Evaluar El Sistema Electrico PDF

Caterpillar Engine Electronics
Lesson Plan 16 - Troubleshooting / Scenarios

Objectives:
The student will gain familiarity with the Electronic Troubleshooting Guide and the
diagnostic process.
The student will be able to recall the electronic components needed to start a PEEC,
EUI, and HEUI engine.
The student will be able to follow the troubleshooting scenarios created in the slide
package.
Literature Needed:
Electronic Troubleshooting Guide SENR5582
PowerPoint Slides
Hardware Needed:
Projector and smartboard
Time Required:
2.75 Hours
Tasks Required by Instructor to Meet Objectives:
1. Present the slides.
2. Explain and review the various topics outlined in the slides pertaining to the
Troubleshooting Guide.
SEGQ4031 - 271 - Lesson Plan
8/02
LAST PRINT SECTION EXIT MAIN NEXT
Slide # 187
PEEC 8 to start
Components Needed To Start
PEEC has 8 PEEC has 8
#2 ECM #2 ECM
#3 P.M. #3 P.M.
#4 Parameters #4 Parameters
#1 POWER
+ Battery
- Battery
#1 POWER
+ Battery
- Battery
#5 Speed sensor
#6 Shut-off solenoid
#7 BTM
#8 Rack position sensor
#5 Speed sensor
#6 Shut-off solenoid
#7 BTM
#8 Rack position sensor
As we discussed earlier, PEEC has eight electronic components needed
to start.
1. Positive and negative battery no power, no start
2. Functional ECM
3. A personality module typically, if communicating with the ECM
the top three are good.
4. Parameters
5. Speed sensor ECM must see engine speed
6. Shutoff solenoid shutoff solenoid must be out of the way of the
rack
7. Rack BTM must have movement of the rack
8. Rack position sensor ECM must know the position of the rack
SEGQ4031 - 272 - Slide/Text Reference
8/02
Slide # 188
EUI 7 to start
EUI has 6 EUI has 6
#2 ECM #2 ECM
#3 P.M. #3 P.M.
#1 POWER
+ Battery
- Battery
#1 POWER
+ Battery
- Battery
#5 Speed/Timing sensor
#6 Good Injectors
#6 Good Injectors
EUI engines need six properly functioning electronic components to
start.
Like PEEC, EUI needs:
- positive and negative battery
- ECM
- P.M.
- Parameters
However, EUI additionally needs:
- speed/timing signal
- good injectors
8/02
Slide # 189
HEUI 7 to start
HEUI has 7 HEUI has 7
#2 ECM #2 ECM
#3 P.M. #3 P.M.
#1 POWER
+ Battery
- Battery
#1 POWER
+ Battery
- Battery
#6 Good Injectors
#7 IAPCV
#6 Good Injectors
#7 IAPCV
A HEUI engine needs seven electronic components to start:
1. Positive and negative battery no power, no start
2. Functional ECM main control
3. A personality module must have the software
4. Parameters theft deterrent, typically, if communicating with the
ECM the top four are good.
5. Speed/Timing sensor ECM must see engine speed while cranking.
6. Injectors properly functioning injector solenoids (click test)
7. Injection Actuation Pressure Control Valve controls the correct
pressure for starting (min. psi 3126 725, 3126B/E 870).
8/02
Slide # 190
Gather information
The Diagnostic Process
Gather information
Driver Questionnaire
Questionnaire response
Performance effect of active diagnostic codes
Check the repair history
What happened, in what order
Gather information
Driver Questionnaire
Questionnaire response
Performance effect of active diagnostic codes
Check the repair history
What happened, in what order
Discuss the information gathering process. This can be a key in
troubleshooting. Typically, the more information that is gathered, the
better the chances of solving the complaint.
The information listed here assists fact finding:
- Driver Questionnare
- Questionnare response
- Performance effect of active diagnostic codes
- The repair history
- Order of occurrence
Note: See Electronic troubleshooting Guide SENR5582 as a reference.
8/02
Slide # 191
Verification
Verify operational problems
Is the complaint due to misunderstanding of
parameters
Is the complaint due to a change of parameters
Is the engine performing as expected
Is the problem repeatable
Verify operational problems
Is the complaint due to misunderstanding of
parameters
Is the complaint due to a change of parameters
Is the engine performing as expected
Is the problem repeatable
Once the information has been gathered, try to repeat the problem.
Some complaints are due to misunderstandings or a parameter that has
been changed. For instance, if a new or different driver is operating a
unit with gear-down protection programmed. (Gear Down Protection
allows a setting of an engine rpm limit for the higher gears that ensures
cruising speed can only be reached in top gear). This may generate a
performance complaint because the operator is not use to the rpm
limiting with his other truck.
8/02
Slide # 192
Active codes
Determine probable causes
Repair ACTIVE diagnostic codes first
What subsystem could cause the problem
What subsystem does the troubleshooting guide
suggest
Determine probable causes
Repair ACTIVE diagnostic codes first
What subsystem could cause the problem
What subsystem does the troubleshooting guide
suggest
An active diagnostic code may be the reason for a complaint. Active
diagnostic codes should be troubleshot and repaired first. Troubleshoot
active codes with the appropriate Electronic Troubleshooting Guide.
Follow step by step in the guide. Do NOT skip steps.
8/02
Slide # 193
Narrow list
Logged codes
Status screen
Narrow the list of causes
Use driver information
Check LOGGED diagnostic codes
Check STATUS SCREENS
If more than one symptom, look for common
causes
Avoid PRE-CONCEIVED IDEAS
Narrow the list of causes
Use driver information
Check LOGGED diagnostic codes
Check STATUS SCREENS
If more than one symptom, look for common
causes
Avoid PRE-CONCEIVED IDEAS
It is important in the troubleshooting procedure to shrink the list of
causes. We can narrow the list by using driver information, verifying
logged codes, and checking the status screens.
If there are no active codes, check the logged codes that could be
causing the symptom or complaint.
In addition, the status screen may assist in the troubleshooting
procedure. Verify that temperatures and pressures are correct for key
on, engine off. For example, if the fuel temperature in the status screen
shows 200 + degrees F with the key on, engine off, and the engine has
not been running, there could be a polarity problem. (wires are
swapped). The temperature of the fuel should be approximately the
ambient temperature. In this example, it is possible to have a
performance complaint.
8/02
Commons
Pre-conceived
ideas
If there is more than one problem, investigate for common causes such
as, common wires, grounding studs and the ECM.
Stay away from Pre-Conceived Ideas. Do Not make any conclusions
until all the facts have been gathered.
8/02
Slide # 194
Basics of
electronic t/s
Test subsystems
Use procedure in manual
Connector checks are extremely important
Check every pin, socket, and wire
Test subsystems
Use procedure in manual
Connector checks are extremely important
Check every pin, socket, and wire
The most common starting point for troubleshooting all electronics are
the connectors. It is extremely important to check every pin, socket,
and wire.
Perform 10 pound pull test on each of the wires associated with the
component.
All connectors/pins/sockets should be completely mated/inserted, and
the harness/wiring should be free of corrosion, abrasion, or pinch points.
Refer to SENR5582 and PB-10: Inspecting Electrical Connectors.
8/02
Slide # 195
Troubleshooting Manual
Electronic system overview
Programming parameters
Troubleshooting without a diagnostic code
Troubleshooting with a diagnostic code
(functional tests)
Diagnostic code listing
(functional tests)
The troubleshooting guide contains the following.
- Electronic system overview
- Programming parameters
- Troubleshooting without a diagnostic code
- Troubleshooting with a diagnostic code
- Diagnostic code listing
8/02
Slide # 196
Brief explanation of component operation
Component diagrams
Sensor and connector locations
Engine and vehicle wiring harness diagrams
Service tools
Brief explanation of component operation
Component diagrams
Sensor and connector locations
Engine and vehicle wiring harness diagrams
Service tools
Briefly walk through the troubleshooting guide. Pointing out the
bulleted items and their locations.
8/02
Slide # 197
Overview of parameters
Customer and factory passwords
Programming a new ECM
Programming or changing a personality module
How to use ECM information
Overview of parameters
Customer and factory passwords
Programming a new ECM
Programming or changing a personality module
How to use ECM information
Additionally, point out the locations in the guide for the following:
- Overview of parameters
- Customer and factory passwords
- Programming a new ECM
- Programming or changing a P/M
- Using ECM information
8/02
Slide # 198
Section designation
General description of symptom
Page number to begin troubleshooting procedure
Example:
PA-19: Engine cranks, but will not start . Page 65
Section designation
General description of symptom
Example:
PA-19: Engine cranks, but will not start . Page 65
Using the Troubleshooting Manual (SENR5582), (Table of Contents)
use the example of PA-19, Engine cranks, but wont start, on page 65.
PA-19 = Section designation
Engine cranks, but wont start = description of symptom
page 65 = starting page for Troubleshooting steps
8/02
Slide # 199
(functional tests)
Section designation
General description of subsystems and circuits
Example:
PC-31: Engine speed/timing circuit test . Page 233
(functional tests)
Section designation
General description of subsystems and circuits
Example:
PC-31: Engine speed/timing circuit test . Page 233
Again, discuss area in Table of Contents. Use the example PC-31:
Engine speed/timimg circuit test on page 233.
8/02
Slide # 200
Diagnostic code
Code description
Flash code
Example:
232-04: 5 volt supply below normal (21) . Page 265
Diagnostic code
Code description
Flash code
Example:
232-04: 5 volt supply below normal (21) . Page 265
Briefly mention slide items. Reference 232-04 dianostic code.
8/02
Slide # 201
Troubleshooting Without a diagnostic code
Step by step elimination of all systems that could
cause symptom
Troubleshooting with a diagnostic code or
functional tests
Beginning of section on a specific subsystem
Begins with System operation overview
Step 1 for that item
Step by step elimination of all systems that could
cause symptom
Troubleshooting with a diagnostic code or
functional tests
Beginning of section on a specific subsystem
Begins with System operation overview
Step 1 for that item
When troubleshooting without a code, the Troubleshooting Manual
provides step by step information to eliminate all of the systems that
cause specific symptoms.
When troubleshooting with a daignostic code, the manual provides a
brief system operation explanation before the troubleshooting steps.
8/02
Slide # 202
Engine Cranks, But Will
Not Start
Not Start
A-19 page 65
Probable root causes
Connect an electronic service tool
Will the ECM communicate
Electrical connection to injectors
Engine speed/timing signal
Incorrect engine software
Theft deterrent active
A-19 page 65
Probable root causes
Connect an electronic service tool
Will the ECM communicate
Electrical connection to injectors
Engine speed/timing signal
Incorrect engine software
Theft deterrent active
3406E
3406E
As mentioned, this is the list of probable root causes. All of these
could cause an engine cranks, but wont start problem. Ruling out
these causes one by one should provide insight to the electronic
problem. Typically, the manuals will have some non-electronic causes
listed toward the end.
8/02
Slide # 203
EUI has 6 EUI has 6
#2 ECM #2 ECM
#3 P.M. #3 P.M.
#1 POWER
+ Battery
- Battery
#1 POWER
+ Battery
- Battery
#6 Good Injectors
#6 Good Injectors
Not Start
Not Start
Example 1 3406E ADEM II
Not an electronic problem
Not an electronic problem
In our first example for an EUI engine, 6 components are needed to
start. We can systematically rule out the electronic components one by
one.
1. We can check for power to the ECM.
2. ECM communicates
3. If the ECM communicates P/M is programmed
4. Check for theft deterrent
5. See engine speed
6. Click test
If all the above is OK, the electronics are not preventing the engine
from starting. Move on to fuel/air etc
8/02
Slide # 204
EUI has 6 EUI has 6
#2 ECM #2 ECM
#3 P.M. #3 P.M.
#1 POWER
+ Battery
- Battery
#1 POWER
+ Battery
- Battery
#6 Good Injectors
#6 Good Injectors
Not Start
Not Start
No speed
No speed
In our second example, the ECM is NOT receiving an engine speed
signal.
8/02
Slide # 205
No engine speed
Not Start
Not Start
Find no speed or
Have code 190-02 loss of engine RPM signal
Refer to SENR5582-06, page 233 or 234 (PC-31)
Page 233 is systems operation
Read several steps to get directional guidance
Step 1 - Check all connectors, pins, & sockets
Step 2 - Check for active code
Step 3 - Connect service tool
Find no speed or
Have code 190-02 loss of engine RPM signal
Refer to SENR5582-06, page 233 or 234 (PC-31)
Page 233 is systems operation
Read several steps to get directional guidance
Step 1 - Check all connectors, pins, & sockets
Step 2 - Check for active code
Step 3 - Connect service tool
With no engine speed signal or 190-02 diagnostic code, refer to PC-31.
It may help to first read the outlined steps. This can familarize yourself
and create a better understanding of the procedures. Make sure to
follow the steps.
Note: Example two fits more appropriately in troubleshooting without a
diagnostic code - Engine Cranks and Wont Start. Step 6 in the
troubleshooting guide refers to PC-31
8/02
Slide # 206
3 pin breakout
Not Start
Not Start
Step 4 Install a 3 - pin breakout T at the harness side
of the sensor connector, J9 only
Step 4 Install a 3 - pin breakout T at the harness side
of the sensor connector, J9 only
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
A
B
C
A
B
C
A
B
C
A
B
C
Install a 3 pin breakout T at the harness side of the sensor connector, J9
ONLY.
8/02
Slide # 207
Measure voltage
pin A to pin B
Not Start
Not Start
Step 4 Measure voltage at J9 pin A, with
reference to J9 pin B
Step 4 Measure voltage at J9 pin A, with
reference to J9 pin B
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
A
B
C
A
B
C
A
B
C
A
B
C
Once the breakout T is installed, measure the voltage at J9 pin A (+V
Engine Speed/Timing) with reference to J9 pin B (Engine Speed/Timing
Common) with the sensor disconnected.
8/02
Slide # 208
Not Start
Not Start
Step 4 Is voltage between 11.5 and 13.5 volts DC
Step 4 Is voltage between 11.5 and 13.5 volts DC
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
+ 13.32 v
+ 13.32 v
A
B
C
A
B
C
A
B
C
A
B
C
YES
YES
Sensor is
receiving the
correct voltage
Sensor is
receiving the
correct voltage
The voltage should be between 11.5 and 13.5 volts DC. It is 13.32
volts, move on to the next step.
8/02
Slide # 209
Connect sensor
side
Not Start
Not Start
Step 5 Connect sensor to the breakout T
Step 5 Connect sensor to the breakout T
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
A
B
C
A
B
C
A
B
C
A
B
C
Now connect the sensor to the breakout T.
8/02
Slide # 210
Measure voltage
Not Start
Not Start
Step 5 Measure the voltage at pin A with reference to
pin B
Step 5 Measure the voltage at pin A with reference to
pin B
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
A
B
C
A
B
C
A
B
C
A
B
C
Measure the voltage at J9 pin A (+V Engine Speed/Timing) with
reference to J9 pin B (Engine Speed/Timing Common).
Is the voltage still between 11.5 and 13.5 volts DC?
8/02
Slide # 211
Between 11.5 &
13.5v? Yes
Not Start
Not Start
Step 5 Is the voltage still between 11.5 and 13.5 volts
Step 5 Is the voltage still between 11.5 and 13.5 volts
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
+ 12.75 v
+ 12.75 v
A
B
C
A
B
C
A
B
C
A
B
C
YES
YES
The sensor is receiving the
correct voltage
The sensor is receiving the
correct voltage
Is the voltage still between 11.5 and 13.5 volts? Yes, the sensor is
receiving the correct voltage. Move to the next step.
8/02
Slide # 212
Remove signal
wire harness side
Not Start
Not Start
Step 6 Remove the signal wire (pin C) from the engine
harness connector J9 to isolate the sensor signal wire
Step 6 Remove the signal wire (pin C) from the engine
harness connector J9 to isolate the sensor signal wire
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
A
B
C
A
B
C
A
B
C
A
B
C
Remove the signal wire (pin C) from the engine harness connector J9 to
isolate the sensor signal wire.
8/02
Slide # 213
Measure voltage C
to B
Not Start
Not Start
Step 6 Measure the voltage from breakout pin-C to
breakout pin-B, before and while cranking
Step 6 Measure the voltage from breakout pin-C to
breakout pin-B, before and while cranking
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
A
B
C
A
B
C
A
B
C
A
B
C
Measure the voltage from the breakout T, pin C to pin B. Do this before
and while cranking.
8/02
Slide # 214
Voltage less than 2
or greater than
10?
Not Start
Not Start
Step 6 Is the voltage less than 2.0 volts DC or more
than 10.0 volts with key on, before cranking
Step 6 Is the voltage less than 2.0 volts DC or more
than 10.0 volts with key on, before cranking
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
+ .162v
+ .162v
A
B
C
A
B
C
A
B
C
A
B
C
Is the voltage less than 2.0 volts DC or more than 10.0 volts with key
on, before cranking?
< 2 volts indicates the sensor is not aligned with a gear tooth.
> 10 volts indicates the sensor is aligned with a gear tooth.
8/02
Slide # 215
During cranking 2
to 9v?
Not Start
Not Start
Step 6 During cranking is the voltage between 2.0
volts DC and 9.0 volts DC
Step 6 During cranking is the voltage between 2.0
volts DC and 9.0 volts DC
Speed timing sensor
Speed timing sensor
A
B
C
A
B
C
ECM
ECM
A
B
C
A
B
C
P9 J9
+ V
Com
+ .162 v
+ .162 v
A
B
C
A
B
C
A
B
C
A
B
C
NO
NO
There is no output signal
or it is out of limits
There is no output signal
or it is out of limits
During cranking is the voltage between 2.0 volts DC and 9.0 volts DC?
No.
This means there is no output signal or it is out of limits.
8/02
Slide # 216
Remove sensor,
check sliphead
Speed Timing Sensor
Speed Timing Sensor
Position the timing wheel in a place not
allowing the slip head to fill a slot
Position the timing wheel in a place not
allowing the slip head to fill a slot
Step 7
Remove the existing
speed/timing sensor
Pull the slip head out
Reinstall the
speed/timing sensor
Remove the Engine Speed/Timing Sensor. If the slip head is in, pull it
out. Reinstall the Speed/Timing Sensor. The engine should start.
NOTE: Position the timing wheel (by turning the crankshaft) in a place
to not allow the slip head to fill a timing wheel slot. Damage to the slip
head or engine could occur if the procedure is not followed.
8/02
Slide # 217
ADEM II
component
diagram
ADEM II Component Diagram
ADEM II Component Diagram
This is an overview of the Component Diagram. The yellow harness
indicates Caterpillar components, and the gray harness indicates the
OEM components.
Pick a few components, and briefly mention their functionality.
8/02
Slide # 218
5 volt sensors
Supply & common
are shared
Oil Pressure Oil Pressure
ECM ECM
Diagnostic Diagnostic
Tool Tool
Fuel Temp Fuel Temp
Boost Pressure Boost Pressure
Coolant Temp Coolant Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
Data link
Data link
5 volt Active Sensors
(36) +5v
(36) +5v
(30) Sensor common
(30) Sensor common
(8) Oil pressure
(8) Oil pressure
(3) Fuel Temp
(3) Fuel Temp
(23) Boost pressure
(23) Boost pressure
(14) Coolant Temp
(14) Coolant Temp
3176B, C-10,
C-12, & 3406E
3176B, C-10,
C-12, & 3406E
Review of the 5 volt active sensors. Shown are the sensors, their
respective wires and connectors. Additionally, the ECM, Data link, and
Diagnostic Tool are shown.
The 5 volt supply and common are shared. However, each sensor has
its own signal wire.
A supply
B common
C - signal
8/02
Slide # 219
Diagnostic Codes
Diagnostic Codes
8/02
Slide # 220
SAE Society of
Automotive
Engineers, PID
FMI
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
03 = Open 04 = Short
Data link
Data link
Diagnostic Codes
Diagnostic Codes
A
A
B
B
C
C
The diagnostic codes on the left are Society of Automotive Engineers
(SAE). They are standard for all engine manufactures. They can be
referred to as Parameter Identifier (PID) numbers.
For example, 100 is an oil pressure indication.
Also, Failure Mode Identifier (FMI) codes are SAE standards. They
follow the PID number.
For example, a 03 would indicate an open circuit. A 04 is a short
circuit.
8/02
Slide # 221
Boost open diag
code 102-03
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Diagnostic Codes
Diagnostic Codes
A
A
B
B
C
C
102 03
102 03
Lets look at an example if an open circuit was to occur with the boost
sensor signal wire. A 102-03 (boost pressure sensor open circuit)
should be indicated with a diagnostic tool.
8/02
Slide # 222
Short between A &
B
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Diagnostic Codes
Diagnostic Codes
A
A
B
B
C
C
232 04
232 04
A shorted to B
A shorted to B
Now lets look at a different scenario. The open remains in place,
however, a short is created between the A and B wire on the oil pressure
sensor connector. What code would appear?
A 232-04 ( 5 volt supply below normal ).
8/02
Slide # 223
Unplug sensor
connectors one at
a time
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
A
A
B
B
C
C
232 04
232 04
Unplug
Unplug
A shorted to B
A shorted to B
After steps 1 5 in the troubleshooting manual have been competed,
start disconnecting individual +5 volt sensor connectors. Does
disconnecting a specific sensor cause the +5 volt diagnostic code to
change to all opens?
In this example, we start by unplugging the coolant temperature sensor
connector, but the code remains a 232-04.
8/02
Slide # 224
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
A
A
B
B
C
C
232 04
232 04
Unplug
Unplug
Unplug
Unplug
A shorted to B
A shorted to B
Unplug the boost pressure sensor connector, and the code is still a 232-
04.
8/02
Slide # 225
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
A
A
B
B
C
C
232 04
232 04
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
A shorted to B
A shorted to B
Unplug the fuel temperature sensor connnector. The code remains a
232-04. Continue...
8/02
Slide # 226
Open, corrosion or
bad sensor
Step 1 importance
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
A
A
B
B
C
C
100-03
174-03
102-03
110-03
100-03
174-03
102-03
110-03
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
A shorted to B
A shorted to B
At this point, disconnecting the oil pressure sensor connector creates all
opens. Connect the sensor suspected of causing the problem (oil
pressure sensor). Does the problem reoccur? Yes, could be corrosion
within the sensor connector or a bad sensor.
Note: Corrosion should have been found by throughly inspecting the
connectors in step 1.
8/02
Slide # 227
T/S the boost open
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
A
A
B
B
C
C
102 03
102 03
Once the 232-04 is corrected connect the sensors. The 102-03 boost
pressure sensor open circuit should return. We would then troubleshoot
the boost pressure sensor open circuit.
8/02
Slide # 228
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
232 04
232 04
A
A
B
B
C
C
Heres another example of a 232-04.
8/02
Slide # 229
Unplug all, wiring
harness back to
ECM
Disconnect J2/P2
measure
resistance pin 36
to other sockets
Should find
resistance
between 36 & 30
less than 20 ohms,
shorted harness
ECM ECM
Tool Tool
100
100
Fuel Temp Fuel Temp
Signal
Signal
+ 5V
+ 5V
Ground
Ground
174
174
102
102
110
110
Data link
Data link
Troubleshooting
Troubleshooting
232 04
232 04
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
Unplug
?
A
A
B
B
C
C
A shorted to B
A shorted to B
We unplug all the sensors and still have the 232-04 diagnostic code. We
have confirmed the problem exists from the wiring harness connectors
back to the ECM.
(Step 7) At this point, disconnect the engine harness connector J2/P2.
Leave the sensor connectors unplugged as well. Measure pin 36 (+ 5v)
to each of the remaining pins/sockets. Multimeter resistance range
should be closest to, but not less than 20 ohms. (Wiggle the harness
during measurement to reveal any intermittent short condition).
In this case, the resistance between pin/socket 36 and pin/socket 30
should read less than 20 ohms. This would indicate a short in the
engine wiring harness. We would replace the engine wiring harness or
make the necessary repairs.
8/02
Slide # 230
ECM ECM
Any 3 wire, Any 3 wire,
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Common
Common
Sensor Signal
Sensor Signal
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
Any 3 wire, 5 volt pressure or temperature sensor requires a supply
voltage of 5 v +/-0.25 volts. It requires a common/ground, (NOT a
battery ground). The last requirement is the sensor signal to the ECM.
8/02
Slide # 231
C wire, analog
scale
C Wire Signal Output Voltage
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short
This is a slide showing the C wire signal output voltage for an oil
pressure sensor. This is called an analog sensor scale. Sensors convert
actual temperatures or pressures to an electrical signal.
In the example:
The good range would be between approximately 0.5 v to 4.5 volts
and 0 to 120 psi of oil pressure. Below 0.5 volts and above 4.5 volts
would be a short.
0 psi = 0.5 volts
60 psi = 2.5 volts
120 psi = 4.5 volts
8/02
Slide # 232
B to C short high
or low?
ECM ECM
Any Any
3 wire 3 wire
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Common
Common
Sensor Signal
Sensor Signal
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
B to C short
B to C short
What happens if a short occurs between the common and signal wire?
Will it short low or high? Next slide...
8/02
Slide # 233
Shorts low
Defaults to 87 psi
& DIAG
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short
X
X
Code 100-04
Code 100-04
B to C short
B to C short
It will short below 0.5 volts because the signal voltage is being drawn
down by the short to ground. The diagnostic code would be 100-04.
- Electronic system response would set the oil pressure to 87 psi.
- ET will indicate approximately 87 psi while the diagnostic code is
active and DIAG will be displayed on the status screen.
- This diagnostic code does not affect engine response.
8/02
Slide # 234
A to C short?
ECM ECM
Any Any
3 wire 3 wire
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Common
Common
Sensor Signal
Sensor Signal
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
C to A short
C to A short
What happens if the sensor signal wire is shorted to the 5 volt supply?
8/02
Slide # 235
Short high
Defaults to 87 psi
& DIAG
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short
X
X
100-04
100-04
C to A short
C to A short
The signal voltage will be above acceptable limits and trigger a 100-04
diagnostic code.
The electronic system response will set the oil pressure to 87 psi.
ET will indicate approximately 87 psi while the diagnostic code is
active and DIAG will be displayed on the status screen.
This diagnostic code does not affect engine response.
8/02
Slide # 236
Code for C
open? PID-03
ECM ECM
Any Any
3 wire 3 wire
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Common
Common
Sensor Signal
Sensor Signal
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
C Open
C Open
What code?
What code?
PID # and -03
PID # and -03
What code will be seen with a signal wire or C open? The
appropriate PID number and - 03. The oil pressure PID number is 100.
So, the diagnostic code would be 100-03.
What is the voltage from B to C when the C wire is opened?
8/02
Slide # 237
Chart shows 0, but
we have pull-up
voltage
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short
Looking at this chart, the C to B voltage could not be 0V, that would
trigger an 04 Short code. The voltage from C to B with B referenced
as ground is called the 5V sensors pull-up voltage. When checking
for this voltage an ADEM II or ADEM III ECM will be approximately
6V DC. Pull-Up Voltage is commonly used in the electronic industry
and this is also how other competitive and automotive sensor faults are
diagnosed.
8/02
Slide # 238
ECMs power
supply
100 volt DC EUI
100 volt DC EUI
13.2 v speed timing sensor
13.2 v speed timing sensor
8 v throttle position sensor
8 v throttle position sensor
6.4 v pull up
6.4 v pull up
5 v sensor supply
5 v sensor supply A
B
C
A
B
C
Micro-processor
Micro-processor
Battery +
Battery -
Battery +
Battery -
How is pull-up voltage produced? An overall explanation of the ECMs
power supply is shown here.
First the ECM must receive battery voltage, this may be 12 or 24VDC.
12 for on-highway trucks and typically 24 V for everything else. The
ECM uses a switching Power Supply to produce about a 100VDC
supply voltage. This 100VDC supply is used to power the
Mechanically or Hydraulically actuated EUIs. The 100V supply is
regulated down to 13.2 volts which is for the Speed Timing Sensor.
Then, an 8V supply is produced for the TPS. (On 3500B engines there
is also a right and left exhaust gas temp sensor which is powered by
8VDC). From the 8V DC supply a 6.25 or 6.4 volt supply is provided,
and then a 5 volt dc supply. The 6.25 or 6.4 supply is not shown on
schematics because it is not brought outside the ECM like the other
supply voltages.
8/02
C wire open
causes the
voltage to float to
6.25v
Technician
awareness
Verified ECM &
wiring to sensor
connector good
As the slide shows, there is a pull-up resistor shown in green. It runs
from the pull-up supply to the sensor signal line internal to the ECM.
The ECM microprocessor monitors the sensor signal line and
annunciates the proper temperature, pressure or fault code depending on
the voltage it receives. When the C wire is open, the voltage on the C
wire will float up to the pull-up voltage which in this case is
approximately 6.25V, and the ECM microprocessor will indicate an 03
code for that sensor as a result. There would be a separate pull-up
resistor for each 5 volt sensor.
The main reason for explaining this is so a technician is not surprised if
he uses a voltmeter and measures this 6+ volt dc level. If someone did
not know this was normal, they may think they have a bad ECM.
Also, if the sensor is unplugged and the pull-up voltage can be read
from C to B, then the following things have been verified: The ECM is
powered, it is producing the pull-up voltage, AND the B to C wiring
from the ECM to the sensor connector on the engine harness is okay.
Note: This does not verify that the A wire is OK.
8/02
Slide # 239
B & C swapped at
connector - No
code
ECM ECM
Any Any
3 wire 3 wire
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
B to C swap
B to C swap
What code?
What code?
No code
No code
What code is triggered if the common and signal wires are swapped at
the connector? No code.
The voltage is floating because the ground has been lost.
8/02
Slide # 240
Status screen
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short
B to C swap
B to C swap
Look at status
screen low oil
pressure or
temp etc.
Look at status
screen low oil
pressure or
temp etc.
What may be helpful is viewing the status screen. With or without the
engine running the status screen may indicate an incorrect pressure or a
temperature, depending on the type ECM software involved.
In this example the voltage floated to 1.0 volt, which equals 20 psi.
Note: Could be a shutdown scenario because the ECM is seeing low
oil pressure .
8/02
Slide # 241
A & C swapped -
No code
ECM ECM
Any Any
3 wire 3 wire
5 volt 5 volt
Pressure Pressure
or temp. or temp.
sensor sensor
A A
B B
C C
5 V + 0.25 V
5 V + 0.25 V
+5 volt
+5 volt
Signal
Signal
Ground
Ground
ECM - Battery
ECM - Battery
ECM + Battery
ECM + Battery
A to C swap
A to C swap
What code?
What code?
No code
No code
A
A
B
B
C
C
What code will be produced by a swapped A and C wire at the
connector?
There may not be any code. It depends on the sensor and how the
program is written for the ECM to interpret the voltage read. On the
3176B, with the boost pressure sensor A & C wires swapped, the
voltage from C to B is 4.98v. This gives a 102-00 code, which is
Boost Pressure Sensor Stuck High.
8/02
Slide # 242
Voltage floats
high, 120 psi
engine running or
not
5.0V 5.0V 4.5 4.5 4.0 4.0 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0 Volt 0 Volt
0 0
20 20
40 40
60 60
80 80
100 100
120 120
- 04 Short
- 04 Short
- 04
Short
- 04
Short
2.5 volts = 60 PSI
2.5 volts = 60 PSI
PSI
PSI
- 04
Short
- 04
Short A to C swap
A to C swap
Look at status
screen High oil
pressure or
temp etc.
Look at status
screen High oil
pressure or
temp etc.
The chart shows by swapping A and C the voltage floats high.
Therefore, the ECM interprets the high voltage to high pressure. Since
this would not generate a code, where could we possibly see this?
The status screen. On the chart, pressure appears to be 120 psi. This
pressure would be there regardless if the engine was running or not.
8/02
Slide # 243
Electronics Class
Electronics Class
Questions so
far?
Questions so
far?
8/02
Lesson Plan 17 - Troubleshooting Lab (Broken Engines)
Objectives:
The student will be able to, with the help of his classmates, properly diagnose,
troubleshoot, and repair the electronic operating engines.
Literature Needed:
Broken engine lab sheet
Hardware Needed:
ET/ECAP comm adapter/cables
Tool Boxes
VOM
3126B, 3406E, 3176B, 3406C engines
Time Required:
6.25 Hours
1. The instructor will make the necesary faults (bugs) before class startup. They are
as follows:
General: unplug comm adapter at each station.
3176B:
1). Battery Cable Disconnected, 2). Run Engine Out Of Fuel, 3). Personality Module
Loose, 4). Intake Man. Air Temp. Sensor Wires B & C Switched At Harness,
5). 12 Pin Bulkhead Connector Loose At Valve Cover Base, 6). Injector Wire #5
& 6 Under Valve Cover Loose, 7). Fuel Temp Sensor, Wires A & C Switched At
Sensor, 8). Atmospheric Pressure Sensor B & C switched
3406E:
1). Battery Cable Disconnected, 2). ESTS Tip Pushed In, 3). ESTS (A) Wire Loose
On Harness Side Of Connector, 4). Oil Pressure Sensor Wire Cut - pigtail, 5).
number 1 & 6 Injector Wires Switched at The Bulkhead Connector Both Gray
Wires, 6). Atmospheric Pressure Sensor A to B Fly Wire on harness side of the
connector, 7). Injector harness swap # 5 & 6 under valve cover.
8/02
PEEC:
1). Battery Cable Disconnected, 2). Wire #1 At 40 Pin OEM Connecter Loose, 3). 9
Pin ATA & 9 Pin Transducer Connectors Switched, 4). Green Wire "A" In 9
Transducer Switched To Hole "F", 5). Shutoff Solenoid Black "A" Wire In The
"C" Hole Solenoid Side, 6). BTM Wire "A" Loose, 7). TPS Sensor Connector
Loose, 9). TPS Sensor Wire "C" Wire Loose On Harness Side.
3126B:
1). Battery Cable Disconnected, 2).Emergency Stop - Pushed In, 3). Emergency Stop
- Loose Wire, 4). Crank Relay Connector Loose, 5). ATA (9) Pin - (H) Wire In
(G) Hole, 6). IAPCV purple wire (62) loose at the ECM, 8). TPS Sensor - (A)
Wire Cut, 9). IAP sensor C wire cut on pigtail.
2. Review the complaints with the students before going to the lab.
3. Explain there may be additional problems due to experiment troubleshooting.
4. Answer any questions
8/02
In completing this lab, you will practice the following skills, on several different engines:
1. Troubleshoot for complaints or problems like the following:
- Engine will not crank
- Cannot communicate with ECM
- Engine cranks, but will not start
- Engine starts but idles only
- Engine has active codes, such as short or open circuits
- Engine has low power
- Engine has rough idle
2. Inspect connectors via "10 pound pull test".
3. Disassemble, inspect, and reassemble Deutsch DT and/or HD Connectors.
4. Use a Multi-Meter to check voltage and/or continuity
5. Use Caterpillar ET (Electronic Technician) to:
- Find and print information
- Monitor status screens
- Retrieve active diagnostic codes
- Retrieve (and clear) logged diagnostic codes
- Perform diagnostic tests
Instructions
1. Fill in the work order for each engine that you repair (or attempt to repair).
2. Check coolant and oil levels before attempting to start the engine.
3. Use the diagnostic procedure - don't simply look for visual "bugs". Remember that these
are simulated problems, which may not be quite so obvious as the "real life" situations
that they represent.
4. Work from the worst problem to the least drastic, in order to find everything that is
wrong.
5. If you need parts, see the instructor.
6. You should be able to do all repairs with the same tooling that was available to you in the
Unbroken Engines Lab performed earlier. All necessary diagnostic tooling is available,
but is unhooked from the engines.
7. When you think you are finished, bring the work order to the instructor. Explain the
symptoms you discovered, the cause of those symptoms, and the steps you took to
correct the problem(s).
8. You have not completed the lab until all codes and symptoms are gone, to the instructor's
satisfaction.
9. When the instructor is satisfied that you have fixed the engine completely, he will tell
you whether or not you need to re-bug it for the next team.
SEGQ4031 - 333 - Lab Sheet - Broken Engines
8/02
10. Be safe -- If you are not sure about something, ask before doing it!
Work Order Number: 0001
Engine Model: 3126B
Engine Serial Number: 7AS00570
Mileage or Hours: 13,500 mi.
Customer Name: Bilge Beer Distribution Inc.
Date Needed: Today -- A.S.A.P
Complaint:
Engine died while idling, and would not crank when the driver tried to restart it. Had to
be towed into the shop.
Technician(s): _______________________________________________________
Time Assigned: ______________ a.m. p.m. (circle)
Time Completed:______________ a.m. p.m. (circle)
Oil Level:
_ O.K.
_ Low: Amount added _________
Coolant Level:
_ O.K.
Problem Statement: ______________________________________________________
______________________________________________________
Corrective Action: ______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
8/02
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Result: ______________________________________________________
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Result: ______________________________________________________
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______________________________________________________
______________________________________________________
Result: ______________________________________________________
8/02
Engine Model: 3406E
Engine Serial Number: 5EK00081
Customer Name: E-Z Haulers Inc.
Complaint:
This cross country heavy hauler was brought in by the yard man, on the hook.
Engine began running rough while traveling down the road, then died. Engine
cranks, but will not restart. Driver complained that engine was low on power
before it died.
Technician(s): _______________________________________________________
Oil Level:
_ O.K.
Coolant Level:
_ O.K.
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
8/02
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Result: ______________________________________________________
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Result: ______________________________________________________
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______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
8/02
Engine Model: 3406C PEEC
Engine Serial Number: 4CK00010
Mileage or Hours: 300,000 miles + unknown hours
Customer Name: Frels Cattle Ranch
Complaint: Low power / poor response.
Background information: This is a salvaged engine from a wrecked highway truck. The
truck had 300,000 miles on it when it was in a bad accident. Rancher Frels bought the
engine and made it into a water pumper for the feed lot 2 years ago. He said it had been
working fine till yesterday. Gomer and his apprentice on 3rd shift already worked on it
for two hours last night, but couldn't find the problem. They had to go on an emergency
call. They said they put it "pretty much back the way they found it".
Technician(s): _______________________________________________________
Oil Level:
_ O.K.
Coolant Level:
_ O.K.
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
8/02
Result: ______________________________________________________
______________________________________________________
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Result: ______________________________________________________
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Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
8/02
Engine Model: 3176B
Engine Serial Number: 9CK00639
Customer Name: Roadburner Trucking Inc.
Date Needed: Urgent - stranded along the road
Complaint:
Driver was on her normal daily run between Chicago and St. Louis. The engine had a
speed burp, then died. She coasted onto the shoulder.
Now it cranks but won't start. It must have active codes, because she said the light is
flashing.
It was in the shop last week, for a low power complaint. Gomer couldn't find anything
wrong.
Technician(s): _______________________________________________________
Oil Level:
_ O.K.
Coolant Level:
_ O.K.
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Result: ______________________________________________________
______________________________________________________
8/02
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Result: ______________________________________________________
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Result: ______________________________________________________
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Result: ______________________________________________________
______________________________________________________
8/02
Lesson Plan 18 - Final Exam
Objectives:
The student will take a final exam to gauge the learning and comprehension level of
the courses material. The student must obtain at least 70% accuracy on this exam to
complete course requirements.
Literature Needed:
Final Test
Course Evaluation
Hardware Needed:
None
Time Required:
.75 Hour
1. Ask the students for questions regarding material covered during the course.
2. Answer all questions using reference material. Be sure the students follow along in
their reference material while the question is answered.
3. Administer the Final Test
4. Review the Final Test, again using reference material to answer questions.
5. Ask the students to fill out the Course Evaluation Form.
8/02
Select the best answer:
1. Battery power is required by this type of engine/s to start:
A. PEEC
B. HEUI
C. EUI
D. All of the above
2. If the Theft Deterrent is programmed to Yes it will NOT prevent the engine from
starting:
A. True
B. False
3. The 3126B requires a minimum of _______ psi actuation pressure for the engine to
start:
A. 755
B. 870
C. 1000
D. 4000
4. If the 3406E throttle position sensor is not calibrated the engine will NOT start:
A. True
B. False
SEGQ4031 - 343 - Final Exam
8/02
5. The (ET ) Speedometer and Tachometer Special Test verifies if the _______ is
driving those gauges.
A. steering wheel
B. Speed / Timing sensor
C. ECM
D. air temperature
6. ____________ codes should be repaired immediately:
A. Inactive
B. Logged
C. Output
D. Active
7. A __________ should always be used for testing the Cooling Fan Output driver:
A. wire
B. test lamp
C. wrench
D. VOM
8. The PM provides the ECM instructions with a _______________.
A. software program
B. sensor signal
C. battery
D. microprocessor
9. An Active Diagnostic Code of 27 is related to ____________.
A. nothing
B. flashing
C. temperature sensor
D. camshaft
8/02
10. A FMI code of 04 indicates____________:
A. the engine is fine
B. a short circuit
C. an open circuit
D. the tire pressure is low
11. A 10 lb. pull test should be done on each __________________.
A. housing
B. pin and wire
C. service manager
D. passive sensor
12. Passive sensors receive 15 volts from the ECM:
A. True
B. False
8/02
Select the best answer:
1. Battery power is required by this type of engine/s to start: D
A. PEEC
B. HEUI
C. EUI
D. All of the above
2. If the Theft Deterrent is programmed to Yes it will NOT prevent the engine from
starting: B
A. True
B. False
3. The 3126B requires a minimum of _______ psi actuation pressure for the engine to
start: A
A. 870
B. 766
C. 1000
D. 4000
4. If the throttle position sensor is not calibrated the engine will NOT start: B
A. True
B. False
SEGQ4031 - 346 - Final Exam Master
8/02
5. The (ET ) Speedometer and Tachometer Special Test verifies if the _______ is
driving those gauges: C
A. steering wheel
B. Speed / Timing sensor
C. ECM
D. air temperature
6. ____________ codes should be repaired immediately: D
A. Inactive
B. Logged
C. Output
D. Active
7. A __________ should always be used for testing the Cooling Fan Output driver: B
A. wire
B. test lamp
C. wrench
D. VOM
8. The PM provides the ECM instructions with a _______________. A
A. software program
B. sensor signal
C. battery
D. microprocessor
9. An Active Diagnostic Code of 27 is related to ____________. C
A. nothing
B. flashing
C. temperature sensor
D. camshaft
8/02
10. A FMI code of 04 indicates____________. B
A. the engine is fine
B. a short circuit
C. an open circuit
D. the tire pressure is low
11. A 10 lb. pull test should be done on each __________________. D
A. housing
B. passive sensor
C. service manager
D. pin and wire
12. Passive sensors receive a 12 volt supply from the ECM: B
A. True
B. False
8/02

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Caterpillar Engine Electronics

Lesson Plan 16 - Troubleshooting / Scenarios

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