troubleshooting & diagnostics manual · 2018. 5. 14. · i westport hd & lng system epa07, epa10,...

Troubleshooting & Diagnostics Manual

Westport HD Engine & LNG Fuel System (EPA07, EPA10, ADR80/02, ADR80/03)

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Westport HD & LNG System EPA07, EPA10, ADR80/02, and ADR80/03 Troubleshooting & Diagnostics Manual Scope of Coverage The purpose of this manual is to provide a reference for all qualified Westport HD & LNG System technicians and field service personnel. This manual contains information to aid in diagnosing and repairing faults on the Westport HD & LNG System.

This manual contains material directly related to or influenced by the Westport HD & LNG System. The faults and system errors identified in this manual are not exhaustive. It does not cover base engine or original equipment manufacturer (OEM) problems. For all other diagnostic and troubleshooting procedures pertaining to the base Cummins ISX engine and truck platform, refer to Cummins and OEM supplied repair manuals respectively. For all work performed, follow the recommended procedures in the Westport HD and LNG System work instructions, found on the Westport HD service website. Replacement part information can be obtained through Westport HD and LNG Service part drawings, also found on the Westport HD service website

Information published in this manual is intended for reference only. This document is written and published by Westport Power Inc. for Westport Fuel Systems Inc. Every precaution has been taken to ensure its accuracy. Westport Power Inc. and Westport Fuel Systems Inc. encourage the user of this manual to report errors, omissions and recommendations for improvement using the contact information listed in this manual. Westport Power Inc. and Westport Fuel Systems Inc. assume no responsibility for errors in this manual, omissions or their consequences. The information is subject to change without notice. If you have any questions about the information in this manual or if you need further service assistance, please contact Westport Service using the contact information listed in the following section.

Patent Notice

The LNG Fuel System and components thereof are covered by one or more of the following U.S. Patents: 6,298,833; 6,336,598; 6,439,192; 6,761,325; 7,124,959; 7,162,995; 7,293,418; 7,302,918; 7,302,939; 7,308,889; 7,344,045; 7,373,931; 7,463,967; 7,546,744; 7,607,898; 7,627,416; 7,637,113; 7,775,391; 7,913,496, 8,028,676; 8,095,294; and 8,104,296. Other U.S. and foreign patents pending.

© 2008-2012, Westport Power Inc.

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form, by any means, without the prior written permission of Westport Power Inc.

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Contact Information If you have found any inaccuracies, have suggestions for improvement or have questions regarding the content of this manual please contact Westport HD Service at:

Service Engineering Head Office: Web: http://service.westport-hd.com

Field Service North America: Address: 2675 Temple Avenue Signal Hill, CA 90755 USA Phone: 1-888-WPT-HPDI 1-888-978-4734 E-mail: [email protected]

Australia: Address: Unit 20 21 Barry St. Bayswater,

Victoria, 3153 Australia Phone: +61-3-9729-5009 E-mail: [email protected]

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Table of Contents Section A - Introduction .......................... ...................................................................................... 4 How to Use the Manual .............................................................................................................................. 4 Terminology Used ...................................................................................................................................... 6 General Safety Instructions ....................................................................................................................... 7 General Repair Instructions ....................................................................................................................... 9 General Cleaning Instructions ................................................................................................................. 10 Section B - Westport HD and LNG System Familiarizat ion ............................................... ....... 12 General Westport HD and LNG System Description ............................................................................... 12 Electronic Control System ....................................................................................................................... 12 Engine Fuel System (EFS) ....................................................................................................................... 14 High Pressure Gas System (HPGS) ......................................................................................................... 14 Westport Driver Display ........................................................................................................................... 18 Westport Gas Detection System .............................................................................................................. 20 Service Tools and Hardware .................................................................................................................... 22 Section C – Troubleshooting Symptoms .............. ..................................................................... 23 General Information ................................................................................................................................. 24 Overview ................................................................................................................................................... 24 TT-EFS: Engine Fuel System Symptoms ................................................................................................ 24 TT-HPGS: High Pressure Gas System Symptoms .................................................................................. 25 TT-EFS: Engine Performance Troubleshooting Tree .............................................................................. 25 TT-EFS: Troubleshooting Steps .............................................................................................................. 26 TT-HPGS: High Pressure Gas System Troubleshooting T ree ................................................................ 58 Section D – Useful Diagnostic Test Procedures ..... .................................................................. 88 Section E – Useful Documents ...................... ............................................................................. 99 Revision History .................................. ...................................................................................... 106

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Section A - Introduction

How to Use the Manual

This troubleshooting guide is intended to aid in determining the cause of problems related to the Westport HD and LNG System. It is not possible to include all the solutions to problems that can occur, however this manual is intended to stimulate a thought process that will lead to the cause and correction of the problem.

A detailed analysis of the customer’s complaint is key to successful troubleshooting. The more information that is known about a complaint, the faster and easier the problem can be solved.

This manual is divided into sections to aid technicians in troubleshooting the Westport HD and LNG System. The sections are organized as follows:

Section A - Introduction:

This section contains general information about the troubleshooting manual and the troubleshooting process. This information includes general cleaning, repair and safety instructions as well as an overview of acronyms and abbreviations used in this manual.

Section B - Westport HD and LNG System Familiarizat ion:

The Westport HD and LNG System is a fuel injection and LNG fuel system developed by Westport Power Inc. This section identifies Westport components and is intended to assist technicians in differentiating between Westport components and base engine or OEM components. This section also includes an electrical overview, which is intended to increase the technicians’ understanding of electrical terms used in this manual.

Section C - Troubleshooting Symptoms:

Symptom based troubleshooting should be used in the event there are no fault codes stored in the Westport Controllers. This section guides the manual user through a series of checks and questions intended to identify problems where there are no fault codes.

Section D - Useful Diagnostic Procedures:

This section contains procedures and tests developed by Westport Power Inc. to assist a qualified technician in sourcing the cause of problems. These procedures and tests are referenced in Section C - Troubleshooting Symptoms, as well as Westport document TSG-10019941 Fault Code Reference Manual where they apply.

Section E - Other Useful Documents:

This section contains reference material to assist a qualified technician when troubleshooting the Westport HD and LNG System.

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Acronyms and Abbreviations

The following list contains acronyms and abbreviations used in this manual.

ADR Australian Design Rules ATSOV Automatic shutoff valve bar bar, unit of pressure measurement CAN Controller Area Network CEN Cummins Engine Network CNG Compressed Natural Gas CPP Cummins Proprietary Protocol DLSR Dome-Loaded Self Relieving regulator DRP Diesel Rail Pressure DTSV Digital Tank Select Valve ECM Electronic Control Module ECU Electronic Control Unit EFS Engine Fuel System EGR Exhaust Gas Recirculation EPS Engine Position Sensor ESS Engine Speed Sensor FCM Fuel Conditioning Module FLT Fuel Level Transducer GDT Gas Discharge Temperature GRP Gas Rail Pressure GSOV Gas Shut Off Valve GSP Gas System Pressure HPDI High Pressure Direct Injection HPGS High Pressure Gas System HSP Hydraulic System Pressure IMV Inlet Metering Valve kPa kilopascals, unit of pressure measurement LED Light Emitting Diode LEL Lower Explosive Limit LHS Left-hand Side LNG Liquid Natural Gas LSSC Level Sensor Signal Conditioner MPa Megapascals, unit of pressure measurement OEM Original Equipment Manufacturer Pa Pascals, unit of pressure measurement PSI Pounds per square inch, unit of pressure measurement PPE Personal Protective Equipment PRV Pressure Relief Valve RHS Right-hand Side ROD Run On Diesel RPM Revolutions Per Minute (engine speed) TSV Tank Selection Valve TSOV Tank Shutoff Valve VDC Volts Direct Current, unit of voltage measurement VGT Variable Geometry Turbine WPP Westport Proprietary Protocol WPT Westport

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Terminology Used

This section provides a more detailed description and explanation of terminology used throughout this manual.

Electronic driver is disabled The EFS and HPGS Controllers are equipped with electronic drivers to provide power to various components. When the controller detects a condition that is potentially damaging to the controller the electronic driver will be disabled to prevent damage to the controller.

Faulty connection A faulty connection means that two mating ends (either harness-to harness or harness to component) are not securely connected. In its simplest form this means the two mating ends are not connected at all. In a broader sense, a faulty connection means the male portion of the connection does not provide adequate electrical contact with the female portion of the connection. A visual inspection of a connection is not sufficie nt to determine if a connection good. This is especially true in cases where the problem being investigated is intermittent.

Flat line The term flat line is used to describe the scenario where the output of a sensor does not change relative to the input. A flat line indicates a faulty sensor. See Section E – Useful Documents for examples of normal pressure sensor response.

LNG pump performance is no longer optimized The Westport HD and LNG System control system uses the hydraulic system pressure trace to accurately determine when LNG pump strokes have been completed. This accurate pump stroke determination allows the control system to respond quickly and command the LNG pump to stroke sooner if need be to maintain GSP. When the hydraulic system pressure trace is unreliable or otherwise unusable, the control system is unable to fine-tune the commanded strokes. Hence LNG pump performance is no longer optimized.

LNG pump retract stroke When a LNG pump is commanded to retract, liquid natural gas is drawn from the LNG tank into the LNG pump. GSP does not increase and HSP is low relative to the extend stroke. See Section D – Ideal Hydraulic System Pressure Trace, for more information

LNG pump extend stroke When a LNG pump is commanded to extend, LNG contained in the LNG pump is compressed and forced through the vaporizer in the LNG pump. When liquid natural gas is forced through the vaporizer it changes from a liquid to a gas. As a result GSP increases over the extend stroke. As well, when liquid natural gas is forced through the vaporizer, HSP sharply increases and is maintained until the extend stroke is completed. See Section D – Ideal Hydraulic System Pressure Trace, for more information

LNG pump is idle When gas system pressure (GSP) is sufficient the LNG pump(s) are not required to supply additional natural gas to meet natural gas fuel consumption. As a result the LNG pump is not commanded to stroke and is considered idle. GSP will vary depending on fuel consumption and HSP is relatively low when compared to the extend stroke.

Lower explosive limit Natural gas must be mixed with air in specific quantities in order to combust. The minimum threshold required for natural gas combustion is referred to as the lower explosive limit. When natural gas is present in quantities less than the LEL the air gas mixture is considered too lean to burn. For safety, the Westport Gas Detection System is designed to detect and alert the operator to the presence of natural gas before the LEL is achieved. For more information see Section - B - Westport HD and LNG System Familiarization – Westport Gas Detection System

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General Safety Instructions

Warning Improper practices, carelessness, or ignoring the w arnings can result in serious personal

injury or death.

Read and understand all of the safety precautions and warnings before performing any repair. This list contains general safety precautions that must be followed to provide personal safety. This list is not exhaustive and supplements base engine or OEM safety recommendations.

• The Westport HD and LNG System contain high-pressure gas, liquid and cryogenic fluids – even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance on a Westport HD and LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or cryogenic burn injuries could occur.

• Westport HD and LNG System repairs must be completed only at certified Westport HD and LNG System shops by qualified Westport HD and LNG System technicians.

• Work in an area surrounding the product that is dry, well lit, ventilated, and free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of and resolve hazardous conditions before working on the Westport HD and LNG System.

• Liquefied natural gas (LNG) is heavier than air and can accumulate near the floor, in sumps, and low-lying areas. However, liquefied natural gas has an extremely low boiling point and will quickly vaporize at room temperature and atmospheric pressures.

• LNG is a cryogenic (extremely cold) fluid, which must be stored at cryogenic temperatures. Avoid contact with LNG and associated plumbing. Freezing burns and lacerations could occur.

• Wear appropriate personal protective equipment (PPE) when working around the LNG tank or plumbing.

• Always wear protective glasses and protective shoes when working. • Do not wear loose-fitting or torn clothing. Remove all jewellery when working. • Natural gas is lighter than air and can accumulate in enclosed spaces, such as under the

hood or under awnings. If there is an ignition source, an explosion could result. Never allow the truck to vent or leak in an enclosed space.

• Parking outside is mandatory due to normal venting of natural gas. • The vehicle may be allowed to park indoors for maintenance provided the shop is

properly equipped and the truck is appropriately prepared to prevent an accumulation of natural gas in a combustible mixture. Truck and shop preparation are often dictated by local and national regulatory codes, which may o r may not allow indoor parking. Always check with the shop foreman to see if your shop has the appropriate equipment. If indoor parking is required for maintenance, contact your local Westport Service representative to discuss upgrades to your building and develop shop procedures specific to your facility.

• Never park indoors for maintenance without completing a thorough leak inspection of the truck.

• Natural gas is colorless and odourless. • Westport HD and LNG System trucks are equipped with a Gas Detection Monitor. You

must check the operation of the Gas Detection Monitor and listen for sounds of a leak in accordance with OEM documentation.

• Do not stay in a natural gas vapour cloud. Natural gas displaces oxygen and will cause asphyxiation.

• Release of high pressure gas or fluid can break or propel components with explosive force. Component removal and installation instructions must be followed and can be obtained from the Westport HD service website.

• Relieve all pressure from the Westport HD and LNG System before any lines, fittings or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from the Westport HD and LNG System. Do not check for pressure leaks with your hand. High pressure fuel can cause personal injury.

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• Damage to the Westport HD and LNG System can occur if the coolant mixture is incorrect. Ensure coolant mixture contains approved antifreeze. Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

• Contain liquid spills as best as possible to prevent liquid or gas from entering the sewage/storm drain system.

• Disconnect the battery (negative [-] terminal cable first) before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment or on the controls.

• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system.

• Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported only by lifting jacks or a hoist.

• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.

• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas flow, and hot fluids in lines, tubes and compartments.

• Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Some repairs require the use of specialized tools which can be obtained via Westport Service.

• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

• California Proposition 65 Warning – Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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General Repair Instructions

The Westport HD and LNG System incorporates the latest technology at the time it was manufactured; yet it is designed to be repaired using normal repair practices performed to quality standards.

Westport Power Inc. and Westport Fuel Systems Inc. does not recommend or authorize any modifications or repairs to engines or componen ts except for those detailed in Westport Service literature. In particular, unautho rized repair to safety related components can cause personal injury or death. Below is a part ial listing of Westport Components classified as safety related. This list does not in clude base engine or OEM components which are classified as safety related. Refer to ba se engine and OEM documentation for listing of those components classified as safety re lated.

1. Westport Gas Detection System 2. Cooling Fan 3. Fuel Shutoff Assemblies 4. Automatic and Manual Pressure Relief Devices 5. High Pressure Hydraulic Plumbing 6. High Pressure Compressed Natural Gas Plumbing 7. Liquefied Natural Gas Plumbing

• Follow all safety instructions noted in the procedu res • Follow the recommendations listed in Westport Work Instructions for cleaning solvents

and other substances used during the repair of the Westport HD and LNG System. For all other non-Westport LNG System components, refer to manufacturer or OEM recommendations. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools and equipment.

• Provide a clean environment and follow the cleaning instructions specified in the procedures.

• The Westport HD and LNG System must be kept clean during repair. Contamination of the engine or components will cause premature wear.

• Perform the inspections specified in the procedures • Replace all components or assemblies which are dama ged or worn beyond the

specifications • Use parts specified in Westport Service Literature • Follow the specified disassembly and assembly proce dures to reduce the

possibility of damage to the components

Welding on a Vehicle with an Electronic Controlled Fuel System

Caution Disconnect both the positive (+) and negative (-) b attery before welding on the vehicle. Attach the welder ground cable no more than 0.61 me ters [2 feet] from the part being welded. Do not connect the ground cable of the weld er to the ECU cooling plate or ECU. Welding on the engine or engine mounted components is not recommended or damage to the engine or components can result.

Clearing of Electronic Fault Codes

In general, any inactive fault codes may be cleared by the technician following a service which is known to have repaired or dismissed the cause of the fault codes, or are known to be caused by the diagnostic process. However, in following good practice, all active and/or inactive fault codes shall be recorded in the service work order for future reference, prior to clearing from the controllers’ memory.

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General Cleaning Instructions

This section contains general cleaning instructions for the Westport HD and LNG System. This list is not exhaustive and supplements base engine or OEM cleaning recommendations. See base engine or OEM documentation for additional cleaning recommendations.

Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear as new.

Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible, leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any attracted dirt. If the part is cleaned and then left exposed it will have to be cleaned again before installation.

Follow specific cleaning instructions listed in procedures.

Steam Cleaning

Do not steam clean the following Westport HD and LNG System components. See base engine and OEM documentation for base engine and OEM components which should not be steam cleaned.

• Electrical components • Wiring harnesses • Injectors • Fuel pumps • Belts and hoses • Electronic Control Units (ECU) • ECU connectors • Natural gas sensors

Cleanliness Considerations

When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas are not cleaned, dirt or contaminants can be introduced into the fuel system.

The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. The Westport HD and LNG System operate at very high pressures. High pressure fuel can convert simple particles of dirt and rust into a highly abrasive contaminant that can damage the Westport HD and LNG System.

Choose lint free towels for fuel system work.

Cap and plug fuel lines, fittings, and ports wherever the fuel system is opened. Rust, dirt, and paint can enter the fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.

When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are removed.

Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter. The micron rating is the size of the smallest particles that will be captured by the filter media. The contaminants being filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.

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The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points regarding your fuel system tools:

• Fuel system tools are to be kept as clean as possible. • Clean and dry tools before returning them to the tool box. • If possible, store fuel system tools in sealed containers. • Make sure fuel system tools are clean before use.

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Section B - Westport HD and LNG System Familiarizat ion

General Westport HD and LNG System Description

The Westport HD and LNG System is a fuel injection and delivery system developed by Westport Power Inc. It allows diesel engines to use natural gas as the primary engine fuel. The Westport HD and LNG System is an electronically operated and controlled fuel system.

The Westport HD and LNG System injects natural gas into the combustion chamber towards the end of the compression stroke in much the same manner as a diesel engine. Natural gas does not auto-ignite as easily as diesel, so a small amount of diesel is injected into the cylinder prior to the natural gas injection. This diesel injection behaves as a liquid spark plug, with the injected natural gas providing the power stroke.

The Westport HD and LNG System is composed of two main subsystems, the Engine Fuel System (EFS) and the High Pressure Gas System (HPGS). The function of the High Pressure Gas System is to provide compressed natural gas to the Engine Fuel System. The Engine Fuel System controls the amount of fuel delivered to the chamber. More detailed information on these subsystems can be found in their respective sections.

Electronic Control System General Overview

The electronic control system for the Westport HD and LNG System consists of two Westport controllers and one Cummins base engine controller. Refer to base engine documentation for details on the Cummins base engine controller.

Each of the two main subsystems, the EFS and the HPGS, in the Westport HD and LNG System has a dedicated Westport ECU. The Westport controllers consist of the same hardware (CM850) but are designated the EFS Controller or the HPGS Controller as a result of the application software on the ECU and the ECU connection to the Chassis Harness. The controllers are configured in a parent/child relationship. The EFS Controller acts as the parent by directly communicating with the base engine controller and providing key information to the HPGS Controller (child).

Both ECU’s process inputs from a variety of sensors and send commands to their associated components. For a listing of components and sensors associated with each subsystem and controller see Engine Fuel System Overview and High Pressure Gas System Overview. Both ECU’s perform diagnostic tests on most of their circuits and will activate a fault code if a problem is detected in one of these circuits. More information on diagnostic fault codes is found later in this section.

The EFS controller (parent CM850), is primarily in charge of controlling the engine fuel system. It is responsible for fueling and timing required to operate the engine at the desired engine speed and required emission levels. Other functions of the EFS Controller include providing key parameters to the HPGS Controller, providing a power return line for the Westport Driver Display as well as physically driving injectors 1, 2 and 3.

The HPGS Controller (child CM850), is primarily in charge of ensuring that compressed natural gas is supplied to the Engine Fuel System. It also physically drives injectors 4, 5, and 6.

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The Westport controllers are typically mounted on the firewall over the valve cover, however other configurations are possible. The following figure shows several possible mounting locations.

Figure 1: Typical locations of Westport controllers (battery box, chassis, and engine bay mounting locations shown)

Diagnostic Fault Codes – General Overview

The Westport and Cummins controllers are capable of storing fault codes, which can be used for diagnostic purposes. The structure of the Westport Fault Code gives the user information about severity of the fault and which controller activated the fault code.

Table 1 - Fault code identifier

Table 2 - Fault code severity

Refer to Westport document TSG-10019941 Fault Code Reference Manual for detailed information on all Westport fault codes.

Controller Identification Associated Controller

3 EFS

4 HPGS

Severity code Fault severity

0 Truck Disabling, Engine will not run when a level 0 fault code is active

1 Noticeable drivability issues

2 Operator may not notice driveability issues. However, indicates issue which needs to be resolved

Controller identification

3000

Fault severity

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Engine Fuel System (EFS) General Overview

The EFS is responsible for fueling and timing required to operate the engine at the desired engine speed and the required emission level. The EFS is directly responsible for controlling and maintaining rail pressure. EFS components are primarily located in the engine bay.

Subsystems of the EFS include: • Diesel system • Fuel conditioning module (FCM) • Westport HPDI Injectors

EFS Controller Inputs • DRP sensor • GRP sensor • EPS sensor • ESS sensor • Base engine parameters broadcast on CEN CAN B private datalink

High Pressure Gas System (HPGS) General Overview

The HPGS is responsible for providing compressed natural gas to the EFS. The HPGS is directly responsible for maintaining GSP. HPGS components are primarily located outside the engine bay starting with the LNG tank(s) and leading up to the FCM.

Subsystems of the HPGS include: • LNG tank and pump • High pressure natural gas plumbing • Hydraulic system, used for tank selection and LNG pump strokes

HPGS Controller Inputs • GSP sensor • HSP sensor • GDT sensor • EPS sensor • ESS sensor • EFS parameters broadcast on the WPP CAN A private datalink • CANditioner outputs

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LNG Tank

The Westport LNG System LNG tank is a thermally insulated, cryogenic fuel storage device with an integral high pressure LNG fuel pump. Depending on the build configuration of the vehicle, it may be equipped with up to four LNG tanks, mounted along the vehicle chassis on either/both the left and right side of the vehicle, and/or or mounted tranversely behind the vehicle cab. Depending on the configuration, the LNG tank internal component layout may differ, but are of either the manual shut-off type, or the automatic shut-off type; see Figure 2, Figure 3, and Figure 4.

T3.1 LNG Tank

Figure 2: LNG Tank with manual shut-off valve (EPA0 7, ADR80/02) (Left hand side configuration shown, other configur ations similar)

Table 3 - T3.1 LNG tank components A Hydraulic feed line O Vent to atmosphere line B Hydraulic return line P Level sensing signal conditioner C Coolant inlet Q Level sensor feed tube D Coolant outlet R Grounding lug E Vent to ATM valve S PRV excess flow drain tube F Vent to STN valve T Manual tank shutoff valve G Liquid drain valve U High pressure gas discharge line H Tank pressure gauge

V Hydraulic directional control valve with manifold I LNG fill receptacle

J LNG fill tube W LNG pump (head) K LNG fill manifold X LNG liquid drain port L Primary PRV manifold Y Secondary PRV (call-out not shown) M Vacuum sensor Z LNG pump PRV N Vacuum port AA Coolant purge valve

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T4.2 LNG Tank

Figure 3: LNG tank, with automatic tank shut-off va lve (EPA07, ADR80/02)

(Left hand side configuration shown, other configur ations similar)

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T4.3 LNG Tank

Figure 4: LNG tank, with automatic tank shut-off va lve (EPA10, ADR80/03)

(Left hand side configuration shown, other configur ations similar)

Table 4 - T4.2 & T4.3 list of LNG tank components w ith automatic shut-off valves A Hydraulic feed line O Vent to atmosphere line B Hydraulic return line P Level sensing CANditioner C Coolant inlet Q Level sensor feed tube D Coolant outlet R Grounding lug E Vent to ATM valve S PRV excess flow drain tube F Vent to STN valve T Automatic tank shutoff valve G Liquid drain valve U High pressure gas discharge line H Tank pressure gauge

V Hydraulic directional control valve with manifold I LNG fill receptacle

J LNG fill tube W LNG pump (head) K LNG fill manifold X LNG liquid drain port L Primary PRV manifold Y Secondary PRV M Vacuum sensor Z Coolant purge valve N Vacuum port AA Gas discharge temperature sensor

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Westport Driver Display

General Overview

The Westport Driver Display is an informational console for the Westport LNG system. The Westport Driver Display has two windows as shown below on the LNG Fuel Monitor and System Message Screen.

Figure 5: Westport driver display - top window summ ary, bottom window message

example

The top window shows: • LNG Fuel Tank Level Meter and LNG Pump Icon(s) • Disabled LNG Pump Indicator (X through the pump icon) • Cold Gas Discharge Temperature Indicator (“snowflake” icon below pump icon)

For trucks equipped with multiple tanks, the tank icon will flash to show which tank fuel is being drawn from. Under normal conditions, this should alternate between tanks.

The bottom window can display the following informational messages to the operator.

Table 5- Westport driver display messages Message Alarm Cause Associated Fault Codes Please Stop Engine YES Significant engine issue Multiple Check for CNG Leak YES Possible high-pressure

gas leak 4173

Prepare to Stop YES Loss of Gas System Pressure (GSP)

4228

Engine Warming Up Max 6 MPH (10 KM/H)

YES1 Coolant has not sufficiently warmed

None

Please Wait… YES1 Coolant has not sufficiently warmed

None

Tank 1/2/3/4 shut-off is closed

NO Emergency shut-off valve is closed 2

4224, 4225, 4226, 4227

LNG Tank 1/2/3/4 is empty NO No LNG fuel in tank 4165, 4166, 4167, 4168 Check ECU Next Stop NO Active Fault Code stored

in ECU Multiple

On Diesel – XXX Seconds Remaining

NO Gas System Pressure (GSP) is not sufficient to run on natural gas

4229

1 Alarm sounds if speed limit is exceeded 2 If available

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No CAN Messages NO Not receiving communication from HPDI system ECU

Communication Fault

If the LNG fuel tank level meter appears striped (Figure 6), this in indicative of a fault with the LNG tank communication.

Figure 6: Westport driver display - LNG tank commun ication error

Additional Driver Display Screens

In addition to the LNG Fuel Monitor and System Message Screen, your driver display may include two additional screens: the Active Fault Code screen and the System Pressures screen. These screens are typically found on EPA10 and ADR80/03 trucks. However, firmware upgrades to existing displays may be possible. Refer to Westport HD service website for additional information.

Active Fault Code Screen

The Active Fault Code screen is used to display Westport HD System specific active fault codes.

These fault codes can be used by trained service technicians to diagnose issues with the Westport HD System. A maximum of 11 fault codes can be displayed concurrently.

When a fault code becomes inactive, it is removed from this screen. Information on individual fault codes can be found in Wesport document TSG-10019941 Fault Code Reference Manual.

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Figure 7: Westport driver display - active fault co de screen

System Pressures Screen

The System Pressures screen is used to display important pressures for the Westport HD System. The three system pressures are displayed as follows:

• GRP: Gas rail pressure, (bar) – Gas pressure present in the engine fuel rail and injection pressure.

• DRP: Diesel rail pressure, (bar) – Diesel pressure present in the engine fuel rail and injection pressure.

• GSP: Gas supply pressure, (MPa) – LNG pump discharge and accumulator pressures.

Figure 8: Westport driver display - system pressure s screen

Westport Gas Detection System

General Overview

Westport HD and LNG System trucks are equipped with a gas detection system. The gas detection system consists of a gas detection monitor and two sensors. One sensor is located in the cab and the second sensor is located on the bulkhead in the engine bay.

Warning Pressure washing the gas detection sensors can dama ge the sensor and prevent the

sensor from detecting natural gas.

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The gas detection monitor displays shown are located inside the cab. The gas detection monitor provides information on the status of the gas detection system and alerts the operator in the event natural gas is detected by the gas sensors.

The gas detection monitor will differ depending on the model of Westport LNG system.

A summary table of the lights and alarms are listed below for each respective model (Amerex or Fireboy-Xintex).

Amerex Gas Detection Monitors

Figure 9: Amerex gas detection

monitor (EPA07)

Figure 10: Amerex gas detection monitor

(ADR80/02, ADR80/03) Table 6 - Summary of Amerex gas detection monitor ( EPA07, ADR80/02, ADR80/03) Label Light Alarm Meaning when Light is Illuminated POWER Green NO Gas detection monitor is powered ALERT or SIGNIFICANT

Red YES A significant natural gas leak has been detected by the corresponding sensor. A significant natural gas means natural gas concentrations are in excess of 50% of the Lower Explosive Limit (LEL)

TRACE Yellow NO A trace natural gas leak has been detected by the corresponding sensor. A trace natural gas leak means natural gas concentrations are between 20-50% of the LEL.

Sensor Fault Yellow NO A problem has been detected with the corresponding gas sensor or the wiring from the monitor to the sensor (open circuit)

Relay Engaged

Red N/A This feature is not used by the Westport Gas Detection System.

The gas detection display has three buttons: [Push to Test]: Tests the LEDs and electrical circuits. [Push to Silence]: Silences audible alarm. [Relay Reset] or [Shutdown Reset]: Resets the external relay after a gas alarm has cleared.

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Fireboy-Xintex Gas Detection Monitor

Figure 11: Fireboy-Xintex gas detection monitor (EP A07, EPA10)

Table 7 - Summary of Fireboy-Xintex gas detection m onitor (EPA07, EPA10) Label Lamp Alarm Meaning when Light is Illuminated OK Green NO Condition Normal DANGER Red YES A significant natural gas leak has been detected

by the corresponding sensor. A significant natural gas means natural gas concentrations are in excess of 50% of the Lower Explosive Limit (LEL)

DANGER Red NO A trace natural gas leak has been detected by the corresponding sensor. A trace natural gas leak means natural gas concentrations are between 20-50% of the LEL.

FAULT Yellow NO Indicates that the sensor is not detected, or sending a fault from the corresponding location.

Power / Fault Green NO Indicates that the display is working normally. Power / Fault Yellow NO Indicates that the display has a fault.

The gas detection display has two buttons: [TEST]: Cycles the LEDs, and triggers the audible alarm temporarily. [RESET SILENCE]: Turns off the audible alarm when the display is in alarm.

NOTE: If gas detection monitor is not as shown, refer to OEM documentation.

Service Tools and Hardware The Westport HD and LNG System uses standard service tools wherever possible. However, additional specialized Westport HD service tools have been created to assist technicians with troubleshooting where standard tools cannot be used.

A complete list of recommended service tools, including standard service tools, can be found on the Westport HD Service website.

http://service.westport-hd.com

HD and LNG System EPA10, EPA07, ADR80/02, and ADR80/03

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Section C – Troubleshooting Symptoms General Information .................................................................................................................................. 24 Overview ................................................................................................................................................... 24 TT-EFS: Engine Fuel System Symptoms ................................................................................................. 24 TT-HPGS: High Pressure Gas System Symptoms .................................................................................. 25 TT-EFS: Engine Performance Troubleshooting Tree .............................................................................. 25 TT-EFS: Troubleshooting Steps .............................................................................................................. 26 TT-EFS Step 1 – Perform basic troubleshooting proce dures ................................................................. 26 TT-EFS Step 2 – Determination of engine symptom ............................................................................... 29 TT-EFS Step 3 – No Start Troubleshooting Procedures ......................................................................... 35 TT-EFS Step 4 – Fuel System Checks ..................................................................................................... 41 TT-EFS Step 5 – Injector Checks ............................................................................................................. 48 TT-EFS Step 6 – Base Engine Checks ..................................................................................................... 54 TT-EFS Step 7 – FCM Vent Checks .......................................................................................................... 55 TT-HPGS: High Pressure Gas System Troubleshooting T ree ................................................................ 58 TT-HPGS Step 1 – Perform basic troubleshooting proc edures .............................................................. 59 TT-HPGS Step 2 – Determination of HPGS symptom ............................................................................. 61 TT-HPGS Step 3 – LNG Tank Vacuum Check .......................................................................................... 68 TT-HPGS Step 4 – LNG Tank Leak Check ............................................................................................... 69 TT-HPGS Step 5 – Pressure Sensor Check ............................................................................................. 75 TT-HPGS Step 6 – Vaporizer Check ......................................................................................................... 76 TT-HPGS Step 7 – Gas system leak check .............................................................................................. 78 TT-HPGS Step 8 – Hydraulic System Check ........................................................................................... 81


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General Information A thorough analysis of the customer’s complaint is the key to successful troubleshooting. The more information that is known about a complaint, the faster and easier the problem can be solved.

The troubleshooting trees are organized so that a problem can be located and corrected by doing the easiest and most logical things first. The troubleshooting steps in this section build upon information obtained in previous steps. The troubleshooting steps in these procedures must be performed in the sequence specified in the troubleshooting procedure.

It is not possible to include all the solutions to problems that can occur; however, these trees are designed to stimulate a thought process that will lead to the cause and correction of the problem. Be aware that the troubleshooting trees contained in t his manual are for the Westport HD and LNG System only , where a faulty Westport HD and LNG System component is the source of a customer’s complaint. Refer to base engine documentation for troubleshooting components that are not part of the Westport HD and LNG System (for example air handling, and aftertreatment checks).

Follow these basic troubleshooting steps; • Get all the facts concerning the complaint • Analyze the problem thoroughly • Relate the symptoms to the basic engine systems and components • Consider any recent maintenance or repair action that may relate to the complaint • Double-check before beginning any disassembly • Determine the cause of the problem and make a thorough repair • After repairs have been made, operate the engine to make sure the cause of the complaint

has been corrected

Overview This section is intended to aid technicians in finding the source of a problem when there are no fault codes . If there are active or inactive fault codes stored in either the EFS or HPGS controller, troubleshoot the fault codes first. Refer to Westport document TSG-10019941 – Fault Code Reference Manual if there are active or inactive fault codes stored in either the EFS or HPGS Controller.

Symptoms are divided into four main troubleshooting trees (TT); Engine Fuel System (TT-EFS), High Pressure Gas System (TT-HPGS), Electronics (TT-E) and Base Engine (TT-BE).

To determine which troubleshooting tree to use, consult the lists on the following pages, locate the symptom which best describes the issue being troubleshot, then start with Step 1 of the respective troubleshooting tree.

TT-EFS: Engine Fuel System Symptoms Symptoms in this category directly relate to engine performance where there are no natural gas supply issues from the HPGS. Components relating to the EFS are predominately mounted on the engine.

TT-EFS should be used for the following symptoms • Engine difficult to start or will not start • Engine shuts down without warning (stalls) • Engine power output is low • Engine power output is high • Engine operating fuel pressure is high • Engine operating fuel pressure is low • Engine runs rough or misfires • Engine acceleration or response is poor • Engine speed surge or engine speed unstable • Engine will not reach rated speed (rpm) • Excessive exhaust smoke • Exhaust temperature is high


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• Constant venting from the FCM vent stack • Venting from the diesel tank

TT-HPGS: High Pressure Gas System Symptoms Symptoms in this category relate to the storage of LNG and supply of high pressure natural gas to the engine. Components relating to the HPGS are predominately mounted off the engine.

TT-HPGS should be used for the following symptoms. • LNG Tank has condensation or frost on the outer tank body • LNG fuel consumption excessively high • LNG tank plumbing and manifold components excessively frosty • Audible gas leak / venting from LNG tank vent stack • Audible gas leak / venting from FCM vent stack • Audible general gas leak from LNG tank • Audible general gas leak from chassis • LNG tank vents to station immediately upon connecting the refuelling line • Engine starts / runs on diesel only, or derates to running-on-diesel (ROD) mode • LNG fuel depletes unevenly on multi-tank equipped vehicles • Insufficient hydraulic system pressure

TT-EFS: Engine Performance Troubleshooting Tree

This troubleshooting procedure should be followed f or the following symptoms: • Engine difficult to start or will not start • Engine shuts down without warning (stalls) • Engine power output is low • Engine power output is high • Engine operating fuel pressure is high • Engine operating fuel pressure is low • Engine runs rough or misfires • Engine acceleration or response is poor • Engine speed surge or engine speed unstable • Engine will not reach rated speed (rpm) • Excessive exhaust smoke • Exhaust temperature is high • Constant venting from the FCM vent stack • Venting from the diesel tank

How to use this troubleshooting procedure: This symptom tree can be used to troubleshoot all performance-based symptoms listed above. Start by performing Step 1 troubleshooting. Step 2 will ask a series of questions and provide a list of troubleshooting steps to perform, depending on the symptom. Perform the troubleshooting in the sequence shown in the Specifications/Repair section of the tree.


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TT-EFS: Troubleshooting Steps TT-EFS Step 1 – Perform basic troubleshooting proce dures TT-EFS Step 1A: Check the Cummins CM871 for active fault codes or high counts of inactive fault codes. Condition : • Connect INSITETM electronic service tool • Turn keyswitch ON Action Specification/Repair Next Step Check the Cummins CM871 for active fault codes or high counts of inactive fault codes. • Use INSITETM electronic

service tool to read the fault codes.

Active fault codes or highcounts of inactive fault codes? YES

Refer to: Base engine documentation for base engine fault code based troubleshooting.

Active fault codes or high counts of inactive fault codes? NO

No repair at this stage

Go to: TT-EFS Step 1B

TT-EFS Step 1B: Check the Westport HD and LNG Syste m for active and inactive fault codes. Condition: • Connect WEST electronic service tool to the EFS and HPGS Controller • Turn keyswitch ON Action Specification/Repair Next Step Check the Westport HD and LNG System for active and inactive fault codes. • Use WEST to view fault codes

activated by the EFS Controller • Use WEST to view fault codes

activated by the HPGS Controller

Note: Ensure fault codes from both controllers have been obtained before fault codes are cleared

Active or inactive fault codes? YES

Note: Verify inactive fault codes are not a potential cause of the customer complaint.

Go to: TSG-10019941

Active or inactive fault codes? NO


Go to: TT-EFS Step 1C


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TT-EFS Step 1C: Perform basic troubleshooting check s. Condition : • None Action Specification/Repair Next Step The following items must be checked or verified before continuing: • Verify there is LNG in the LNG

tank(s) • Check LNG fuel is correct for

application • Verify there is diesel in the

diesel tank • Verify there are no diesel leaks • Check diesel fuel is correct for

application • Verify engine oil is at the

correct level • Verify hydraulic fluid is at the

correct level • Verify battery voltage is within

specification • Verify manual FCM vent valve

is closed • Verify accumulator shut off

valve is open • Verify manual tank shut off

valves are open (if equipped) • Verify that engine idle RPM is

set to 700rpm minimum (for proper Hydraulic / LNG pump operation)

• Verify the calibration suite is correct

All steps have been verified to be correct? YES

Go to: TT EFS Step 1D

All steps have been verified to be correct? NO

Repair: Correct the failure and verify complaint is no longer present after repair

Repair Complete


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TT-EFS Step 1D: Perform INSITE TM electronic service tool monitor test. Condition: • Connect INSITETM electronic service tool • Engine running at the speed and load where the symptom occurs Action Specification/Repair Next Step Use INSITETM electronic service tool to monitor the parameter ‘User Fueling State’ at the same engine operating conditions where the symptom occurs.

Refer to base engine troubleshooting manuals or Advanced Engine Performance Troubleshooting Techniques Service Bulletin 4021686 (Cummins Literature) for a description of ‘User Fueling States’ or ‘Engine Operating States’ which can cause engine derates.

Note: The Westport EFS and HPGS Controllers do not command an engine derate.

Is ‘User Fueling State’ reading a value that can cause an engine derate? YES

Repair: Refer to base engine documentation for appropriate repair procedures.

Repair Complete

Is ‘User Fueling State’ reading a value that can cause an engine derate? NO


Go to: TT-EFS Step 2A-1


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TT-EFS Step 2 – Determination of engine symptom TT- EFS Step 2A-1: Engine difficult to start or wil l not start Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine difficult to start or will not start? YES



Is the engine symptom engine difficult to start or will not start? NO



TT-EFS Step 2A-2: Engine does not crank Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine does not crank? YES

Repair: Refer to base engine documentation for troubleshooting recommendations. The Westport HD and LNG System does not control cranking.

Perform the troubleshooting steps suggested in the repair procedure

Is the engine symptom engine does not crank? NO



TT-EFS Step 2A-3: Engine cranks but will not start on diesel Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine cranks but will not start on diesel? YES

Repair: Perform the troubleshooting steps in the recommended order listed below:

TT-EFS Step 3 – No Start Checks TT-EFS Step 4 – Fuel System Checks TT-EFS Step 5 – Injector Checks


Is the engine symptom engine cranks but will not start on diesel? NO




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TT-EFS Step 2A-4: Engine runs on diesel but will no t run on natural gas Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine runs on diesel but will not run on natural gas? YES

Repair: This symptom indicates a problem with GSP and is handled in the troubleshooting tree for the high pressure gas system (TT-HPGS)

Note: Westport HD and LNG System trucks have the ability to start and run on diesel in limp mode when there is no high pressure gas on board. There is a significant power deficit associated with this mode.

Refer to: TT-HPGS

Is the engine symptom engine runs on diesel but will not run on natural gas? NO



TT-EFS Step 2B: Engine shuts off without warning (s talls): Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine shuts off without warning (stalls)? YES


TT-EFS Step 3 – No Start Checks TT-EFS Step 4 – Fuel System Checks TT-EFS Step 5 – Injector Checks


Is the engine symptom engine shuts off without warning (stalls)? NO




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TT-EFS Step 2C: Low power, poor acceleration, or po or response Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Note: Ensure the engine is not in running on diesel mode as identified in TT-EFS Step 2A-3

Is the engine symptom low power, poor acceleration, or poor response? YES


TT-EFS Step 4 – Fuel System Checks TT-EFS Step 5 – Injector Checks


Is the engine symptom low power, poor acceleration, or poor response? NO


Go to: TT-EFS Step 2D

TT-EFS Step 2D: Engine runs rough or misfires Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine runs rough or misfires? YES




Is the engine symptom engine runs rough or misfires? NO


Go to: TT-EFS Step 2E


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TT-EFS Step 2E: Engine power output is high Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine power output is high? YES




Is the engine symptom engine power output is high? NO


Go to: TT-EFS Step 2F

TT-EFS Step 2F: Engine speed surge or engine speed unstable Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine speed surge or engine speed unstable? YES



Perform troubleshooting steps suggested in the repair procedure

Is the engine symptom engine speed surge or engine speed unstable? NO


Go to: TT-EFS Step 2G


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TT-EFS Step 2G: Excessive exhaust smoke Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Note: White smoke in the exhaust may be normal and only indicating the presence of condensation, especially in cold and/or damp operating conditions. Natural gas engine exhaust contains significantly more water than diesel exhaust.

Is the engine symptom excessive exhaust smoke? YES


TT-EFS Step 6 – Base Engine Checks TT-EFS Step 5 – Injector Checks


Is the engine symptom excessive exhaust smoke? NO


Go to: TT-EFS Step 2H

TT-EFS Step 2H: Exhaust temperature is high Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom engine exhaust temperature is high? YES

Repair: Perform the troubleshooting steps in the recommended order listed below: TT-EFS Step 4 – Fuel System Checks TT-EFS Step 5 – Injector Checks TT-EFS Step 6 – Base Engine Checks


Is the engine symptom engine exhaust temperature is high? NO


Go to: TT-EFS Step 2I


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TT-EFS Step 2I: Constant venting from the FCM vent stack Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint.

Note I: Venting from the FCM vent stack is normal when DRP is fluctuating. It is normal for Gas Rail Pressure (GRP) to be relieved through the FCM vent stack on shutdown.

Note II: Small constant vents may not be heard from the FCM vent stack. Wrap and tape a shop nitrile glove onto the vent stack, if a small constant leak from the FCM vent stack is suspected. An inflated glove indicates a venting from the FCM vent stack.

Is the engine symptom constant venting from the FCM vent stack? YES


TT-EFS Step 7 – FCM Vent Checks


Is the engine symptom constant venting from the FCM vent stack? NO


Go to: TT-EFS Step 2J

TT-EFS Step 2J: Venting from the diesel tank Condition: • None Action Specification/Repair Next Step Interview the driver and verify the complaint

Is the engine symptom venting from the diesel tank during startup? YES


TT-EFS Step 5 – Injector Checks


Is the engine symptom venting from the diesel tank during startup? NO


Return to correct symptom tree


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TT-EFS Step 3 – No Start Troubleshooting Procedures TT-EFS Step 3A-1: Check the status of the EPS (cam) and ESS (crank) signals Condition: • Connect WEST electronic service tool to EFS controller and the HPGS controller • Turn keyswitch ON • Engine cranking Action Specification/Repair Next Step Open the following built in views EFS Eng Pos Sensing HPGS Eng Pos Sensing

While the engine is cranking check the parameters listed in Specification/Repair.

Note I: Two views can be opened with WEST at one time. However only one view will update at a time . See the WEST Manual for more details

Note II: Crank for 2 seconds and then read the parameter value while continuing to crank. This step allows for ECU processing time.

Note III: Both the EFS and HPGS Controller need to detect and synchronize with the engine position signal (cam) in order to start. If the engine speed signal is lost by only one controller (after starting) the engine will run on half of its cylinders

Note IV: Engine Speed parameters (rpm) are not reliable for troubleshooting ESP and ESS signal problems. The EFS and HPGS controllers have the capability to estimate engine speed if the ESS signal is compromised.

Do the parameters meet the specifications below?

EPS parameters Cam No Pulse = 0 (Cam signal detected) Cam Have Sync = 1 (Cam position known)

ESS parameters Crank No Pulse = 0 (Crank signal detected) Crank Have Sync = 1 (Crank position known)

YES


Go to: TT-EFS Step 3B-1


EPS parameters Cam No Pulse = 0 (Cam signal detected) Cam Have Sync = 1 (Cam position known)

ESS parameters Crank No Pulse = 0 (Crank signal detected) Crank Have Sync = 1 (Crank position known)

NO

No repair at this stage, investigation ongoing, faulty EPS or ESS signal identified.


TT-EFS Step 3A-2: Interpret results from TT-EFS Ste p 3A-1 Condition: • None Action Specification/Repair Next Step Interpret the results from TT-EFS step 3A-1

Did the EPS (cam) parameters meet the specification in Step 3A? NO



Did the ESS (crank ) parameters meet the specification in Step 3A? NO




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TT-EFS Step 3A-3: Faulty EPS signal identified Condition: • None Action Specification/Repair Next Step Interpret the results from TT-EFS Step 3A-2

Did only one controller fail to meet the specification for the EPS (cam) parameters? YES

Repair: Perform the checks in the order specified below • Check controller connections • Repair or replace the chassis harness

Note: The EPS signal is split to the EFS and HPGS controllers in the chassis harness.

Repair Complete

Did only one controller fail to meet the specification for the EPS (cam) parameter? NO

Repair: Perform the checks in the order specified below • Verify base engine EPS (cam) signal

is problem free. • Verify harness connections are

secure • Repair or replace the injector

breakout harness, the engine harness or the chassis harness.

Note: The Westport HD and LNG System obtains the EPS signal from base engine circuitry. If there is a problem with the base engine EPS signal the Westport HD and LNG System will be affected.

Repair Complete


37

TT-EFS Step 3A-4: Faulty ESS signal identified Condition: • None Action Specification/Repair Next Step Interpret the results from TT-EFS Step 3A-2

Did only one controller fail to meet the specification for the ESS (crank) parameters? YES

Repair: Perform the checks in the order specified below • Check controller connections • Repair or replace the Chassis

Harness

Note: The ESS signal is split to the EFS and HPGS controllers in the chassis harness.

Repair Complete

Did only one controller fail to meet the specification for the ESS signal? NO

Repair: Perform the checks in the order specified below • Verify base engine ESS (crank) signal

is problem free. • Verify harness connections are

secure • Repair or replace the injector

breakout harness, the engine harness or the chassis harness.

Note: The Westport HD and LNG System obtains the ESS signal from base engine circuitry. If there is a problem with the base engine ESS signal the Westport HD and LNG System will be affected.

Repair Complete


38

TT-EFS Step 3B-1: Check EFS overall status Condition: • Connect WEST electronic service tool to EFS controller • Turn keyswitch ON • Engine cranking Action Specification/Repair Next Step Open the following built in view EFS Overall


Note I: Crank for 2 seconds and then read the parameter value while continuing to crank. This step allows for ECU processing time.

Note II: The gas fuel shutoff valve will only be commanded to open if the engine is spinning

Note III: The diesel transfer pump will be commanded OFF if the engine does not start after extended cranking (approx 30 seconds). This is normal controller behaviour.


Gas Fuel Shutoff Open = 1 (ON) Diesel Transfer Pump On = 1 (ON) Boost Voltage is greater than 55 V YES




Gas Fuel Shutoff Open = 1 (ON) Diesel Transfer Pump On = 1 (ON) Boost Voltage is greater than 55 V NO

Repair: Call for pre-authorization.

Replace the EFS controller.

Refer to INS-10012162: Replacing the Controller Assembly and Components

Repair Complete

TT-EFS Step 3B-2: Check HPGS overall status Condition: • Connect WEST electronic service tool to HPGS controller • Turn keyswitch ON • Engine cranking Action Specification/Repair Next Step Open the following built in view HPGS Overall


Note I: Crank for 2 seconds and then read the parameter value while continuing to crank. This step allows for ECU processing time.


Boost Voltage is greater than 55 V YES


Go to: TT-EFS Step 3C-1


Boost Voltage is greater than 55 V NO

Repair: Call for pre-authorization.

Replace the HPGS controller.

Refer to INS-10012162: Replacing the Controller Assembly and Components

Repair Complete


39

TT-EFS Step 3C-1: Check gas fuel shut off valve vol tage Condition: • Turn keyswitch OFF • Disconnect the engine harness from the gas fuel shut off valve • Connect WEST electronic service tool to EFS controller • Turn keyswitch ON Action Specification/Repair Next Step Open the following built in view EFS Manual Overrides

Command the gas fuel shut off valve to open.

Measure the voltage from the gas fuel shut off valve signal to the gas fuel shut off valve return (harness Side).

Note: The gas fuel shut off valve is a normally closed solenoid valve.

Is the voltage greater than 11 VDC? YES

No repair at this stage.


Is the voltage greater than 11 VDC? NO

Repair: Repair or replace the engine harness or the chassis harness.

Repair Complete

TT-EFS Step 3C-2: Check gas fuel shut off valve res istance Condition: • Turn keyswitch OFF • Disconnect engine harness from the gas fuel shut off valve Action Specification/Repair Next Step Measure the resistance between pins 1 and 2 on the gas fuel shut off valve.

Note: The gas fuel shut off valve is a normally closed solenoid valve.

Does the gas fuel shut off valve resistance meet the specifications listed below?

pin 1 to pin 2 < 10 Ω at 25°C YES

No repair at this stage. Reconnect the engine harness to the gas fuel shut off valve.

Go to: TT-EFS Step 3D

Does the gas fuel shut off valve resistance meet the specifications listed below?

pin 1 to pin 2 < 10 Ω at 25°C NO

Repair: Replace the gas fuel shut off valve. Refer to INS-10012034: Replacing the Gas Fuel Shut Off Valve

Repair Complete


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TT-EFS Step 3D: Test transfer pump output pressure Condition: • Turn keyswitch OFF • Attach diesel transfer pump pressure tester (p/n 10011397) • Turn keyswitch ON Action Specification/Repair Next Step Measure the output pressure of the diesel transfer pump

Note I: The diesel transfer pump will operate for 30 seconds after key ON. After 30 seconds the pump will be commanded OFF by the controller.

Note II: A complete list of service tools and their user instructions can be found on the Westport HD Service website. Service Tool: Diesel transfer pump pressure tester (p/n 10011397) Instructions: Diesel Pressure Meter (p/n 10012640)

Is the diesel transfer pump output pressure between 10 to 18 PSI? YES


Perform the next troubleshooting procedure as outlined in TT-EFS Step 2.

Is the diesel transfer pump output pressure between 10 to 18 PSI? NO

Repair: Replace the diesel transfer pump. Refer to INS-10012738: Replacing the Diesel Transfer Pump

Repair Complete


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TT-EFS Step 4 – Fuel System Checks TT-EFS Step 4A: Perform basic diesel system checks Condition: • None Action Specification/Repair Next Step The following items must be checked or verified before continuing:

• Verify fuel lines are in good condition and fittings are tight

• Verify there are no diesel leaks • Verify there are no natural gas

leaks • Verify diesel transfer pump

filter is in good condition and water separator is free of water

• Verify the high pressure diesel pump belt is in place and is not skipping or sliding on the pulleys

Note: Clogged or dirty diesel fuel filters may indicate an overdue filter change or an incompatible type of diesel fuel.

All steps have been verified to be correct? YES



All steps have been verified to be correct? NO

Repair: Correct the failure and verify complaint is no longer present after repair.

Repair Complete

TT-EFS Step 4B-1: Check coalescence filter on the F CM gas vent line Condition: • None Action Specification/Repair Next Step Check the coalescence filter on the FCM gas vent line for diesel fuel.

Is there diesel fuel in the coalescence filter? YES

Repair: Drain and dispose of diesel fuel from filter in accordance with local rules and regulations.

No repair at this stage. Investigation is ongoing.

Note: Diesel fuel in the coalescence filter can be caused by the engine running on diesel for an extended period of time.


Is there diesel fuel in the coalescence filter? NO




42

TT-EFS Step 4B-2: Verify DLSR functionality Condition: • Engine running at idle (while cranking if troubleshooting no start) Action Specification/Repair Next Step Check the coalescence filter on the FCM gas vent line for diesel fuel.

Note: Diesel fuel in the coalescence filter can be caused by the engine running on diesel for an extended period of time.

Is there diesel fuel in the coalescence filter after the filter has been drained in TT-EFS Step 4B-1? YES

Repair: Drain diesel fuel from filter in accordance with local rules and regulations.

Replace DLSR. Refer to INS-10011742: Replacing the DLSR.

Repair Complete

Is there diesel fuel in the coalescence filter after the filter has been drained in TT-EFS Step 4B-1? NO



TT-EFS Step 4C-1: Verify engine symptom Condition: • None Action Specification/Repair Next Step None Is the engine symptom Engine will not

start?

YES


Go to: TT-EFS Step 4F-1

Is the engine symptom Engine will not start? NO




43

TT-EFS Step 4C-2: Check Diesel Rail Pressure at idl e Condition: • Connect WEST electronic service tool to EFS controller • Turn keyswitch ON • Engine running at idle Action Specification/Repair Next Step Open the following built in view EFS VIP Performance

Observe Diesel Rail Pressure Error after the truck has been idling for two minutes.

Note I: Diesel Rail Pressure Error computes the difference between Diesel Rail Pressure Command and Diesel Rail Pressure.

When Diesel Rail Pressure Error is a positive number the commanded DRP is greater than the measured DRP

When Diesel Rail Pressure Error is a negative number the commanded DRP is less than the measured DRP.

Note II: This test must be performed after the truck has idled for 2 minutes. At startup DRP is commanded high. As the truck idles the commanded DRP is ramped down to pressures required to maintain idle. During this time the Diesel Rail Pressure Error will be outside the 10 bar tolerance.

See Sample 1: Example of Diesel Rail Pressure Error during Startup in Section E for more details

At Idle: Is Diesel Rail Pressure Error between 0 and + 10 bar? YES


Perform next troubleshooting procedure as outlined in TT-EFS Step 2.

At Idle : Is Diesel Rail Pressure Error between 0 and + 10 bar? NO


Go to: TT-EFS Step 4D-1


44

TT-EFS Step 4D-1: Check maximum Diesel Rail Pressur e (DRP) Condition: • Connect WEST electronic service tool to EFS controller • Disconnect the engine harness from the high pressure diesel pump (IMV) • Turn keyswitch ON • Engine running at idle Action Specification/Repair Next Step Observe DRP Does DRP increase to and stabilize (no

dropouts) at a value greater than 290 bar? YES

No repair at this stage. Connect the engine harness to the high pressure diesel pump (IMV).


Does DRP increase to and stabilize (no dropouts) at a value greater than 290 bar? NO

Repair: No repair at this stage.

Go to: TT-EFS Step 4D-2

TT-EFS Step 4D-2: Perform Test 3 - Testing pressure sensors in Section D Condition: • None Action Specification/Repair Next Step Perform Test 3: Testing Pressure Sensors located in Section D.

Did Test 3: Testing Pressure Sensors Identify a faulty pressure sensor? YES

Did replacing the pressure sensor fix the problem? YES

Repair complete

Repair Complete

Did Test 3: Testing Pressure Sensors Identify a faulty pressure sensor? YES

Did replacing the pressure sensor fix the problem? NO



Did Test 3: Testing Pressure Sensors Identify a faulty pressure sensor? NO




45

TT-EFS Step 4E: Check Diesel Drain Valve Functional ity Condition: • Connect WEST electronic service tool to EFS controller • Turn keyswitch ON • Engine running at idle Action Specification/Repair Next Step Open the following built in view EFS Manual Overrides

Open the diesel drain valve (0% duty cycle)

Close the diesel drain valve (85% duty cycle)

Observe Diesel Flow Command

Repeat the sequence 4 times.

Note: The diesel drain valve is a normally open solenoid valve, requiring power to close.

Does Diesel Flow Command increase when the diesel drain valve opened? YES



Does Diesel Flow Command increase when the diesel drain valve is opened? NO

Repair: Replace the diesel drain valve. Refer to INS-10012010: Replacing the Diesel Drain Solenoid and Diesel Drain Valve.

Repair Complete


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TT-EFS Step 4F-1: High-pressure diesel pump verific ation Condition: • Connect WEST electronic service tool to EFS controller • Turn keyswitch ON • Engine running at idle Action Specification/Repair Next Step Open the following built in view EFS VIP Performance

Observe Diesel Rail Pressure Error after the truck has been idling for two minutes.

Note I: Diesel Rail Pressure Error computes the difference between Diesel Rail Pressure Command and Diesel Rail Pressure.

When Diesel Rail Pressure Error is a positive number the commanded DRP is greater than the measured DRP

When Diesel Rail Pressure Error is a negative number the commanded DRP is less than the measured DRP.

Note II: This test must be performed after the truck has idled for 2 minutes. At startup DRP is commanded high. As the truck idles the commanded DRP is ramped down to pressures required to maintain idle. During this time the Diesel Rail Pressure Error will be outside the 10 bar tolerance.

See Sample 1: Example of Diesel Rail Pressure Error during Startup in Section E for more details

Is Diesel Rail Pressure Error greater than 10 bar or is the engine symptom engine will not start after all previous checks have been completed? YES

Repair: Replace the high pressure diesel pump. Refer to INS- Replacing the High Pressure Diesel Pump


Is Diesel Rail Pressure Error greater than 10 bar or is the engine symptom engine will not start after all previous checks have been completed? NO


Go to: TT-EFS Step 4G


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TT-EFS Step 4F-2: Symptom verification – post repai r Condition: • None Action Specification/Repair Next Step Repeat the test specified in TT-EFS Step 4F-1

Did replacing the high pressure diesel pump resolve the customer complaint? YES

Repair complete.

Repair Complete

Did replacing the high pressure diesel pump resolve the customer complaint? NO


Perform the next troubleshooting procedure as outlined in TT-EFS Step 2.


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TT-EFS Step 5 – Injector Checks TT-EFS Step 5A: Start the engine and read the fault codes Condition: • Connect WEST electronic service tool to the EFS and HPGS controllers • Engine is running at low idle (engine cranking if troubleshooting no start) Action Specification/Repair Next Step Check for fault codes with the engine running (engine cranking if troubleshooting no start).

Active fault codes? YES

No repair at this stage. Resolve active fault codes before continuing.

Refer to TSG-10019941 – Fault Code Reference Manual

Active fault codes? NO



TT-EFS Step 5B: Verify Engine Symptom: Check for di esel tank pressurization Condition: • Turn keyswitch ON • Engine running at idle Action Specification/Repair Next Step Let the truck idle for 5 minutes then check the diesel tank for signs of pressurization.

Note I: Check for diesel tank pressurization during start-up. Symptom is more pronounced when the engine is cold.

Note II: Indicators of diesel tank pressurization include whistling sounds from the diesel tank and GSP dropping quickly.

Warning Use high-pressure precautions when investigating diesel tank

pressurization. An uncontrolled release of pressure can cause diesel spray or personal injury.

Is the diesel tank pressurized? YES

Repair: Use a gas leak detector to verify the pressurization is due to natural gas.

Replace all the injector o-rings. Refer to INS-10012758: Replacing the HPDI Injector O-rings.

Repair Complete

Is the diesel tank pressurized? NO




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TT-EFS Step 5C-1: Verify engine symptom: Engine wil l not start Condition: • None Action Specification/Repair Next Step None Is the engine symptom engine will not

start on diesel and all other TT-EFS Step 2 checks for engine will not start on diesel have been completed? YES

Repair: • Verify injectors are seated properly • Verify injector terminals are damage

free • Verify terminals are secure

If the above checks pass Replace injectors

Refer to INS-10014070: Replacing HPDI Fuel Injector(s)

Repair Complete

Is the engine symptom engine will not start on diesel and all other TT-EFS Step 2 checks for engine will not start on diesel have been completed? NO



TT-EFS Step 5C-2: Verify engine symptom: Excessive exhaust smoke on start up Condition: • None Action Specification/Repair Next Step None Is the engine symptom excessive smoke

on startup and the smoke goes away once the engine warms up? YES

Repair:

Replace all the injector o-rings. Refer to INS-10012758: Replacing the HPDI Injector O-rings.

Repair Complete

Is the engine symptom excessive smoke on startup and the smoke goes away once the engine warms up? NO




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TT-EFS Step 5C-3: Verify engine symptom: Continuous exhaust smoke Condition: • None Action Specification/Repair Next Step None Is the engine symptom continuous

exhaust smoke? YES

Repair: • Verify injectors are seated properly • Verify injector terminals are damage

free • Verify terminals are secure

If the above checks pass Replace all injectors

Refer to INS-10014070: Replacing HPDI Fuel Injector(s)

Repair Complete

Is the engine symptom continuous exhaust smoke? NO
