Mack Iii 8 211 V Service Manual

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®
V-MAC III OCTOBER 2008

SERVICE MANUAL (REVISED)

8-211

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 V-MAC III SERVICE MANUAL
1

V-MAC III Diagnostic Equipment

OCTOBER 2008 © MACK TRUCKS, INC 2008

(REVISED — SUPERSEDES ISSUE DATED JULY 2006) 8-211
 ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.

The information, specifications, and illustrations in this

publication are based on information that was current at
the time of publication.

No part of this publication may be reproduced, stored in a

retrieval system, or be transmitted in any form by any
means including (but not limited to) electronic,
mechanical, photocopying, recording, or otherwise
without prior written permission of Mack Trucks, Inc.

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TABLE OF CONTENTS

TABLE OF CONTENTS

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 TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clean Air Act . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V-MAC III SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab and Dashboard Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V-MAC III MAJOR FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reading Diagnostic Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SAE Message Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BLINK CODE 1-1 — ENGINE OIL PRESSURE (EOP) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BLINK CODE 1-1 — ENGINE OIL PRESSURE (EOP) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
BLINK CODE 1-2 — BAROMETRIC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
BLINK CODE 1-3 — FUEL TEMPERATURE (FT) SENSOR (ASET™ IEGR ENGINE) . . . . . . . . . 67
BLINK CODE 1-3 — FUEL TEMPERATURE (FT) SENSOR (ASET™ CEGR ENGINE) . . . . . . . . 76
BLINK CODE 1-4 — AMBIENT AIR TEMPERATURE (AAT) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
BLINK CODE 1-4 — AMBIENT AIR TEMPERATURE (AAT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
BLINK CODE 1-6 — STARTER ENGAGED INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BLINK CODE 1-7 — COOLANT LEVEL SENSOR (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . 106
BLINK CODE 1-7 — COOLANT LEVEL SENSOR (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . 112
BLINK CODE 1-8 — ESTIMATED % FAN SPEED (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . 118
BLINK CODE 1-8 — ESTIMATED % FAN SPEED (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . 125
BLINK CODE 1-10 — AUXILIARY COOLING RELAY OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 132
BLINK CODE 2-1 — ENGINE COOLANT TEMPERATURE (ECT) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
BLINK CODE 2-1 — ENGINE COOLANT TEMPERATURE (ECT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
BLINK CODE 2-2 — BOOST AIR PRESSURE (BAP) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
BLINK CODE 2-2 — BOOST AIR PRESSURE (BAP) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
BLINK CODE 2-3 — INTAKE AIR TEMPERATURE (IAT) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
BLINK CODE 2-3 — INTAKE MANIFOLD TEMPERATURE (IMT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
BLINK CODE 2-4 — TRANSMISSION OIL TEMPERATURE (TOT) SENSOR . . . . . . . . . . . . . . 189
BLINK CODE 2-5 — FRONT DRIVE AXLE OIL TEMPERATURE (FAOT) SENSOR . . . . . . . . . . 197

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 TABLE OF CONTENTS
BLINK CODE 2-6 — REAR DRIVE AXLE OIL TEMPERATURE (RAOT) SENSOR . . . . . . . . . . . 206
BLINK CODE 2-7 — ENGINE OIL TEMPERATURE (EOT) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
BLINK CODE 2-7 — ENGINE OIL TEMPERATURE (EOT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
BLINK CODE 2-8 — INTAKE AIR TEMPERATURE (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . 233
BLINK CODE 2-8 — INTAKE AIR TEMPERATURE (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . 240
BLINK CODE 2-9 — INTAKE AIR HUMIDITY (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . 247
BLINK CODE 2-9 — INTAKE AIR HUMIDITY (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . 255
BLINK CODE 3-1 — EXHAUST TEMPERATURE (ET) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 263
BLINK CODE 3-2 — ENGINE SPEED/TIMING (RPM/TDC) SENSOR
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
BLINK CODE 3-2 — ENGINE SPEED/TIMING (RPM/TDC) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
BLINK CODE 3-3 — REDUNDANT ENGINE SPEED MONITORING
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
BLINK CODE 3-3 — REDUNDANT ENGINE SPEED MONITORING
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
BLINK CODE 3-4 — ENGINE POSITION (EP) SENSOR (ASET™ IEGR ENGINE) . . . . . . . . . . 296
BLINK CODE 3-4 — ENGINE POSITION (EP) SENSOR (ASET™ CEGR ENGINE) . . . . . . . . . 304
BLINK CODE 3-5 — ENGINE BRAKE OUTPUT #1 (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . 312
BLINK CODE 3-5 — ENGINE BRAKE OUTPUT #1 (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . 317
BLINK CODE 3-6 — ENGINE BRAKE OUTPUT #2 (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . 322
BLINK CODE 3-6 — ENGINE BRAKE OUTPUT #2 (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . 327
BLINK CODE 3-8 — TRANSMISSION SPLITTER POSITION MECHANICAL
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
BLINK CODE 3-10 — ENGINE BRAKE OUTPUT #3 (ASET™ CEGR ENGINE) . . . . . . . . . . . . . 333
BLINK CODE 4-1 — VEHICLE SPEED (MPH) SENSOR (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . 334
BLINK CODE 4-2 — FAN CLUTCH OUTPUT (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . 345
BLINK CODE 4-2 — FAN CLUTCH OUTPUT (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . 350
BLINK CODE 4-3 — AUXILIARY OUTPUT #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
BLINK CODE 4-4 — AUXILIARY OUTPUT #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
BLINK CODE 4-5 — CCRS WASTEGATE OPERATION (ASET™ IEGR ENGINE) . . . . . . . . . . 369
BLINK CODE 4-5 — VARIABLE TURBINE GEOMETRY (VTG) POSITION SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
BLINK CODE 4-6 — TACHOMETER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
BLINK CODE 4-7 — SPEEDOMETER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
BLINK CODE 4-8 — CUSTOM DEFINED STATEMENT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . 398
BLINK CODE 4-9 — EGR VALVE MECHANISM (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . 399
BLINK CODE 4-10 — PARALLEL FAN CIRCUIT (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . 414
BLINK CODE 5-1 — THROTTLE POSITION (TP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
BLINK CODE 5-2 —THROTTLE POSITION (TP) SENSOR REFERENCE VOLTAGE . . . . . . . . 433
BLINK CODE 5-3 — SHUTDOWN LAMP AND DRIVER ALARM . . . . . . . . . . . . . . . . . . . . . . . . . 440
BLINK CODE 5-5 — ELECTRONIC MALFUNCTION LAMP (EML) . . . . . . . . . . . . . . . . . . . . . . . 446
BLINK CODE 5-6 — SPARE RELAY #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
BLINK CODE 5-8 — EGR TEMPERATURE (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . 458
BLINK CODE 5-9 — EGR MASS AIR FLOW (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . 464
BLINK CODE 6-1 — FUEL LEVEL (FL) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
BLINK CODE 6-2 — TURBOCHARGER WHEEL SPEED (TWS) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
BLINK CODE 6-3 — J1587 SERIAL DATA LINE (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . 480

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BLINK CODE 6-3 — J1587 SERIAL DATA LINE (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . 487
BLINK CODE 6-4 — J1939 SERIAL DATA LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
BLINK CODE 6-4 — J1939 SERIAL DATA LINE (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . 502
BLINK CODE 6-5 — LOSS OF SERIAL DATA COMMUNICATION
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
BLINK CODE 6-5 — LOSS OF SERIAL DATA COMMUNICATION
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
BLINK CODE 6-6 — INTERNAL COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
BLINK CODE 6-7 — ENGINE ELECTRONIC CONTROL UNIT (EECU) POWER RELAY
(CV, LE, MR) (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
BLINK CODE 6-7 — ENGINE ELECTRONIC CONTROL UNIT (EECU) POWER RELAY
(DM, RB, RD) (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
BLINK CODE 6-7 — ENGINE ELECTRONIC CONTROL UNIT (EECU) POWER RELAY
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
BLINK CODE 6-8 — ALLISON HD TRANSMISSION J1939 SERIAL DATA LINE . . . . . . . . . . . . 530
BLINK CODE 6-9 — OTHER ECU AFFECTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
BLINK CODE 7-1 — SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
BLINK CODE 7-2 — PARK BRAKE (MR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
BLINK CODE 7-2 — PARK BRAKE (CH, CL, CV, CX, DM, LE, RD) . . . . . . . . . . . . . . . . . . . . . . 547
BLINK CODE 7-3 — SPEED CONTROL SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
BLINK CODE 7-4 — SPEED CONTROL RESUME SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
BLINK CODE 7-5 — VEHICLE ELECTRONIC CONTROL UNIT (VECU) INPUT
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
BLINK CODE 7-6 — ENGINE ELECTRONIC CONTROL UNIT (EECU) SWITCHED
VOLTAGE (ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
BLINK CODE 7-6 — ENGINE ELECTRONIC CONTROL UNIT (EECU) SWITCHED
VOLTAGE (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
BLINK CODE 7-7 — EXHAUST TEMPERATURE REFERENCE THERMOCOUPLE . . . . . . . . . 576
BLINK CODE 7-9 — VARIABLE TURBINE GEOMETRY (VTG) CONTROL VALVE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
BLINK CODES 8-1 THROUGH 8-6 — ELECTRONIC UNIT PUMP (EUP)
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
BLINK CODE 8-1 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 590
BLINK CODE 8-2 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 596
BLINK CODE 8-3 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 602
BLINK CODE 8-4 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 608
BLINK CODE 8-5 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 614
BLINK CODE 8-6 — ELECTRONIC UNIT PUMP (EUP) (ASET™ CEGR ENGINE) . . . . . . . . . . 620
BLINK CODE 8-9 — ELECTRONIC UNIT PUMP (EUP) SOLENOID BOOST VOLTAGE
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
BLINK CODE 9-1 — TRANSPORT PROTOCOL PROGRAMMING FAILURE . . . . . . . . . . . . . . . 628
BLINK CODE 9-2 — POWER RESET WITHOUT KEY SWITCH
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
BLINK CODE 9-2 — POWER RESET WITHOUT KEY SWITCH
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
BLINK CODE 9-3 — AFTERCOOLER OUTLET TEMPERATURE (AOT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
BLINK CODE 9-5 — COMPRESSOR DISCHARGE TEMPERATURE (CDT) SENSOR
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
BLINK CODE 9-8 — AUXILIARY OUTPUT DEVICE #1 (ASET™ CEGR ENGINE) . . . . . . . . . . . 656
BLINK CODE 9-9 — AUXILIARY OUTPUT DEVICE #2 (ASET™ CEGR ENGINE) . . . . . . . . . . . 657

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BLINK CODE 9-10 — AUXILIARY OUTPUT DEVICE #3 (ASET™ CEGR ENGINE) . . . . . . . . . . 658
BLINK CODE 10-1 — INTERNAL SENSOR VOLTAGE (ASET™ CEGR ENGINE) . . . . . . . . . . . 659
BLINK CODE 10-2 — 5 VOLT SUPPLY (ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . 662
BLINK CODE 10-3 — SENSOR SUPPLY VOLTAGE #1 (ASET™ CEGR ENGINE) . . . . . . . . . . 667
BLINK CODE 10-4 — SENSOR SUPPLY VOLTAGE #2 (ASET™ CEGR ENGINE) . . . . . . . . . . 671
BLINK CODE 10-5 — FUEL FILTER DIFFERENTIAL PRESSURE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
BLINK CODE 10-6 — FUEL DELIVERY PRESSURE (ASET™ CEGR ENGINE) . . . . . . . . . . . . 676
BLINK CODE 10-7 — ODOMETER SAVE AREA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
BLINK CODE 10-8 — GPS POSITION DATA NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . 678
BLINK CODE 10-9 — VECU WATCHDOG TIMER RESET
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
BLINK CODE 10-10 — EECU WATCHDOG TIMER RESET
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
INTERMITTENT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
INTERMITTENT PROBLEMS NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . . . . . . . . . . . . . . 682
ENGINE SPEED HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
ENGINE SPEED HIGH NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
LOW OIL PRESSURE WITH DRIVER ALARM (IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
LOW OIL PRESSURE WITH DRIVER ALARM NO DIAGNOSTIC BLINK CODE
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
LOW OIL PRESSURE WITH DRIVER ALARM (CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
LOW OIL PRESSURE WITH DRIVER ALARM NO DIAGNOSTIC BLINK CODE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
INACCURATE OIL PRESSURE (IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
INACCURATE OIL PRESSURE NO DIAGNOSTIC BLINK CODE
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
INACCURATE OIL PRESSURE (CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
INACCURATE OIL PRESSURE NO DIAGNOSTIC BLINK CODE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
ROAD SPEED HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
ROAD SPEED HIGH NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
ENGINE COOLANT TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
ENGINE COOLANT TEMPERATURE HIGH NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . . 696
FAN ALWAYS ON (CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
FAN ALWAYS ON NO DIAGNOSTIC BLINK CODE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
TRANSMISSION OIL TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
TRANSMISSION OIL TEMPERATURE HIGH NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . 699
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
Allison HD Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
EXHAUST TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
EXHAUST TEMPERATURE HIGH NO DIAGNOSTIC BLINK CODE . . . . . . . . . . . . . . . . . . . . . . 700

vii
 TABLE OF CONTENTS
ENGINE CRANKS BUT WILL NOT START (IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
ENGINE CRANKS BUT WILL NOT START NO DIAGNOSTIC FAULT CODE
(ASET™ IEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
ENGINE CRANKS BUT WILL NOT START (CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
ENGINE CRANKS BUT WILL NOT START NO DIAGNOSTIC FAULT CODE
(ASET™ CEGR ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
VIP DIGITAL DASH DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
VIP DIGITAL DASH DISPLAY NO DIAGNOSTIC FAULT CODE . . . . . . . . . . . . . . . . . . . . . . . . . 707
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
V-MAC III SENSOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Aftercooler Outlet Temperature Sensor (AOT) Sensor (CEGR — #64MT450A) . . . . . . . . . . . 712
Intake Air Temperature Sensor (CEGR — #64MT450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Intake Air Temperature Sensor (IEGR — #64MT2102) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Ambient Air Temperature (AAT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Boost Air Pressure (BAP) Sensor (IEGR — #64MT2101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Boost Air Pressure (BAP) Sensor (CEGR — #64MT446) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Compressor Discharge Temperature (CDT) Sensor
(CEGR — #64MT450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Engine Coolant Temperature (ECT) Sensor (#64MT2103M) . . . . . . . . . . . . . . . . . . . . . . . . . 713
Engine Oil Pressure (EOP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Engine Oil Temperature (EOT) Sensor (Oil Filter Pedestal Mounted
Sensor #64MT2107) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Engine Oil Temperature (EOT) Sensor (Oil Pan Mounted Sensor #64MT2113) . . . . . . . . . . . 713
Engine Position (EP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Engine Speed/Timing (RPM/TDC) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Front Drive Axle Oil Temperature (FAOT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
Fuel Temperature (FT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
Fuel Level (FL) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
Intake Air Temperature and Humidity (IATH) Sensor (CEGR — #64MT463M) . . . . . . . . . . . . 714
Intake Air Temperature and Humidity (IATH) Sensor (CEGR — #64MT463M) . . . . . . . . . . . . 714
Intake Manifold Temperature (IMT) Sensor (IEGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
Intake Manifold Temperature (IMT) Sensor (CEGR — #64MT450) . . . . . . . . . . . . . . . . . . . . 714
Rear Drive Axle Oil Temperature (RAOT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Throttle Position (TP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Transmission Oil Temperature (TOT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Vehicle Speed (MPH) Sensor (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
V-MAC III E-TECH™ ENGINE FUEL RATE SPECIFICATIONS
(1997 THROUGH 1999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
SYSTEM CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
6-Pin Serial Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
9-Pin Serial Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
Vehicle Electronic Control Unit (VECU) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
Engine Electronic Control Unit (EECU) Connectors (ASET™ IEGR Engine) . . . . . . . . . . . . . 720
Engine Electronic Control Unit (EECU) Connectors (ASET™ CEGR Engine) . . . . . . . . . . . . 723
CAB AND CHASSIS CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
Cab-Chassis Bulkhead Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
Cab-Transmission Harness Bulkhead Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
Transmission-Engine Transition Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
Cab-Chassis-Transmission Harness Hinge Point Connector . . . . . . . . . . . . . . . . . . . . . . . . . 729

viii
 TABLE OF CONTENTS
Cab-Chassis-Transmission Bulkhead Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
Cab-Chassis Body Power Bulkhead Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
Digital Gauge Cluster Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
VIP Digital Dash Display Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
J1939 Serial Port Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
Bulkhead Deutsch Connector and Serial Communication Port Repair . . . . . . . . . . . . . . . . . . 736
Weather-Pack Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
Metri-Pack Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
Micro-Pack Connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
V-MAC SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746

ix
 NOTES

x
INTRODUCTION

INTRODUCTION

Page 1
 INTRODUCTION
SAFETY INFORMATION

Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:

Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.

Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.

Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.

A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.

Page 2
 INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.

Please note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.

1. Before starting a vehicle always be seated in the driver’s seat, place the
transmission in Neutral, be sure that parking brakes are set, and
disengage the clutch (if equipped).
2. Before working on a vehicle, place the transmission in Neutral, set the
parking brakes, and block the wheels.
3. Before towing the vehicle, place the transmission in Neutral and lift the
rear wheels off the ground, or disconnect the driveline to avoid damage to
the transmission during towing.

Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing away from
these components to prevent serious personal injury. Be aware of PTO
engagement or non-engagement status. Always disengage the PTO when not
in use.

REMEMBER,
SAFETY ... IS NO ACCIDENT!

Page 3
 INTRODUCTION
Clean Air Act
The federal government expressly prohibits
individuals and facilities from removing,
modifying, or bypassing any component or design
element that affects a vehicle’s exhaust emission
levels. Any individual who removes, modifies, or
bypasses any vehicle emission controls is subject
to a fine of up to $2500. Any repair facility that
removes, modifies, or bypasses any vehicle
emission controls is subject to a fine of up to
$25,000.
Page 4
ABOUT THIS MANUAL
This Manual is intended to provide the technician
with the information necessary to diagnose and
repair the V-MAC III (Vehicle Management and
Control) System on the CH, CL, CV, CX, DM, LE,
MR, RB and RD models. Although every effort
has been made to ensure that all the information
is as accurate as possible, due to our product
upgrades, some information may not be
applicable to all chassis. Not all chassis are
equally equipped, and care should be taken to
determine exactly what equipment is installed on
the vehicle.
Please pay particular attention to the Notes,
Cautions and Warnings which are placed
throughout the manual. These are intended to
call attention to specific procedures which must
be followed.
No part of this manual may be reproduced, stored
in a retrieval system, or be transmitted in any
form without the prior written permission of Mack
Trucks, Inc.
Please take the time to familiarize yourself with
the contents of this manual before attempting to
work on a vehicle. Make sure you completely
understand the instructions for performing a test
before beginning the test procedure. Do not
attempt to save time by skipping steps or using
procedures other than those listed in this manual.
References in this manual to ASET™ IEGR
engines include the AI and AMI model engines.
References to ASET™ CEGR engines include
the AC models.
Many of the electrical schematic diagrams in this
manual show multiple occurrences of the Vehicle
Electronic Control Unit (VECU) or the Engine
Electronic Control Unit (EECU). The diagrams
are formatted in this way for clarity and ease of
use, and do not imply that more than one VECU
or EECU is installed on any vehicle.
DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

Page 5
 DESCRIPTION AND OPERATION
V-MAC III SYSTEM OVERVIEW
The V-MAC III System uses two electronic control
modules; the Engine Electronic Control Unit
(EECU), and the Vehicle Electronic Control Unit
(VECU). Together, the two modules operate and
communicate through the J1939 high speed
serial data line to control a variety of engine and
vehicle cab functions. The Engine Electronic
Control Unit (EECU) primarily controls fuel timing
and delivery, fan operation, engine protection
functions and engine brake operation. On
ASET™ CEGR engines, the EECU also controls
the EGR valve and the turbocharger vane
position. The Vehicle Electronic Control Unit
(VECU) controls engine speed, cruise control
functions, accessory relay controls and idle
shutdown functions. The Vehicle Electronic
Control Unit also performs the trip recorder
functions. Both the EECU and the VECU have
the capability to communicate over the J1587 low
speed data lines to provide data to the Co-Pilot
display, Vehicle Information Profiler (VIP™), scan
tools and other electronic modules.
In addition to their control functions, both
modules have on-board diagnostic capabilities.
The on-board diagnostics are designed to detect
faults or abnormal conditions that are not within
normal operating parameters. When the system
detects a fault or abnormal condition, the fault will
be logged in one or both of the modules’ memory,
and the vehicle operator will be advised that a
fault has occurred by illumination of the Electronic
Malfunction Lamp (EML). The module will also
initiate the engine shutdown procedure if the
system determines that the fault will severely
damage the engine.
In some situations when a fault is detected, the
system will enter the 'limp home' mode. The limp
home mode allows continued vehicle operation
but the system may substitute a sensor or signal
value that may result in poor performance. In
some instances, the system will continue to
function but engine power may be limited to
protect the engine and vehicle. Fault codes
logged in the system memory can later be read,
to aid in diagnosing the faults, with a diagnostic
computer or by counting the blink code from the
Electronic Malfunction Lamp (EML). Faults read
using the blink code method are always active
faults, meaning the fault is occurring presently.
When diagnosing an intermittent code or
condition, it is necessary to use a diagnostic
Page 6
computer connected to the Serial Communication
Port. Additional data and diagnostic tests are
available when a diagnostic computer is
connected to the Serial Communication Port.
The Vehicle Electronic Control Unit (VECU) is
mounted on a panel underneath the dashboard
directly in front of the passenger seat on
conventional models. On the LE, the VECU is
located under the left side floor panel. On the MR,
the VECU is mounted under the tunnel cover.
The VECU is a microprocessor based controller
programmed to perform several functions, these
include:
앫 Controlling the cruise control and engine
speed
앫 Providing output signals to the speedometer
and tachometer
앫 Controlling the Electronic Malfunction Lamp
(EML) Operation
앫 Operating the Engine Shutdown and Driver
Alarm
앫 Broadcasting data on the serial data lines
앫 Trip recorder functions
앫 Diagnostic fault logging and password
processing
The VECU performs these functions by
monitoring the signals from sensors and
switches, and data received over the serial data
lines from the EECU. The VECU receives input
signals from seven sensors. They are:
앫 Exhaust Temperature (ET) Sensor
앫 Fuel Level (FL) Sensor
앫 Front Drive Axle Oil Temperature (FAOT)
Sensor
앫 Rear Drive Axle Oil Temperature (RAOT)
Sensor
앫 Transmission Oil Temperature (TOT)
Sensor
앫 Throttle Position (TP) Sensor
앫 Vehicle Speed (MPH) Sensor (VSS)
 DESCRIPTION AND OPERATION
The VECU also monitors the position or state of a 앫 Boost Air Pressure (BAP) Sensor
number of switches to perform its control and
앫 Engine Coolant Level (ECL) Sensor
diagnostic functions. They are:
앫 Engine Coolant Temperature (ECT) Sensor
앫 Clutch Switch
앫 Engine Oil Level (EOL) Sensor (if equipped)
앫 Engine Brake Switches
앫 Engine Oil Pressure (EOP) Sensor
앫 Fan Override Switch
앫 Engine Oil Temperature (EOT) Sensor (if
앫 Ignition Key Switch
equipped)
앫 PTO Switches (if equipped)
앫 Engine Position (EP) Sensor
앫 Service and Park Brake Switches
앫 Engine Speed (RPM/TDC) Sensor
앫 Speed Control Switches (Set/Decel,
앫 Fuel Temperature (FT) Sensor (if equipped)
Resume/Accel)
앫 Intake Manifold Temperature (IMT) Sensor
앫 Torque Limit Switch
The EECU on the ASET™ CEGR engine controls
Two different configurations of the Mack ASET™
the operation of the Electronic Unit Pumps
engine are currently in production. The ASET™
(EUPs), engine brake solenoids, EGR valve,
IEGR (Internal Exhaust Gas Recirculation)
turbocharger vanes, and cooling fan clutch based
engine is similar in design to previous Mack
on input information it receives over the serial
E-Tech engines in that they share common
data lines and from the following sensors:
appearance, hardware, and sensors. The
ASET™ CEGR (Cooled Exhaust Gas 앫 A/C Pressure Sensor (if equipped)
Recirculation) engine has many new features
앫 Aftercooler Outlet Temperature (AOT)
including a redesigned Engine Electronic Control
Sensor
Unit (EECU), a cooled EGR system, and a
Variable Turbine Geometry (VTG) Turbocharger 앫 Ambient Air Temperature (AAT) Sensor
system.
앫 Barometric Pressure (BP) Sensor (inside the
EECU)
The Engine Electronic Control Unit (EECU) is
bolted to a fuel cooled mounting plate which is on 앫 Boost Air Pressure (BAP) Sensor
the left side of the engine on the air intake
앫 Compressor Discharge Temperature (CDT)
manifold. The EECU is a microprocessor based
Sensor
controller programmed to perform fuel injection
quantity and timing control, diagnostic fault 앫 Cooling Fan Speed (CFS) Sensor
logging, and password processing and to
앫 EGR Mass Air Flow (EGRMAF) Sensor
broadcast data to other modules. The fuel
quantity and injection timing to each cylinder is 앫 Engine Coolant Level (ECL) Sensor
precisely controlled to obtain optimal fuel
앫 Engine Coolant Temperature (ECT) Sensor
economy and reduced exhaust emissions in all
driving situations. 앫 Engine Oil Level (EOL) Sensor (if equipped)
앫 Engine Oil Pressure (EOP) Sensor
The EECU on the ASET™ IEGR engine controls
the operation of the Electronic Unit Injection 앫 Engine Oil Temperature (EOT) Sensor (if
Pumps, Engine Brake Solenoids, and Fan equipped)
Control Solenoid based on input information it
앫 Engine Position (EP) Sensor
receives over the serial data lines and from the
following sensors: 앫 Engine Speed (RPM/TDC) Sensor
앫 A/C Pressure Sensor (if equipped) 앫 Fuel Temperature (FT) Sensor (if equipped)
앫 Ambient Air Temperature (AAT) Sensor 앫 Intake Air Temperature and Humidity (IATH)
Sensor
앫 Barometric Pressure (BP) Sensor (inside the
EECU)

Page 7
 DESCRIPTION AND OPERATION
앫 Intake Manifold Temperature (IMT) Sensor
앫 Turbocharger Wheel Speed (TWS) Sensor
앫 Variable Turbine Geometry (VTG) Position
Sensor
The Vehicle Electronic Control Unit (VECU) and
Engine Electronic Control Unit (EECU) are
dependent on each other to perform their specific
control functions. In addition to switch and sensor
data the broadcast of data between modules also
includes various calculations and conclusions
each module has developed, based on the input
information it has received.
Sensors
AFTERCOOLER OUTLET TEMPERATURE
(AOT) SENSOR
The Aftercooler Outlet Temperature Sensor is a
thermistor whose resistance varies inversely to
temperature. The sensor has a negative
temperature coefficient, which means the sensor
resistance will decrease as the inlet air
temperature increases.
The Aftercooler Outlet Temperature Sensor is
located on the EGR mixer. The sensor signal is
used to control fuel injection timing and quantity.
AMBIENT AIR TEMPERATURE (AAT) SENSOR
The Ambient Air Temperature Sensor is a
thermistor whose resistance varies inversely to
temperature. The sensor has a negative
temperature coefficient, which means the sensor
resistance will decrease as the ambient air
temperature increases.
The Ambient Air Temperature Sensor is located
toward the front of the chassis. The sensor may
be mounted in several locations including the
front cross member, hood hinge, spring bracket,
grill guard, and behind the bumper. The ambient
air temperature signal is used to validate the
intake air temperature sensor signal to prevent
the formation of white smoke when the engine is
started after hot soak.
Page 8
BAROMETRIC PRESSURE (BP) SENSOR
The Barometric Pressure Sensor contains a
pressure sensitive diaphragm and an electrical
amplifier. Mechanical pressure applied to the
diaphragm causes the diaphragm to deflect and
the amplifier to produce an electrical signal
proportional to the deflection.
The Barometric Pressure Sensor is built into the
Engine Electronic Control Unit (EECU).
BOOST AIR PRESSURE (BAP) SENSOR
On vehicles equipped with an electronic gauge
panel, the Boost Pressure Sensor provides input
to the EECU. On vehicles equipped with a
standard gauge panel, the Boost Pressure
Sensor provides input directly to the gauge panel.
The Boost Air Pressure Sensor contains a
pressure sensitive diaphragm and an electrical
amplifier. Mechanical pressure applied to the
diaphragm causes the diaphragm to deflect and
the amplifier to produce an electrical signal
proportional to the deflection.
On ASET™ CEGR engines, the Boost Air
Pressure (BAP) Sensor is located on the EGR
mixer. The sensor monitors the pressure of the
air leaving the charge air cooler. The Engine
Electronic Control Unit (EECU) uses the pressure
signal to optimize EGR valve and turbocharger
vane position.
On ASET™ IEGR engines the Boost Air Pressure
Sensor is threaded into the top of the intake
manifold on the left side of the engine.
COMPRESSOR DISCHARGE TEMPERATURE
(CDT) SENSOR
The Compressor Discharge Temperature Sensor
is a thermistor whose resistance varies inversely
to temperature. The sensor has a negative
temperature coefficient, which means the sensor
resistance will decrease as the inlet air
temperature increases.
The Compressor Discharge Temperature Sensor
is located in the air intake pipe between the
turbocharger and the charge air cooler. The
sensor signal is used for turbocharger protection.
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DESCRIPTION AND OPERATION
COOLING FAN SPEED (CFS) SENSOR
On ASET™ CEGR engines with an electronically
controlled viscous fan drive, the electronic fan
drive contains a Hall effect speed sensor. When
the engine is running, a series of vanes in the the
fan drive housing rotates past a magnet in the the
fan drive solenoid generating a pulsed voltage
signal. The Engine Electronic Control Unit
(EECU) monitors the status of the engine brake
solenoids and the air conditioning system and
signals from the Engine Coolant Temperature
(ECT) Sensor, the Engine Oil Temperature (EOT)
Sensor, and the Engine Speed/Timing
(RPM/TDC) Sensor and calculates the optimal
cooling fan speed. The EECU transmits a pulse
width modulated signal to the fan drive solenoid
which opens and closes a valve in the primary
drive plate, allowing fluid to fill or drain from the
fan drive housing until the target fan speed is
achieved.
The Cooling Fan Speed Sensor is located in the
fan drive on the front of the engine.
EGR MASS AIR FLOW (EGRMAF) SENSOR
The EGR Mass Air Flow (EGRMAF) Sensor
consists of an exhaust gas temperature probe, a
heater probe, and a dedicated electronic
processor. The EGR Electronic Control Unit
(EGR ECU) supplies the heater probe with a
12 volt power source. The EGR ECU then
monitors the amount of current required to
maintain the heater probe at 752°F (400°C). The
EGR ECU also monitors the exhaust gas
temperature signal from the temperature probe
and uses this signal and the heater current signal
to calculate EGR flow. The EGR ECU transmits
error messages and EGR Mass Air Flow data to
the Engine Electronic Control Unit (EECU) over
the J1939 serial data lines.
The EGR Mass Air Flow Sensor is located in the
outlet of the EGR cooler at the front of the engine.
The sensor signal is used to monitor the quantity
and temperature of the exhaust gas being
introduced into the air intake system.
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ENGINE COOLANT LEVEL (ECL) SENSOR
The Engine Coolant Level (ECL) Sensor is a
continuity device with two measuring probes. The
sensor measures continuity through the engine
coolant in the reservoir. If engine coolant level
falls below a calibrated point the sensor will not
sense continuity between the two measuring
probes and the sensor will warn the driver.
The Engine Coolant Level (ECL) Sensor is
located in the upper radiator tank or in the cooling
system overflow tank.
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
The Engine Coolant Temperature Sensor is a
thermistor whose resistance varies inversely to
temperature. The sensor has a negative
temperature coefficient, which means the sensor
resistance will decrease as coolant temperature
increases.
The Engine Coolant Temperature Sensor is
usually located in the rear of the water manifold.
The sensor will indicate a high coolant
temperature caused by problems like radiator
blockage, thermostat failure, heavy load, or high
ambient temperatures. This sensor is also used
for cold start enhancement and for fan clutch
engagement.
ENGINE OIL PRESSURE (EOP) SENSOR
The Engine Oil Pressure Sensor contains a
pressure sensitive diaphragm and a electrical
amplifier. Mechanical pressure applied to the
diaphragm causes the diaphragm to deflect and
the amplifier to produce an electrical signal
proportional to the deflection.
The Engine Oil Pressure Sensor is located on top
of the oil filter assembly. The sensor monitors
engine oil pressure to warn of lubrication system
failure.
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