BS4 Pocket Guide New - 4.4.17
BS4 Pocket Guide New - 4.4.17
BS4 Pocket Guide New - 4.4.17
BS IV
POCKET GUIDE
BS IV - Pocket guide
● List of Sensors
● Guidelines for Component checking
● Do’s & Don’ts
● Serviceability of EDC, SCR & EGR Components
●T
CRS
COMMON RAIL SYSTEM.................................................................................................................. 1
CB 18 - MAIN FILTER........................................................................................................................ 3
AIR BLEEDING PROCEDURE FOR CB18 PUMP FUEL SYSTEM....................................................... 4
EDC - 17
CIRCUIT DIAGRAM.......................................................................................................................... 5
EDC - ECU CONNECTOR PIN NUMBERS @ WIRING HARNESS..................................................... 6
SENSOR SERVICEABILITY................................................................................................................ 7
DIAGNOSTIC..................................................................................................................................... 15
SCR
SELECTIVE CATALYTIC REDUCTION................................................................................................ 19
ACU WIRING HARNESS................................................................................................................... 20
ACU PIN DIAGRAM.......................................................................................................................... 21
SERVICEABILITY............................................................................................................................... 22
BS IV - Pocket guide
CONTENTS
EGR
COMPARISON - FIE COMPONENTS................................................................................................ 31
EXHAUST GAS RECIRCULATION...................................................................................................... 32
EGR COOLER ASSEMBLY ................................................................................................................. 33
EGR COOLER & EGR VALVE ............................................................................................................ 34
EGR PIPES & EGR COOLANT PIPES................................................................................................. 35
EGR EXHAUST AFTER TREATMENT SYSTEM.................................................................................. 36
TROUBLE SHOOTINGS..................................................................................................................... 37
SCAN TOOL
SCAN TOOL....................................................................................................................................... 40
EDC - 17 DIAGNOSTIC - LIVE DATA................................................................................................. 43
PRV
Advantages: Flat engine torque curve for better drivability and better KMPL.
CRS
EDC-17 2
SENSORS AND ACTUATORS
3 CRS
EDC-17
CB 18 - MAIN FILTER
CB18 - Main Filter (No Bubble Breaker) CB18 - Main Filter (With Bubble Breaker)
NO Yellow Dots OR Production code less than 520 4 Yellow dots OR Production code 520 and above
above
CRS
EDC-17 4
F4 – 5A K88
Starter
Motor
K02
F5 – 30A V2 K04
K06
* Empty base for future up-grada on
F1 F2 F3 F4 F5 * ECU-EDC 17
* * * *
EDC-17 6
EDC - ECU CONNECTOR PIN NUMBERS @ WIRING HARNESS
7 EDC-17
SENSOR SERVICEABILITY
Wiring Continuity Value
Accelerator Pedal Module APM Connector
Connector Lock
K61 1-A
K45 2-C A 1 2 3 4 5 6
E 6 5 4 3 2 1
K62 3-B P
C K83 4-F Male End Female End
U M
K44 5-D
K84 6-E Metri Pack
A B C D E F
A
B
C
D
E
F
Male Female
EDC-17 8
2 25 A54
24 A39
1
26 A38
2 1 1 2
Shield
Male End Female End
860 Ohm ± 10% at 20° C
A52
1 34
35
2
A37
33 A53 2 1 1 2
Shield
Male End Female End
860 Ohm ± 10% at 20° C
EDC-17 12
1
K87
2 Water in
K17
ECU Fuel
Sensor
3
K68
Actuator
AC Switch signal – for 800 rpm
K22
K68
AC SWITCH
IGN SUPPLY
THERMISTOR
13 EDC-17
A – CAN High
B – CAN Low
C – CAN shield
Female End
EDC-17 14
Don’ts
Don’t try to repair the sensors at the
following
Remove INJECTORS, only if Injector High Pressure Pump
Common Rail
prevent dust entry Don’t step on the Injectors
Injector caps to be removed immediate Don’t Loosen High Pressure Pipes for
Bleeding
Checking Voltage / Resistance at Component or ECU End - Allowed with proper
instrument & care.
Avoid Checking at ECU. In case of utmost requirement ensure ECU body is always
Care to be taken not to short the supply voltage / Sensor Output with earth /
19 SCR
SELECTIVE CATALYTIC REDUCTION
This is (Exhaust gas) after treatment system. Adblue is injected into SCR housing pipe. By chemical
reaction ammonia is formed in the catalyst housing. Ammonia reacts with NOx in Exhaust gas
at SCR housing, and reduces NOx level. This has set of sensors, ACU and set of actuators. ACU
controls adblue (Aqueous urea solution – AUS32) injection. Adblue will be consumed in operation
and it is to be refilled periodically. With SCR, emission levels of BS-IV can be met.
SCR - Albonair System 20
ACU WIRING HARNESS
1. A
2. a) Interface connector for supply and CAN- bus (10 pin)
b) Interface connector for exhaust temperature sensors and cooling water valve (6 pin)
3. Air control valve UDS (cable length 170 mm)
21 SCR - Albonair System
4. Dosing pump UDS (cable length 270 mm)
5. Level / temperature sensor
6. Pressure sensor UDS (air)
7. Temperature / pressure sensor UDS (Ad-Blue®)
4 8 12 16 ……………………………….52 59 62
SCR - Albonair System 22
SERVICEABILITY
Value
Adblue Temp & Pre sensor Ω-1&4
Female End
23 1 10C-4.48KΩ
19 2 20C-2.81KΩ
30C-1.81KΩ 4 3 2 1
33 3 40C-1.2KΩ
24 4 50C-0.8KΩ
56 1
54 2
4 3 2 1
32 3
23 SCR - Albonair System
Ambient Temp sensor 10C-19.87K
25C-10KΩ
37 1 40C-5.33KΩ
38 2 50C-3.61KΩ
25C-220Ω
200C-352Ω
400C-495Ω
600C-627Ω
Urea level sensor 1&2 –Level
22 1 144mm-1058Ω
129mm-849Ω
29 2 84mm-409Ω
30 3 54mm-240Ω 12 3
2&3 - Temp
20C-4.1KΩ; 25C-3.3KΩ; 30C-2.7KΩ;
35C-2.2KΩ; 40C-1.8KΩ; 45C-1.4KΩ
SCR - Albonair System 24
Air Valve 1 45
2 41
Sensor ECU
25 SCR - CES
CUMMINS SCR SOLUTION SYSTEM
46 47…………….........………………………………….60
SCR - CES 26
SERVICEABILITY
Inlet Temp sensor
0C- 477000Ω
23 1 200C- 6220-7840Ω
400C-1130- 1270Ω
28 2
NOx sensor
1 ery (+)
2 42
3 43
4 ery (-)
27 SCR - CES
Urea level cum Temp sensor At pins 1 & 2 At pins 1 & 2
C7 Connector
M 60 M : METERING INJECTOR (+)
B D
T 45 T : METERING INJECTOR (-)
P 14 P : 5 V SUPPLY
S 09 S : DEF SENSOR
V 29
V : SENSOR RETURN
R 07
R : MIX PRESSURE
L 06 E
M
S
L : DEF TEMEPRATURE P
E 04 R
D 55 E : PUMP MOTOR (+)
U : RETURN
L T U V
29 SCR - CES
Air Valve
B 1
59 2
EGR 30
EXHAUST GAS RECIRCULATION
In EGR Engines, metered quantity (controlled by ECU) of Exhaust gas after cooling is re-circulated
back to the Engine cylinders. As the EGR reduces the air (oxygen) intake, it controls the pollutant
NOx (oxides of Nitrogen) . With EGR, emission levels of BSIII and BS-IV can be met.
Lower cost
Lower weight of total system
Less maintenance
31 EGR
COMPARISON – FIE COMPONENTS
BS III BS IV
Particulars EDC 17 EDC 17 with EGR EDC 17 with SCR
Pump model CB18 CB28 CB18 CB28 CB18 CB28
ECU part X3995300 X3995300 F6N15300 - - X3995300
number
Injector Part FKS00100 FKS00900 FKS00100 - - FKS00900
Number
High pressure FHL00100 F7V03900 FHL00100 - - F7V03900
pump
High pressure X7401010 X7401010 X7401010 - - X7401010
rail
Pre Fuel filter FHJ00400 F7A04700 FHJ00400 - - F7A04700
(P1301640 –
Insert)
Main Fuel filter FHN00100 B9806701 FHN00100 - - B9806701
Note 1: Note 2:
Don’t interchange BSIII and BSIV ECU and also don’t • BS IV – ECU with Electric EGR drive –
interchange the CB18/CB28 injectors which adversely ‘H’ Bridge ECU
affects engine performance • Current EDC 17 with Non EGR (SCR,
BS III, Neptune – Existing vehicles)
EGR 32
EXHAUST GAS RECIRCULATION
Exhaust
Hot
Pipe
Coolant IN
Coolant out
Electrically actuated EGR
valve
Coolant DC Electric motor
Hot Exhaust Gas (From cooler) Hot side EGR valve
IN – Regulated Engine ECU controlled
Exhaust Gas Valve operation
(Regulated) 100% - 6 mm
Common for H4 & H6
Cooled Exhaust Coolant
Gas OUT (From cooler)
Coolant IN
Parameter Value
Flow 120kg/hr @ 100dP
Parameter Dimensions Valve dia 30mm
• 36 (4 X 9) Weight 1.48kg
No of tubes
• 255mm length
Weight 2.8kg
Flow type Counter flow
35 EGR
EGR PIPES & EGR COOLANT PIPES
Exhaust second pipe to EGR valve Coolant inlet pipe (Single pipe)
CO2
H2O
PM (NVF)
NO2
CO
HC
PM (SOF+NVF)
NOx
37 EGR
Trouble Shootings
• Scan tool version - 2.43
2 1
Usage
Scan Tool
Key Function
√ Select a menu op on / Con nue / Yes
X Exit a menu / No
▲ Scroll up within a menu / text
► Scroll down within a menu / text
◄► Scroll le and right
? Provide context sensi ve help
41 SCAN TOOL
Main Menu
1. ► EOBD Use the ▲ and ▼
2. User Menu
Establishing Data
Link with the vehicle
CMs – Please Wait…
Press the √ key to view the results or the X key to bypass the results and go straight to EOBD
SCAN TOOL 42
View DTCs
fault.
If more than one DTC is displayed, required DTC can be selected by using ► and ▼ keys. Press
Erase DTCs
on vehicle.
Live Data
the vehicle and can provide a quick way of telling if a component is working correctly
The list of components monitored under ‘Live Data’ can vary between manufacturers and even
between models
43 SCAN TOOL
EDC - 17 DIAGNOSTIC TESTER – LIVE DATA
Sl.No Parameter Unit
Parameter Set 1
1 Epm_nEng Engine Speed Rpm
2 Vehv_V Vehicle speed Kmph
3 APP_rUnFlt %
4 Injctl_qSetUnBal mg/st
5 Injctl_qCurr mg/st
6 Air_pIntkVUs Boost pressure Hpa
7 EnvP_p Atmospheric pressure Hpa
8 CengDst_t Engine coolant temperature ºC
9 Oil_tSwmp ºC
10 Air_tCACDs ºC
SCAN TOOL 44
11 Oil_pSensPSwmp Hpa
12 mV
13 EpmCas_nCas_mp Rpm
14 Epm_dnEng Engine Speed gradient Rpm
15 EISGov_nSetPLo Low Idle Speed Rpm
Parameter Set 2
17 Railp_pFlt Rail pressure – actual hpa
18 Rail_pSetPoint Rail pressure – setpoint hpa
19 MeUn_iSet Me unit set point current mA
20 MeUn_iActFlt mA
21 MeUn_rPs Me unit PWM signal output %
22 MeUn_dVolset mm3/sec
23 Rail_stCtlLoop Rail pre control loop status -
45 SCAN TOOL
24 CoETS_rTrq -
25 PthSet_TrqInrSet Final torque Nm
26 CoETS_stCurrLim -
27 Injcrv_qMI1Des mg/st
28 Injcrv_qPiI1Des mg/st
29 Injcrv_qPoI2Des mg/st
30 ExhFlpLp_rPs %
Parameter Set 3
31 APP_uRaw1 Accelerator pedal 1 raw value mV
32 APP_uRaw2 Accelerator pedal 2 raw value mV
33 RailP_uRaw Raw voltage of Rail pressure mV
34 Air_uRawPIntkVUs Boost pre sensor raw voltage mV
SCAN TOOL 46
48 Epm_StSync -
49 Clth_stRaw Clutch status -
50 Brk_st Brake status -
51 Brk_stMn Brake status main -
52 Brk_stRed Brake status redundant -
53 T15_st -
54 Ebrk_stSwtRaw Eng Brake sw signal raw value -
55 ErrLmp_stSVSReq SVS request status -
56 ErrLmp_stMILReq MIL request status -
57 GlwLmp_st Glow lamp status -
SCAN TOOL 48
Parameter Set 6
58 AirC_stSwt AC switch status -
59 ACCtl_stOut -
60 Fan_nFlt rpm
61 Fan_r Fan speed setpoint %
62 Fan_rPs Fan duty cycle output %
63 CrC_stPlusRaw Cruise Control Plus Switch -
64 CrC_stMinusRaw Cruise Control Minus Switch -
65 -
76 hpa
SCAN TOOL 50
Freeze frame data
S.No Unit
1 Engine rpm rpm
2 Rail pressure bar
3 Coolant temperature deg C
4 mg/st
5 -
6 %
7 Vehicle speed Km/hr
ADJUSTMENT PARAMETERS
Low High Unit Remarks
Start Torque 0 200 Nm
Low Idle Trimming value for the low idle set -50 200 rpm
point from the tester
51 SCAN TOOL
Low High Unit Remarks
Engine Torque limit adjust value 0.9 1
Torque
Max Veh Sp Maximum Speed Limit 0 150 km
Secondary Secondary Max speed limit 0 150 km
Max Veh Sp
High Idle Sp Maximum Engine speed 0 2800 rpm
PRV
PRV opened Reset
Time to zero
WIFS Reset to zero
VIN
Service Date Engine Test Date
Program Date Programming Date
SCAN TOOL 52
Actuator Test - Engine idle speed 600 rpm
S.No Actuator tests S.No Actuator tests
1 Lamps - Water in fuel 7 EGR actuator
2 Grid heater lamp 8 EGR Valve learning
3 MIL Lamp 9 Engine brake test
4 High coolant temp lamp 10 Grid heater actuator
5 SVS lamp 11
6 Low Oil pressure lamp 12 Metering Unit
53 EDC - Diagnostic Codes
EDC - Diagnostic Codes
S.No Pcodes Blink Codes Description Reaction on Engine/Vehicle
1 P1523 87 Water in Fuel Detection 40% Torque Limitaion
Maximum negative rail pressure deviation
2 P1106 32 with metering unit on lower limit is exceeded 40% Torque Limitaion
(Actual Rail pressure exceeded the set point)
3 P0090 21 Metering unit output open load error 40% Torque Limitaion
4 P1100 25 PRV open 40% Torque Limitaion
Setpoint of metering unit in idle mode not
5 P1117 34 40% Torque Limitaion
plausible
Metering unit high side short circuit to
6 P1120 21 40% Torque Limitaion
ground error
Metering unit high side short circuit to
7 P1119 21 40% Torque Limitaion
battery error
8 P0203 22 Open load Injector3 40% Torque Limitaion
9 P1108 37 Maximum rail pressure exceeded 40% Torque Limitaion
36 P0267 22 Injector 3 short circuit Low Side to High Engine rpm limitation at 1750.
38 P0264 22 Injector 2 short circuit Low Side to High Side Engine rpm limitation at 1750.
39 P0262 22 Injector 1 general short circuit Engine rpm limitation at 1750.
40 P0261 22 Injector 1 short circuit Low Side to High Side Engine rpm limitation at 1750.
41 P0202 22 Open load Injector2 Engine rpm limitation at 1750.
42 P0201 22 Open load Injector1 Engine rpm limitation at 1750.
Cam shaft sensor signal Error - disturbed
43 P0341 52 Engine rpm limitation at 1750.
signal
57 EDC - Diagnostic Codes
S.No Pcodes Blink Codes Description Reaction on Engine/Vehicle
Crank shaft sensor signal Error - disturbed
44 P0336 52 Engine rpm limitation at 1750.
signal
45 P2135 11 Non-plausibility error between APP1 & APP2 Limp home function (1350rpm)
Water-in-Fuel Sensor signal voltage below
46 P1522 87 No Reactions
lower limit
Water-in-Fuel Sensor signal voltage above
47 P1521 87 No Reactions
upper limit
48 P1505 84 Diagnostic lamp Short circuit to ground error No Reactions
49 P1503 84 Diagnostic lamp Open load error No Reactions
Maximum oil pressure error in plausibility
50 P1700 82 No Reactions
check
Boost pressure sensor signal voltage above
51 P0238 61 No Reactions
upper limit
Boost pressure sensor signal voltage below
52 P0237 61 No Reactions
lower limit
53 P0236 61 Boost Pressure sensor High plausibility error No Reactions
54 P0235 61 Boost Pressure sensor low plausibility error No Reactions
EDC - Diagnostic Codes 58