ASE L2 Composite Vehicle 2007

7/29/2019 ASE L2 Composite Vehicle 2007

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ELECTRONICDIESEL ENGINEDIAGNOSISSPECIALISTTEST(L2)

MEDIUM/HEAVYCOMPOSITEVEHICLETYPEREFERENCEBOOKLET

This booklet is intended only for reference when preparing for and taking the ASEElectronic Diesel Engine Diagnosis Specialist (L2) Test. The medium/heavy compositevehicle type 2 control system is based on designs common to many engine and vehiclemanufacturers, but is not identical to any actual production engine or vehicle.

1998 - 2006 National Institute for AUTOMOTIVE SERVICE EXCELLENCE

All rights reserved


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PAGE 1 ASEMEDIUM/HEAVYCOMPOSITE VEHICLE TYPE 2REFERENCE BOOKLET

ASEELECTRONICDIESEL ENGINEDIAGNOSISSPECIALISTTESTMEDIUM/HEAVYCOMPOSITEVEHICLETYPE2INFORMATION

GENERAL DESCRIPTIONThis generic four cycle, in-line six cylinder diesel engine is equipped with aturbocharger, wastegate, charge air cooler, and electronic unit injectors. The enginerating is 330 hp at 1,800 rpm and develops a peak torque of 1150 lb. ft. at 1,200rpm.

THEELECTRONICCONTROLMODULE(ECM)The electronic control module is the microprocessor that receives electronic inputsfrom sensors and switches, and is calibrated to control fuel metering, injectiontiming, diagnostics, and engine protection. The ECM receives power from the battery

and ignition switch and provides a reference voltage for some sensors. The software(instructions) contained in the ECM determines how the electronic diesel enginecontrol system operates. The ECM stores the calibration values that define ratedhorsepower, torque curves, and rpm specifications. The ECM is mounted on theengine.

FUEL SYSTEMFuel supply (transfer) is provided by a positive displacement, mechanically drivenpump. A regulating valve is used to maintain fuel pressure. Fuel delivery is providedby electronically controlled unit injectors. The injector solenoids are energized by theECM.

PROGRAMMABLEPARAMETERSProgrammable parameters are the specifications that can be set within the ECM tocontrol operating functions. The parameters are stored in non-volatile memory. Acustomer password is available for programming protection. A list of parameterranges and their settings are shown below.

Feature Range Setting Feature Range SettingMax Vehicle Speed in Top Gear 35-99 mph 60 mph One Gear Down Ratio .5-1.5 1.0Max Cruise Control Set Speed 35-99 mph 60 mph Min. Engine Cooling Fan On Time 0-999 sec. 240 sec.Min cruise set speed 35-99 35 A/C Pressure Switch On/Off OnMax Engine Speed with VSS Signal 1600-2500 rpm 2100 rpm PTO / Remote PTO:Max Engine Speed w/o VSS Signal 1200-2500 rpm 1800 rpm max PTO speed 600-2500 rpm 1000 rpm

Idle Set Speed 600-850 rpm 700 rpm min PTO speed 600-2500 rpm 700 rpmGear Down Max Vehicle Speed: 35-99 mph 58 mph set PTO speed 600-2500 rpm 900 rpmCruise Control and Engine Brakes: mph above cruise set speed resume PTO speed 600-2500 rpm 900 rpm

engine brake low 1-20 mph 6 mph remote PTO speed 600-2500 rpm 1000 rpmengine brake medium 1-20 mph 6 mph Idle Shutdown Timer 3-60 min. 5 min.engine brake high 1-20 mph 8 mph Tire Revolutions per Mile 400-700 501

Road Speed Governor Droop 0-4 mph 2 mph Rear Axle Ratio 2.50-12.0 4.10Max Progressive Shift Speed 1500-2500 rpm 1800 rpm # of VSS Wheel Teeth 5-16 16Mph at Max Progressive Shift Speed 6-99 mph 18 mph Engine Braking with fan On/Off OnEngine Protection System warning/

derate/shutdownshutdown Engine Cooling Fan Enable/

DisableEnable


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ASEMEDIUM/HEAVYCOMPOSITE VEHICLE TYPE 2REFERENCE BOOKLET PAGE 2

ENGINEPROTECTIONSYSTEMThe engine protection system monitors coolant temperature, coolant level, oiltemperature, intake manifold temperature, oil pressure, and fuel temperature. Thesystem has three levels of protection: warning, derate, and shutdown.In the warning mode, the yellow warning/diagnostic lamp alerts the operator of a

potential problem. In the derate (limp home) mode, the ECM will gradually reduceengine power after lighting the red warning/diagnostic lamp. Power derating willbegin 30 seconds after the initial warning. The shutdown mode will activate forengine coolant temperature, coolant level, engine oil pressure, orengine oiltemperature failures only. Shutdown will occur when the condition reaches a presetvalue, after the warning and derate modes have been activated. The engineprotection override switch can be used to temporarily override the shutdown mode.

High EngineCoolantTemperatureThe ECM will turn the engine cooling fanon at 205F.

Engine Coolant Power Derate/Temperature Shutdown

210 F 100% Power215 F 75% Power220 F 50% Power225 F 25% Power230 F Shutdown

High Engine Oil TemperatureThe ECM will turn the engine cooling fan

on at 245F. Power derate begins whenthe oil temperature reaches 260 F.Shutdown occurs after 2 minutes if thetemperature remains high.

High Intake Manifold TemperatureECM will turn the engine cooling fan on at190F. Power derate begins when themanifold air temperature reaches 210 F.

A 60% power derate remains if thetemperature stays high.

ENGINEOPERATINGSPECIFICATIONS

Fuel Pressure - Cranking: 20 psi. min.Rated rpm: 90-100 psi.

Engine Coolant Temperature 195 F

Low Engine Coolant LevelAfter the initial warning, shutdown willoccur if the coolant level remains low.

Low Engine Oil PressurePower derate/shutdown set points aredependent on the relationship between oilpressure and engine speed. If the oilpressure falls below these specifications,power derate will begin, and shutdown willoccur if oil pressure continues to decrease.

Engine Oil PressureEngine Speed Begin Derate Shutdown

2000 rpm 40 psi 20 psi1800 rpm 35 psi 17 psi1400 rpm 25 psi 12 psi1000 rpm 15 psi 8 psi

600 rpm 5 psi 2 psi

High Fuel TemperatureA power derate begins when the fuel

temperature reaches 180F. A 60% powerderate remains if the temperature stayshigh.

Engine Oil Pressure - Idle: 15-35 psi. min.Rated rpm: 50-70 psi.

Engine Oil Temperature 210 F

Turbo Boost Pressure - Rated rpm and load: 20-30 psi.


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SENSORSThrottle Position Sensor (TPS)

The TPS is a potentiometer that senses the position of the accelerator pedal. Areference voltage is sent to the TPS, and as the angle of the accelerator pedalchanges, the TPS varies the signal voltage to the ECM. This sensor includes an

integral idle validation switch (IVS). (PID 91)

Engine Oil Pressure Sensor (EOP)The solid-state EOP sensor monitors engine oil pressure, and is installed in themain lube oil gallery. The ECM uses this signal for engine protection. (PID 100)

Boost Pressure Sensor (BP)The solid-state BP sensor monitors positive intake manifold pressure, and islocated on the intake manifold. The ECM uses this signal to control fuel meteringand injection timing and to limit smoke during acceleration. (PID 102)

Intake Manifold Temperature Sensor (IMT)The IMT sensor monitors air temperature in the intake manifold. The ECM usesthis signal to control injection timing, fuel metering, engine protection, and fancontrol. (PID 105)

Barometric Pressure Sensor (BARO)The solid-state BARO sensor monitors ambient air pressure, and is located onthe side of the engine block. The ECM uses this signal to adjust fuel timing andmetering based on altitude. (PID 108)

Engine Coolant Temperature Sensor (ECT)

The ECT sensor monitors coolant temperature in the engine block, and ismounted in the engine coolant jacket. The ECM uses this signal to control fuelmanagement and fan operation. During an overheating situation, it is also usedfor engine protection. (PID 110)

Coolant Level Sensor (CL)The CL sensor detects the presence or absence of coolant at the probe, and islocated in the radiator top tank. The ECM uses this signal for engine protectionwhen coolant is not detected. (PID 111)

Fuel Temperature Sensor (FT)

The FT sensor monitors fuel temperature, and is mounted on the secondary fuelfilter housing. The ECM uses this signal to adjust calculated fuel measurementsin order to compensate for fuel temperature changes and for engine protectionwhen the fuel is overheated. (PID 174)


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SENSORS(CONTINUED)Engine Oil Temperature Sensor (EOT)The EOT sensor monitors engine oil temperature, and is installed in the main lube oilgallery. The ECM uses this signal for the engine protection. (PID 175)

Engine Position Sensor (EPS)The EPS is a Hall-effect sensor that generates a digital signal whose frequencyvaries with the speed of the engine. The ECM uses the frequency and pulsewidthof this signal to determine engine speed and cylinder position for fuel control andinjector timing. The EPS is located in the engine front cover facing the triggerwheel which is mounted on the camshaft gear. (PID 190)

Vehicle Speed Sensor (VSS)The magnetic pick-up VSS measures vehicle speed at the transmission output.The ECM uses this AC voltage signal for the speedometer, cruise controloperation, and vehicle (road) speed limiting. (PID 84)

Inlet Air Temperature Sensor (IAT)The inlet air (ambient) temperature sensor monitors air temperature in the inletpipe before the turbocharger. The ECM uses this signal for fuel managementduring cold start operation. (PID 171).

SWITCHESEngine Cooling Fan Manual Switch

This is a normally open switch that, when closed by the operator, requests thatthe ECM deenergize the engine cooling fan solenoid. This will cause the coolingfan to operate continuously.

Diagnostic On/Off SwitchThis is a normally open momentary switch that, when pressed and released,requests that the ECM enter diagnostic mode. The yellow warning/diagnosticindicator lamp will come on and flash inactive fault codes. The redwarning/diagnostic indicator lamp will come on and flash active fault codes. Ifboth lights remain on only momentarily, no fault codes are present. Inactivecodes can be erased by disconnecting the unswitched ECM circuit breaker for 10seconds.

Air Conditioning High Pressure Switch

This normally closed pressure switch opens when the air conditioner high-sidepressure reaches a preset value. This signals the ECM to operate the enginecooling fan. (SID 228)


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SWITCHES(CONTINUED)Idle Validation Switch (IVS)

The IVS is an integral part of the throttle position sensor (TPS). This two-positionswitch indicates idle position when one set of contacts is closed, and off-idleposition when the other set of contacts is closed. For safety, the ECM will

command idle speed whenever the off-idle position contacts are open, regardlessof the signal from the TPS. When the IVS is in the idle position, the displayeddata screen shows on, and if the IVS is in the off-idle position, the display datashows off. (SID 230)

Cruise Control On/Off SwitchThis normally open switch enables cruise control operation when it is closed bythe operator. (SID 244)

Cruise Set/Resume SwitchThis switch has two momentary positions: set/coast and resume/accelerate.

Vehicle cruising speed can be set by pressing the set switch. Once a speed hasbeen set, and then disengaged using the brake or clutch, the ECM will return tothe previously set speed when the resume switch is pressed. (Set - SID 243,Resume - SID 242)

Clutch SwitchThis normally closed switch opens when the clutch pedal is depressed. Thissignals the ECM to cancel cruise control, power take-off mode, and enginebraking, and to override the idle shutdown timer. (SID 245)

Service Brake Switch

This normally closed pressure switch opens when the service brake pedal isdepressed. This signals the ECM to enable engine braking, cancel cruise controland power take-off mode, and to override the idle shutdown timer. (SID 246)

Engine Brake On/Off SwitchThis normally open switch enables engine brake operation when closed by theoperator. (PID 121)

Engine Brake Selector SwitchThis three-position switch sets the level of engine braking (low, medium or high).(Low/High - PID 121, Med/High - PID 122)

Power Take-Off (PTO) On/Off SwitchThis normally open switch enables PTO mode operation when closed. In thismode, the cruise control switches are used to set and hold engine speed. (PID150)


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SWITCHES(CONTINUED)Power Take-Off (PTO) Remote Switch

This normally open switch is mounted outside the cab and enables remote PTOmode operation when closed. (PID 150)

Engine Protection Override SwitchThis is a normally open momentary switch that, when pressed and releasedduring the shutdown warning period, requests that the ECM override (delay) anengine protection shutdown for 30 seconds.

ACTUATORSElectronic Unit Injectors (EUI)

These electromechanical diesel fuel injectors contain a solenoid controlled by theECM to manage fuel timing and metering. The injector solenoid driver circuitry inthe ECM sends a high voltage signal to energize the injector solenoid. Injectorcalibration codes need to be programmed into the ECM to compensate for

manufacturing tolerances. (SID 1, 2, 3, 4, 5, 6)

Engine Cooling Fan SolenoidWhen energized by the ECM, this normally closed solenoid supplies air pressureto disengage the engine cooling fan clutch and turn the fan off. The solenoid canbe de-energized by the ECM, shutting off air pressure to engage the fan clutchand turn the fan on. The ECM engages the fan during engine braking when theselector switch is in the high position and for engine protection. The ECM will

operate the fan when coolant temperature reaches 205F, engine oil temperature

at 245F, and intake manifold temperature at 190F. (SID 33)

Warning/Diagnostic Indicator Lamps

The Red "stop engine lamp" (SEL) lights when the engine protection system is inthe derate and shutdown modes. The Red lamp can also be used to read activefault flash codes when in the diagnostic mode. (SID 238)

The Yellow "check engine lamp" (CEL) lights when the engine protection systemis in the warning mode, or when electronic control system failures are occurringand an active fault is present. The Yellow lamp can also be used to read inactivefault flash codes when in the diagnostic mode. (SID 239)

Engine Brake SolenoidsThese three solenoids can be energized by the ECM to provide engine brakingon two, four or all six cylinders. The engine brake can be operated in cruisecontrol (switch on) and will be energized after the set speed has been exceededor when the service brake pedal is depressed and the throttle pedal is released.The ECM will not energize the solenoids when the clutch pedal is depressed.(Low/High Solenoid - PID 121, Med/High Solenoids - PID 122)


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ACTUATORS(CONTINUED)Wastegate Controller Solenoids

These two turbocharger wastegate solenoids (drivers) are energized by the ECMto provide quick turbocharger response, and turbocharger overspeed/overheatprotection. Opening the wastegate decreases turbine speed (low boost

pressure). Closing the wastegate increases turbo speed (high boost pressure).The ECM has a 4-step control strategy for wastegate operation:Setting 0 - Wastegate fully opened; very low boost; driver 1 ON/driver 2 OFFSetting 1 - Minimal wastegate closure; nominal boost; driver 1 OFF/driver 2 OFFSetting 2 - Partial wastegate closure; high boost; driver 1 ON/driver 2 ONSetting 3 - Wastegate closed; maximum boost; driver 1 OFF/driver 2 ON(SID 32)

DATA LINKCONNECTORS The J1939 data link allows the ECM to communicate with other vehicle controlsystems such as transmission, automatic traction control, and anti-lock brake

controllers. (SID 231) The J1587 data link is used by an electronic Diagnostic Tool to communicate withthe ECM. This allows for diagnostic information retrieval and parameter calibrationsetting. (SID 250)The 9 pin ATA type data link connector is located in the cab.

DIAGNOSTICEQUIPMENTA Breakout Tool can be connected into a circuit to measure voltage signals andresistance values with a DMM (Digital Multimeter). A Diagnostic Tool (Scan, PCbased) can be connected to the ATA data link connector to read engine data,diagnostic codes, and set programmable parameters. The Displayed Data chartbelow shows how Diagnostic Tool data will be presented in some test questions. If arange of values is given, the sensor reading is varying in that range.

DISPLAYED DATAEngine Coolant Temperature (ECT) FIntake Manifold Temperature (IMT) FEngine Oil Temperature (EOT) FFuel Temperature (FT) FEngine Oil Pressure (EOP) psiBoost Pressure (BP) psiBarometric Pressure (BARO) In.HgThrottle Position (TPS) %

Idle Validation Switch (IVS) On/OffEngine Position (EPS) rpmVehicle Speed (VSS) mphBattery Voltage (B+) VoltsCoolant Level (CL) Normal/LowInlet Air Temperature (IAT) FEngine Cooling Fan Command On/OffWastegate Solenoid 1 Command On/OffWastegate Solenoid 2 Command On/OffCruise Control Set Speed mph

Cruise Control Switch On/OffCruise Control Set/Coast Switch On/OffCruise Control Resume/Accel Sw On/OffPTO Switch On/OffRemote PTO Switch On/OffEngine Cooling Fan Switch On/OffA/C High Pressure Switch Open/ClosedClutch Switch Depressed/Released

Service Brake Switch Depressed/ReleasedEngine Brake Switch On/OffEngine Brake Selector Low/Med/HighProtection Override Switch On/OffDiagnostic Lamp - Yellow On/Off

- Red On/OffDiagnostic Trouble Codes

Active:Inactive:


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IDENTIFIERSDiagnostic Trouble Codes (DTC)

Trouble codes can be active or inactive. Active codes indicate that the problemcurrently exists and inactive codes indicate that a problem once existed. Flashcodes represent digits assigned to diagnostic trouble codes, so that DTCs can be

retrieved through the diagnostic lamps. Active codes are indicated by the redstop engine lamp (SEL). Inactive codes are indicated by the yellow check enginelamp (CEL). When using the diagnostic tool, DTC's are formatted under SAEJ1587 standards. The first set of numbers is the Parameter or SubsystemIdentifier and the second set is the Failure Mode Identifier. Both can be retrievedand cleared from the ECM via the data link.

SubSystem Identifier (SID)The SID is a one, two, or three digit code assigned to identify a section of acontrol system without a related parameter identifier.

Parameter Identifier (PID)The PID is a two or three digit code which is assigned to each component.

Failure Mode Identifier (FMI)The FMI is a one or two digit code that describes the type of failure detected inthe system component.

FAILURE MODE IDENTIFIERS (FMI)

Number Description

0 Data valid but above normal operational range1 Data valid but below normal operational range2 Data erratic, intermittent, or incorrect3 Voltage above normal or shorted high4 Voltage below normal or shorted low5 Current below normal or open circuit6 Current above normal or grounded circuit7 Mechanical system not responding properly8 Abnormal frequency, pulse width, or period9 Abnormal update rate

10 Abnormal rate of change11 Failure mode not identifiable12 Bad intelligent device or component13 Out of calibration14 Special instructions


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PID/SIDCODELISTINGCode Description Flash CodeS1 Cylinder 1 11S2 Cylinder 2 12S3 Cylinder 3 13

S4 Cylinder 4 14S5 Cylinder 5 15S6 Cylinder 6 16S32 Wastegate Controller Solenoid 17S33 Engine Cooling Fan Solenoid 18P71 Idle Shutdown 19P84 Vehicle Speed Sensor 20P91 Throttle Position Sensor 21P100 Engine Oil Pressure Sensor 22P102 Boost Pressure Sensor 23P105 Intake Manifold Temperature Sensor 24

P108 Barometric Pressure Sensor 25P110 Engine Coolant Temperature Sensor 26P111 Engine Coolant Level Sensor 27P121 Engine Brake Solenoid Lo/Hi 28P122 Engine Brake Solenoid Med/Hi 29P150 PTO On/Off Switch 30P168 Battery Supply 31P171 Inlet Air Temperature Sensor 32P174 Fuel Temperature Sensor 33P175 Engine Oil Temperature Sensor 34P187 PTO 35

P190 Engine Position Sensor 36S228 A/C High Pressure Switch 37S230 Idle Validation Switch 38S231 J1939 Data Link 39S232 5 Volt Supply 40S238 Warning/Diagnostic Lamp-Red 41S239 Warning/Diagnostic Lamp-Yellow 42S242 Cruise Control Resume Switch 43S243 Cruise Control Set Switch 44S244 Cruise Control On/Off Switch 45S245 Clutch Switch 46

S246 Service Brake Switch 47S250 J1587 Data Link 48S252 Incorrect Engine Software 49S253 Check System Parameters 50S254 ECM 51NOTE: S = System Identifier (SID)

P = Parameter Identifier (PID)


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ELECTRICALSPECIFICATIONSJ1587 Data Link

Positive Wire to chassis ground:2.5 to 5.0 VDC

Negative Wire to chassis ground:

0.0 to 2.5 VDCJ1939 Data Link

Positive wire to negative wire:50 to 70 ohms

Resistance of termination resistors:110 to 130 ohms

ECM9.0 to 16.0 VDC supply voltageMaximum voltage drop on allcircuits (except injectors): 0.05 VDC

All Shorts to External VoltageOK: if less than 1.5 VDC

5 V Reference Power SupplyAt ECM: 4.75 to 5.25 VDC

At Harness: 4.75 to 5.25 VDCAll Shorts to Ground

OK: If greater than 100K ohms(No short circuit)

All Continuity ChecksOK: if less than 10 ohms(No open circuit)

Fuel Injectors0.5 to 5.0 ohms resistance100 to 120 VDC supply voltage

Wastegate Solenoid

Coil Resistance: 7 to 8 ohms

SENSORSPECIFICATIONSVehicle Speed Sensor

Coil Resistance: 1100 to 1500 ohmsThrottle Position Sensor

Potentiometer Resistance:Between supply and return wires:

2000 to 3000 ohmsBetween supply and signal wires:

released pedal -

1500 to 3000 ohmsdepressed pedal -200 to 1500 ohms

Released minus depressed: Must begreater than 1000 ohms

Boost Pressure SensorPressure Voltage

psig in. Hg VDCatmospheric atmospheric 0.42 - 0.58

12.5 25.45 1.42 - 1.5825.0 50.90 2.42 - 2.58

37.5 76.35 3.42 - 3.5850.0 101.80 4.42 -4.58

Coolant Level SensorCoolant present: CL Normal signal =

5 VDC, CL Low signal near 0 VDCCoolant NOT present: CL Low signal

= 5 VDC, CL Normal signal near 0 VDC

Barometric Pressure SensorPressure Altitude VoltageIn. Hg. feet VDC29.9 0 (sea level) 4.0 - 4.626.8 3000 3.6 - 4.424.0 6000 3.2 - 4.021.4 9000 3.0 - 3.8

19.1 12000 2.6 - 3.4Engine Oil Pressure Sensor

Pressure VoltagekPa psi VDC

0 0 0.4 - 0.6172 25 1.4 - 1.6345 50 2.4 - 2.6517 75 3.4 - 3.6689 100 4.4 - 4.6

All Temperature SensorsTemperature Voltage

C F VDC-40 -40 0.50

0 32 0.7532 90 1.5054 130 2.5082 180 3.60

120 248 4.50


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ASE L2 Composite Vehicle 2007

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