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Electrical Review
Basic Electrical Review
Three (3) parts to electricity:
– V = Voltage (electrical “pressure”)
Resistance = load
12 volts 0 volts
2 amps 2 amps
Basic Electrical Review
6Ω
12 volts 0 volts
2 amps
Basic Electrical Review
Does not work without:
– Source (voltage & current)
Battery or alternator/generator
Cables and connections
– Load (resistance)
“Drops” or uses up the voltage
Too little = high current = thermal event
– Return (ground)
Basic Electrical Review
Two Wire Temperature Sensor Circuit
Sensor Signal 5V
Sensor Return
(Ground)
ECU
Basic Electrical Review
Three Wire Sensor Circuit
5V
5 V Reference
Signal
V
Ground
ECU
Basic Electrical Review
Two Wire Temperature Sensor Signal
Voltages:
Signal
V
Ground / return
ECU
Basic Electrical Review
Two Wire Inductive Pick-up Speed
Sensors:
Humidity
– Four (4) wires: B+, GND, CAN +, CAN -
– Smart device; detects relative humidity of
intake air, intake air temp, and
– Communicates info to ECU on E-CAN
– No direct testing
Basic Electrical Review
Other Sensors (cont.):
Lambda
– Detects Oxygen content in exhaust
– Five (5) wires:
Heater B+ & GND
Sensor Signals
– No direct testing of signals, only heater circuit
NOx
– Smart Device like Humidity sensor
– Four (4) wires: B+, GND, CAN+, CAN-
– Communicates information via A-CAN
– No direct testing of sensor function/response
Basic Electrical Review
Actuator Circuit
Actuator
12V B+ Power
ECU
Ground
Basic Electrical Review
Actuator operation:
– Coiled wire wrapped around movable
pintle (will have resistance spec)
Pulse
ECU Pintle
Return Spring
Coil
Circuit ON
Ground
Flow ON
Basic Electrical Review
Actuator
12V B+ Actuator
PowerCircuit
ECU
Circuit OFF
Ground
Flow OFF
ON
Basic Electrical Review
Diagnostic Testing:
– ALWAYS check source (battery, circuit
breakers, fuses, relays, etc.), grounds,
and connections to/from ALL components in
question (Including ECU!)
– Check for:
Corrosion at connection points
Reference or supply voltage
Ground back to ECU, Chassis, and Batt
A-CAN Aftertreatment Controller Area Network
Gro
12V
Gas Analysis: NOx
Humidity
Humidity
Reports on A & E-CAN
NOX Sensors
Humidity
Sensor
Injectors & Unit Injection Pumps
Switches and Lamps
E-CAN
PACCAR engine and aftertreatment
systems use sophisticated software models
within their electronic control units to control
their respective systems…
Software models:
Load
CPU Lambda
Crank Sensor
Turbo Boost
Driver + Driver -
Injector
PMCI-2 & EAS-3: Inputs and Outputs
Temps EGR Valve
Load
HC Doser
Pressure
Unit Pumps
RPM ECM / PMCI-2
DEF Doser
Position or
Lambda
CEL / MIL
Veh Speed
CAN bus
CAN Bus Information
AND / OR
– OR –
– AND –
– The sensor or system monitor has run and the ECM recognizes that
the new conditions to are currently within the expected range.
Fault Codes:
– System Parameter Out of Range – High or Low
This type of fault code sets when the system is out of range and
has a problem: i.e. the sensor and circuit are operating properly
but the system is outside of expected parameters
For example…
Coolant temp is
calculated using
sensor voltage
Expected
coolant temp
(after engine
off for 3 hrs)
is too high
Fault code is
set
Fault Codes:
– Sensor Voltage Out of Range – High or Low
Sensor voltage is above or below the operating range*
– Too High: voltage > 4.75 V
– Too Low: voltage < 0.25 V
This fault code type –set at the extreme ends of the sensor value
range- is due to an ELECTRICAL CIRCUIT problem
Example…
*These are general values – consult Rapido for specific values for
a particular sensor or fault code.
Boost temp
sensor signal
input
monitored on
pin A43
If voltage goes
below
programmed
value (0.15 V),
fault code sets
Fault Codes:
– Plausibility Faults
Example…
Vehicle speed
increase is
monitored
If signal value
is outside of an
expected
range, code
sets
Fault Codes:
– Irrationality Faults
Example…
ECM monitors
Turbo speed
and compares
with expected
programmed
values
If speed
difference is
detected, fault
code is set
Fault Codes:
– Filter or Catalyst Efficiency:
Example…
DPF Filter Efficiency Too Low
– Aftertreatment ECU monitors:
1. Soot level – Calculated:
Expected soot output based on combustion parameters
1. Coolant temp
2. Air mass entering engine
3. Fuel volume injected into cyl
4. EGR rate, flow, temp
2. Exhaust Flow – Calculated: based on measured exhaust
pressure and temperature sensors
3. Temperature – Measured by exhaust temperature sensors
4. Ash level – Calculated: based on pre & post DPF pressure sensors
5. Filter condition – Calculation: based on hours since DPF filter condition
reset in ECU
Fault Codes:
– Cascading Faults
Example…
Fault code P1510 is set as a result of P151A being set…
…and P151A is set as result of P3796 being set…
…so certain Fault Codes, such as P3796, will also trigger
two or more additional codes, i.e. P151A and P1510
Fault Codes: