2007 Emissions: Fundamentals

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1 A N AV I S TA R C O M PA N Y 2007 Emissions: Fundamentals Study Guide TMT Study Guide 2007 Emissions: Fundamentals TMT

2 2007 International Truck and Engine Corporation 4201 Winfield Road, Warrenville, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of International Truck and Engine Corporation.

3 Table of Contents Introduction...3 Module 1: Emissions Basics...5 Module 2: Exhaust Aftertreatment...7 Diesel Oxidation Catalyst... 7 Diesel Particulate Filter... 8 Module 3: Engine System...9 Module 4: Regeneration...11 Level 1 Warning Level 2 Warning Level 3 Warning Level 4 Warning Parked Regeneration... 16

4 Emissions: Fundamentals

5 Introduction Emissions: Fundamentals Welcome to the International 2007 Emissions Fundamentals DVD program. This program is designed to provide you with a basic understanding of 2007 emission standards set forth by the Environmental Protection Agency for diesel powered vehicles, and what International Truck and Engine Corporation is doing to meet those standards. It also provides you with key service information for the exhaust aftertreatment system on International vehicles. Objectives After completion of this program, you will be able to:..identify the makeup of diesel exhaust...explain the operation of the exhaust aftertreatment...identify the different types of regeneration...identify the levels of emission control warnings...perform the Parked Regeneration procedure. To receive credit for completing this program, you are required to take a post-test on ISIS /Education/Service/ Online Testing.

6 Emissions: Fundamentals NOTES

7 Module 1: Emissions Basics 5 Emissions Basics Module 1 You don t have to drive very far to see for yourself the importance of reducing automotive exhaust emissions. As of January 2007, all diesel-powered trucks weighing over 8500 lbs. are subject to more stringent emission control standards. These are designed to reduce particles in truck exhaust by 90% and nitrogen oxides by 50%. Exhaust emissions from internal combustion engines are made up of hydrocarbons, carbon monoxide, carbon dioxide and nitrogen oxides. Diesel engine exhaust also produces solid particles, or particulates. Particulate matter is commonly referred to as soot. Diesel particulates include ash, metallic abrasives, sulfates and silicates. Hydrocarbons are the remnants of unburned fuel that make it through to the exhaust. They may be toxic and are a major contributor to urban smog. Carbon monoxide, or CO, is odorless and invisible. In the body, It reduces the blood s ability to carry oxygen, and poses very serious health risks to people. Hydrocarbons are the remnants of unburned fuel that make it through to the exhaust.

8 Emissions: Fundamentals Carbon dioxide, or CO 2, is not harmful to humans and is essential to plants. It is not currently regulated, but is believed to be a contributing factor to the greenhouse effect reportedly causing global warming. Nitrogen oxides contribute to smog and acid rain. Nitrogen oxides are the various combinations of nitrogen and oxygen produced when normal air is taken into an engine and subjected to high temperature and pressure. Nitrogen oxides contribute to smog and acid rain.

9 Module 2: Exhaust Aftertreatment 7 Exhaust Aftertreatment Module 2 For the purposes of this program we are using International medium and heavy duty vehicles to demonstrate the information presented in the rest of this program. The vehicles are equipped with 2007 emissions-compliant International and Cummins engines and exhaust aftertreatments emissions-compliant engines systems may use different equipment in shape and size, but all work under the same principles to reduce exhaust particulate matter. Diesel Oxidation Catalyst The Diesel Oxidation Catalyst, or DOC, functions the same as it did on previous vehicles. There is no need to service the DOC since it s a flowthrough component with the same life expectancy as the engine. The DOC is the first line of defense in removing particulate matter from the exhaust gases. As long as the engine is running above oxidation temperatures, the particulate matter is burnt off as the exhaust gases pass through the DOC. The DOC is the first line of defense in removing particulate matter from the exhaust gases.

10 Emissions: Fundamentals Diesel Particulate Filter A Diesel Particulate Filter, or DPF, is added to the system and used to burn off soot collected when the exhaust system is not running above oxidation temperatures. The DPF is made out of porous ceramic material and follows the DOC in the exhaust flow. This ceramic filter has plugged channels in a checkerboard pattern, forcing the exhaust gas through filtration material to collect the particulates on the surfaces of these channels. The collection of soot on the surfaces is then burned to ash. The collection of soot on the surfaces is then burnt away and transformed into gases that pass through the filter with some ash remaining. On medium duty vehicles this is a separate component. On heavy duty vehicles it is integrated with the DOC.

11 Module 3: Engine System 9 Engine System Module 3 The 2007 emissions regulations cannot be met with just the addition of the DPF. The DPF is just one part of the equation in a complex formula required to meet the standard. Most diesel engine manufacturers have had to modify the way the entire engine system operates. These modifications may include the cooling system, the EGR system, fuel specifications, lubrication, and vehicle electronics. The federal government has also mandated the use of ultra low sulfur diesel fuel, which contains a maximum sulfur content of 15 parts per million. Most diesel engine manufacturers have had to modify the way the entire engine system operates. The use of particulate filters that accumulate soot and ash require the use of new low-ash lube oil, since some of this oil burns in the combustion process. The aftertreatment system includes three temperature sensors and one pressure sensor with two inputs. The temperature sensors are placed in front of the DOC, one between the DOC and DPF, and one behind the DPF.

12 Emissions: Fundamentals The Delta pressure sensor has two inputs connected to the front and back of the DPF to determine the amount of backpressure caused by contaminant build-up. This sensor relays information to the control module, which monitors the entire process and alerts the driver when exhaust system maintenance is necessary.

13 Module 4: Regeneration 11 Regeneration Module 4 Periodically, the soot and ash particulates in the DPF must be burned off. This process is called regeneration and it can occur passively, actively, or by a driver-initiated procedure. Passive regeneration of the DPF simply means that, at normal highway operating temperatures, the exhaust system gets hot enough to ignite these particulates in the DPF. This automatically cleans, or regenerates, the filtration material in the DPF, extending its usable life. Active regeneration is initiated automatically by the aftertreatment system when passive regeneration is not effective enough by itself. This can be necessary in cold climates or during light duty cycles in which normal operating temperatures are not always reached. During the Active Regeneration process, fuel is injected into the exhaust stream and ignited at the DOC, raising the temperature of the DPF enough to burn the particulates. Active regeneration is initiated automatically by the aftertreatment system. Then, there is a third, driver-initiated method referred to as Parked Regeneration. When the opportunities for effective passive and active strategies aren t adequate enough to

14 Emissions: Fundamentals! Warning Whenever you are required to perform a Parked Regeneration, park the vehicle in a safe area, away from people, objects, any flammable materials, vapors, or structures. Pulling over on the side of the road is not adequately safe. Use a vacant parking space away from any roadway. Parked Regeneration may increase engine speed.! Warning Respond immediately to the exhaust filter indicators and initiate the proper regeneration procedure. Failure to do so may lead to reduction in engine power, reduction of vehicle speed, and an unexpected stalled engine. do the job alone, Parked Regeneration is required. This procedure will be detailed later in this program. Finally, ash residue from regeneration must be periodically cleaned out of the DPF. International vehicles are equipped with a warning system letting the driver know when the system needs to be regenerated and cleaned. There are four levels of warnings indicating the DPF has accumulated too much material, each with an increasing urgency for action. Level 1 Warning A Level 1 warning is indicated by a solid yellow light and means that the DPF needs to be regenerated to maintain efficient operation. If the vehicle is driven at highway speed for an extended period of time, allowing the engine and exhaust to reach normal operating temperature and passively regenerate, a Level 1 indication may disappear. If the Level 1 warning does not disappear after the engine reaches normal operating temperature, the driver needs to drive the vehicle to a location away from traffic, people and objects and perform a Parked Regeneration.

15 Module 4: Regeneration 13 NOTES

16 Emissions: Fundamentals Note Indicators and locations may differ depending on the vehicle. Refer to ISIS for the most current information.! Warning The vehicle must be pulled safely off the road to avoid an engine shut-down and a Parked Regeneration must be initiated as soon as possible. Level 2 Warning A Level 2 warning is indicated by a flashing yellow light and means that the material accumulated in the DPF has reached a critical level. If the Level 2 warning does not reduce to Level 1 or disappear after the engine reaches normal operating temperature, as before, the driver needs to drive the vehicle to a location away from traffic, and perform a Parked Regeneration. Level 3 Warning A Level 3 warning is indicated by a flashing yellow light plus an additional solid yellow indicator light and an audible alarm. This means that the DPF is severely clogged.! Warning If the engine shuts down, it can be restarted and will operate in a de-rated mode for an additional 30 seconds. The vehicle must be pulled safely off the road to avoid an engine shut-down. Stop the engine, turn on the emergency flashers, place warning devices, and seek service assistance immediately. Level 4 Warning A Level 4 warning is indicated by a solid red light and an audible alarm. This means that a serious engine problem has occurred, such as an overfull DPF, and the engine may shut down soon.

17 Module 4: Regeneration 15 NOTES

18 Emissions: Fundamentals! Warning Failure to follow the Parked Regeneration instructions may result in a loss of engine power or vehicle speed, increased exhaust temperatures, and may cause an accident or fire.! Warning Shift the transmission to park or neutral, set the parking brake, remove your feet from the accelerator, brake and clutch pedals, and block the wheels before performing a Parked Regeneration. If any of these conditions change during the Parked Regeneration, the process will stop and you must start over. Parked Regeneration To perform a Parked Regeneration in response to warning Levels 1, 2 or 3, first park the truck safely off the road and away from flammable materials. Do NOT shut the engine off. Press the PARKD REGEN switch to initiate the regeneration cycle. The engine speed automatically ramps up to a preset rpm and the switch indicator illuminates when the cycle is started. If the indicator is blinking, check to be sure the transmission is in neutral, the parking brake is set, and your feet are off all the pedals. The exhaust temperature lamp will go on during regeneration to indicate the exhaust is hot and will go out after regeneration stops. Once started, the regeneration cycle lasts approximately 20 minutes.

19 Module 4: Regeneration 17 When the regeneration cycle is complete, the switch light will go off, the engine rpm returns to normal idle, and all exhaust filter indicators will be off. The vehicle may now be driven normally. The regeneration process leaves an ash residue in the DPF that must be cleaned out periodically. The filters used by International are designed to go at least 150,000 miles between cleanings, depending on how the truck is used. This could mean a maintenance cycle of 12 months to 5 years or more. Note In the event of an emergency requiring the vehicle to be moved before Parked Regeneration is completed, you can cancel the process by pressing the PARKD REGEN switch to the off position, or by depressing the brake pedal. Conclusion This concludes the International 2007 Emissions Fundamentals DVD training program. Completion of this educational process is a key component towards International Technician Certification. You are now required to take a post-test via ISIS / Education/Service/Online Testing.

20 Emissions: Fundamentals NOTES

21 2007 Emissions: Fundamentals 19 NOTES

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23 2007 Emissions: Fundamentals 21 NOTES

24 Emissions: Fundamentals NOTES

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