STAI Technician workshop 2012

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1 1 STAI Technician workshop 2012 Mike Stotler Manager Service Education Center for Education

2 2 Hero Center for Education

Center for Education Thomas Built Buses 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.

3 Center for Education Thomas Built Buses 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

4 Center for Education Thomas Built Buses 4 Hero s ability To meet schedules To meet deadlines To repair it correctly To make someone s day

5 Center for Education Thomas Built Buses 5 Hero s strength To handle the pressure To do the job right To tighten the fastener To protect the passengers To protect the environment

6 Center for Education Thomas Built Buses 6 Hero s knowledge Buses Systems Specifications Tools

7 Buses Center for Education Thomas Built Buses 7

8 Systems Center for Education Thomas Built Buses 8

9 Specifications Center for Education Thomas Built Buses 9

10 Tools Center for Education Thomas Built Buses 10

11 Center for Education Thomas Built Buses 11 Hero s wisdom To use the tools available Follow procedures Invest in technology

12 Using tools Center for Education Thomas Built Buses 12

13 Procedures Center for Education Thomas Built Buses 13

14 Technology Center for Education Thomas Built Buses 14

15 Center for Education Thomas Built Buses 15 Typical analog circuit What do you use to test this kind of circuit? Today we use. V v 12v 12v 0-0.2v

16 C2 Circuit example dome lights 12v 12v 0v 0v 3v V - + Drawing Center for Education Thomas Built Buses 16

17 17 Using the ICU Dash Diagnostics Center for Education

Center for Education Thomas Built Buses 18

LED Screen will Show MID #s of Active Fault

Push & Release Button to See diag x (x = #

18 Center for Education Thomas Built Buses 18 Electrical Dash diag Fault 1 ECU FAIL PID 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)

19 Electrical Dash Center for Education Thomas Built Buses 19 This Example Code was: 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

20 Electrical Dash Center for Education Thomas Built Buses 20 What are these numbers? 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

21 Center for Education Thomas Built Buses 21 Dash lights Mechanical problem ie. Oil, Temp, etc Major issue stop engine immediately Emissions malfunction drive to service area

22 Electrical Dash Center for Education Thomas Built Buses 22 CHECK Amber Warning Lamp (On) Most Sensor Faults Engine is Operational Continue to Use as Necessary With a Derate in Horsepower Low Oil Pressure Coolant Temperature High Various EGR Codes

23 Electrical Dash Center for Education Thomas Built Buses 23 CHECK Amber Warning Lamp (On) Red Stop Lamp (On) & Derate STOP Very High Coolant Temperature Very Low Oil Pressure Low Coolant Level

24 24 Tools And Budgets Center for Education

25 Software Center for Education Thomas Built Buses 25

26 DVOM Center for Education Thomas Built Buses 26 Voltage Check v M Open 12.5 V - + Since there is no current flow, there is no voltage drop

27 Center for Education Thomas Built Buses 27 Voltage Check v Completed Circuit M 1200 RPM V - + Voltage Drop is normal on Non-Load components as long as the maximum drop is 0.5v on 12v systems

28 Center for Education Thomas Built Buses 28 Voltage Check v Green Connection M 300 RPM V - + Voltage Drop that is Significantly less than full system voltage indicates High Resistance

29 Center for Education Thomas Built Buses 29 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!!

30 Center for Education Thomas Built Buses 30 Ghost Voltage 0.00 V This is eliminated by touching the probes together giving you Zero volts. - +

31 Center for Education Thomas Built Buses 31 Voltage Check v If the meter reads V True Zero you V - + have Continuity - +

32 Center for Education Thomas Built Buses 32 Voltage Check v Open Connector +- Blown Fuse Ghost V - + Ghost Voltage indicates that you have an Open Circuit Ghost V - +

33 Center for Education Thomas Built Buses 33 Voltage Checks Review V - + Could you make these checks with an Ohmmeter?? V Ghost V V - +

34 Center for Education Thomas Built Buses 34 Power Probe ECT2000 Save time and labor in tracing circuits without removing panels

35 Center for Education Thomas Built Buses 35 High Resistance Checking Tool TESlite Voltmeter Leads TESlite Enhanced Voltmeter Leads -

36 Center for Education Thomas Built Buses 36 High Resistance Checking Tool V Without Current Flow there is No Voltage Drop Corroded Terminal - + TESlite Leads V PUSH the Button Now a Circuit is Completed, there is Load, Current flows and Voltage Drop can be read

37 Center for Education Thomas Built Buses 37 First Corrosion Check 12.55v Corrosion 4.75v 1. Remove load 2. Test across Load Connection 3. Low Voltage Bad Circuit M M V 4. Retest w/ Good Ground Low Voltage Power Circuit is Bad 6. If Good Voltage Ground is Bad

38 Center for Education Thomas Built Buses 38 Power Side Corrosion Check 12.55v Corrosion 12.55v 12.53v v M V - + TESlite Leads

39 Center for Education Thomas Built Buses 39 Ground Side Corrosion Check 12.55v 12.53v 4.75v M V - + Corrosion

40 Center for Education Thomas Built Buses 40 Maintenance - Front Tire Balance

41 Center for Education Thomas Built Buses 41 Body Panel & Glass Removal Video

Center for Education Thomas Built Buses 42

Parking Brake Key Off / Hazard Switch On Pull Turn

Cycle Key Off to Acc 3 Times Release Turn Signal

(Clockwise from Front) Look out for the Crossing

42 Center for Education Thomas Built Buses 42 Maintenance Chassis 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 On units after 3/1/11 activate with switch!

Center for Education Thomas Built Buses 43 Maintenance Transmissions Allison 09

Drive is selected Change transmission fluid.

43 Center for Education Thomas Built Buses 43 Maintenance Transmissions Allison 09 Prognostics 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 Series Dash Lamp 3000 Series Indicator

DEF & DPF Filters 15K Miles / 6 Months 60K Miles / 24 Months 12 Months 250 Hours / 3 or 4

44 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 Center for Education Thomas Built Buses 44

45 Center for Education Thomas Built Buses 45 Cost of a Service Cummins ISB example 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

46 Center for Education Thomas Built Buses 46 $ saving per service Examples for going from 4 to 2 services a year 2 services saved x 80 bus fleet = $31, services saved x 250 bus fleet = $97, service saved x 800 bus fleet = $312, service saved x 80 bus fleet = $15, service saved x 250 bus fleet = $48, service saved x 800 bus fleet = $156, How much could you save? $$$$$

47 47 Using the Websites Center for Education

48 48 Electronic Resource Parts Pro EZ Wiring Service Pro Center for Education Product Support Bulletin Manuals Parts/Drawings

49 Center for Education Thomas Built Buses 49 Electronics - Parts Pro 1. Click on the Parts Pro icon 2. Enter the last six digits of the vin#.

50 Center for Education Thomas Built Buses 50 Electronics - Parts Pro 3. Click on the Retrieve Group Design

51 Center for Education Thomas Built Buses 51 Electronics - Parts Pro 4. For chassis parts, Click on FCC You must click on FCC to continue

52 Center for Education Thomas Built Buses 52 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

53 Center for Education Thomas Built Buses 53 Electronics - Parts Pro 8. Click on desired Subgroup 9. Click Retrieve Parts List

54 Center for Education Thomas Built Buses 54 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

55 Example - Parts Pro Center for Education Thomas Built Buses 55

56 Center for Education Thomas Built Buses 56 Electronics Service Pro 1. Enter VIN number of chassis

57 Center for Education Thomas Built Buses 57 Electronics Service Pro 2. Basic Information displays automatically If unit has an open Freightliner recall, a recall message will show on screen

58 Center for Education Thomas Built Buses 58 Electronics Service Pro 3. Major Components show S/N and oil type

59 Center for Education Thomas Built Buses 59 Electronics Service Pro 4. Recall / Campaigns show current status A Claim Number indicates a Completed Claim

60 Center for Education Thomas Built Buses 60 Electronics Service Pro 5. Air Management Unit Information

61 Electronics Service Pro Center for Education Thomas Built Buses 61

62 Electronics Service Pro Center for Education Thomas Built Buses 62

63 Electronics Service Pro Center for Education Thomas Built Buses 63

64 Electronics Service Pro Center for Education Thomas Built Buses 64

65 Electronics Service Pro Center for Education Thomas Built Buses 65

66 Electronics Service Pro Center for Education Thomas Built Buses 66

67 Center for Education Thomas Built Buses 67

68 Electronics - News Center for Education Thomas Built Buses 68

69 Electronics - Registration Center for Education Thomas Built Buses 69

70 Electronics - Parts Center for Education Thomas Built Buses 70

71 Electronics - Parts Center for Education Thomas Built Buses 71

72 Electronics - Parts Center for Education Thomas Built Buses 72

73 Electronics - Parts Center for Education Thomas Built Buses 73

74 Center for Education Thomas Built Buses 74 Electronics - Parts Areas shown on left ELEC- parts & circuits LAYOUT- as shown LIGHTS- parts used, drawings MODULE- parts used, drawings OPERATION- instructions

75 Center for Education Thomas Built Buses 75 Electronics - Parts ELEC-LPS STOP/TAIL/TURN

76 Electronics - Parts Center for Education Thomas Built Buses 76

77 Center for Education Thomas Built Buses 77 Electronics - Parts ELEC-HTR U/SEAT POS

78 Electronics - Parts Center for Education Thomas Built Buses 78

79 Electronics PSB s Center for Education Thomas Built Buses 79

80 Electronics PSB s Center for Education Thomas Built Buses 80

81 Electronics PSB s Center for Education Thomas Built Buses 81

82 Electronics PSB s Center for Education Thomas Built Buses 82

83 Electronics PSB s Center for Education Thomas Built Buses 83

84 Electronics PSB s Center for Education Thomas Built Buses 84

85 Electronics - Manuals Center for Education Thomas Built Buses 85

86 Center for Education Thomas Built Buses 86 Electronics - Manuals The FS65 & C2 Service Manuals are produced by Freightliner

Vehicle Components. Vehicle Key Data Points

Vehicle Components. Vehicle Key Data Points VIN Vehicle Make Model Model Year 2HSCUAPR48C687071 International Prostar 2008 Vehicle s Serial Number Software Version Network Engine Cummins 15.0L ISX1 79277503 03684275 05000708 072209134739 08000062