OBD Distubuter training.ppt
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Transcript of OBD Distubuter training.ppt
BMC TRAINING CENTER
Controls and On Board Diagnostics
BMC TRAINING CENTER
Controls and On Board Diagnostics
OBD 1 Overview OBD 1 Specific diagnostics OBD 1+ OverviewOBD 1+ Specific diagnostics
BMC TRAINING CENTER
Euro 4 OBD 1Euro 4 OBD 1 Product OverviewEuro 4 OBD 1 System Overview
BMC TRAINING CENTER
-OOR Diagnostics
EuroIV Diagnostic Set
Non-OBD Diagnostics which remain in an OBD product.
Standard Diagnostic Set
OBD Diagnostics
New Diagnostics
Cummins EuroIV OBD Product
-System Monitors
-In-Range Diagnostics
BMC TRAINING CENTER
Euro 4 OBD 1 Product Overview
Cummins Euro 4 Products– All Euro 4 engines feature electronic fuel systems.– Euro 4 emissions levels are met on all platforms
using selective catalytic reduction (SCR) NOx aftertreatment.
– This means 4 and 6 liter platforms - all applications.– Cummins has integrated the engine, aftertreatment,
and OBD System into one control module. – Engine Platforms
• ISBe4 6 Cylinder• ISBe4 4 Cylinder
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Diagnostics– Fuel System
• Electrical disconnection of any component that results in an emissions increase exceeding any of the OBD threshold limits
– Engine System• Electrical disconnection of any component that results in an
emissions increase exceeding any of the OBD threshold limits
– SCR System• Electrical disconnection of any component that results in an
emissions increase exceeding any of the OBD threshold limits• Bulleted failure modes identified in the regulation specific to a deNOx
system
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Fuel System: Electrical Disconnection– Fuel Pressure Sensor
• Sensor disconnection – FC 451– High Pressure Fuel Pump Injection Metering Valve
• Actuator disconnection – FC 272– Fuel Injectors 1-6
• Injector disconnection – FC 322-325, 331, 332– Engine Speed Sensor (Crank)
• Sensor disconnection – FC 689– Engine Position Sensor (Cam)
• Sensor disconnection – FC 778
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Engine System: Electrical Disconnection– Coolant Temperature Sensor
• Sensor disconnection – FC 144
– Charge Temperature Sensor (Intake Manifold Temperature)• Sensor disconnection – FC 153
– Charge Pressure Sensor (Boost Pressure)• Sensor disconnection – FC 123
– Ambient Air Pressure Sensor• Sensor disconnection – FC 222
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview SCR System
Mixing
SCR Catalyst
Exhaust Gas Processor (EGP)
Exhaust Gas
Urea Injector
Urea Tank
Level Sensor
Temperature Sensor
Tank Heater
Dosing UnitUrea Supply
Urea ReturnAir Supply
Exhaust Gas Temperature Sensors
Air SolenoidElectronic Control Module (ECM)
CAN bus (SAE J1939)
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
SCR System: Electrical Disconnection– Catalyst Input Temperature Sensor
• Sensor disconnection – FC 1666– Catalyst Output Temperature Sensor
• Sensor disconnection – FC 1675– SCR Air Solenoid
• Solenoid disconnection – FC 1698– Urea Level Sensor
• Sensor disconnection – FC 1668– Urea Temperature Sensor
• Sensor disconnection – FC 1678– Urea Tank Heater Relay
• Relay disconnected – FC 1683
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
SCR System: Failure Detection– Urea Tank Level Monitor
– Urea Tank Heater Monitor
– Urea Consumption Monitor (SCR System Monitor)
– SCR Dosing Unit
– SCR Catalyst Presence
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Urea Tank Level Monitor – 1671 – Detects a low urea tank level
when the urea level sensor reads below 12%. (Yellow Diagnostic Lamp)
– 1673 - Detects an empty urea tank when the urea level sensor reads less than 6% urea. (Flashing MI)
Watch outs– The weema sensor steps need to be
able to read between 18%-12%, 12%-6% and 6%-0%
Level Sensor
Temperature Sensor
Tank Heater
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Urea Tank Heater Monitor – FC 1712– Detects a disconnected urea tank
heater
Malfunction– Heater unable to heat urea tank– 50 minutes with temperature
increase below 2 Deg C, -5 Deg is considered a frozen tank
Watch outs– If no heater fitted and disabled in
Insite the diagnostic will still
Level Sensor
Temperature Sensor
Tank Heater
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Urea Consumption Monitor – FC 1699– Detects SCR system failures by comparing
commanded urea injection to actual urea consumed. Malfunction
– Abnormal Adblue usage– If 3.2 letters of Adblue have been commend and the
level sensor dose not indicate this– If the level has changes by 3.2 letters but this has
not be commanded by the ECM– Leaking tanks, Nozzle directed back into the tank,
Dosing pump incorrectly working Watchouts
– Tank correctly setup in Insite– No more than 2 letters over the 100% mark on the
sensor– Liner Adblue volume Vs sensor level– Level sensor step size
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview SCR Dosing Unit
– Missing Dosing Unit – FC 1711– Power Disconnect – FC 1711– No Communication with ECM – FC 1711– Disconnected Air Supply Line – FC 1682– Disconnected Urea Supply Line – FC 1682– Restricted Air Supply Line – FC 1682– Restricted Urea Supply Line – FC 1682– Restricted Return Line – FC 1682– Restricted Injection Line – FC 1682
Watchouts– Heated lines if needed frozen line will cause a 1682 if trying to
dose– Correct connections for the Line, Urea build up around
connection– Drawing air in the supply lines – J1939 Can communication
Dosing UnitUrea Supply
Urea ReturnAir Supply
Air Solenoid
CAN bus (SAE J1939)
Injection
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Exhaust Gas Processor (EGP) - Production
Catalyst Brick
Exhaust Gas Temperature Sensors
Euro 4 OBD 1 System Overview SCR Catalyst Presence – FC 1664
– 8 hours cold soak (no engine starts), Delta temperature between the temperature sensor needs to be over 25 DegF within the first minute of engine idle
Malfunction– Catalyst Brick Missing– Catalyst Brink Deteriorated – Exhaust gas by passing the brick– High back pressure after the EGP
Watchouts– Catalyst temperature sensor wrong
away around– Diesel particulate filters increasing
back pressure Missing Catalyst Brick
Exhaust Gas Temperature Sensors
Exhaust Gas Processor (EGP) - Limit
BMC TRAINING CENTER
Euro 4 OBD 1 System Overview
Clearing of the MIL– Once the failure has been removed the monitor has
to run and passed 3 consecutive times. • At a minimum this will be 3 x 10 seconds engine runs• Some monitors will have to see specific conditions to
run therefore these will have to be met 3 time before the MIL can switch off.
– At OBD 1 fault code will be able to be cleared
– OBD Diagnostic in Insite will be state if the MIL lamp is being illuminated for the particular fault code
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Real Time Clock Real time clock is a requirement for the OBD regulations
– Time and Date stamps for the fault codes– Diagnostic need to know a real time to determine 8 hours
cold soaks The ECM has no way of determining time with no power.
– The ECM can gain the time from the tachograph of a datalink message TD (Time Date)
– If no tachgraph and no permanent power supply a battery backup will be needed• Plugs into the harness
– Permanent power supply to the ECM This needs to be setup in Insite
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Euro 4 OBD 1+
Euro 4 OBD 1+ Product OverviewEuro 4 OBD 1+ System Overview
BMC TRAINING CENTER
Euro4 OBD 1+ Product Overview
Product Architecture Similar to Euro4:– Electronic Fuel System– Euro4 Emissions– Integrated Controls– All Engine Platforms:
• ISBe 6 Cylinder
• ISBe 4 Cylinder
• ISLe 6 Cylinder
With Catalyst Outlet NOx Sensor
Mixing
SCR Catalyst
Exhaust Gas Processor (EGP)
Exhaust Gas
Urea Injector
Urea Tank
Level Sensor
Temperature Sensor
Tank Heater
Dosing UnitUrea Supply
Urea ReturnAir Supply
Exhaust Temp Sensors
Air Solenoid
CAN bus (SAE J1939)
NOx Sensor
ECM
BMC TRAINING CENTER
Euro4 OBD 1+ Product Overview
Key Differences From OBD 1 to OBD 1+– Monitoring of tail pipe out NOx with NOx sensor
• Fault codes for exceedence of over 5 g/kwh and 7 g/kwh
– OBD derate strategy• 25% or 40% torque derate depending on vehicle
classification (Settable in Insite within the first 25 miles)• Instant and 50 hour OBD derates depending on
severity for the fault on the emissions
– Non-erasable faults code, These will stay in the ECM’s memory for 9600 hours of engine run time
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New fault code in OBD1+
1692 – Catalyst NOx sensor internal error1694 – NOx sensor in range error2771 – Aftertreatment NOx sensor
communication error2772 – Aftertreatment NOx exceedence least
server > 5 g/kwh2773 – Aftertreatment NO exceedence most
severe > 7 g/kwh
BMC TRAINING CENTER
OBD 1+ Overview
1692 – Catalyst NOx sensor internal error– If an internal error has been hound in the NOx sensor
Malfunction– Sensor will report internal errors through the J1939 Can bus to
the ECM– Internal heater error – Internal heater with the sensor malfunction– Low power supply – voltage to the sensor below voltage threshed– Sensor internal error – Other electrical failure within the sensor
Watchouts– Sensor location – possibility of splash back and thermal shock– Maximum temperature of the sensor control unit– Sensor orientation
BMC TRAINING CENTER
OBD 1+ Overview
1694 – NOx sensor in range error– Designed to determine if the sensor has drifted or is reading a
constant high or low value Malfunction
– Sensor Reading vs. Estimate if the reading is lower than expected• Under specific operation conditions:
– Engine speed– Reagent dosing– Non-transient fueling
– When the engine is in a motoring condition (Zero Fuelling) NOx reading should be 0 ppm if over the threshold then error will be set
Watchouts– Sensor location out of exhaust gas flow– High back pressure– Exhaust leaks– Over dosing
BMC TRAINING CENTER
OBD1+ Overview
2771 – Aftertreatment NOx sensor communication error– To determine if there is a communication error between
the NOx sensor and the engine ECM
Malfunction– Communication between the engine ECM and NOx
sensor has been lost
Watchouts– Poor can bus, connections, connectors, etc– Fuse to the sensor the sensor need a large fuse due to
the internal heater
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OBD1+ Overview 2772 & 2773 – Aftertreatment NOx exceedence least server > 5 g/kwh
& 7g/kwh– To determine if the exhaust out NOx levels are grate than the above
thresholds Malfunction
– Sensor Reading vs. Estimate if the reading is lower than expected• Under specific operation conditions:
– Engine speed– Reagent dosing– Non-transient fueling
– intrusive:• Under normal dosing, measure NOx• Under disabled dosing (for minimal time) measure NOx again• Compare observed efficiency vs. minimum allowed
Watchouts– Exhaust design per the AEB– Doser line connections– Adblue Injector positioning – Adblue???– Doser issues
BMC TRAINING CENTER
Euro4 OBD 1+ System Overview
Clearing of the MIL– If the diagnostic is non erasable the MIL can switch of
once the monitor has run and passed. – If the Diagnostic is erasable the monitor will have to run
and pass 3 consecutive times for the MIL to switch off.• At a minimum this will be 3 x 10 seconds engine runs
• Some monitors will have to see specific conditions to run therefore these will have to be met 3 time before the MIL can switch off.
– The fault will be in the DM1 message (Active Trouble Codes) until the MIL is off, then in DM2 message (Previously Active Trouble Codes)
BMC TRAINING CENTER
Euro4 OBD 1+ System Overview
OBD Derate– Activation of instant derate
• If a fault becomes active and it is an instant derate then the next time vehicle speed = 0 then the derate will become active.
• Only 2 faults in the Cummins system that cause an Instant derate– Empty urea tank– NOx exceedence most severe
– Activation of 50 hour derate• If a fault becomes active and is active for 50 hours of ‘engine run
time’ the next time the vehicle speed = 0 the derate will engage • Any faults that have a direct link the engine emission will be a 50
hours derate
– Deactivation of the derate• Once the failure is corrected the monitor will have to run and pass
once this has happened the derate will ramp out over a period of time and the MIL will switch off.
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OBD Derate Torque Curve
OBD Torque Derates for 300PS rating
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800
Phase Number
40%
Torq
ue/Torq
ue (
Nm
)
300ps [40% Torque] 300ps [Torque (Nm)] 300ps [25% Torque]