Elect Sect03

SEGQ4031 - 216 - Lesson Plan
8/02
Caterpillar Engine Electronics

Lesson Plan 13 - Electronic Component Summary
Objectives:
The students will be able to recall which electronic components are needed to for an
engine to start and run.
The students will be able to associate possible engine malfunctions with the
electronic component most likely to cause the given symptoms.
The students will sort all electrical components into three catergories: input, output,
and control.
The student will state which components are found on or off the engine.
Literature Needed:
PowerPoint Slides
Hardware Needed:
Whiteboard and markers
Projector and smartboard
Time Required:
1.5 Hours
Tasks Required by Instructor to Meet Objectives:

1. Shut off the projector, and describe the following scenario to the class:
Imagine that a brand new, electronically controlled engine has just been delivered from
the factory. It is sitting on a shipping stand here in the classrooom. We know that the
engine will run -- it passed the test cell at the factory. What would we need in order to
start it up here in the classroom?
Ask the students to brainstorm a list of items. Note the responses on the board. They
should include the following:
fuel
coolant
oil
starter
battery power
LAST PRINT SECTION EXIT MAIN NEXT

SEGQ4031 - 217 - Slide/Text Reference
8/02
harness and cables

fuses
relays

8/02
Yesterday, we discussed a wide variety of electronic components. It can

seem overwhelming when we look at all the different components that
have been used over the years, on all the different engines, and on the
different applications of those engines. Today, we will simplify those
components as far as troubleshooting is concerned. There are really only
twenty five types of components, and they all can be sorted into three
main categories.
After summarizing the electronic components, we will have two lab
sessions, where you will explore the functions and uses of diagnostic
tooling. We will use ECAP (Electronic Control Analyzer and
Programmer), Caterpillar Electronic Technician (ET), a VOM, and a
test lamp. Yes, there is at least one troubleshooting procedure that still
requires the use of a test lamp.
The first lab will be conducted in the classroom, using engine
simulators. This will be followed by a lab in the shop area, with
runnable engines.
The engines are all in normal operating order. You will be able to
perform a variety of tests to see how a normal engine should respond.
Tomorrow afternoon, you will have another lab on the same engines. In
tomorrows lab, the engines will have some actual problems for you to
troubleshoot.
Imagine that a brand new, electronically controlled engine has just been
delivered from the factory. It is sitting on a shipping stand here in the
classrooom. We know that the engine will run -- it passed the test cell at
the factory. What would we need in order to start it up here in the
classroom?
Ask the students to brainstorm a list of items. Note the responses on the
board. They should include the following:
fuel
coolant
oil
starter
battery power
harness and cables
fuses
relays

8/02
These are basic to any engine, electronic or mechanical. Weve always

needed these things. You are already comfortable with troubleshooting
problems related to the items on the list.
People often see an ECM on the side of the engine, and panic. If they
cannot hook up an electronic service tool and find a code, they are lost
as far as troubleshooting is concerned. Remember that the items we just
listed are necessary for any engine.
Earlier in the week, we discussed the various engines that Caterpillar

has built over the years, sorting them into categories according to their
fuel system. What were the categories? (PEEC, MEUI, HEUI)
Instructor Note: Start the projector, and go to slide #153. Distribute the
handout for the summary of the twenty five electronic components.

8/02
PEEC
EUI
HEUI
Slide # 152
We sort by fuel Although we have many engines, and many applications for those
systems engines, they can be sorted according to their fuel system into broad
categories for ease of troubleshooting. We will use these three
categories in our summary of electronic components.
PEEC, EUI, HEUI

8/02
Symptoms
Will
Will not
not
crank
crank
+Battery
+Battery
-Battery
-Battery
PEEC has 8
ECM
Personality Module
Parameters
EUI has 6
ECM
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 153
Meaning of dead? All engines, regardless of the type of fuel system must have the items
that are listed at the left side of the chart.
The statement, The engine is dead, can have different meanings to
different people.
Is is completely dead, such that there is no clicking sound when the
starter switch is engaged?
Does the starter solenoid click once, followed by silence?
Is there a click, click, click sound?
Does the starter crank the engine slowly, and then stop?
Does the engine crank at normal starting speed, but will not start?
Each of these symptoms is a clue to the problem. With the possible

exception of the last bulleted item above, none of these are symptoms of
an electronic problem.

8/02
Ask the class the following questions:

Question: What could cause the engine to be completely dead (no
clicking sound when the starter switch is turned to the start position?
Answer: Either a completely dead battery, or an open connection
somewhere in the starting circuit (bad starter switch, open fuse relay or
disconnect, broken or disconnected wire or cable).
Question: What could cause the starter solenoid to click once, followed
by silence?
Answer: A bad solenoid or starter, a nearly dead battery, or a locked
engine (hydraulically or mechanically locked up).
Question: What could cause a click, click, click sound?

Answer: A bad solenoid or starter, or a nearly dead battery.
Question: What could cause the engine to crank slowly, and then stop?
Answer: A low battery.
Question: What could cause the engine to crank at normal starting

speed, yet not start?
Answer: Possibilities include lack of fuel, lack of air, mechanical
damage to the engine wherein it has no compression, or a problem with
an electronic component. In this situation, there is not a problem with
the battery or starting circuit. All engines must have a complete circuit
with the battery.

8/02
Symptoms
Will
Will not
not
crank
crank
+Battery
+Battery
-Battery
-Battery
PEEC has 8
Starter
Starter ECM
Harness
Harness Personality Module
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
EUI has 6
ECM
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 154
First, Battery & Battery power, together with the starting circuit, is the first item on our
starter circuit list of conditions needed for the engine to start and run. Battery power is
needed by all engines, mechanical as well as PEEC, EUI, or HEUI
electronic engines.

8/02
Symptoms
Will
Will not
not
crank
crank
+Battery
+Battery
-Battery
-Battery
PEEC has 8
Starter
Starter ECM
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 155
Typically, the battery and starting circuit are OEM supplied. Problems
in this category are really not even engine problems.

8/02
Symptoms
Will
Will not
not Cranks will Will
Cranks will Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery
-Battery
-Battery
PEEC
Starter
Starter ECM
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI
ECM
Personality Module
Parameters
Slide # 156
Regardless of whether the engine has a PEEC, EUI, or HEUI fuel

system, it must have:
A functional ECM: The way to check the ECM is to rule out all other
ECM
causes. However, in nearly every case, if you can communicate with the
ECM, the ECM is not defective.
A functional Personality Module: People sometimes dont realize that

P/M a new ECM will not communicate until it has been FLASHed with
software (or had a chip installed in the older ECMs). Also, like any
other computer file, the personality module can be corrupted . Be
careful to select the correct file to be Flashed in an ECM. In nearly
every case, if the service tool can communicate with the ECM, the
Personality Module is not defective.

8/02
Properly configured parameters: Some parameters will allow the

engine to crank, but not start. Some will even limit or prevent cranking.
Parameters are very useful. Programmable with an electronic service

Parameters tool, such as ET, they are really the only thing possible to work on
inside an ECM.
Theft Deterrent is an example of a truck engine parameter that could

Theft Deterrent cause the condition of cranks but wont start. If this parameter is
enabled, it prevents the engine from starting until the operator has
entered a four character password. To enable the system, the operator
must enter the password before the engine is shut off. Then, when the
engine is shut off, it will not restart until the password has been entered
correctly via the CAT ID dash display (the operator could also use
Pocket Tech to enter the password). Passwords can be any combination
of numeric or alpha characters.
3500 Series engines are shipped without oil or coolant, to save

Shipping w/out oil transportation costs. To protect the engine, the following parameters are
or coolant
set to zero to prevent startup until the engine has been properly
commissioned:
Crank cycle & Crank Cycle parameter limits how many times the engine can try to
duration set to 0
crank.
Crank Duration parameter limits how long the engine can crank on each
attempt.
Review - Battery,
ECM, P/M, So far, we have looked at four items on the chart that could prevent an
Parameters engine from starting, even if it will crank properly. These requirements
apply to all electronic engines:
Battery Power
ECM
Personality Module
Parameters

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery
-Battery
-Battery
PEEC has 8
Starter
Starter ECM
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 157
Separate For the remaining items that are necessary to start an engine, we need to
be specific as to what type of engine we are working on:
PEEC - 8
PEEC engines have four more requirements in order to start (eight

altogether).
EUI - 6
EUI engines have two more requirements (six altogether).
HEUI - 7
HEUI engines have three more requirements (seven altogether).

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery
-Battery
-Battery
PEEC has 8
Starter
Starter ECM
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 158
Inputs The arrows pointing into the ECM represent inputs from sensors that are
required to start the engine.
The arrows pointing out of the ECM represent outputs to actuators that
Outputs
are required to start the ECM.
We will first consider the PEEC engines, then EUI, and then the HEUI.

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
VSS
VSS
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 159
8v input - engine The PEEC engine must have an input signal from its 8 volt engine speed
speed sensor. Remember, this is a sensor that provides speed information only.
It is not a speed/timing sensor. The PEEC engine will start and run
without input from its timing position sensor.

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 160
5v/2vshutoff The PEEC engine must also have a working shutoff solenoid. If there is
solenoid, a problem in the shutoff solenoid, or in its related circuit, the fuel rack
will not move from the shutoff position, and the engine will get no fuel.
With all other systems functional, the engine would crank but would not
start.
Note to instructor: Demonstrate the sound made by a functional shutoff
Demonstrate click
if possible
solenoid on a classroom engine simulator. When the key is turned to the
on position, but the engine is not started, the solenoid should click once
loudly, then once again more softly. The first click is the solenoid
plunger being pulled in as the coil is energized. The second click is the
plunger being released. This is an example of an ETR (Energized To
Run) solenoid.
Notice the 5V/2V notation on the chart. The ECM supplies five volts to
pull the plunger back, then drops to two volts to hold it back during
normal engine operation. This gives longer coil life.

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
Harness Personality Module 00-4v
-4v Rack
Rack BTM/Actuator
BTM/Actuator
Switches
Switches Parameters
Fuses
Fuses
Relays
Relays
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 161
Rack BTM The PEEC engine must have a working 0V-4V Rack BTM (Brushless
Torque Motor) on 3400 product, or an Actuator on 3512 PEEC.

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator
Switches
Switches Parameters
Fuses
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,
Relays
Relays wont
wont shut
shut down
down
Maybe
Maybe all
all OEM
OEM EUI has 6
Mech.
Mech. & & Elect
Elect Eng
Eng ECM
Not
Not engine
engine problem
problem
Personality Module
Parameters
HEUI has 7
ECM
Personality Module
Parameters
Slide # 162
Rack sensor, The final requirement for any PEEC engine to start is a functional rack
wont shutdown if position sensor. The notation on the chart that says, wont SD means
signal lost
wont shut down. This is a reminder that the engine will continue to
run if the rack position sensor signal is lost while the engine is running.
If the signal is lost while the engine is running, the PEEC ECM
Speed governing, automatically uses speed governing. In this mode, it compares the
wont restart current duty cycle from the throttle position and the current rpm from
without rack
the speed sensor to set a ratio. It then maintains this ratio of speed
sensor
versus duty cycle to run the engine. However, once the engine is shut
off it will not restart without a rack position signal.

8/02
We have now covered the eight required items for any PEEC engine to
start and run. Except for the rack position signal, the loss of any of the
other requirements will shut down a running engine.
The PEEC engines are perhaps the most difficult to troubleshoot. The
older technology gives only limited codes to indicate what is wrong.
If you have verified that all eight electronic requirements are functional,
Non electronic yet the engine will still not start and run, it is not due to an electronic
problem -- look elsewhere. Remember, even electronic engines wont
run without fuel!

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator
Switches
Switches Parameters
Fuses
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,
Relays
Relays wont
wont shut
shut down
down
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
Personality Module
Parameters
13.2v
13.2v
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
ECM
Personality Module
Parameters
Slide # 163
Now lets consider the EUI and HEUI requirements.

You still need Battery, ECM, Personality Module, and Parameters.
You also need a working speed/timing sensor (or sensors), so that the
EUI, HEUI ECM will know when to actuate the injectors.
Varieties of speed/timing sensors are:
ADEM II active
12.5v & 13.2v
The brass bodied, 12.5 volt active S/T sensor used on the 3176
The aluminum alloy bodied, 13.2 volt active S/T sensor on ADEM II
engines
The passive sensors used on ADEM III (ADEM 2000) engines.
ADEM III passive
Note: the passive speed/timing sensors work the same way on EUI and
HEUI engines, and troubleshoot in the same manner.

8/02
Symptoms
Will
Will not
not
crank
crank not
not start
start communicate
communicate
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator
Switches
Switches Parameters
Fuses
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,
Relays
Relays wont
wont shut
shut down
down
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
Personality Module
Parameters 95-105v
95-105v EUI
EUI
13.2v
13.2v
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
ECM
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Slide # 164
Injectors EUI and HEUI engines also need proper functioning injectors.
95 to 105v dc
Remember that the injectors are powered by 95 to 105 Volts pulsating
SAFETY DC. Be careful when working around the injectors or the wiring for the
injectors. You could injure yourself, or someone else. For example,
dont perform an injector solenoid test while your partner is working
under the valve covers.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
burps
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor
-Battery
-Battery
PEEC has 8
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator
Switches
Switches Parameters
Fuses
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,
Relays
Relays wont
wont shut
shut down
down
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
Personality Module
Parameters 95-105v
95-105v EUI
EUI
13.2v
13.2v
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
ECM
0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Slide # 165
HEUI - IAPCV On HEUI engines, the final requirement to start and run the engine is a
working IAPCV (Injection Actuation Pressure Control Valve). Without
the IAPCV regulating the pressure of the actuation oil (under control of
the ECM) there will not be enough pressure available to actuate the unit
injectors.
Note: Although the IAP (Injection Actuation Pressure) sensor is not
IAP sensor listed on the chart, it could fail in a mode where it would prevent the
engine from starting. If the sensor is incorrectly signaling the ECM that
the actuation pressure is below 870 psi (735 psi on the older 3126
engines), regardless of what the actuation pressure really is, the ECM
will not actuate the injectors.
IAP sensor open - If the IAP sensor is simply unhooked, or has an open circuit, the ECM
defaults
will provide a default voltage to the IAPCV, and the engine will start
and run without a functioning IAP sensor.

8/02
Instructor Note: Point out the header information across the top of the
Information on top slide (also on the student handouts).
No crank
No Crank: If the engine will not crank at all, there is a starting system
problem, as described earlier.
One of the
requirements
Cranks & Wont Start: This is the symptom that might indicate a lack of
lacking one or more of the eight requirements for the PEEC engines, the six
requirements for the EUI engines, or the seven requirements for the
HEUI engines.
No Communication: This could be caused by a defective ECM, a

ECM, P/M, battery,
service
missing or corrupted Personality Module, lack of battery voltage to the
tool/cables ECM, or a problem with the electronic service tool or its connecting
cables.
Intermittent Starts but Stalls, or Speed Burps: These conditions could be caused by
problem intermittent problems with one or more of the components that are
needed to start and run the engine, if the problem occurs after the engine
is started (lost battery power to the ECM, loose personality module
chip, lost speed or speed/timing signal, lost power to the shutoff
solenoid, lost connection to the rack BTM or actuator, or lost
connection to the IAPCV, depending on what engine is involved).

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
burps performance Fault
performance Fault codes
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery PEEC has 8 Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Shut-off solenoid Temperature
Temperature sensors
sensors
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
Personality Module
Parameters 95-105v
95-105v EUI
EUI
13.2v
13.2v
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Slide # 166
Proper operation Electronic components not yet mentioned on the chart are necessary for
components proper engine operation, but none of them will prevent the engine from
starting. Some components may cause the engine to shut down after it
starts, depending on the way the protection parameters are set. For
example, a defective oil pressure sensor that reads lower than actual oil
pressure could cause a shutdown if the parameter for low oil pressure is
set to shutdown mode.
PEEC Boost, The 3406 PEEC truck engine has a transducer module to measure boost
timing & BTM pressure. It also has a timing position sensor and a timing position BTM
that are needed to maintain proper timing advance for the engine. None
of these will prevent the engine from starting. They also will not shut
the engine down if a fault occurs. They could cause the engine to have
poor performance if they are faulty or mis-calibrated.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Personality Module Brake
95-105v Saver
Saver
Parameters 95-105v EUI
EUI
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Engine
Engine retarder
retarder
Slide # 167
Exhaust brakes, Exhaust brakes are electronic components found on many truck engines.
brakesaver,
Jacobs & PAC 3406 PEEC, 3406E, C-15, and C-16 may have a brake saver that is
controlled electronically.
The EUI engines may have Jacobs or PAC brakes.
The 3126 HEUI engines may have a guillotine type exhaust brake that
is at least partially controlled by the ECM.
Braking circuits All of these brake circuits can be complex to troubleshoot, because of
complex the number of switches and sensor inputs that are involved. See the
appropriate Electronic Troubleshooting Guide for the engine with which
you are working.
Also, a Jacobs or PAC brake should never be engaged with cold engine
Cold operation of
oil. The cold, viscous oil may not drain rapidly enough from the brake
brakes
housing and could lead to a condition where the engine is braking and
fueling the injectors at the same time.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
Parameters 95-105v EUI
EUI
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Engine
Engine retarder
retarder
Slide # 168
Vehicle speed - Another electronic component (physically located off the engine) is the
speed vehicle speed sensor. Older engines also have a speed buffer to
misinterpreted,
speed limit
strengthen the vehicle speed sensor signal.
A faulty or misadjusted vehicle speed sensor can lead to engine
complaints. For example:
A sensor that incorrectly sends a speed signal when a truck is not
moving may cause the ECM to take the engine out of P.T.O. mode.
A faulty signal could interract with parameters such as vehicle speed
limit, and cause the engine to cut off or limit fuel to the engine.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
TPS Parameters 95-105v EUI
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Engine
Engine retarder
retarder
Slide # 169
TPS - idle only A throttle position sensor (typically physically located off the engine)
that is not calibrated, or is defective, will not prevent the engine from
starting. However, without a valid TPS signal, the engine will only idle.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch
Engine
Engine retarder
retarder
Slide # 170
Exhaust brakes There are also various OEM supplied switches that provide input to the
ECM.
The exhaust brake switch is one example

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch
PTO
PTO switch
switch Engine
Engine retarder
retarder
Slide # 171
PTO switch The P.T.O. switch is another example.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch
PTO
PTO switch
switch Engine
Engine retarder
retarder
Fan
Fan switch
switch
Slide # 172
Cooling fan - The cooling fan switch may or may not be controlled by one of the
output of ECM ECMs multi-function outputs.
Note to Instructor: If possible, look at this circuit during the diagnostic

tooling lab later today.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Engine
Engine retarder
retarder
Fan
Fan switch
switch
Slide # 173
Service brake, There are other switches, such as the service brake, clutch, and cruise
clutch, cruise control, that provide inputs to the ECM.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan
Fan & & inlet
inlet
air
air heater
heater
Slide # 174
Cooling fan or Output signals from the ECM may control the engine cooling fan, or the
inlet air heater inlet air heater (on 3126 and C-9 engines).

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
95-105v
95-105v EUI
EUI
Parameters
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater
Slide # 175
Lamps Additional outputs are lamps that indicate modes or conditions. Some
examples are: fast idle, P.T.O., Warning, Check Engine, or Inlet Air
Heater lamps.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
ECM 0-12v
0-12v IAPCV
IAPCV
Personality Module
Speedo/Tach 95-105v
95-105v EUI
EUI
Speedo/Tach Parameters
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater
Slide # 176
Speedo/Tach - The ECM may also control the speedometer and / or tachometer. We
special tests will see some special tests for these outputs in the diagnostic tooling lab
later today.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
J1587
J1587 Data
Data links
links HEUI has 7 Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
J1922
J1922 ECM
J1939
J1939 0-12v
0-12v IAPCV
IAPCV
Personality Module
Speedo/Tach 95-105v
95-105v EUI
EUI
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater
Slide # 177
Data Links Data links are used more and more frequently with newer engines for a
multitude of functions. Some examples are:
Communication ABS (Antilock Braking System) has been required on all trucks since
with ABS, the 1999 model year. A separate ECM is used for ABS. It can control
heating/AC, our engine in some cases. For example, if ABS sees wheel slip, it can
transmission
signal our ECM to shut off cruise control and derate the engine to
prevent an accident.
Heating and air conditioning systems may have their own ECM that
communicates with the engine ECM via the data link.
A transmission ECM communicates with the engine ECM.
Corrupted signal If something on the data link is corrupted, engine problems can result.
use process of
The best way to troubleshoot this is to start unhooking components. If
elimination
the engine trouble goes away when you unhook a component from the
data link, it is not an engine problem. It is a problem with the
disconnected component.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,,
sensor Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
J1587
J1587 Data
Data links
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
J1922
J1922 ECM
J1939
J1939 0-12v
0-12v IAPCV
IAPCV
Personality Module
Speedo/Tach 95-105v
95-105v EUI
EUI
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater 24
24 components
components
Slide # 178
Missing one So far, by grouping some items together, we have a list of twenty four
component? components. We have left out one major item, which would round out
the number to twenty five.
Can anyone think of what the last component might be?

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor,,
sensor Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
J1587
J1587 Data
Data links
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
J1922
J1922 ECM
J1939
J1939 0-12v
0-12v IAPCV
IAPCV
Personality Module Engine
Engine
Speedo/Tach 95-105v
95-105v EUI
EUI Harness
Harness
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater 25
25 total
total components
components
Slide # 179
Harness - approx. The harness is the final component for our list. It is one of the most
80% of problems important items to consider when troubleshooting. Perhaps 80% of all
electronic problems occur in the harness or the connectors.
Although we have mentioned a lot of different components, many of
them are similar enough (or we troubleshoot them in a similar enough
way) that we can lump them together. An analogy might be a residential
electrician who knows how to install a simple, two-way switch in a
lighting circuit. There may be fifty or more brands of two-way switches,
but if he can work with one of them we can work with any of them.

8/02
Symptoms
Will
Will not
not Starts
Starts Speed
Speed Poor
Poor Shutdown
Shutdown
crank
crank not
not start
start communicate
communicate but
but stalls
stalls burps
codes
+Battery
+Battery 8v
8v eng.
eng. speed
speed sensor
sensor Transducer
-Battery Pressure
Pressure sensors
sensors
Starter
Starter ECM 5v/2v
5v/2v Shut-
Shut-off solenoid
Temperature sensors
sensors
VSS
VSS
Harness
-4v Rack
Rack BTM/Actuator
BTM/Actuator +5v
+5v &
& +8v
+8v
Switches
Switches Parameters
Fuses 5v/8v
5v/8v Rack
Rack position
position sensor,
sensor, Timing
Timing pos.
pos.
Fuses VSB
VSB
Relays
Relays wont
wont shut
shut down
down sensor
sensor
Maybe
Maybe all
all OEM
OEM EUI has 6 13.2v
13.2v Timing
Timing BTM
BTM
Mech.
Mech. & & Elect
Elect Eng
Eng ECM 12.5v
12.5v
Not
Not engine
engine problem
problem Passive
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
VSS
VSS 95-105v Saver
Saver
EUI
TPS
13.2v
13.2v Exhaust
Exhaust
J1587
J1587 Data
Data links
Passive eng.
eng. speed/timing
speed/timing sensor
sensor Brake
Brake
J1922
J1922 ECM
J1939
J1939 0-12v
0-12v IAPCV
IAPCV
Personality Module Engine
Engine
Speedo/Tach 95-105v
95-105v EUI
EUI Harness
Harness
Exhaust
Exhaust
Brake
Brake switch
switch General
General Switches
Switches Lamps
Lamps
PTO
PTO switch
switch Brake,
Brake, Clutch,
Clutch, Cruise
Cruise Fast
Fast Idle
Idle Check
Check Engine
Engine Engine
Engine retarder
retarder
Fan
Fan switch
switch Fan PTO
PTO Inlet
Inlet air
air heater
heater
Fan & & inlet
inlet Warning
Warning
air
air heater
heater 25
25 total
total components
components
Slide # 180
25 total This completes our chart of the 25 total components. We will now look
components at how to catergorize these components.

8/02
Electronic Components
All electronic Components fit into one of

three categories .
Input
Sensors, switch inputs, ground, power
Control
Personality module, parameters, ECM, Data links
Output
Injectors, actuators,warning lights, gages
Slide # 181
3 catergories Although there are many different electronic components, they can all
be sorted into one of three major categories.
They are either an input device, an output device, or a control device.
Examples of input devices are the sensors, switches, ground
Input devices connections, power connections (such as switched or unswitched battery
power).
Control devices Examples of control devices are the p/m, parameters, ECM, or data
links.
Output devices Examples of output devices are the injectors, rack actuators, warning
lights, and gages.

8/02
25 Key Components
14 Engine Components
Input Control Output
- Engine speed sensor - ECM - Shutoff solenoid
- Rack position sensor - PM - BTM (2)
- Speed/timing sensor - Parameters - Injectors
- 8 volt sensors - Harness and - IAPCV
- 5 volt sensors Connectors - Retarder (Jake)
11 OEM Components Outputs are two wire
- Throttle position sensor - Data links - Speedo / Tack

- Vehicle speed - Fan switch (Diagnostic tools) - Lamps
- Speed buffer - Engine brake (Gauge panel) - Drivers
- Switches - PTO
Slide # 182
Here is a chart that lists the twenty five components. The list is sorted
into input, output, and control columns.
It is also sorted into components that are physically located on the

engine, versus the components that are located off the engine.
Of all the twenty five electronic components, fourteen are located on the
engine, and eleven are located off the engine.
No engine will have all of the twenty five components. Typically, there
will be about fifteen. Taken from this perspective, the troubleshooting
process does not seem quite so bleak.

8/02
Components Needed To Start
PEEC has 8 #5 Speed sensor

#1 POWER
#2 ECM #6 Shut-off solenoid
++ Battery
Battery
#3 P.M.
-- Battery
Battery #7 BTM
#4 Parameters
#8 Rack position
position sensor
sensor
Slide # 183
It is worthwhile to memorize the requirements needed to start each of

the three types of engines.
PEEC has the eight requirements shown here.

8/02
EUI has 6 #5 Speed/Timing sensor

#1 POWER
#2 ECM #6 Good Injectors
++ Battery
Battery
#3 P.M.
-- Battery
Battery
#4 Parameters
Slide # 184
EUI has the six requirements shown here.

8/02
HEUI has 7 #5 Speed/Timing sensor

#1 POWER
#2 ECM #6 Good Injectors
++ Battery
Battery
#3 P.M.
-- Battery
Battery #7 IAPCV
#4 Parameters
Slide # 185
HEUI has the seven requirements shown here.

8/02
Electronics Class
Questions so
far?
Slide # 186
Note to instructor: Answer any questions about the twenty five

component summary, then shut off the projector and introduce the E.T.
Lab, using the engine simulators in the classroom.

8/02

Lesson Plan 14 - Electronic Technician Lab
Objectives:
The students will complete the ET lab sheet.
Literature Needed:
ET Lab sheet
Hardware Needed:
Computer / Laptop with Electronic Technician installed
communication adapter / cables
40 pin breakout harness
Test lamp
Engine simulator or engine
Time Required:
1.25 Hours

1. Provide necessary equipment to complete lab:
a. Computer/Laptop with ET
b. Engine simulator or engine
c. Communication adapter / cables
d. Necessary Tool box with 40 pin breakout and test lamp
2. Assist students connect to engine (as necessary).
3. Answer any questions

SEGQ4031 - 260 - Lab Sheet -- Electronic Technician
8/02
In completing this lab, you will practice the following skills:

1. Connect the computer to the Communication Adapter / Electronic Control Module.
2. Navigate through the menu screens in ET.
3. View and change engine parameters.
4. Complete special tests.
The instructor will provide the necessary tools, computers, communication adapters, Flash
Code/Failure Mode Identifier (FMI) paper, and any other pertinent items.
(Students)
Part 1. Connecting to ECM/ET
1. Connect the laptop computers and communication adapters to simulators/engines.
2. Power on the computers, and select ET.
3. Look at the communication adapter. What lights are lit on the communication adapter?
___________________. The 9-pin connector gives us power and ground to the
communication adapter. Also, positive and negative data-link.
4. The communication adapter may have power, but ET will NOT communicate until the
key switch is ON or OFF?
Note: For industrial engines there will be a 9 - pin connector at the engine with 4 wires in it. For
+/- battery and +/- data link. For truck you need additional adapters.
Note: On the simulators they represent an engine with key on/engine off. There are no injectors
so we can't do the click test. Driver ID is not entered. On a real truck, theft deterrent could be
turned on. The rest of the simulator is like a production engine: you have a production ECM,
harness, and sensors. We view ET on the simulators just like it was a production engine with
key on/engine off.
Part 2. ECM Summary

1. In the "ECM Summary" screen, what are the corresponding numbers for the following:
ET version number ________________, ET serial number_________________ and the
subscription number_______________.
2. What is the engine serial number?_________________.
3. What is the Personality Module part number and code? ________________, ________.

8/02
4. What is the ECM serial number? ________________. This is also stamped on the ECM.
Note: The ET Serial number is recorded in the ECM when parameters/settings are changed.
Note: Printing the ECM Summary screen and the parameters is advised.
Part 3. Diagnostics
1. In the Toolbar, click on Diagnostics. What are the four items listed?
________________,__________________,________________,______________.
2. How many active codes?_________. Active codes should be repaired first? Yes or No.
3. Create an active code by unplugging the boost pressure sensor connector. Record how
long it took for the code to become active after unplugging the sensor.______seconds.
What is the diagnostic code number?___________. Note: These are SAE codes, not Cat
codes. After recording the time and the diagnostic code number, plug the connector
together.
4. How many logged codes?_____________. If logged codes are present, what is the
highest number of occurences?_______________. What is its First
occurrence?___________, Last___________hours.
5. Under Diagnostic Tests, how many items are listed?______. What are they?
__________________, __________________________,____________________,
_________________________,________________________________________.
6. Click on the Injector Solenoid Test. In the lower left part of the screen click on change.
What happened?_________________________? Click on Power All.
7. Under Diagnostic/Diagnostic tests/Systems Troubleshooting. What are the descriptions
listed?________________________,_________________________,
__________________________________,_______________________________.
The descriptions listed can be changed for assistance in troubleshooting. For example, the
Fuel Temperature Power Correction can be turned "off" while PAR testing an on-
highway truck.
8. Under Diagnostic/Diagnostic Tests/Special Tests. Click on Tachometer Test. In the
lower left screen click start. What does the tachometer do?____________.
Note: If the tach goes to 1500 rpm, the ECM is driving the tachometer.
9. Under Diagnostic/Diagnostic Tests/Cylinder Cutout Test. Click on start, click in the "5
cylinder cutout test". Click "Continue", What screen
appears?_________________________________.
Why?____________________________________________________________.
10. Slightly loosen the Boost Pressure Sensor connector. Under Diagnostic/Diagnostic

8/02
Tests/Wiggle Test. Click OK, Click start, and "wiggle" or shake the boost sensor harness
connector. What
happens?__________________________________________________________.
11. Select Diagnostic/Events/Logged Events. Are any present?________________.
Note: These are NOT component/part failures. These are recordings of events that could harm
the engine.
- quick stop
- vehicle overspeed
- engine overspeed
- very low oil pressure
- very high coolant temp
- very low coolant level
- very high air inlet temp
Part 4. Information
1. Select Information/Status. Click on Groups, select group 3 and OK. Click on Active
codes (bottom). What should fuel, coolant, or air inlet manifold temperatures read in the
status screen? _________________________________. They should read room or
ambient temperatures (if on simulator or engine has not been running). This is important
to check if temperatures are high or low for fuel temperature especially. If some wires
are reversed, there could be no active code on the sensor, and the ECM may have an
incorrect input. Fuel temperature compensation could be turned off automatically if the
sensor incorrectly shows above 194 F degrees. This could cause a driver to complain of
low power.
2. These are real time screens showing current conditions. Look at some of the pressures
and temperatures. If the engine has not been running, what should they be with the key
on, engine off?
_____________________________________________________________.
3. Click on Groups, select Group 2 and OK. Observe the boost pressure status, it should be
0 with the key on, engine off. It should still be 0 if the engine is started, but has no load.
4. Select Information/Current Totals. What is the Total Idle time value?_________.
Part 5. Service
1. Select Service/Configuration. Find "Security Access Parameters" and Total Tattletale.
What is the Total Tattletale value?______. Scroll down to "Trip Parameters". What is
the value for "Theft Deterrent System Control"?_______. How many Tattletales are there
for Theft Deterrent Security Control (TT)?______. Scroll down to "Passwords". Note:

8/02
If customer passwords were entered here, those customer passwords would have to be
entered before changing parameters like Theft Deterrent. If the customer passwords
were unknown, factory passwords would have to be obtained to view the customer
passwords. This is done under Information/Passwords. What are the FLS/FTS
values?________.
2. Select Service/Parameter Lockout. Select a description that is Locked. Write down what
it is._________________________. Click change, and Yes. In order to change this
Parameter, factory passwords would have to be obtained. Parameter Lockout is available
to restrict access to changing some applicable parameters. (JAN95 or later Personality
Modules) We will NOT enter factory passwords. Click Cancel.
Now let's do the Cooling fan/Output # 4 driver test (Diagnostics/Diagnostic Tests/Special

Tests).
Note: Fan logic is output on, fan off. Output off, fan on.
1. Key off, connect the 40 pin breakout Tee to the OEM side.
2. Check the engine wiring schematic for the appropriate pin number for the Cooling fan
driver. For our case it is output # 4, pin 28.
3. Place a red breakout Tee lead into pin 28, and black breakout Tee lead into battery pin 5.
4. Using test lamp 5P7277, place test lamp into red breakout Tee (pin 28), and ground other
side to black breakout Tee (pin 5, or other ground).
Note: The VOM cannot be used for this test, because the VOM may not go from 12 to 0 when
you turn the output on and off. The ECM has a 200 milliamp output to power a relay for the fan.
A light on the output pin will light up or turn off as we activate and deactivate the multifunction
output. The output may be sitting at 5 or 6 volts even when off. The voltmeter may show voltage
condemning the ECM. If you use VOM in amp meters mode, it acts as a short and the output
goes into current limit and you will read 0 output. Bottom line, a test lamp MUST be used.
5. Key on, in ET go to Diagnostics/Diagnostic Tests/Special Tests

6. Hi-light Cooling Fan test, and Click start (lower left corner).
7. Test lamp should light because output is turned off to activate the output.
8. Click on stop to end the test.
9. Turn key off, and disconnect the 40-pin breakout Tee, connect the engine harness to the
ECM.
Note: This test lets the technician know if the ECM Cooling fan/Output driver # 4 is functioning
properly.

8/02

Lesson Plan 15 - Open/Short Exploration Lab (Unbroken Engines)
Objectives:
The students will complete the Open/Short Exploration Lab.
The students will share results with other classmates upon completion of the lab.
Literature Needed:
Open/Short Exploration Lab sheet
Appropriate Electronic Troubleshooting Guides with Schematics
Hardware Needed:
Multimeter
Pin and socket removal tool
Computer/Laptop with ET installed
Proper Datalink/connections for communication
Time Required:
3.0 Hours

1. Provide necessary tools and engines for student completion of the lab.
2. Assemble groups in electronic knowledge equivalency.
3. Answer any questions.

SEGQ4031 - 265 - Lab Sheet - Unbroken Engines
8/02
In completing this lab, you will practice the following skills:

1. Use a schematic to identify:
- Electronic component locations
- Wire numbers, and colors
- Pin and socket locations in Deutsch DT Connectors
2. Disassemble and reassemble Deutsch DT Connectors.
3. Use a Multi-Meter to check voltage.
4. Use Caterpillar ET (Electronic Technician) to:
- Find and print information
- Monitor status screens
- Retrieve active diagnostic codes
- Retrieve (and clear) logged diagnostic codes
- Use (and program) function keys
- Find tattletale values
- Change a parameter
- Change display between Metric or U.S. units
- Perform diagnostic tests
Instructions
Your group is assigned to the following engine: _____________
Part 1:
Using the schematic from the Service Manual for this engine, locate the following electronic
components on the engine. Put a check mark on the line next to the name of each
component as you find its location on the engine. For any components that are not
present on your engine, leave the check box blank. Be prepared to point out the check
marked components to the instructor:
_ Boost Pressure Sensor

_ Oil Pressure Sensor
_ Atmospheric Pressure Sensor

8/02
_ Intake Air Pressure Sensor

_ Intake Manifold Air Temperature Sensor
_ Fuel Pressure Sensor
_ Speed / Timing Sensor(s)
_ IAP Sensor
_ IAPC Valve
_ Coolant Temperature Sensor
_ Fuel Temperature Sensor
_ Engine Ground Stud
_ ECM Ground Strap
_ Intake Air Heater Relay
_ Injector Harness Connector
_ J1/P1 Harness Connector
_ J2/P2 Harness Connector
_ Shut-off Solenoid
- Engine Calibration Timing Probe Connector
Part 2:
Fill in the blanks for the following questions:
1. Is (are) the Speed / Timing Sensor(s) on your engine active or passive?

_________________
2. How many Speed / Timing Sensors are there on your engine?
_________________
3. Where does the injector common for cylinders #1 and #2 branch into two separate wires
-- inside or outside of the valve cover? _________________
4. How many of the pin connections in the 12 pin injector connector are used for the
exhaust brake on your engine? _________________
5. How many wires are connected to the Intake Manifold Air Temperature Sensor on your
engine? _________________
6. How many wires are connected to the Boost Pressure Sensor on your engine?
7. On the sensor side of the connector, what color is the sensor common wire for the
Coolant Temperature Sensor? _________________

8/02
8. On the harness side of the connector, what color is the sensor common wire for the
Coolant Temperature Sensor? _________________
9. What number is stamped on the supply wire to the #6 injector? _______________
Part 3:
Plug Refer to this picture as you complete the following steps:

Receptacle
1. Locate the Deutsch 3-pin connector for the Boost Pressure Sensor.
2. Write down the wire color for each pin location on the receptacle side of the connector:
A = ____________, B = ____________, C = ____________
3. Separate the plug and receptacle.
4. Leave the plug side of the connector intact, but remove the wedge from the receptacle
and set it aside for later reassembly.
5. Remove all three wires from the receptacle, and set the receptacle aside for later
reassembly.
6. Insert the pins (without the receptacle) into the proper A, B, C, locations in the plug.
7. Connect E.T. to the data link. With the key on, engine off, access the status screen that
shows boost pressure.
8. Set up the conditions described in the first column of the following table by:
- unplugging pin connections to create open circuits
- using a jumper wire with alligator clips to create short circuits
- switching pin connections to simulate assembly errors
9. For each abnormal condition that you create:
- Use E.T. to check for active codes, and record the code in the second column of the
following table. If there is no code, write "no code" in the table.
- Refer to the E.T. status screen, and record the boost pressure in the third column of the
following table.
- Use a Multi-Meter to measure the voltage from the pin in the "C" position of the plug to

8/02
the pin in the "B" position of the plug, and record the result in the fourth column of the
table.
Voltage from C to
Condition Code Boost Pressure B
A open
B open
C open
A and B shorted
B and C shorted
A and C shorted
A and B switched
"B" and "C" switched
"A" and "C" switched
10. Properly reassemble the connector.

11. Check for active codes - fix the problem if any codes are present.
12. Clear logged codes.
Part 4:
With key on, engine off, use E.T. to do the following:
1. Find and print the "ECM Summary" Screen.
2. Find and print the "Current Totals" Screen.
3. Perform the Injector Solenoid Test. (Hint: See "Diagnostics" Menu, then "Diagnostic
Tests" Menu, then "Injector Solenoid Test" Menu.)
4. Check the throttle position sensor for proper duty cycle. (Hint: See "Service" Menu, then
"Calibrations" Menu, then "Monitor Throttle Position Sensor" Menu.)
5. Press F8 (Function Key 8). What happens?
_________________________________________________________________.
6. Press the F8 key (Function Key 8) again. What happens?
_________________________________________________________________.

8/02
7. Program the F10 key (Function Key 10) so that it will bring up the ECM Summary
Screen when you press it. (Hint: See "View" Menu, then "Custom" Menu, then "Function
Keys" Menu.)
8. Look at Parameters and find the following:
- Total Tattletale = ________
- Low Idle Engine RPM Tattletale = ________
9. Change Low Idle Engine RPM to 750.
10. Find Total Tattletale and Low Idle Engine RPM Tattletale values again:
- Total tattletale value = ________
- Low Idle Engine RPM Tattletale = ________
With engine running, use E.T. to do the following:
11. Start the engine and find the boost pressure in PSI ____________.
12. Switch to metric units and find the boost pressure in KPa ____________.
13. Perform the cylinder cutout test.

8/02
Voltage from C to
Condition Code Boost Pressure
B
A open
B open
C open
A and B shorted
B and C shorted
A and C shorted
A and B switched
Voltage from C to
B
A open
B open
C open
A and B shorted
B and C shorted
A and C shorted
A and B switched
Voltage from C to
B
A open
B open
C open
A and B shorted
B and C shorted
A and C shorted
A and B switched

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SEGQ4031 - 216 - Lesson Plan

Caterpillar Engine Electronics

Tasks Required by Instructor to Meet Objectives:

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harness and cables

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Yesterday, we discussed a wide variety of electronic components. It can

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These are basic to any engine, electronic or mechanical. Weve always

Earlier in the week, we discussed the various engines that Caterpillar

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Each of these symptoms is a clue to the problem. With the possible

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Ask the class the following questions:

Question: What could cause a click, click, click sound?

Question: What could cause the engine to crank at normal starting

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Regardless of whether the engine has a PEEC, EUI, or HEUI fuel

A functional Personality Module: People sometimes dont realize that

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Properly configured parameters: Some parameters will allow the

Parameters are very useful. Programmable with an electronic service

Theft Deterrent is an example of a truck engine parameter that could

3500 Series engines are shipped without oil or coolant, to save

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PEEC engines have four more requirements in order to start (eight

EUI engines have two more requirements (six altogether).

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Now lets consider the EUI and HEUI requirements.

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No Communication: This could be caused by a defective ECM, a

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PTO switch The P.T.O. switch is another example.

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Note to Instructor: If possible, look at this circuit during the diagnostic

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All electronic Components fit into one of

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- Throttle position sensor - Data links - Speedo / Tack