Professional Documents
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Aps
Aps
Issue 3 en-GB
Troubleshooting
©
Scania CV AB 2013, Sweden
Contents
Introduction .................................................................................. 3
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Scania CV AB 2013, Sweden 10:25-01
APS, Air processing system
Introduction
Faults in the APS unit are most often faults on the Always read any fault codes for the system at the
mechanical components such as check valves, start of troubleshooting using SDP3. Continue the
solenoid valves and O-rings. A very small troubleshooting using the fault codes. If
percentage of the faults can be found in the necessary, use this troubleshooting guide to
control unit. support you.
It is important to have a good understanding of the Check whether there are fault codes in other
complete system which the APS unit is part of. A systems which indicate an interruption in CAN
symptom in the APS unit does not always mean communication and whether the different system
that there is a fault in the APS unit. Therefore, warning lamps are lit on the instrument cluster. If
always check all circuits in the system to ensure this is the case check whether there is moisture in
that there are no leaks or any other faults. the APS unit electrical connector and whether the
cable harness is damaged at the bumper.
Also see APS function description in the
workshop manual, 10-25 Brakes, Supply circuit,
before starting troubleshooting.
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Scania CV AB 2013, Sweden 3
The APS unit and the systems which it is part of
The APS unit air dryer is connected to the After a prolonged period of high air
compressor via a cooling coil. The incoming air consumption a message about high air
from the compressor is dried and cleaned when consumption is first displayed in the instrument
it passes the desiccant container in the air dryer cluster. Then a critical air consumption
part. The desiccant container can dry and clean warning is displayed.
up to approximately 250 dm3 of air before the
The APS unit control unit interacts with other
filter is saturated.
vehicle systems which enables intelligent
The APS unit control unit calculates the control of the air supply. This control unit has
volume of air which has passed through the pressure sensors which register and transmit
desiccant container based on compressor model information about the air pressure in the
and engine speed. When the volume of air various circuits to the instrument cluster via
passed through the desiccant container has CAN communication. Necessary information is
reached the level where the filter should be retrieved from its own sensors and the sensors
saturated, desiccant is regenerated. The control of other systems via the CAN network.
unit activates regeneration using the
The APS unit control unit continuously
regeneration solenoid valve and air is blown
attempts to reduce the load on the engine and
back through the desiccant container. It is not
therefore primarily charges the pneumatic
possible to pressurise the pneumatic system
system when the vehicle is using engine
during regeneration.
braking. The compressor may be in a relief
In order for regeneration to take place the air phase or working phase. The APS unit relieves
pressure must exceed 10 bar. The pneumatic the compressor by activating the solenoid valve
system will not carry out regeneration in case for compressor control so that the control line
of high air consumption or leakage when the air is pressurised. The compressor is relieved when
pressure fails to reach 10 bar. The APS unit the pressure in the control line actuates a piston
will then lower the limit for regeneration to in the compressor ESS system (Energy Saving
System) or when the compressor crankshaft is
9 bar1.
released, depending on the type of compressor.
1. This does not apply to vehicles with unlimited load trans-
fer or some special-purpose vehicles.
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Scania CV AB 2013, Sweden 10:25-01
1 APS unit
2 Compressor:
A. Working phase
B. Relief phase
3 Cooling coil
4 Instrument cluster
5 Air horn
6 Compressed air tank
7 Steering wheel
8 Seat
9 Disc brake
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Scania CV AB 2013, Sweden 5
Various components of the APS unit
1 Air dryer
2 Circuit protection valve
3 Control unit
4 Regeneration check valve
5 Accessory circuit check valve
6 Parking brake circuit check valve
7 Regeneration solenoid valve
8 Compressor control solenoid valve
9 Safety valve
10 Control line
11 Intermediate piece for connecting the
regeneration tank
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Symptom and cause
This section includes a summary of the faults Based on this information and any fault codes,
which can occur in the APS unit and the continue to the relevant troubleshooting
systems which it is part of. diagram.
Start by asking the customer whether they
noticed anything unusual when the problem
occurred or whether there is anything else that
might be linked to the problem.
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Scania CV AB 2013, Sweden 7
A. Low pressure in the complete pneumatic system
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A1. The pressure in the complete
system is below 6 bar
Check the compressor. See A3b and A3c.
Check the solenoid valves. See B3.
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A3a. Leakage from the vehicle or the road train
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No
Continue to troubleshooting diagram
A3b.
Activate the solenoid valves at component level using SDP3 to check for any leakage in the air supply to the various vehicle systems.
Note: It may be difficult to identify leakage simply through listening, therefore, use your hand to feel around components and connections to locate
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A3b. Problem with the compressor
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Troubleshooting the compressor 10-15.
Yes, the compressor is
switched off.
Does the compressor never switch off?
Check the solenoid valve, ESS piston and
cylinder head.
No
Does the vehicle have high air
consumption? See section C, Critical air
consumption.
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Yes
Does the compressor Check whether there is any air leakage from the control
charge? line through the compressor ESS system. If there is no
air leakage, continue to troubleshooting diagram A2c.
No The control line was pressurised and the compressor
started to charge when the control line was
detached.
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Instructions for troubleshooting
diagram A3b, Check solenoid valve,
ESS piston and cylinder head
Compressor control solenoid valve
• Decrease the pressure to 9 bar or lower so
that the compressor reaches charging
mode. Run the engine at idling speed.
Detach the control cable. If air comes out
of port 4 of the APS unit with a pressure
below 4 bar, the solenoid valve is faulty.
ESS piston
• Check whether the ESS piston in the
compressor is dirty or corroded.
Cylinder head
• Detach the cylinder head and check that
the internal parts are in good condition.
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A3c. Problem with the control mechanism of the compressor
Before starting troubleshooting:
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Pressurise the system to normal system pressure (9 bar or higher) using compressed air or by leaving the engine running.
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valve.
The port is not blocked. The control line is No
pressurised.
Blow air through the control line into Deactivate the solenoid valve Renew both solenoid
port 4. Check that air is leaking from for compressor control. Is the valves with O-rings.
port 3.2 (outflow for air from control line not pressurised?
solenoid valves).
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B. Leakage from the APS unit
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B1. Leakage at the pressure limiting valve, position A
Before starting troubleshooting:
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Depressurise the pneumatic system. Detach the block circuit coupling.
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Scania CV AB 2013, Sweden
A. Check valve with cylindrical shape has been softened by oil and must be renewed.
B. The check valve must have a conical shape.
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B2. Leakage at port 3, drain valve, during low pressure
Before starting troubleshooting:
Connect compressed air with the 15 voltage in the off position or with the compressor in charging mode and the engine running. The compressor
working phase is reached by repeatedly applying the brakes so that the pressure falls under 9 bar. The pressure must never exceed 9 bar.
Note: If the compressor is being relieved and air is blowing from the drain valve, regeneration of the APS unit is taking place.
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Renew the regeneration check valve.
Leakage at port 3.2
stops.
Depressurise the feed pipe and the desiccant
container, see instructions. Check for leakage at
port 3.2 (outflow for air from solenoid valves).
Yes Leakage at port 3.2
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Instructions for troubleshooting diagram B2, Leakage at port 3, drain valve, during
low pressure
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Scania CV AB 2013, Sweden 17
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B3. Leakage at port 3.2, outflow for air from solenoid valves
Before starting troubleshooting:
The compressor must be in charging mode with the engine running. The compressor working phase is reached by repeatedly applying the brakes so
that the pressure falls under 9 bar. The pressure must never exceed 9 bar.
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Leave the engine running. from port 4 on the APS unit.
Detach the compressor Renew the solenoid valve for compressor
control line. control.
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Instructions for B3, Leakage at port 3.2, outflow for air from solenoid valves
Depressurise the feed pipe and desiccant container
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B4. Leakage at port 3.1, safety valve
Before starting troubleshooting:
Start the engine and leave it running during troubleshooting.
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12.5 bar? The compressor can cause the safety
valve to break.
Renew the safety valve, see No The control line is pressurised.
instructions.
Yes Detach the compressor control line
and check that it is intact and
pressurised.
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Instructions for troubleshooting diagram B4, Leakage at port 3.1, safety valve
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B5. Leakage at the circuit protection valve, (position B)
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Solenoid valve test
Before starting troubleshooting:
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The solenoid valve test follows after completion of troubleshooting diagram B2 or B3. Pressurise the system to normal system pressure (9 bar or
higher) using compressed air or by leaving the engine running.
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Leakage from port 3.2 (outflow for air from solenoid
valves) does not stop. Activate both solenoid valves.
The drain valve, port 3, is Continued leakage at port 3.2.
leaking.
Activate the regeneration Leakage from port 3.2 (outflow for Renew the circuit protection
solenoid valve in SDP3. air from solenoid valves) stops. valve, see instructions.
Renew the regeneration solenoid valve.
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Instructions for the solenoid valve test
Check that the control line between the It is not possible to determine whether there is
compressor and the APS unit is intact and a fault on both solenoid valves, more than one
without kinks. fault on one solenoid valve or a fault on the
circuit protection valve. If no test valves are
If one of the solenoid valves is broken there is a available, the most economical solution is to
risk that the other solenoid valve will break renew the circuit protection valve. This action
shortly. Therefore, it may be appropriate to will solve the issue in all three cases.
renew both solenoid valves when the APS unit
is dismantled.
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C. Critical air consumption displayed in the instrument cluster
Before starting troubleshooting:
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Switch off any air consumers. Air consuming bodywork must be connected as described in the bodywork manual, BWM 07:60-01.
Note: Critical air consumption does not necessarily mean that there is leakage. Save and analyse operational data using SDP3, see instructions.
No leakage. During high air consumption the APS unit can be converted to the
high capacity version, see instructions (High values for the compressor
operating time).
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Check for leakage on the whole vehicle
combination, see instructions (Leakage).
The APS unit is working
correctly.
The pressure increases to
10 bar.
Zero the air counter in SDP3 or run the Check the compressor, see section A (A2b Problem with the
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Instructions for troubleshooting diagram C, Critical air consumption
displayed in the instrument cluster
The example below shows the compressor 2 Talk to the customer to find out whether
operating time. The bars show the time the anything specific may be causing any
compressor has been active in relation to the variations in the histogram. In the example,
total engine operating time as a percentage. the left column has increased significantly
over the last period. What has changed?
1 Save stored operational data using SDP3. Driving conditions? Has a fault occurred,
Then use SVAP (Scania Vehicle Analysis for example leakage? Has there been a
Portal) to analyse the operational data. change to a different trailer?
Each bar represents 168 operational hours.
For a vehicle with approximately 7 h 3 Click "Description" for an explanation of
driving per 24 hours there may be data the contents of the graph.
stored for up to 200 days available. The bar
at the bottom left may represent a value
less than 168 operational hours. The values
should normally be approximately the
same across the entire diagram.
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High values for the compressor operating time
The histogram below shows the compressor It is possible to convert a standard APS unit to
operating time. The compressor operating time a high capacity APS unit to handle a higher air
must not exceed 50%. consumption. See Workshop manual,
10-25 Brakes, Supply circuit, APS, Work
The value for the compressor operating time is description.
based on engine speed and the compressor
capacity. When the capacity decreases due to
wear, fault code 727 is generated earlier.
A high value for the compressor operating time may be because of:
• Leakage on the vehicle or the trailer.
• Worn compressor.
• Compressor control malfunction.
• Abnormally high air consumption.
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Leakage
Listen for any leakage from the whole vehicle
combination, including trailer. Listen with the
parking brake both applied and released.
Check the connection to any bodywork, see
Bodywork manual, chassis modifications.
The APS unit carries out a regeneration when
the starter key is switched off to ensure that the
compressed air system is dry. Regeneration can
carry on for up to one minute.
1 Check whether there is any leakage at the
control line and the cooling coil between
the compressor and the APS unit when the
compressor is charging.
2 Activate the V107 at component level
using SDP3 to check for any leakage in the
air supply to the EGR valve, exhaust brake,
venturi and SCR system.
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Information for troubleshooting diagram C, Critical air consumption is
displayed in the instrument cluster
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D. No pressure displayed in the instrument cluster
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E. Noise
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F. Parking brake cannot be released
Before starting troubleshooting:
Pressurise the system to normal system pressure (9 bar or higher) using compressed air or by leaving the engine running.
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Below 6 bar.
Check that there is no leakage in the parking
brake circuit.
Check the value on the pressure limiting valve, see
Instructions.
Is the value lower than 8.1 bar or higher
than 8.5 bar? Adjust the value.
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Instructions for troubleshooting diagram F, Parking brake cannot be
released
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G. Low pressure in the parking brake and accessory
circuits
Note: This applies to vehicles manufactured 6 Read the pressure in the parking brake
between March and September 2010 and APS circuit using SDP3 after about 10 seconds
units and air dryers delivered as spare parts of air consumption. Do not wait too long.
during the same time period. If the pressure decreases in the brake
circuits, the pressure will increase in the
parking brake circuit.
7 If the pressure is below 7 bar the APS unit
Symptoms has a piston which is outside tolerance
limits. If this is the case, renew the air
On some APS units the piston for the pressure dryer. Refer to the workshop manual,
limiting valve is outside tolerance limits. As a section 10-25, APS air processing system.
result, the pressure in the parking brake and
accessory circuits may sometimes be too low.
• It takes a long time to fill the parking brake
and accessory circuits.
• The low pressure warning lamp flashes or
comes on temporarily when air
consumption is high, e.g. when the parking
brake is released.
• The clutch pedal is hard to depress.
• Low pressure fault codes are generated in
the SCR or EGR circuits.
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