STATION3-CAB_CHASSIS_ELECTRICS_SUSPENSION_AND_STEERING.PDF

7/25/2019 STATION3-CAB_CHASSIS_ELECTRICS_SUSPENSION_AND_STEERING.PDF

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Technical Product Meeting 2015

Station 3 Electrics, Suspension &

Steering

Alagesan Nandakumar

Technical Engineer


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Field Quality

FQIT 231545: Output shaft seal 2262467 leak

Problem description:

The seal introduced in FQ104028 fails aftera short time in operation.

This due to compression of the rubber and

the friction between the seal and housing.

Product solution:

Revert back to the old solution in production

and redesign of the seat for the seal.

Old seal introduced in production during

week 42, chassis numbers in assignment.

Service solution:

Old seal and v-ring available as spare part.

Market measure:

TI and TMI to be released.

Part description:Seal

Part n:2262467


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Field Quality

FQIT 212901: RB662/835/735: Differential manoeuvering device


Steel sleeve in maneuvering device for the

diff moves during operation. Causing

damage to diff parts.

Product solution:

Sleeve glued and also locked by punching

of the aluminum around the sleeve.

Service solution:

New parts in spare part stock

Market measure:

n/a

Part description:

Differential lock Part n:

2245990


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Technical Product Meeting Loughborough U.K. 24th26thNovember 2015

FQ228655: Steering: Tyre in contact with draglink


Tyre and draglink in contact when steering

to the end position.R&D are aware that there may be contact

between the tyre and the draglink but since

it only happens in maximum turn and

thereby in low speed we do not see this as

a safety concern and it is allowed from a

design point of view.

Production solution:This item is in waiting status and as soonas there is design resources a pre studywill be started.

Service solution:

Adjust the wheel end lock according to

WSM in order to decrease the steering. Part number:

1912757


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FQ232308: Interference between steering column and rubber boot


On right hand driven P-cab trucks there have

been cases where the bellow for the steeringcolumn has been chafing against the rubber

boot surrounding the steering column. Production solution:

Pre-study ongoing. Possibility to remove thebellow from the steering column isinvestigated. This would create more space inthe area and chafing could be avoided.

Service solution:Use latest steering column 1784689 with

removed bellow. Part numbers:

Steering column: 1784689, 1540425Rubber boot: 1376709


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FQ235602: Hydraulic steering hose internally blocked

Problem description:Failure reports have been received about internallyblocked hydraulic steering hoses in pipe assemblybetween the hydraulic pump and the steering fluidreservoir. A material defect in the rubber compoundcauses the hoses to get blocked internally. This leadsto strong hydraulic noise, leakages and decreasedservo assistance.The material deviation is connected to a small part ofbatch 03/2015

Production solution:

All hoses marked with 03-2015 has been sorted outfrom all production units.

Service solution:

TC151305

TMI 13-150908

Part numbers:2124548, 2132815, 2130335 and 2124552


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Field Quality

FQ223482: Steering malfunction caused by pressure sensor T56


Deviation with pressure sensor T56 is causing

malfunction of the 2nd steering circuit. Production solution:

1404: New COO7 software that secures that we

get correct engine RPM data since it is important

that the RPM=0 when the check is done.

1412: New cable routing and connectors for

pressure sensor introduced.

Service solution:

Change flow indicator and position sensor to the

latest execution.

Part number

Flow indicator 1506413 has been replaced by

1936501

Position sensor 1506414 has been replaced by2266487


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Field Quality

FQIT 216374: ELC4, Contamination in the pressure sensor


We have received more complaintsregarding blocked pressure sensor with the

introduction of ELC4.

The problem seems to be more frequent in

the tag axle circuit due to higher air flow

around the sensor.

Also environmental factors seems to havean impact on the problem, i.e. temperature,

moisture etc.

Product solution:

None

Service solution:

Field test of using the ELC3 installation is

ongoing.

Part description:Pressure sensor (T70 & T71)

Part no:1889798


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Field Quality

FQIT220894 Deviations in the axle pressure


Complains that the pressure to weightcalculations is less accurate on ELC4 compared

to ELC3.

The problem is both related to the displayed

axle load & cargo weight information in ICL and

also regarding load handling, tag axle lift and

load transfer.The tolerances of the air suspension could

explain this behaviour, but it doesnt explain why

the ELC3 system didnt have the same

complains.

Product solution:FQIT241212:

On 8x4/4 with ARA 950 trucks we have

calculated with the wrong volume in the tag axle

circuit and that will be solved with a new SDP3

release in March 2016.

Service solution:

We have indication that the pressure sensor

installation might have an impact on the

accuracy, therefore we have suggested to try

the ELC3 installation on a couple of vehicles.

Part description:

ELC4

Part n:

Several


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Field Quality

ELC4 items

FQ189614 Tag axle will not lift completely:

Tag axle will not lift completely in some configurations. Related to the rest pressure introduced

with ELC4.

FQ227808 Calibration of level sensor on ELC4 fails:

Calibration of level sensor fails on ELC4. Error usually manifests itself after carrying out a

software update on ELC4.

FQ237982 Takes a long time to change level:It takes a very long time to change the suspension level, the reason seems to be that the air

pressure is to low and that APS doesn't activate the compressor raising the pressure.

FQ239907 Fault code SMS 61676, replace ECU:

The ELC4 doesn't communicate on the CAN-bus and fault code SMS 61676 present in the

ECU.

FQ241255 Not possible to access ELC4 parameters in SDP3:

Not possible to access adjustable parameters in ELC4 due to a faulty parameter settings

module in SDP3. For instance the function: Type of load distribution

Solved with SDP3 2.24.1


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Field Quality

FQIT229111 Windscreen wipers on all the time


Failure on ECU CUV2 on buses, especiallyOmni Express.

Wipers constantly on and not possible to

turn off without cutting power to ECU

Reports needed about effected

products.-Tucks?

-Other bus body's than Omni Express ?


Root cause to be defined

Part description:

VIS System ECU CUV 2

Part n:

2326553

2382793

2438186

Service solution:Exchange of ECU

Failure rate have been reduced in

some cases by connecting the wiper

motor over relays.


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Field Quality

FQIT 184782: AUS3: Volume fade down after 4-5 hours

and temperature related issues


After using the radio for some time it will be

overheated and the volume fade down, it is

also possible that the display will switch off.

Product solution:

No solution available. Work ongoing to find

a solution.

Service solution:

No service solution available.

Part description:

Premium Radio Part n:

2325235


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Field Quality

FQIT 234415: AUS3: Freezing


During driving the radio freezes, somefunctionality will stop until the ignition has

been switched off and on. Functionality that

may freeze: Volume, buttons, navigation.

Product solution:

Not available since root cause not defined.

Logging of vehicles with freezing problem is

ongoing.

Service solution:

No service solution available.

Part description:Premium Radio

Part n:2325235


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Field Quality

FQIT 115655: AUS2, Microphone, too low volume & interference

FQIT168674: AUS3: Noise when using handsfree


Howling/alternator noise for the persontalking to the driver.

Product solution:

No solution introduced in production since

not all drivers experience the problem.

Service solution:

Replace cable harness for the microphonein the seat with a twisted cable.

Market measure:

TMI 17150529

Part description:

Medium RadioPremium Radio

Part n:2024938

2325235


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Field Quality

FQ175671:LED Tail lamp; Moisture in the lamp


It was seen water condensation on LED lampslenses

Product solution:

Introduction of Nitto Caps in order to avoid

moisture and dust to go inside lamps, at same

time permits moisture to go out.

Introduction period: from March 2014 in SEU

and May 2014 in SLA.

Designation Discont PN Introduced PN

Lamp cluster [LED] 1905041 2241857





Service solution:

Replace the part

Part description:Combination Lamp LED

Part n:1905041, 1905042, 1905043, 1905044,

1939011


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Field Quality

FQIT 173164: LED Tail lamp stopped working or different luminance


LEDs from tail lamps dimly shined. Most of

cases found during pre delivery inspection.

Product solution:

The found root cause was broken regulator

caused by ESD (electrostatic discharge).

The solution was to introduce an ESD-proof

package on parts delivered from supplier

(pink bubble wrap).

Service solution:

Pink bubble packing was also introduced on

spare parts


Part n:2241857, 2241858, 2241859, 2241860,

2241861

ESD package protection


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Field Quality

FQIT 237987: MTR Request LED Tail Lamp


Warranty claims and FQFRs about dimmingLED tail lamps after introduction of ESD

protective packing FQ173164

Product solution:

Investigation on all Production Units to find

out and solve all possible electrostatics

discharge during assembly process

PR215231 open and running

Service solution:

Replace the part

Market measure:

Material Request opened to CWP markets

in order to get more parts from field for

investigation.

Please write Failure Reports if you see any

failure mode on this parts (good pictures in

attachments are always appreciated)


Part n:2241857, 2241858, 2241859, 2241860,

2241861


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Field Quality

Incorrect fitted bulb in Front Fog Light


Bulb holder shakes loose if incorrectly

mounted. If it is loose can come in contact

with flammable material (plastic).

Product solution:

Introduction of new ring with rotation stop,

to prevent the bulb holder from being

mounted or dismounted without

disconnecting the cable.

Designation Discont PN Introduced PN

Front Fog lamp LHS 1852572 2080688

Front Fog lamp RHS 1852573 2080689

Spot Lamp LHS 1852569 2248103

Spot Lamp RHS 1852570 2248114

Service solution:

Replace part

Part description:Spot lamp / Fog lamp

Part n:1852569, 1852570, 1852572, 1852573


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Field Quality

Incorrect fitted bulb in Front Fog Light

Part description:Spot lamp / Fog lamp

Part n:1852569, 1852570, 1852572, 1852573

Old ring

New ring


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Field Quality

FQIT209798 COO7 Hardware problems


High failure rate for COO7 on vehicles that hasrun two to four years in operation.

The problem has started to occur on vehicle

produced from the end of 2010 and has mainly

on vehicle running in colder environmental.

Product solution:Securing the manufacturing process of the

circuit board at the supplier since the middle of

2014.

Introducing an under filler between the circuit

board and the main CPU during W35 2015

Serial number limits: 1507170061

New part numbers has been introduced in

October 2015, PN: 2456999 (only as spare

part), 2457000 & 2457001

Service solution:

EPS released in July 2015, covering up to

four year in operation for vehicle produced

from November 2010 until September 2014.

Part description:

COO7

Part n:

Several


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Technical Product Meeting Loughborough U.K. 24th

26thNovember 2015

Suspension

FQIT159780: KUB Small cracks

FQIT171942: NUB Small cracks FQIT137697: K/NUB Bellow jump off.

FQIT191498: K/NUB Small cracks

FQIT185534: KEB Small cracksFQIT 175659:KEB Chafing brake hose

FQIT141254: Anti-roll bar bearing: KIB premature wear


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26thNovember 2015


Rubber bearing anti-roll bar front causing squeaking

and nocking noise.

Product solution:

New bearing and bearing housing is developed with

improved clamping force for the rubber bearing.

Service solution:

No service solution.

Market measure:T.I. to be released

FQIT 141254: Anti-roll bar bearing: KIB premature wear

Part description:Anti-roll bar bearing

Part n:sc1798776

New design


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26thNovember 2015

FQIT 159780: Air Bellows small cracks & leakage


K/NUB/KEB: Air leakage from air bellow due to smallcracks, mainly countries with hot climate.

Affected part no: 2024285/7/8; 1726238.

Product solution:

Root cause: small cracks origin from the inside of the air

bellow. This occur due to accelerated aging of the

rubber material due to high ambient temperatures aswell as ozone.

Next step: Introduction of new rubber compound,

removal of venting lines and reduced cover thickness.

Estimated introduction date December 2015.

Service solution:

Change bellows. There is no need to change all bellows

on the same axle.

New bellows have the same dynamics as current.

Market measure:

Not decided


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26thNovember 2015

Cracks at 1st ply splice

Cross section of bellow


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Station 3 Cab, Chassis,

Transmission & Bus Body

Robert Hirons

Technical Engineer


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26thNovember 2015

Failure Report Parts requestPilot

Transport direct from workshop to Field Quality department in Sweden

Scania Field Quality take the cost for shipment

Five countries in pilot phase

Reduced lead-time 40days below 10days in average

Bottleneck reduction and workshop to do the shipment booking via SAIL

Plan to roll out globally end of Q1 2016


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26thNovember 2015


New concept for parts return (FQFR-goods) booking via SAIL


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26thNovember 2015



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26thNovember 2015


Labels for parts return (FQFR-goods)

All packages & parts must be labelled

Labels must be filled out correctly

Label for package, part number 1585562

Label for parts, part number 1583844


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26thNovember 2015


Update DRFR with Waybill No


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Transmission & Cab

Field Quality


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Field Quality

FQIT 211296: ECANo Fault Found


The ECA has been exchanged on a vehicle inthe workshop, which has solved a problem,

but upon inspection and testing of the ECA

unit at the factory, no fault can be found.

The customer and workshop do often

experience that exchanging the ECA solves

the problem.

To be able to solve the remaining quality

problems, it is important to get as much

information as possible about each ECA

case.

If the cable harness of the ECA is exchangedduring the repair, it should be send to thefactory along with the ECA.

Market measure:Ti 04-15 081ECA troubleshooting with SDP3Ti 04-15 06 16

Part description:ECA

Part n:2392193

?

Field Quality


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Field Quality

FQIT 211296: ECANo Fault Found

Questions to the NFF process

Problem description

What is the problem?

When do the problem occurs?

Assistance case?

Has work been done earlier on the clutch system or on the ECA?

Failure code

What OPC failure codes are present?

Any Active failure codes?

The underlying failure code for the exchange of the ECA?

This failure code needs to be mentioned in the claim/FR.

Please do a failure code readout and upload to the system.

Others

Add the serial number of the ECA.

Have the points in TI 04-15 06 16 been checked?

Any leakage noticed? Connectors ok?

Field Quality


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Field Quality

FQIT 192032: ECAfluid reservoir level sensor faulty after improvement in FQIT143718


Low clutch fluid warning in ICL although fluid

level is correct in the ECA reservoir.

Fault code OPC 50170 is active.

Root causes:

Insufficient soldering of the level sensor

(FQ143718)

- mismatch material in the sensor connector

Product solution:

Improved soldering introduced in January 2013.

New sensor connector in December 2014.

Service solution

1. Change reservoir and the cable harness.

2. If that does not solve the problem,

change the ECA.

Market measure:

TI 04-15 081ECA troubleshooting with SDP3TI 04-15 06 16

Part description:

ECA fluid reservoir

Part n:2340075


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26thNovember 2015

FQIT196170: New Valeo release bearing collapsed


Release bearing 2164195 collapsing/failing.

Considerable improvement work was done when this

new part number 2164195 replaced 1851631 in

FQ64559.

Two sub-suppliers of the bearing; INA and ORS, all

failures are on the ORS bearing.

Product solution:

Only INA bearings in supplier production since

wk 27 2015.

Current status:

Re-design of the faulty ORS bearing. Prototypes in

February 2016.

Market measure:

T&A plan

Part description:

Release bearing

Part n:sc2164195


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26thNovember 2015

FQIT 145224: Range fork


Premature worn range fork which results in

gear shift malfunction

Product solution:

New coating with aluminum/bronze will be

introduced in the spring 2016

Part description:

Selector fork

Part n:sc1523647

FQIT 187590: Planetary gear scratching noise


Problems (noise, malfunction & damage) related to

gear shifting in the planetary gear. Important to check

the status of the range springs, output shaft and

selector fork in events like these.

Product and service solution:

Stiffer springs and the piston introduced, described in

TI 05-15 03 13.

Field Quality


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Field Quality

FQIT66493: End yoke screws for P400/P500 propeller shafts brakes or come loose


The screw that holds the propeller shaftcomes loose on the gearbox and/or axle

from factory. Problem mainly/only seen on

P500 prop shafts.

Product solution:

New screw with bigger flange headintroduced.

Torque + angle to be introduced soon.

Parameters under analysis.

Service solution:

Replace failed screws.

Market measure:

T&A plan.

Part description:

Flange screw. Part n:

2145983 (Old: 1757877).

Field Quality


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Field Quality

FQIT 221052: Faulty motor for door window winder


Faulty motor for door window winder

Product solution:

Investigation ongoing

Service solution:

N/a

Market measure:

N/a

Part description:Window winder motor

Part n:2303350, 2303355

Field Quality


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Field Quality

FQIT 79767: Worn out potentiometer water valve


Problem with cab temperature. Could not

cool the cab when temperature adjusted

between 17 ~20 degrees due to heater

valve was not closed completely.

Root cause has been found to be excessive

wear of the potentiometer which makes the

water valve to fail.

Production solution:The Actuator is replaced with a more robust

version from a different supplier

New parts introduced

Scania Sdertlje 2117092

Scania Zwolle 5402679

Scania Angers 9201502

Market measure:

TI

Part description:

Water valve

Part n:

Old: 1793197 New 2160199

Old New

Field Quality


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Field Quality

FQIT233899: Tilting sensor of refrigerator malfunctioning


It has been reported some complains that

the refrigerator is not working or

malfunctioning.

Collecting parts from field to understand the

caused component and root cause of

failure.

For workshop technician diagnosis is veryimportant to follow the WSM procedure in

Multi 18-30 Refrigerator Check

Troubleshoot.

Part description:Tilting sensor

Part n:1940667

Field Quality


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Field Quality

FQIT 218508: Premium Seat, Foam gets pushed through seat pan


Seat foam gets pushed through the seat pan.

Product solution:

New design in seat pan for G- and R-cabs.

Introduction date not yet decided. Preliminary

introduction date 201602.

Suggested solution for P-cabs is an integrated

reinforcement mesh in underside of foam to

prevent separation between felt and foam.

Preliminary introduction date 201603.

Service solution:

New design of seat pan available as spare part. Use

this together with comfort cushion (FQIT224218) as

solution for G- and R-cabs.

Cushion with reinforced mesh as solution for P-cabs

if it is approved.

Market measure:

G- and R-cab: TI 18-15 07 08is released. It will be

updated to clarify that the solution is valid also for

problem with foam pushed through seat pan.

Part description:

Seat pan, Seat cushion foam

Part n:

Several
http://global.scd.scania.com/dep/rod/Vehicle_quality/internal/02_field_quality/02_group_activities/Meetings/TPM/2015/Presentations/Team%20Chassis_Cab/Final%20presentation%20TPM_15/QXP/TI%2018-15%2007%2008.pdfhttp://global.scd.scania.com/dep/rod/Vehicle_quality/internal/02_field_quality/02_group_activities/Meetings/TPM/2015/Presentations/Team%20Chassis_Cab/Final%20presentation%20TPM_15/QXP/TI%2018-15%2007%2008.pdfhttp://global.scd.scania.com/dep/rod/Vehicle_quality/internal/02_field_quality/02_group_activities/Meetings/TPM/2015/Presentations/Team%20Chassis_Cab/Final%20presentation%20TPM_15/QXP/TI%2018-15%2007%2008.pdfhttp://global.scd.scania.com/dep/rod/Vehicle_quality/internal/02_field_quality/02_group_activities/Meetings/TPM/2015/Presentations/Team%20Chassis_Cab/Final%20presentation%20TPM_15/QXP/TI%2018-15%2007%2008.pdf


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Bus Chassis


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26thNovember 2015

FQIT 223632: Coolant leakage, level sensor housing.

Prototype Current

Proposed solution from R&D

is to fill empty space.

Probable root cause is variation

in thickness and bubbles together

with fatigue from dynamic heat loads.

Field Quality


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y


Incorrect claiming of new black

expansion tank connected to

change of old white tank or leakage

in sensor housing.Field quality follow up weekly last months

claims to prioritize items.

Warranty claims last three months


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26thNovember 2015


p/n 2203729 alt. p/n 2203730 both new black tanks.

Parts from field are verified at Scania with full function.

p/n 1779713

Mis-understanding of which

part is leaking. Same area

as before but new failure

mode.


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26thNovember 2015

FQIT 223632: Coolant leakage, level sensor housing


Coolant leaking from cracked coolant level

sensor housing under expansion tank

Product solution:

Level sensor housing is updated with new

design in weak area.

Prototypes are tested w.41

Service solution:

Change level sensor housing

Market measure:

Inform the market to check the level sensor

housing before considering changing thecomplete expansion tank.

Follow the T&A-plan for latest updates.

Part description:

Sensor housing

Part n:

1779713

Field Quality


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y


KEB: Air bellows on the front axle chafe

against the brake hose. This interferenceseems to occur after the bus has been in

use for a while. It has not been possible to

re create on new produced chassis on

assembly line.

Product solution:Next step: Improved bracket for brake hose

Service solution:

Not decided

Market measure:

TI to be released

FQIT175659 : Air spring chafe against brake hose

Part description:Air spring

Part n:1 726 238

YQR/YQP - Technical Product Meeting - 2015-11-3/5 Created: 2015-10-12 Updated: 2015-10-14


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26thNovember 2015


Different failure modes on current

DC9/DC13 belt tensioner. Belt fluttering,worn roller bearing, dust penetration

and spring rupture.


Sealing plug (2013-08)

Carbon strip inside spring (2013-12)

Introduction of alternator decouple

pulley 2016-06.

Service solution:

Not decided

Part description:Belt Tensioner

Part numbersc2197391, 2197388

FQIT 127632: Belt Tensioner bus

Field Quality


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FQIT 116144: AC Flexible coupling breaks on N-series EEV with EcoMat gearbox


Flexible coupling breaks after short time in

operation


N/Aserial production not affected

Service solution:

Until campaign release, use service kit p/n 2191372

Campaign solution contains the new belt drive

Field Test in IL (V.46), GB & ES (V.49)

Market measure:

RA151806 was approved for whole affected

population (804 buses). Solution includes also

replacement of the PTO from 1.88 to 1.35 ratio

Campaign release: 2016-Q1

Part description:

Flexible coupling / Service kit

Part n:2160038 / 2191372


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26thNovember 2015

FQIT 116144: AC Flexible coupling breaks on N-series EEV with EcoMat gearbox

Field Quality


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FQIT 108101: N-series - Fuel spill during fuel filter replacement


Fuel leakage/spill during fuel filterreplacement. This problem occurs as

the fuel tanks are located higher than

the fuel filter housing.


A manual shut-off valve on the feedside as well as a non-return valve on

the return will be introduced

Service solution:

Same as production solution. Until TI

release keep 25% of fuel volume when

replacing fuel filters

Market measure:

TIestimated Q2-2016

Field Quality


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FQIT 108101: N-series - Fuel spill during fuel filter replacement


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Paint


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26thNovember 2015

Paint how to report

Changes in coding to divide the different parts

The sub group paint is added for main groups below

Main group 09 Hubs and Wheels (Hubs)

Main group 11 Frame Bumpers headlights seal etc.

Main group 18 sub paint Cab related parts

Main group 19 Accessories side skirts, MCC etc.

Main group 20 load carrying equipment

To get your FQFR to the system group make sure the correct main group is used.

This will be used for follow up and reports within Scania R&D. Meaning the information yousend will be forwarded No action does not mean we wont use the information.

Field Quality


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Stone chipping and flaking on plastic parts


Changes have been made in to production

equipment. New pumps is introduced making the

paint mixture more accurate. Paint shop will also

introduce measure equipment to ensure they deliver

good quality according to Scania Standards. The

analyse work done both internally at Scania and at

the university has not pointed to a root cause.

Changes are introduced in spring of 2015 no clear

chassis limits to report.

Market measure:

T&A

FQIT Several : Paint stone chipping

Field Quality


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FQIT 149031: Paint flaking


Paint flaking of on several different colors.

Product solution:

Prioritized item within paint

Investigation made in a Research project. Parts sent to a University in

England without finding a clear root cause. The investigation is ongoing.

Part description:

Plastic parts

Field Quality


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FQIT129364 Paint: Orange peel effect on plastic parts

Problem description:Orange peel effect on painted plastic

parts.

Product solution:

This is the texture of the part shining

through. To get a better result the part

will need another texture.The current texture of plastic parts has

been reviewed and approved by R&D.

Market measure:

If a better surface is needed a new

PRS must be sent in using SAIL

(Found on SAIL and the application tabon the start page)

Part description:Mirrors, Handles, Elongation of side air

deflector mudguard seal etc.

Part n:Several

P i


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26thNovember 2015

Paint system group

Paint expert engineer responsible for surface treatment

Production responsible From Oskarshamn (Cab)

Production responsible From Meppel (Plastic painted parts)

Product manager from KT (PRS item)

Red arrow M&H assignment leader

Purchase SQA (Responsible for supplier Quality)

Development engineers

Field Quality Engineer


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Questions?


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STATION3-CAB_CHASSIS_ELECTRICS_SUSPENSION_AND_STEERING.PDF

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