stai technician workshop 2012 - kerlin bus...
TRANSCRIPT
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Center for Education
STAI Technician workshop 2012
Mike StotlerManager Service Education
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Center for Education
Hero
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Hero
• Definition: a person who, in the opinion of others, has heroic qualities or has performed a heroic act and is regarded as a model or ideal.
• Example: He was a hero when he repaired the bus in time to make the run to take the kids to the museum. The kids and driver all called him a hero.
• A hero exhibits the following:• Abilities• Strength • Knowledge• Wisdom
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Hero’s ability
• To meet schedules
• To meet deadlines
• To repair it correctly
• To make someone’s day
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Hero’s strength
To handle the pressure
To do the job right
To tighten the fastener
To protect the passengers
To protect the environment
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Hero’s knowledge
Buses
Systems
Specifications
Tools
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Buses
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Systems
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Specifications
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Tools
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Hero’s wisdom
To use the tools available
Follow procedures
Invest in technology
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Using tools
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Procedures
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Technology
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Typical analog circuit
• What do you use to test this kind of circuit?
• Today we use.
V
- +
12v 12v 12v 0 -0.2v
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C2 Circuit example –
dome lights
12v 12v0v
0v
3v
V
- +
Drawing 103975
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Using the ICU DashDiagnostics
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1. Set Park Brake2. Turn Key to “ON”3. LED Screen will Show MID #s of Active Fault
Codes If Present4. Push & Release Button to See “diag x” (x = #
faults)
5. Push & Hold Button to See “Fault 1”6. “P & R” Button for MID,PID/SID & FMI
(Repeat Steps 5 & 6 for Add. Codes)
ECU 128diag 1
Fault1
ECU 128PID 110FAIL 03
Electrical –
Dash
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• This Example Code was: 128 110 03
• MID 128 – Engine
• PID 110 – Engine Coolant Temperature
• FMI 03 – Sensor Voltage Above Normal
• The Engine Diagnostic Manual Defines this as:
• Engine Coolant Temp Sensor – Open Circuit
(or)
• The Sensor is Un-Plugged or Circuit Broken
Electrical –
Dash
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MID Which System is Having Problems
128
Engine System (Cat, Cummins, Mercedes)
PID/SID Which Part/Area Has the Problem
110
Engine Coolant Temperature
FMI
Identifies the Component’s Problem
03
Sensor Voltage Above Normal
(SAE J1587)
What are these numbers? 128 110 03
Electrical –
Dash
Fault
Codes
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Dash lights
Mechanical problem ie. Oil, Temp, etc
Major issue stop engine immediately
Emissions malfunction drive to service area
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• Amber Warning Lamp (On)
• Most Sensor Faults
• Engine is Operational
• Continue to Use as Necessary
Electrical –
Dash
With a Derate
in Horsepower
• Low Oil Pressure
• Coolant Temperature High
• Various EGR Codes
CHECK
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• Amber Warning Lamp (On)
• Red Stop Lamp (On) & Derate
• Very High Coolant Temperature
• Very Low Oil Pressure
• Low Coolant Level
Electrical –
Dash
CHECK
STOP
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Tools And
Budgets
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Software
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Voltage Check 1
M
V
- +
12.5
Open
Since there is no current flow, there is no voltage drop
12.5v
DVOM
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Voltage Drop is normal on Non-Load
components as long as the maximum drop is ≤
0.5v on 12v systems
Voltage Check 2
M
V
- +
12.512.4712.450.00
Completed Circuit12.5v
1200 RPM
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Voltage Check 3
M
V
- +
12.512.479.45 Voltage Drop that is Significantly less than full system voltage indicates
High Resistance
Green
Connection12.5v
300 RPM
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Ghost Voltage
Ghost
V
- +
The meter is so sensitive that it is picking up voltage
from the atmosphere
Your body even generates an electrical field!!
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Ghost Voltage
0.00
V
- +
This is eliminated by touching the probes together
giving you Zero volts.
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Voltage Check 4
V
- +
+-
V
- +
If the meter reads “True Zero”
you have Continuity
0.00 0.00
12.5v
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Voltage Check 5
V
- +
+-
V
- +
Open Connector
Blown Fuse
Ghost Voltage indicates that you
have an Open Circuit
Ghost Ghost
12.5v
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Voltage Checks Review
V
- +
V
- +
12.55
Ghost
12.55 V
V
- +
0.00
Could you make these checkswith an Ohmmeter??
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Power Probe ECT2000
www.powerprobe.com
Save time and labor in tracing circuits without removing panels
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High Resistance Checking ToolTESlite Voltmeter Leads
TESlite
®
Enhanced Voltmeter Leads -
www.teslite.com
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High Resistance Checking Tool
V
- +
Corroded Terminal12.55
12.55 V
Without Current Flow there is No Voltage Drop12.55
Now a Circuit is Completed, there is Load, Current flows and Voltage Drop can be read
3.75
PUSH the Button
TESlite
®Leads
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Corrosion
First Corrosion Check
12.55v
V
- +
M M4.75v4.75v
1.
Remove load2.
Test across Load Connection3.
Low Voltage –
Bad Circuit
5.
Low Voltage –
Power Circuit is Bad
6.
If Good Voltage –
Ground is Bad
4.
Retest w/ Good Ground
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Power Side Corrosion Check
V
- +
M
12.55v
12.55v12.53v12.523.78v
Corrosion
TESlite
®Leads
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Ground Side Corrosion Check
12.55v
V
- +
M12.53v4.75v
Corrosion
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Maintenance
- Front Tire Balance
www.tru-bal.com
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Body Panel & Glass Removal
www.theinductor.com
Video
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Bulb Check (Automatic)
• Set Parking Brake
• Key Off / Hazard Switch On
• Pull Turn Signal Stalk Back to “Flash to Pass” & Hold Back
• Cycle Key “Off” to “Acc” 3 Times
• Release Turn Signal Stalk
• Review Lights / Crossing Arm / Stop Signs (Clockwise from Front)
• Look out for the Crossing Arm!!
• Test Complete at Horn Blow
!
Maintenance –
Chassis
On units after 3/1/11 activate with switch
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Maintenance –
Transmissions
Allison ’09 Prognostics 2000
SeriesDash Lamp
3000
SeriesIndicator
• Oil Life Monitor• Indicator or Lamp remains illuminated for 2 minutes
after Drive is selected• Change transmission fluid.
• Filter Life Monitor• Indicator or Lamp remains flashing for 2 minutes
after Drive is selected.• Change transmission filter(s)
• Transmission Health Monitor• Indicator or Lamp remains illuminated at all times
during vehicle operation.• Clutch system may have exceeded specified limits.
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CHECK ALL LEVELS DAILY
Maintenance –
Engine
Lube Oil & Lube, Fuel, Coolant Filters 15K Miles / 6 MonthsCoalescing Filter (Cummins Engine) 60K Miles / 24 Months
Air Filter (Paved Roads) 12 MonthsCoolant Test 250 Hours / 3 or 4 Months
Overhead Adj. 150K Miles / 48 MonthsDEF & DPF Filters 200K Miles
Install Fuel Filters “DRY”
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Cost of a Service
• What does it cost for a pm service?
• Engine Oil 21 quarts $4.24/qt avg $89.04
• Oil Filter $12.13
• Fuel Filter primary $24.63
• Fuel Filter Secondary $19.59
• Labor $50.00
• Total per bus $195.39
Cummins ISB example
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Examples for going from 4 to 2 services a year
• 2 services saved x 80 bus fleet = $31,262.40
• 2 services saved x 250 bus fleet = $97,695.00
• 2 service saved x 800 bus fleet = $312,624.00
• 1 service saved x 80 bus fleet = $15,631.20
• 1 service saved x 250 bus fleet = $48,847.50
• 1 service saved x 800 bus fleet = $156,312.00
• How much could you save?
$195.39 saving per service
$$$$$
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Center for Education
Using the Websites
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Center for Education
Electronic Resource
Parts ProEZ Wiring
Service Pro
Product Support BulletinManuals
Parts/Drawings
www.thomasbusonline.com
www.accessfreightliner.com
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1. Click on the Parts Pro icon 2. Enter the last six digits of the vin#.
Electronics -
Parts Pro
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3. Click on the Retrieve Group Design
Electronics -
Parts Pro
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Electronics -
Parts Pro
4. For chassis parts, Click on FCC
You must click on “FCC” to continue
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5. Freightliner parts are organized by Group number and Module number
6. Click on the desired Group Number7. Click on Retrieve Design Subgroup
Electronics -
Parts Pro
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8. Click on desired Subgroup9. Click Retrieve Parts List
Electronics -
Parts Pro
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12. Drawings can be viewed by clicking on electrical description of harness assembly, schematic or installation drawing
13. Click on EZ on toolbar at top
Electronics –
EZ Wiring
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Example -
Parts Pro
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Electronics –
Service Pro
1. Enter VIN number of chassis
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Electronics –
Service Pro
2. Basic Information displays automatically
If unit has an open Freightliner recall, a “recall message”
will show on screen
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Electronics –
Service Pro
3. Major Components show S/N and oil type
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Electronics –
Service Pro
4. Recall / Campaigns show current status
A “Claim Number” indicates a Completed Claim
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Electronics –
Service Pro
5. Air Management Unit – Information
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Electronics –
Service Pro
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Electronics –
Service Pro
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Electronics –
Service Pro
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Electronics –
Service Pro
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Electronics –
Service Pro
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Electronics –
Service Pro
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Electronics -
News
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Electronics -
Registration
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Electronics -
Parts
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Electronics -
Parts
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Electronics -
Parts
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Electronics -
Parts
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Electronics -
Parts
Areas shown on leftELEC- parts & circuitsLAYOUT- as shownLIGHTS- parts used, drawingsMODULE- parts used, drawingsOPERATION- instructions
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Electronics -
Parts
ELEC-LPS STOP/TAIL/TURN…
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Electronics -
Parts
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Electronics -
Parts
ELEC-HTR U/SEAT POS…
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Electronics -
Parts
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Electronics –
PSB’s
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Electronics –
PSB’s
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Electronics –
PSB’s
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Electronics –
PSB’s
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Electronics –
PSB’s
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Electronics –
PSB’s
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Electronics -
Manuals
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Electronics -
Manuals
The FS65 & C2 Service Manuals are produced by Freightliner