STAI Technician workshop 2012 - Kerlin Bus...

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Center for Education

STAI Technician workshop 2012

Mike StotlerManager Service Education

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Hero

Thomas Built BusesCenter for Education 3

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


Hero’s ability

• To meet schedules

• To meet deadlines

• To repair it correctly

• To make someone’s day


Hero’s strength

To handle the pressure

To do the job right

To tighten the fastener

To protect the passengers

To protect the environment


Hero’s knowledge

Buses

Systems

Specifications

Tools


Buses


Systems


Specifications


Tools


Hero’s wisdom

To use the tools available

Follow procedures

Invest in technology


Using tools


Procedures


Technology


Typical analog circuit

• What do you use to test this kind of circuit?

• Today we use.

V

- +

12v 12v 12v 0 -0.2v

Presenter

Presentation Notes

Simple circuit that you can trace from one end to the other if needed. What carry’s the load of the light or consumer? SWITCH What are you looking for when testing this circuit? Always looking for POWER All the circuits were 12v so the test light worked great. Today we use a DVOM because not all circuits are 12v.


C2 Circuit example –

dome lights

12v 12v0v

0v

3v

V

- +

Drawing 103975

Presenter

Presentation Notes

Where is the switch located in this circuit? Out of the circuit. Is it carrying a load? NO When testing this circuit what are you looking for, power or ground? GROUND Since the computer completes the ground you are looking for ground to be triggered. How much load am I putting on the module? NONE Is the switch carrying any load or completing the circuit? NO

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Using the ICU DashDiagnostics


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


• 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


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


Dash lights

Mechanical problem ie. Oil, Temp, etc

Major issue stop engine immediately

Emissions malfunction drive to service area


• 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


• Amber Warning Lamp (On)

• Red Stop Lamp (On) & Derate

• Very High Coolant Temperature

• Very Low Oil Pressure

• Low Coolant Level

Electrical –

Dash

CHECK

STOP

24


Tools And

Budgets


Software


Voltage Check 1

M

V

- +

12.5

Open

Since there is no current flow, there is no voltage drop

12.5v

DVOM


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


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


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!!


Ghost Voltage

0.00

V

- +

This is eliminated by touching the probes together

giving you Zero volts.


Voltage Check 4

V

- +

+-

V

- +

If the meter reads “True Zero”

you have Continuity

0.00 0.00

12.5v


Voltage Check 5

V

- +

+-

V

- +

Open Connector

Blown Fuse

Ghost Voltage indicates that you

have an Open Circuit

Ghost Ghost

12.5v


Voltage Checks Review

V

- +

V

- +

12.55

Ghost

12.55 V

V

- +

0.00

Could you make these checkswith an Ohmmeter??


Power Probe ECT2000

www.powerprobe.com

Save time and labor in tracing circuits without removing panels


High Resistance Checking ToolTESlite Voltmeter Leads

TESlite

®

Enhanced Voltmeter Leads -

www.teslite.com


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


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


Power Side Corrosion Check

V

- +

M

12.55v

12.55v12.53v12.523.78v

Corrosion

TESlite

®Leads


Ground Side Corrosion Check

12.55v

V

- +

M12.53v4.75v

Corrosion


Maintenance

- Front Tire Balance

www.tru-bal.com

http://www.tru-bal.com/


Body Panel & Glass Removal

www.theinductor.com

Video

http://www.theinductor.com/


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


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.


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”

Presenter

Presentation Notes

Analysis Kits: Oil 23520989 Fuel23516922 Coolant23516921 Coolant Test Strips: 1 - 23519401 (Foil Wrapped) 10 - 23522774 50 - 23519402


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


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




• How much could you save?

$195.39 saving per service

$$$$$

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Using the Websites

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Electronic Resource

Parts ProEZ Wiring

Service Pro

Product Support BulletinManuals

Parts/Drawings

www.thomasbusonline.com

www.accessfreightliner.com


1. Click on the Parts Pro icon 2. Enter the last six digits of the vin#.

Electronics -

Parts Pro


3. Click on the Retrieve Group Design

Electronics -

Parts Pro


Electronics -

Parts Pro

4. For chassis parts, Click on FCC

You must click on “FCC” to continue


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


8. Click on desired Subgroup9. Click Retrieve Parts List

Electronics -

Parts Pro


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


Example -

Parts Pro


Electronics –

Service Pro

1. Enter VIN number of chassis


Electronics –

Service Pro

2. Basic Information displays automatically

If unit has an open Freightliner recall, a “recall message”

will show on screen


Electronics –

Service Pro

3. Major Components show S/N and oil type


Electronics –

Service Pro

4. Recall / Campaigns show current status

A “Claim Number” indicates a Completed Claim


Electronics –

Service Pro

5. Air Management Unit – Information


Electronics –

Service Pro


www.thomasbusonline.com

http://www.thomasbusonline.com/


Electronics -

News


Electronics -

Registration


Electronics -

Parts


Electronics -

Parts

Areas shown on leftELEC- parts & circuitsLAYOUT- as shownLIGHTS- parts used, drawingsMODULE- parts used, drawingsOPERATION- instructions


Electronics -

Parts

ELEC-LPS STOP/TAIL/TURN…


Electronics -

Parts


Electronics -

Parts

ELEC-HTR U/SEAT POS…


Electronics -

Parts


Electronics –

PSB’s


Electronics -

Manuals


Electronics -

Manuals

The FS65 & C2 Service Manuals are produced by Freightliner

STAI Technician workshop 2012 - Kerlin Bus...

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