OBD Distubuter training.ppt

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Controls and On Board Diagnostics

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Controls and On Board Diagnostics

OBD 1 Overview OBD 1 Specific diagnostics OBD 1+ OverviewOBD 1+ Specific diagnostics

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Euro 4 OBD 1Euro 4 OBD 1 Product OverviewEuro 4 OBD 1 System Overview

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-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

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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

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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

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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

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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

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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)

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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

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SCR System: Failure Detection– Urea Tank Level Monitor

– Urea Tank Heater Monitor

– Urea Consumption Monitor (SCR System Monitor)

– SCR Dosing Unit

– SCR Catalyst Presence

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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

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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

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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

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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



Air Solenoid

CAN bus (SAE J1939)

Injection

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Exhaust Gas Processor (EGP) - Production

Catalyst Brick


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 Processor (EGP) - Limit

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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

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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



Exhaust Temp Sensors

Air Solenoid

CAN bus (SAE J1939)

NOx Sensor

ECM

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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

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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

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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

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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

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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)

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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]

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OBD Distubuter training.ppt