313 Powertrain Electronics

Basic Electrical Review

• Three (3) parts to electricity:
– V = Voltage = electrical “pressure”

– A = Amps or Amperage (or Current)

= electrical “flow rate”

– Ω = Ohms or resistance= electrical

flow resistance (more resistance
= slower/lower flow rate)
 Basic Electrical Review
• Current (“pushed” by voltage) wants
to return to the source: battery

• Resistance = load

• Circuits need resistance to eliminate

the voltage push on the current
 Basic Electrical Review
6Ω
6Ω

12 volts 0 volts

2 amps 2 amps
 Basic Electrical Review
• Electricity/Electronics do 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)
 Review - Sensor Circuit Types
• Variable Voltage (Modify reference voltage)
• Temperature: Coolant, Intake and Exhaust gases
• Pressure: Intake and exhaust gases
• Position: EGR valve, BPV, throttle pedal position
• Rotational Speed: Water pump
• Variable Frequency (AC voltage generators)
• Rotational Speed: Crank/Cam Position; Turbo Speed
• Gas analysis (generate voltage)
• Lambda: Exhaust gas O2 content
• Smart Devices (communicate info on CAN buses)
• Humidity Sensor: Intake air temp, humidity, pressure
• NOx: Engine out NOx, Exhaust out NOx
 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:

– Normal: 0.25 - 4.75 V

– Operating: 0.5 - 4.5 V

 Basic Electrical Review
• System (Temperature) Out-of-Range:
– Low: 0.25 - 0.5 V = -40° F/C

– High: 4.5 - 4.75 V = 554°/1472°F (290/800 C)

• Voltage Out-of-Range:
– Low: 0.0 - 0.25 V

– High: 4.75 - 5.0 V

 Basic Electrical Review
• Three Wire Temperature Sensor Signal
Voltages:

– Normal: 0.25 - 4.75 V

– Operating: 0.5 - 4.5 V

 Basic Electrical Review
• System Out-of-Range:
– Low: 0.25 - 0.5 V = Minimum
Pressure/Position

– High: 4.5 - 4.75 V = Maximum

Pressure/Position

• Voltage Out-of-Range:
– Low: 0.0 - 0.25 V
– High: 4.75 - 5.0 V
 Sensor Voltage Range Graph
Electronic Circuit / Sensor Fault
System or Unlikely Fault

VORL SORL SORH VORH

0.5 4.5
0.25 Normal System Range 4.75

0.0 5.0
Circuit Operating Range
 Basic Electrical Review
• Diagnostic Hints:

– DAVIE: With sensor unplugged (and good power,

ground, and wiring), Individual Component
Monitor will show reference voltage and/or max
or min temp/press/position value.

– Also: watch for CHANGE in reading on DAVIE

when unplugging/re-plugging connector.
 Basic Electrical Review
Two Wire Inductive Speed Sensor Circuit

Signal

V
Ground / return

ECU
 Basic Electrical Review
• Two Wire Inductive Pick-up Speed Sensors:

– Coiled wire around permanent magnet; wire

ends return to ECU as Signal and Ground Wires

– Magnet positioned near rotating tone wheel

 Basic Electrical Review
• Two Wire Inductive Pick-up Speed Sensors
(cont.) :
– As tone wheel “tooth” passes magnet, magnetic field
around wires shifts, generating voltage pulse

– Voltage pulses compared against internal ECU clock to

determine frequency

– Pulse frequency converted to RPM inside ECU

 Basic Electrical Review
Other Sensors:
• Hall Effect
– detects RPM
– three wire; 5V Ref, Signal, ground; similar to other
three wire 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 (at ECU):
• 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)

– Pintle held closed/at rest by return spring

– Energizing coil causes electromagnetic field to

move pintle against return spring
 Basic Electrical Review
• Actuator operation (cont.) :
– De-energizing coil causes electromagnetic field to
collapse; return spring returns to rest position

– Coil energized with PWM

 Basic Electrical Review
• Pulse Width Modulation (PWM):
– ECM turns on/off a ground (and sometimes
power as well depending on the circuit)

– Switch closes (voltage ON) at regular,

periodic intervals

– Length of time switch is closed varies

– Low DUTY CYCLE = short ON time

– High DUTY CYCLE = long ON time
 Basic Electrical Review
Low Duty Cycle
12V
Voltage applied
to actuator is
average of on
0V time vs. length
of clock period
Pulse
High Duty Cycle
12V i.e. 50% Duty
Cycle = 6 V
applied to the
actuator
0V

Pulse

Period = fixed by ECM clock

 Basic Electrical Review
Actuator Circuit
ECU
Circuit ON
 Actuator
12V B+ Power

ECU Coil

Ground

Flow Off
 Actuator
12V B+ Power

ECU Pintle

Ground

Flow Off
 Actuator
12V B+ Power

ECU Return Spring

Ground

Flow Off
 Actuator
12V B+ Power

ECU

Ground

Flow Off
 Actuator
12V B+ Power

ECU

Ground

Flow ON
 Basic Electrical Review
Actuator Circuit
ECU
Circuit OFF
 Actuator
12V B+ Power

ECU

Ground

Flow ON
 Actuator
12V B+ Power

ECU

Ground

Flow OFF
 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!)

– w/DAVIE connected and system powered up,

monitor circuit in question while unplugging
connector – should see a change in reading if ECU
and wiring to/from are good
 Basic Electrical Review
• Basic Testing (continued) :
– Consult Rapido for additional testing parameters;
i.e. resistance or voltage spec

– Check for:
• Corrosion at connection points
• Reference or supply voltage
• Ground back to ECU, Chassis, and Batt
 Sensor Voltage Range Graph
Electronic Circuit / Sensor Fault
System or Unlikely Fault

VORL SORL SORH VORH

0.5 4.5
0.25 Normal System Range 4.75

0.0 5.0
Circuit Operating Range
2010 CAN Buses
A-CAN Aftertreatment Controller Area Network

B-CAN Body Controller Area Network

C-CAN Cab Controller Area Network

D-CAN Diagnostic Controller Area Network

E-CAN Engine Controller Area Network

F-CAN Frame Controller Area Network
I-CAN Instrumentation Controller Area Network

V-CAN Vehicle Controller Area Network

 Review - Sensor Circuit Types
• Variable Voltage (Modify reference voltage)
• Temperature: Coolant, Intake and Exhaust gases
• Pressure: Intake and exhaust gases
• Position: EGR valve, BPV, throttle pedal position
• Rotational Speed: Water pump
• Variable Frequency (AC voltage generators)
• Rotational Speed: Crank/Cam Position; Turbo Speed
• Gas analysis (generate voltage)
• Lambda: Exhaust gas O2 content
• Smart Devices (communicate info on CAN buses)
• Humidity Sensor: Intake air temp, humidity, pressure
• NOx: Engine out NOx, Exhaust out NOx
 Review - Sensor Circuit Types
• Temperature – Variable Voltage
• Pressure – Variable Voltage
• Pressure Differential – Variable Voltage
• Position – Variable Voltage
• Speed (rotation) – Variable Frequency AC
• Speed (rotation) – Variable Frequency DC
• Gas Analysis – Data Bus
• Humidity – Data Bus
Temperature Sensors
Temperature Sensors
Temperature Sensors - PTC
Temperature Sensors - NTC
Pressure Sensors
Pressure Sensors
Pedal Position Sensor
EGR Position Sensor
BPV Position Sensor
BPV Position Sensor
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – AC
Rotation – Hall Effect
Rotation – Hall Effect
Rotation – Hall Effect
Coolant Level
Gas Analysis – Lambda (λ)

12V
Gas Analysis: NOx
Humidity
Humidity
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:

• …receive information from sensors (Input);

• …perform calculations and logic decisions based
on software instructions;
• …send operational commands to various
actuating devices (Output);
• …and monitor the outcome of its commands via
the Input and other sensors (Feedback);

• …and the cycle repeats

 Fuel Characteristics
Accelerator Pedal
Fuel Temperature
Driver Demand

Fuel Delivery Pressure

A to D

Load
Crank Sensor CPU Lambda

Air Mass Inlet Air Temps. Injector MAP

Turbo Boost
Injector Selection Cam Sensor

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

NOx AECU / EAS-3 Injectors

Lambda
CEL / MIL
Veh Speed
CAN bus
CAN Bus Information

System Inputs System Outputs

• Sensor / System Monitors:

– Sensors modify a reference voltage based on operating

conditions in the subsystems (EGR,
DPF, SCR, etc.)

– The computers monitor the input voltages and

use that information to monitor the overall subsystem
operation

– Monitor criteria (when/how often) can vary but

generally depends on engine run or off time, ign key
cycles, and/or drive or warm up cycle parameters
Fault Codes:
Example 1)
Monitor
criteria:
Fault Codes:
Example 2)
Monitor
criteria:
 Fault Codes – Set Criteria:

– Fault codes are set when:

• Monitored sensor voltage is currently a value
that was or is not expected by the ECM

AND / OR

• Monitored subsystem operation is currently

faulty, as calculated from sensor inputs and
software models
Fault Codes:
Example 1)
Set Criteria:
Fault Codes:
Example 2)
Set Criteria:
• Fault Codes - Types of Codes:
• Active vs. Inactive
• System Parameter Out of Range – High or Low
• Sensor Voltage Out of Range – High or Low
• Plausibility Faults
• Irrationality Faults
• CAN Message Rate too High/Low
• Filter or Catalyst Efficiency
• Cascading Faults
• Fault Codes - Active vs. Inactive
– Active Fault Codes:

• Active codes set because:

– The sensor or system monitor

conditions have been met
– The monitor HAS run
– A possible fault has been found
• Fault Codes - Active vs. Inactive
– Active Fault Codes:

• Codes remain Active because:

– Monitors continue to run and the faulty

conditions have not changed

– OR –

– Faulty conditions may have changed back

to acceptable but the monitor has not run
again to discover the change
• Fault Codes - Active vs. Inactive

– Inactive Fault Codes:

• Active Codes will change to Inactive when:

– The operating conditions of the sensor or system

have changed to an acceptable reading

– 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

• ECM reads sensor voltage and calculates a value

• Calculated value is compared to an expected range

based on other, related parameters

• Fault code sets if/when the calculated value falls

outside of the expected range

• 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

• If sensor voltage is too high or too low the ECM sets

a fault code.

• This fault code type –set at the extreme ends of the sensor value range-
is due to an ELECTRICAL CIRCUIT problem

• Example…
• Boost temp
sensor signal
input
monitored on
pin A43

• If voltage goes
below
programmed
value, fault
code sets
• Fault Codes:
– Plausibility Faults

• ECM compares input data to programmed possibilities

• If input data is not found to be “plausible” (likely) a

Plausibility Fault is set

• Example…
• Vehicle speed
increase is
monitored

• If signal value is
outside of an
expected range,
code sets
• Fault Codes:
– Irrationality Faults

• ECM converts sensor voltage to a parameter value (i.e. temperature,

pressure, etc.) and compares this calculation
to its expectations…

• …If sensor or system parameter is outside of the range

of expected values (i.e. very high engine temperature
after engine off for 10 hours) ECM believes reading to “impossible” and
an irrationality fault code is set.

• 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:

• ECM monitors multiple sensor inputs and calculates

an “actual” efficiency and compares it to its programmed
software efficiency expectations

• Efficiencies below a preset threshold will cause the

ECM to set a fault code

• 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

• Higher order faults that automatically trigger other,

faults

• When multiple fault codes are set, refer to Rapido

for hints or instructions on where to begin – i.e.
which faults to trouble shoot first/last, etc.

• 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:

– Cascade Faults - Additional information

• Some Cascade Faults are ONLY triggered by higher

order fault codes – these codes have no diagnostic
information and Rapido refers you directly to the code
that caused the cascade fault

• Other Cascade Faults MAY be triggered by higher or equal

order fault codes, or they MAY be triggered individually
– These codes generally refer you to the other code first if it
has been set, otherwise Rapido will have discrete diagnostic information for the code