/porta...ader=false

Aftertreatment SCR catalyst compatibility with ECM Calibrations released after June 21, 2013 can be found in Table 1.

Aftertreatment SCR catalysts that are compatible with ECM calibrations released after June 21, 2013 can also be visually identified by dimples in the aftertreatment SCR catalyst heat shield. These dimples go around the circumference of the aftertreatment SCR catalyst heat shield and can be found in three different locations equidistant around the circumference. See Figure 1.


Figure 1, Aftertreatment SCR Catalyst Heat Shield Dimples

Resolution

Prior to performing any resolution which includes an ECM calibration and SCR catalyst part number update, troubleshoot any fault codes or symptoms included in the original complaint.

Follow the verification steps outlined above to determine an appropriate ECM calibration and aftertreatment SCR catalyst dependent on the level of repair being performed.

In addition, reference QuickServe Online under the Service tab for any applicable Temporary Repair Practices (TRP) or Campaigns for the subject engine.

If the ISX12/15 CM2350 Calibration Selection Tool directs replacement of the aftertreatment SCR catalyst, the compatible part numbers are located in Table 1.

Table 1, Aftertreatment SCR Catalyst Compatibility with ECM Calibration Revisions Released After June 21, 2013

Non-Compatible
5303895
5303897
5303893
5303865
5303910
5308328
5308330
5303914
5303912
5303917
4328765
5303811
5303813
4328754
4328755
4328756
4328757
4328758
4328767
5309391
5309557
5308460
5308401
5308405
5309247
5312174
5308417
5308439
5311483
5309396
5309546
5309552
5309903
5308703
5308705
5308707
5311261
5310478
5310482
5310298
5308450
5308452
5309243
5308360
5311785
5310179
5308395
5312382
5312171
5312342
5310474
4328775

Compatible
4328791
4328792
4328793
4328794
4328795
4328796
4328797
4328798
4328799
4328800
4328801
4328802
5313981
5313982
5313983
5313984
5313985
5313986
5313987
5313988
5313989
5313990
5313991
5313992
5313993
5313995
5313996
5313997
5313998
5313999
5314000
5314001
5314002
5314003
5314004
5314005
5314006
5314007
5314008
5314009
5314010
4328804
4328780
4328781
4328782
4328783
4328784
4328785
4328786
4328787
4328789
4328790

Stand-alone Part Numbers
5308751
4328788
5308454
5309911
5311328
5311330
4329551
4353331
4353333
4323335
4353337
4353339
4353341
4353343
4353345

Warranty Statement

The information in this document has no effect on present warranty coverage or repair practices, nor does it authorize TRP or Campaign actions.
Document History

Date Details
2013-6-21 Module Created
2013-7-3 Added part number cross reference
2014-7-7 none
2014-10-6 Work Order 64494
2015-1-19 Added references to Calibration Selection Tool and updated Table 1.
2015-4-9 Updated language.
Last Modified: 15-Apr-2015