l 2 Composite Vehicle

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E LECTRONIC D IESEL E NGINE D IAGNOSIS S PECIALIST T EST (L2)

M EDIUM /H EAVY C OMPOSITE V EHICLE P REPARATION /R EFERENCE B OOKLET

I NTERNET V ERSION 1998 National Institute for A UTOMOTIVE S ERVICE EXCELLENCE . All rights reserved.

This booklet is intended only for preparation and reference when taking the ASE Electronic Diesel Engine Diagnosis Specialist (L2) Test. The medium/heavy composite vehicle control system is based on designs common to many engine and vehicle manufacturers, but is not identical to any actual production engine or vehicle.


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ASE M E D I U M /H EAVY C OMPOSITE V E H I C L E P REPARATION /R EFERENCE B OOKLET P AGE 1

A SE E LECTRONIC D IESEL E NGINE D IAGNOSIS S PECIALIST T EST

M EDIUM /H EAVY C OMPOSITE V EHICLE I NFORMATION

G ENERAL D ESCRIPTION This generic four cycle, in-line six cylinder diesel engine is equipped with aturbocharger, charge air cooler, and electronic unit injectors. The engine rating is330 hp at 1,800 rpm and develops a peak torque of 1150 lb. ft. at 1,200 rpm.

T HE E LECTRONIC C ONTROL M ODULE (ECM) The electronic control module is the microprocessor that receives electronic inputsfrom sensors and switches, and is calibrated to control fuel metering, injectiontiming, diagnostics, and engine protection. The ECM receives power from thebattery and ignition switch and provides a reference voltage for some sensors. Thesoftware (instructions) contained in the ECM determine how the electronic dieselengine control system operates. The ECM stores the calibration values that definerated horsepower, torque curves, and rpm specifications. The ECM is mounted onthe engine.

F UEL S YSTEM Fuel supply (transfer) is provided by a positive displacement, mechanically drivenpump. A regulating valve is used to maintain fuel pressure. Fuel delivery is providedby electronically controlled unit injectors. The injector solenoids are energized bythe ECM.

P ROGRAMMABLE P ARAMETERS Programmable parameters are the specifications that can be set within the ECM tocontrol operating functions. The parameters are stored in non-volatile memory. Acustomer password is available for programing protection. A list of parameter ranges and their settings are shown below.

Feature Range Setting Feature Range SettingMax Vehicle Speed in Top Gear 35-99 mph 60 mph One Gear Down Ratio .5-1.5 1.0Cruise Control Set Speed 35-99 mph 60 mph Min. Engine Cooling Fan On Time 0-999 sec. 240 sec.Max Engine Speed with VSS Signal 1600-2500 rpm 2100 rpm PTO / Remote PTO:Max Engine Speed w/o VSS Signal 1200-2500 rpm 1800 rpm max PTO speed 600-2500 rpm 1000 rpmIdle Set Speed 600-850 rpm 700 rpm min PTO speed 600-2500 rpm 700 rpmGear Down Max Vehicle Speed: 35-99 mph 58 mph set PTO speed 600-2500 rpm 900 rpmCruise Control and Engine Brakes: mph above cruise set speed resume PTO speed 600-2500 rpm 900 rpm engine brake low 1-20 mph 6 mph remote PTO speed 600-2500 rpm 1000 rpm engine brake medium 1-20 mph 6 mph Idle Shutdown Timer 3-60 min. 5 min. engine brake high 1-20 mph 8 mph Tire Revolutions per Mile 400-700 501Road Speed Governor Droop 0-4 mph 2 mph Rear Axle Ratio 2.50-12.0 4.10Max Progressive Shift Speed 1500-2500 rpm 1800 rpm # of VSS Wheel Teeth 5-16 16Mph at Max Progressive Shift Speed 6-99 mph 18 mph


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P AGE 2 ASE M E D I U M /H EAVY C OMPOSITE V E H I C L E P REPARATION /R EFERENCE B OOKLET

E NGINE P ROTECTION S YSTEM The engine protection system monitors coolant temperature, coolant level, oiltemperature, intake manifold temperature, and oil pressure. The system has threelevels of protection: warning, derate, and shutdown.In the warning mode , the yellow warning/diagnostic lamp alerts the operator of apotential problem. In the derate (limp home) mode , the ECM will gradually reduceengine power after lighting the red warning/diagnostic lamp. Power deration willbegin 30 seconds after the initial warning. The shutdown mode will activate for engine coolant temperature, coolant level, or engine oil pressure failures only.Shutdown will occur when the condition reaches a preset value, after the warningand derate modes have been activated. The diagnostic on/off switch can be used totemporarily override the shutdown mode.

High Engine Coolant Temperature Low Engine Oil Pressure

Engine Coolant Power Derate/ dependent on the relationship betweenTemperature Shutdown oil pressure and engine speed. If the oil

210 E F 100% Power pressure falls below these specifications,215 E F 75% Power power derate will begin, and shutdown220 E F 50% Power will occur if oil pressure continues to225 E F 25% Power decrease.230 E F Shutdown

Low Engine Coolant LevelPower derate begins after an additional20 second delay, and shutdown occursif the coolant level remains low.

High Intake Manifold TemperaturePower derate begins when the mani-fold air temperature reaches 210 E F.

Power derate/shutdown set points are

Engine Oil PressureEngine Speed Begin DerateShutdown2000 rpm 40 psi 20 psi1800 rpm 35 psi 17 psi1400 rpm 25 psi 12 psi1000 rpm 15 psi 8 psi 600 rpm 5 psi 2 psi

High Engine Oil TemperaturePower derate begins when the oiltemperature reaches 260 E F.

E NGINE O PERATING S PECIFICATIONS

Fuel Pressure - Cranking: 20 psi. min. Engine Oil Pressure - Idle: 15-35 psi. min. Rated rpm: 90-100 psi. Rated rpm: 50-70 psi.

Engine Coolant Temperature - 195 E F Engine Oil Temperature - 210 E F

Turbo Boost Pressure - Rated rpm: 20-30 psi.


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S ENSORS Throttle Position Sensor (TPS)

The TPS is a potentiometer that senses the position of the accelerator pedal. Areference voltage is sent to the TPS, and as the angle of the accelerator pedalchanges, the TPS varies the signal voltage to the ECM. This sensor includes anintegral idle validation switch (IVS). (PID 91)

Engine Oil Pressure Sensor (EOP)The solid-state EOP sensor monitors engine oil pressure, and is installed in themain lube oil gallery. The ECM uses this signal for engine protection. (PID 100)

Boost Pressure Sensor (BP)The solid-state BP sensor monitors positive intake manifold pressure, and islocated on the intake manifold. The ECM uses this signal to control fuel meteringand injection timing and to limit smoke during acceleration. (PID 102)

Intake Manifold Temperature Sensor (IMT)The IMT sensor monitors air temperature in the intake manifold. The ECM usesthis signal to control injection timing, fuel metering, and engine protection. (PID105)

Barometric Pressure Sensor (BARO)The solid-state BARO sensor monitors ambient air pressure, and is located onthe side of the engine block. The ECM uses this signal to adjust fuel timing andmetering based on altitude. (PID 108)

Engine Coolant Temperature Sensor (ECT)The ECT sensor monitors coolant temperature in the engine block, and ismounted in the engine coolant jacket. The ECM uses this signal to controlinjection timing and fan clutch operation. During an overheating situation, it isalso used for engine protection. (PID 110)

Coolant Level Sensor (CL)The CL sensor detects the presence or absence of coolant at the probe, and islocated in the radiator top tank. The ECM uses this signal for engine protectionwhen coolant is not detected. (PID 111)

Fuel Temperature Sensor (FT)The FT sensor monitors fuel temperature, and is mounted on the secondary fuelfilter housing. The ECM uses this signal to adjust calculated fuel measurementsin order to compensate for fuel temperature changes. (PID 174)

Engine Oil Temperature Sensor (EOT)The EOT sensor monitors engine oil temperature, and is installed in the mainlube oil gallery. The ECM uses this signal for the engine protection. (PID 175)


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S ENSORS ( CONTINUED ) Engine Position Sensor (EPS)

The EPS is a Hall-effect sensor that generates a digital signal whose frequencyvaries with the speed of the engine. The ECM uses the frequency andpulsewidth of this signal to determine engine speed and cylinder position for fuelcontrol and injector timing. The EPS is located in the engine front cover facingthe trigger wheel which is mounted on the camshaft gear. (PID 190)

Vehicle Speed Sensor (VSS)The magnetic pick-up VSS measures vehicle speed at the transmission output.The ECM uses this AC voltage signal for the speedometer, cruise controloperation, and vehicle (road) speed limiting. (PID 84)

S WITCHES Engine Cooling Fan Manual Switch

This is a normally open switch that, when closed by the operator, requests thatthe ECM deenergize the engine cooling fan solenoid. This will cause the coolingfan to operate continuously.

Diagnostic On/Off SwitchThis is a normally open momentary switch that, when pressed and released,requests that the ECM enter diagnostic mode. The yellow warning/diagnosticindicator lamp will come on and flash inactive fault codes. The redwarning/diagnostic indicator lamp will come on and flash active fault codes. If both lights remain on only momentarily, no fault codes are present. The operator may also override the engine protection system shutdown by depressing and

holding the switch on.

Air Conditioning High Pressure SwitchThis normally closed pressure switch opens when the air conditioner high-sidepressure reaches a preset value. This signals the ECM to operate the enginecooling fan. (SID 228)

Idle Validation Switch (IVS)The IVS is an integral part of the throttle position sensor (TPS). This two-positionswitch indicates idle position when one set of contacts is closed, and off-idleposition when the other set of contacts is closed. For safety, the ECM willcommand idle speed whenever the off-idle position contacts are open,regardless of the signal from the TPS. (SID 230)

Cruise Control On/Off SwitchThis normally open switch enables cruise control operation when it is closed bythe operator. (SID 244)


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S WITCHES ( CONTINUED ) Cruise Set/Resume Switch

This switch has two momentary positions: set/coast and resume/accelerate.Vehicle cruising speed can be set by pressing the set switch. Once a speed hasbeen set, and then disengaged using the brake or clutch, the ECM will return tothe previously set speed when the resume switch is pressed. (Set - SID 243,Resume - SID 242)

Clutch SwitchThis normally closed switch opens when the clutch pedal is depressed. Thissignals the ECM to cancel cruise control, power take-off mode, and enginebraking, and to override the idle shutdown timer. (SID 245)

Service Brake SwitchThis normally closed air pressure switch opens when the service brake pedal isdepressed. This signals the ECM to enable engine braking, cancel cruise controland power take-off mode, and to override the idle shutdown timer. (SID 246)

Engine Brake On/Off SwitchThis normally open switch enables engine brake operation when closed by theoperator. (PID 121)

Engine Brake Selector SwitchThis three-position switch sets the level of engine braking (low, medium or high).(Low/High - PID 121, Med/High - PID 122)

Power Take-Off (PTO) On/Off SwitchThis normally open switch enables PTO mode operation when closed. In thismode, the cruise control switches are used to set and hold engine speed. (PID150)

Power Take-Off (PTO) Remote SwitchThis normally open switch is mounted outside the cab and enables remote PTOmode operation when closed. (PID 150)

A CTUATORS Electronic Unit Injectors (EUI)

These electromechanical diesel fuel injectors contain a solenoid controlled bythe ECM to manage fuel timing and metering. The injector solenoid driver circuitry in the ECM sends a high voltage signal to energize the injector solenoid. (SID 1, 2, 3, 4, 5, 6)

Engine Cooling Fan SolenoidWhen it is energized by the ECM, this normally closed solenoid supplies air pressure to disengage the engine cooling fan clutch. (SID 33)


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DISPLAYED DATAEngine Coolant Temperature ( ECT ) E FIntake Manifold Temperature ( IMT) E FEngine Oil Temperature ( EOT ) E FFuel Temperature ( FT ) E FEngine Oil Pressure ( EOP ) psiBoost Pressure ( BP ) psiBarometric Pressure ( BARO ) In.HgThrottle Position ( TPS ) %Idle Validation Switch ( IVS) On/Off Engine Position ( EPS ) rpmVehicle Speed ( VSS ) mphBattery Voltage ( B+ ) VoltsCoolant Level ( CL ) Normal/Low

Cruise Control Set Speed mphCruise Control Switch On/Off PTO Switch On/Off Remote PTO Switch On/Off Engine Cooling Fan Switch On/Off

A/C High Pressure Switch Open/ClosedClutch Switch Depressed/ReleasedService Brake Switch Depressed/ReleasedEngine Brake Switch On/Off Engine Brake Selector Low/Med/HighDiagnostic Lamp - Yellow On/Off

- Red On/Off Diagnostic Trouble Codes

Active:Inactive:

A CTUATORS ( CONTINUED ) Warning/Diagnostic Indicator Lamps

The Red "engine shutdown" lamp lights when the engine protection system is inthe derate and shutdown modes. The Red lamp can also be used to read activefault flash codes in diagnostic mode. (SID 238)The Yellow "warning" lamp lights when the engine protection system is in thewarning mode, or when electronic control system failures are occurring and anactive fault is present. The Yellow lamp can also be used to read inactive faultflash codes in diagnostic mode. (SID 239)

Engine Brake SolenoidsThese three solenoids can be energized by the ECM to provide engine brakingon two, four or all six cylinders. The engine brake can be operated in cruisecontrol (switch on) and will be energized after the set speed has been exceededor when the service brake pedal is depressed and the throttle pedal is released.The ECM will not energize the solenoids when the clutch pedal is depressed.(Low/High Solenoid - PID 121, Med/High Solenoids - PID 122)

D ATA L INK C ONNECTORS The J1939 data link allows the ECM to communicate with other vehicle controlsystems such as transmission, automatic traction control, and anti-lock brakecontrollers. The J1939 data link connector is mounted on the engine. (SID 231) The J1587 data link is used by an electronic Diagnostic Tool to communicate withthe ECM. This allows for diagnostic information retrieval and parameter calibrationsetting. The J1587 data link connector is located in the cab. (SID 250)

D IAGNOSTIC E QUIPMENT A Breakout Tool can be connected into a circuit to measure voltage signals andresistance values with a DMM (Digital Multimeter). The Displayed Data chart belowshows how Diagnostic Tool data will be presented in some Composite Vehicle testquestions. If a range of values is given, the sensor reading is varying in that range.


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I DENTIFIERS Diagnostic Trouble Codes (DTC)

Trouble codes can be active or inactive. Active codes indicate that the problem currentlyexists and inactive codes indicate that a problem once existed. Flash codes representdigits assigned to diagnostic trouble codes, so that DTCs can be retrieved through the

diagnostic lamps. The DTC's are formatted under SAE J1587 standards. The first set of numbers is the Parameter or Subsystem Identifier and the second set is the Failure ModeIdentifier. Both can be retreived from the ECM via the Data Link.

SubSystem Identifier (SID)The SID is a one, two, or three digit code assigned to identify a section of acontrol system without a related parameter identifier.

Parameter Identifier (PID)The PID is a two or three digit code which is assigned to each component.

Failure Mode Identifier (FMI)The FMI is a one or two digit code that describes the type of failure detected in thesystem component.

FAILURE MODE IDENTIFIERS (FMI)

Number Description

0 Data valid but above normal operational range1 Data valid but below normal operational range2 Data erratic, intermittent, or incorrect3 Voltage above normal or shorted high4 Voltage below normal or shorted low5 Current below normal or open circuit6 Current above normal of grounded circuit7 Mechanical system not responding properly8 Abnormal frequency, pulse width, or period9 Abnormal update rate10 Abnormal rate of change11 Failure mode not identifiable12 Bad intelligent device or component13 Out of calibration14 Special instructions


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PID/SID C ODE L ISTING

Code Description Flash CodeS1 Cylinder 1 11S2 Cylinder 2 12S3 Cylinder 3 13S4 Cylinder 4 14S5 Cylinder 5 15S6 Cylinder 6 16S33 Engine Cooling Fan Solenoid 17P71 Idle Shutdown 18P84 Vehicle Speed Sensor 19P91 Throttle Position Sensor 20P100 Engine Oil Pressure Sensor 21P102 Boost Pressure Sensor 22P105 Intake Manifold Temperature Sensor 23P108 Barometric Pressure Sensor 24P110 Engine Coolant Temperature Sensor 25P111 Engine Coolant Level Sensor 26P121 Engine Brake Solenoid Lo/Hi 27P122 Engine Brake Solenoid Med/Hi 28P150 PTO On/Off Switch 29P168 Battery Supply 30P174 Fuel Temperature Sensor 31P175 Engine Oil Temperature Sensor 32P187 PTO 33P190 Engine Position Sensor 34S228 A/C High Pressure Switch 35S230 Idle Validation Switch 36S231 J1939 Data Link 37S232 5 Volt Supply 38S238 Warning/Diagnostic Lamp-Red 39S239 Warning/Diagnostic Lamp-Yellow 40S242 Cruise Control Resume Switch 41S243 Cruise Control Set Switch 42S244 Cruise Control On/Off Switch 43S245 Clutch Switch 44

S246 Service Brake Switch 45S250 J1587 Data Link 46S252 Incorrect Engine Software 47S253 Check System Parameters 48S254 ECM 49

NOTE: S = System Identifier (SID) P = Parameter Identifier (PID)


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E LECTRICAL S PECIFICATIONS Data Links (Vehicle and Control) All Shorts to External Voltage

Positive Wire to chassis ground: OK: if less than 1.5 VDC2.5 to 5.0 VDC

Negative Wire to chassis ground: 5 V Reference Power Supply0.0 to 2.5 VDC At ECM: 4.75 to 5.25 VDC

Fuel Injectors0.5 to 5.0 ohms resistance100 to 120 VDC supply voltage

ECM9.0 to 16.0 VDC supply voltageMaximum voltage drop on allcircuits (except injectors): 0.05 VDC

At Harness: 4.75 to 5.25 VDC

All Shorts to GroundOK: If greater than 100 Kohms(No short circuit)

All Continuity ChecksOK: if less than 10 ohms(No open circuit)

S ENSOR S PECIFICATIONS Vehicle Speed Sensor Barometric Pressure Sensor

Coil Resistance: 1100 to 1500 ohms Pressure Altitude Voltage

Throttle Position Sensor 29.9 0 (sea level) 4.0 - 4.6Potentiometer Resistance: 26.8 3000 3.6 - 4.4Between supply and return wires: 24.0 6000 3.2 - 4.0

2000 to 3000 ohms 21.4 9000 3.0 - 3.8Between supply and signal wires: 19.1 12000 2.6 - 3.4

released pedal -

1500 to 3000 ohms Engine Oil Pressure Sensor depressed pedal - Pressure Voltage200 to 1500 ohms kPa psi VDC

Released minus depressed: Must be 0 0 0.4 - 0.6greater than 1000 ohms 172 25 1.4 - 1.6

Boost Pressure Sensor 517 75 3.4 - 3.6Pressure Voltage 689 100 4.4 - 4.6

psi in. Hg VDC0.0 0.0 0.42 - 0.58

12.5 25.45 1.42 - 1.5825.0 50.90 2.42 - 2.5837.5 76.35 3.42 - 3.5850.0 101.80 4.42 - 4.58

Coolant Level Sensor Coolant present: CL Normal signal =

5 VDC, CL Low signal near 0 VDCCoolant NOT present: CL Low signal

= 5 VDC, CL Normal signal near 0 VDC

In. Hg. feet VDC

345 50 2.4 - 2.6

All Temperature Sensors Temperature Voltage

E

CE

F VDC-40 -40 0.50

0 32 0.7532 90 1.5054 130 2.5082 180 3.60

120 248 4.50


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