313 Powertrain Electronics Ver4 May 10 2012

313 Powertrain Electronics
Electrical Review
Basic Electrical Review
Three (3) parts to electricity:
– V = Voltage (electrical “pressure”)
– A = Amps or Amperage (or Current =

electrical “flow rate”)
– Ω = Ohms or resistance (electrical flow

resistance)
Current (“pushed” by voltage) wants
to return to the source: battery
Resistance = load
Circuits need resistance to eliminate

the voltage push on the current
6Ω
6Ω
12 volts 0 volts
2 amps 2 amps
6Ω
12 volts 0 volts
2 amps
Does not work without:
– Source (voltage & current)
Battery or alternator/generator
Cables and connections
– Load (resistance)
“Drops” or uses up the voltage
Too little = high current = thermal event
– Return (ground)
Two Wire Temperature Sensor Circuit
Sensor Signal 5V
Sensor Return
(Ground)
ECU
Three Wire Sensor Circuit
5V
5 V Reference
Signal
V
Ground
ECU
Two Wire Temperature Sensor Signal
Voltages:
– Normal: 0.25 - 4.75 V
– Operating: 0.5 - 4.5 V

System (Temperature) Out-of-Range:
– Low: 0.25 - 0.5 V = -40° F/C
– High: 4.5 - 4.75 V = 554°/1472°F (290/800 C)
Voltage Out-of-Range: 0.0 - 0.25 V or

4.75 - 5.0 V
Three Wire Temperature Sensor Signal
Voltages:
– Normal: 0.25 - 4.75 V
– Operating: 0.5 - 4.5 V

System Out-of-Range:
– Low: 0.25 - 0.5 V = Minimum
Pressure/Position
– High: 4.5 - 4.75 V = Maximum

Pressure/Position
Voltage Out-of-Range: 0.0 - 0.25 V or

4.75 - 5.0 V
Diagnostic Hint:
– DAVIE: With sensor unplugged (and good
power, ground, and wiring), Individual
Component Monitor will show reference
voltage and/or max or min
temp/press/position value.
– Also watch for CHANGE in reading on
DAVIE when unplugging/re-plugging
connector.
Two Wire Inductive Speed Sensor Circuit
Signal
V
Ground / return
ECU
Two Wire Inductive Pick-up Speed
Sensors:
– Coiled wire around permanent magnet;

wire ends return to ECU as Signal and
Ground Wires
– Magnet positioned near rotating tone

wheel
Two Wire Inductive Pick-up Speed
Sensors (cont.) :
– As tone wheel “tooth” passes magnet, magnetic
field around wires shifts, generating voltage pulse
– Voltage pulses compared against internal ECU

clock to determine frequency
– Pulse frequency converted to RPM inside ECU

Other Sensors:
Hall Effect
– detects RPM
– three wire; 5V Ref, Signal, ground; similar to
other three wire sensors
Humidity
– Four (4) wires: B+, GND, CAN +, CAN -
– Smart device; detects relative humidity of
intake air, intake air temp, and
– Communicates info to ECU on E-CAN
– No direct testing
Other Sensors (cont.):
Lambda
– Detects Oxygen content in exhaust
– Five (5) wires:
Heater B+ & GND
Sensor Signals
– No direct testing of signals, only heater circuit
NOx
– Smart Device like Humidity sensor
– Four (4) wires: B+, GND, CAN+, CAN-
– Communicates information via A-CAN
– No direct testing of sensor function/response
Actuator Circuit
Actuator
12V B+ Power
ECU
Ground
Actuator operation:
– Coiled wire wrapped around movable
pintle (will have resistance spec)
– Pintle held closed/at rest by return spring
– Energizing coil causes electromagnetic

field to move pintle against return spring
Actuator operation (cont.) :
– De-energizing coil causes electromagnetic
field to collapse; return spring returns to
rest position
– Coil energized with PWM

Pulse Width Modulation (PWM):
– ECM turns on/off a ground (and sometimes
power as well depending on the circuit)
– Switch closes (voltage ON) at regular,

periodic intervals
– Length of time switch is closed varies
– Low DUTY CYCLE = short ON time

– High DUTY CYCLE = long ON time
Low Duty Cycle
12V
Voltage applied
to actuator is
average of on
0V time vs. length
of clock period
Pulse
High Duty Cycle
12V i.e. 50% Duty
Cycle = 6 V
applied to the
actuator
0V
Pulse
Period = fixed by ECM clock

Actuator
12V B+ Actuator
PowerCircuit
ECU Pintle
Return Spring
Coil
Circuit ON
Ground
Flow ON
Actuator
12V B+ Actuator
PowerCircuit
ECU
Circuit OFF
Ground
Flow OFF
ON
Diagnostic Testing:
– ALWAYS check source (battery, circuit
breakers, fuses, relays, etc.), grounds,
and connections to/from ALL components in
question (Including ECU!)
– w/DAVIE connected and system powered up,

monitor circuit in question while unplugging
connector – should see a change in reading if
ECU and wiring to/from are good
Basic Testing (continued) :
– Consult Rapido for additional testing
parameters; i.e. resistance or voltage spec
– Check for:
Corrosion at connection points
Reference or supply voltage
Ground back to ECU, Chassis, and Batt
A-CAN Aftertreatment Controller Area Network
B-CAN Body Controller Area Network

C-CAN Cab Controller Area Network
D-CAN Diagnostic Controller Area Network
2010 CAN Buses
E-CAN Engine Controller Area Network
F-CAN Frame Controller Area Network
I-CAN Instrumentation Controller Area Network
V-CAN Vehicle Controller Area Network

Sensor Circuits Types
• Temperature – Variable Voltage
• Pressure – Variable Voltage
• Pressure Differential – Variable Voltage
• Position – Variable Voltage
• Speed (rotation) – Variable Frequency AC
• Speed (rotation) – Variable Frequency DC
• Gas Analysis – Data Bus
• Humidity – Data Bus
Temperature Sensors
Temperature Sensors
Temperature Sensors - PTC
Temperature Sensors - NTC
Pressure Sensors
Pressure Sensors
Pedal Position Sensor
EGR Position Sensor
Gro
Ground controlled duty cycle Pulse Width Modulation

BPV Position Sensor
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – Hall Effect
Coolant Level
Gas Analysis – Lambda (λ)
12V
Gas Analysis: NOx
Humidity
Humidity
Reports on A & E-CAN
NOX Sensors
Humidity
Sensor
Injectors & Unit Injection Pumps
Switches and Lamps
E-CAN
PACCAR engine and aftertreatment
systems use sophisticated software models
within their electronic control units to control
their respective systems…
Software models:
…receive information from sensors (Input);

…perform calculations and logic decisions
based on software instructions;
…send operational commands to various
actuating devices (Output);
…and monitor the outcome of its commands
via the Input and other sensors (Feedback);
…and the cycle repeats

Driver Demand
Fuel Characteristics
Accelerator Pedal
Fuel Temperature
Fuel Delivery Pressure

A to D
Load
CPU Lambda
Crank Sensor
Air Mass Inlet Air Temps. Injector MAP
Turbo Boost
Injector Selection Cam Sensor
Driver + Driver -
Injector
PMCI-2 & EAS-3: Inputs and Outputs
Temps EGR Valve
Load
HC Doser
Pressure
Unit Pumps
RPM ECM / PMCI-2
DEF Doser
Position or
NOx AECU / EAS-3 Injectors
Lambda
CEL / MIL
Veh Speed
CAN bus
CAN Bus Information
System Inputs System Outputs

Sensor / System Monitors:
– Sensors modify a reference voltage based on

operating conditions in the subsystems (EGR,
DPF, SCR, etc.)
– The computers monitor the input voltages and

use that information to monitor the overall
subsystem operation
– Monitor criteria (when/how often) can vary but

generally depends on engine run or off time, ign key
cycles, and/or drive or warm up cycle parameters
Fault Codes:
Example 1)
Monitor
criteria:
Fault Codes:
Example 2)
Monitor
criteria:
Fault Codes – Set Criteria:
– Fault codes are set when:

Monitored sensor voltage is currently a value
that was or is not expected by the ECM
AND / OR
Monitored subsystem operation is currently

faulty, as calculated from sensor inputs and
software models
Fault Codes:
Example 1)
Set Criteria:
Fault Codes:
Example 2)
Set Criteria:
Fault Codes - Types of Codes:
Active vs. Inactive
System Parameter Out of Range – High or Low
Sensor Voltage Out of Range – High or Low
Plausibility Faults
Irrationality Faults
CAN Message Rate too High/Low
Filter or Catalyst Efficiency
Cascading Faults
Fault Codes - Active vs. Inactive
– Active Fault Codes:
Active codes set because:
– The sensor or system monitor

conditions have been met
– The monitor HAS run
– A possible fault has been found
– Active Fault Codes:
Codes remain Active because:
– Monitors continue to run and the faulty

conditions have not changed
– OR –
– Faulty conditions may have changed back

to acceptable but the monitor has not run
again to discover the change
– Inactive Fault Codes:
Active Codes will change to Inactive when:
– The operating conditions of the sensor or system

have changed to an acceptable reading
– AND –
– The sensor or system monitor has run and the ECM recognizes that
the new conditions to are currently within the expected range.
Fault Codes:
– System Parameter Out of Range – High or Low
ECM reads sensor voltage and calculates a value
Calculated value is compared to an expected range

based on other, related parameters
Fault code sets if/when the calculated value falls

outside of the expected range
This type of fault code sets when the system is out of range and
has a problem: i.e. the sensor and circuit are operating properly
but the system is outside of expected parameters
For example…
Coolant temp is
calculated using
sensor voltage
Expected
coolant temp
(after engine
off for 3 hrs)
is too high
Fault code is
set
Fault Codes:
– Sensor Voltage Out of Range – High or Low
Sensor voltage is above or below the operating range*
– Too High: voltage > 4.75 V
– Too Low: voltage < 0.25 V
If sensor voltage is too high or too low the ECM sets

a fault code.
This fault code type –set at the extreme ends of the sensor value
range- is due to an ELECTRICAL CIRCUIT problem
Example…
*These are general values – consult Rapido for specific values for
a particular sensor or fault code.
Boost temp
sensor signal
input
monitored on
pin A43
If voltage goes
below
programmed
value (0.15 V),
fault code sets
Fault Codes:
– Plausibility Faults
ECM compares input data to programmed possibilities
If input data is not found to be “plausible” (likely) a

Plausibility Fault is set
Example…
Vehicle speed
increase is
monitored
If signal value
is outside of an
expected
range, code
sets
Fault Codes:
– Irrationality Faults
ECM converts sensor voltage to a parameter value (i.e.

temperature, pressure, etc.) and compares this calculation
to its expectations…
…If sensor or system parameter is outside of the range

of expected values (i.e. very high engine temperature
after engine off for 10 hours) ECM believes reading to
“impossible” and an irrationality fault code is set.
Example…
ECM monitors
Turbo speed
and compares
with expected
programmed
values
If speed
difference is
detected, fault
code is set
Fault Codes:
– Filter or Catalyst Efficiency:
ECM monitors multiple sensor inputs and calculates

an “actual” efficiency and compares it to its programmed
software efficiency expectations
Efficiencies below a preset threshold will cause the

ECM to set a fault code
Example…
DPF Filter Efficiency Too Low
– Aftertreatment ECU monitors:
1. Soot level – Calculated:
Expected soot output based on combustion parameters
1. Coolant temp
2. Air mass entering engine
3. Fuel volume injected into cyl
4. EGR rate, flow, temp
2. Exhaust Flow – Calculated: based on measured exhaust
pressure and temperature sensors
3. Temperature – Measured by exhaust temperature sensors
4. Ash level – Calculated: based on pre & post DPF pressure sensors
5. Filter condition – Calculation: based on hours since DPF filter condition
reset in ECU
Fault Codes:
– Cascading Faults
Higher order faults that automatically trigger other,

faults
When multiple fault codes are set, refer to Rapido

for hints or instructions on where to begin – i.e.
which faults to trouble shoot first/last, etc.
Example…
Fault code P1510 is set as a result of P151A being set…
…and P151A is set as result of P3796 being set…
…so certain Fault Codes, such as P3796, will also trigger
two or more additional codes, i.e. P151A and P1510
Fault Codes:
– Cascade Faults - Additional information
Some Cascade Faults are ONLY triggered by higher

order fault codes – these codes have no diagnostic
information and Rapido refers you directly to the code
that caused the cascade fault
Other Cascade Faults MAY be triggered by higher or equal

order fault codes, or they MAY be triggered individually
– These codes generally refer you to the other code first if it
has been set, otherwise Rapido will have discrete diagnostic information for the
code

313 Powertrain Electronics Ver4 May 10 2012

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

313 Powertrain Electronics Ver4 May 10 2012

Încărcat de

Drepturi de autor:

Formate disponibile

313 Powertrain Electronics

– A = Amps or Amperage (or Current =

– Ω = Ohms or resistance (electrical flow

Circuits need resistance to eliminate

– Normal: 0.25 - 4.75 V

– Operating: 0.5 - 4.5 V

– High: 4.5 - 4.75 V = 554°/1472°F (290/800 C)

Voltage Out-of-Range: 0.0 - 0.25 V or

– Normal: 0.25 - 4.75 V

– Operating: 0.5 - 4.5 V

– High: 4.5 - 4.75 V = Maximum

Voltage Out-of-Range: 0.0 - 0.25 V or

– Coiled wire around permanent magnet;

– Magnet positioned near rotating tone

– Voltage pulses compared against internal ECU

– Pulse frequency converted to RPM inside ECU

– Pintle held closed/at rest by return spring

– Energizing coil causes electromagnetic

– Coil energized with PWM

– Switch closes (voltage ON) at regular,

– Length of time switch is closed varies

– Low DUTY CYCLE = short ON time

Period = fixed by ECM clock

– w/DAVIE connected and system powered up,

B-CAN Body Controller Area Network

V-CAN Vehicle Controller Area Network

Ground controlled duty cycle Pulse Width Modulation

…receive information from sensors (Input);

…and the cycle repeats

Fuel Delivery Pressure

Air Mass Inlet Air Temps. Injector MAP

Injector Selection Cam Sensor

NOx AECU / EAS-3 Injectors

System Inputs System Outputs

– Sensors modify a reference voltage based on

– The computers monitor the input voltages and

– Monitor criteria (when/how often) can vary but

– Fault codes are set when:

Monitored subsystem operation is currently

Active codes set because:

– The sensor or system monitor

Codes remain Active because:

– Monitors continue to run and the faulty

– Faulty conditions may have changed back

– Inactive Fault Codes:

Active Codes will change to Inactive when:

– The operating conditions of the sensor or system

ECM reads sensor voltage and calculates a value

Calculated value is compared to an expected range

Fault code sets if/when the calculated value falls

If sensor voltage is too high or too low the ECM sets

ECM compares input data to programmed possibilities

If input data is not found to be “plausible” (likely) a

ECM converts sensor voltage to a parameter value (i.e.

…If sensor or system parameter is outside of the range

ECM monitors multiple sensor inputs and calculates

Efficiencies below a preset threshold will cause the

Higher order faults that automatically trigger other,

When multiple fault codes are set, refer to Rapido

– Cascade Faults - Additional information

Some Cascade Faults are ONLY triggered by higher

Other Cascade Faults MAY be triggered by higher or equal

S-ar putea să vă placă și