Thomas Built Buses Template

STAI Technician workshop 2012
Mike Stotler
Manager Service Education
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Hero
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Hero
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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.
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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.
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A hero exhibits the following:
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Abilities
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Strength
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Knowledge
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Wisdom
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Hero’s ability
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To meet schedules
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To meet deadlines
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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
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What do you use to test this kind of circuit?
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Today we use.
V
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12v
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12v
12v
0 -0.2v
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C2 Circuit example – dome lights
12v
12v
0v
0v
3v
V
-
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Drawing 103975
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Using the ICU Dash
Diagnostics
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Electrical – Dash
diag
Fault
ECU
FAIL
PID
128
110
03
1
1
1.
Set Park Brake
2.
Turn Key to “ON”
3.
LED Screen will Show MID #s of Active Fault
Codes If Present
4.
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)
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Electrical – Dash
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This Example Code was: 128 110 03
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MID 128 – Engine
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PID 110 – Engine Coolant Temperature
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FMI 03 – Sensor Voltage Above Normal
The Engine Diagnostic Manual Defines this as:
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Engine Coolant Temp Sensor – Open Circuit
(or)
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The Sensor is Un-Plugged or Circuit Broken
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Electrical – Dash
What are these numbers? 128 110 03
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)
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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Electrical – Dash
CHECK
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Amber Warning Lamp (On)
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Most Sensor Faults
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Engine is Operational
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Continue to Use as Necessary
With a Derate in Horsepower
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Low Oil Pressure
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Coolant Temperature High
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Various EGR Codes
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Electrical – Dash
CHECK
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Amber Warning Lamp (On)
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Red Stop Lamp (On) & Derate
STOP
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Very High Coolant Temperature
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Very Low Oil Pressure
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Low Coolant Level
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Tools And Budgets
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Software
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DVOM
Voltage Check 1
12.5v
Open
M
12.5
V
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Since there is no
current flow, there
is no voltage drop
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Voltage Check 2
12.5v
Completed Circuit
M
12.5
12.47
0.00
12.45
V
-
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1200 RPM
Voltage Drop is normal on
Non-Load components as
long as the maximum drop
is ≤ 0.5v on 12v systems
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Voltage Check 3
12.5v
Green Connection
M
12.5
12.47
9.45
V
-
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300 RPM
Voltage Drop that is
Significantly less than full
system voltage indicates
High Resistance
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Ghost Voltage
Ghost
The meter is so sensitive
that it is picking up voltage
from the atmosphere
V
-
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Your body even generates
an electrical field!!
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Ghost Voltage
0.00
V
-
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This is eliminated by
touching the probes together
giving you Zero volts.
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Voltage Check 4
12.5v
+-
0.00
0.00
V
-
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If the meter reads
“True Zero” you
have Continuity
V
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Voltage Check 5
Open Connector
12.5v
+-
Blown Fuse
Ghost
V
-
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Ghost Voltage
indicates that you
have an Open
Circuit
Ghost
V
-
+
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Voltage Checks Review
12.55
Could you make these checks
with an Ohmmeter??
V
-
+
12.55 V
Ghost
V
-
0.00
+
V
-
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Power Probe ECT2000
Save time and
labor in tracing
circuits without
removing panels
www.powerprobe.com
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High Resistance Checking Tool
TESlite Voltmeter Leads
TESlite ® Enhanced Voltmeter Leads - www.teslite.com
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High Resistance Checking Tool
Without Current Flow there is No Voltage Drop
12.55
3.75
Corroded Terminal
V
-
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TESlite ®
Leads
12.55 V
PUSH the Button
Now a Circuit is Completed, there is Load,
Current flows and Voltage Drop can be read
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First Corrosion Check
Corrosion
12.55v
4.75v
V
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1. Remove load
2. Test across Load Connection
3. Low Voltage – Bad Circuit
M
M
4. Retest w/ Good Ground
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5. Low Voltage – Power Circuit is Bad
6. If Good Voltage – Ground is Bad
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Power Side Corrosion Check
Corrosion
12.55v
12.53v
12.52
3.78v
12.55v
M
V
-
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TESlite ®
Leads
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Ground Side Corrosion Check
12.55v
12.53v
4.75v
V
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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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Maintenance – Chassis
Bulb Check (Automatic)
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Set Parking Brake
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Key Off / Hazard Switch On
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Pull Turn Signal Stalk Back to “Flash to Pass” & Hold Back
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Cycle Key “Off” to “Acc” 3 Times
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Release Turn Signal Stalk
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Review Lights / Crossing Arm / Stop Signs (Clockwise from Front)
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Look out for the Crossing Arm!!
Test Complete at Horn Blow
On units
after 3/1/11
activate with
switch
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Maintenance – Transmissions
Allison ’09 Prognostics
2000 Series
Dash Lamp
• Oil Life Monitor
• Indicator or Lamp remains illuminated for 2 minutes
after Drive is selected
• Change transmission fluid.
3000 Series
Indicator
• 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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Maintenance – Engine
CHECK ALL LEVELS DAILY
Lube Oil & Lube, Fuel, Coolant Filters
Coalescing Filter (Cummins Engine)
Air Filter (Paved Roads)
Coolant Test
Overhead Adj.
DEF & DPF Filters
15K Miles / 6 Months
60K Miles / 24 Months
12 Months
250 Hours / 3 or 4 Months
150K Miles / 48 Months
200K Miles
Install Fuel Filters “DRY”
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Cummins ISB example
Cost of a Service
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What does it cost for a pm service?
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Engine Oil
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Oil Filter
$12.13
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Fuel Filter primary
$24.63
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Fuel Filter Secondary
$19.59
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Labor
$50.00
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Total per bus
$195.39
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21 quarts
$4.24/qt avg
$89.04
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$195.39 saving per service
Examples for going from 4 to 2 services a year
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2 services saved
x 80 bus fleet
= $31,262.40
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2 services saved
x 250 bus fleet
= $97,695.00
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2 service saved
x 800 bus fleet
= $312,624.00
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1 service saved
x 80 bus fleet
= $15,631.20
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1 service saved
x 250 bus fleet
= $48,847.50
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1 service saved
x 800 bus fleet
= $156,312.00
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How much could you save?
$$$$$
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Using the Websites
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Electronic Resource
www.accessfreightliner.com
Parts Pro
EZ Wiring
Service Pro
www.thomasbusonline.com
Product Support Bulletin
Manuals
Parts/Drawings
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Electronics - Parts Pro
1. Click on the Parts Pro icon
2. Enter the last six digits of the vin#.
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Electronics - Parts Pro
3. Click on the Retrieve Group Design
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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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Electronics - Parts Pro
5. Freightliner parts are organized by Group number
and Module number
6. Click on the desired Group Number
7. Click on Retrieve Design Subgroup
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Electronics - Parts Pro
8. Click on desired Subgroup
9. Click Retrieve Parts List
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Electronics – EZ Wiring
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
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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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www.thomasbusonline.com
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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 left
ELEC- parts & circuits
LAYOUT- as shown
LIGHTS- parts used, drawings
MODULE- parts used, drawings
OPERATION- 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
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