Evaluar el sistema electrico.pdf

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Caterpillar Engine Electronics

Lesson Plan 16 - Troubleshooting / Scenarios

Objectives:

The student will gain familiarity with the Electronic Troubleshooting Guide and the

diagnostic process.

The student will be able to recall the electronic components needed to start a PEEC,

EUI, and HEUI engine.

The student will be able to follow the troubleshooting scenarios created in the slide

package.

Literature Needed:

Electronic Troubleshooting Guide SENR5582

PowerPoint Slides

Hardware Needed:

Projector and smartboard

Time Required:

2.75 Hours

Tasks Required by Instructor to Meet Objectives:

1. Present the slides.

2. Explain and review the various topics outlined in the slides pertaining to the

Troubleshooting Guide.

SEGQ4031 - 271 - Lesson Plan

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LAST PRINT SECTION EXIT MAIN NEXT


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Slide # 187

PEEC 8 to start

Components Needed To StartComponents Needed To Start

PEEC has 8PEEC has 8

#2 ECM#2 ECM

#3 P.M.#3 P.M.

#4 Parameters#4 Parameters

#1 POWER

+ Battery

- Battery

#1 POWER

+ Battery

- Battery

#5 Speed sensor

#6 Shut-off solenoid

#7 BTM

#8 Rack position sensor

#5 Speed sensor

#6 Shut-off solenoid

#7 BTM

#8 Rack position sensor

As we discussed earlier, PEEC has eight electronic components needed

to start.

1. Positive and negative battery no power, no start

2. Functional ECM

3. A personality module typically, if communicating with the ECM

the top three are good.

4. Parameters

5. Speed sensor ECM must see engine speed

6. Shutoff solenoid shutoff solenoid must be out of the way of the

rack

7. Rack BTM must have movement of the rack

8. Rack position sensor ECM must know the position of the rack

SEGQ4031 - 272 - Slide/Text Reference

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Slide # 188

EUI 7 to start


EUI has 6EUI has 6

#2 ECM#2 ECM

#3 P.M.#3 P.M.


#1 POWER

+ Battery

- Battery

#1 POWER

+ Battery

- Battery

#5 Speed/Timing sensor

#6 Good Injectors


#6 Good Injectors

EUI engines need six properly functioning electronic components to

start.

Like PEEC, EUI needs:

- positive and negative battery

- ECM

- P.M.

- Parameters

However, EUI additionally needs:

- speed/timing signal

- good injectors


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Slide # 189

HEUI 7 to start


HEUI has 7HEUI has 7

#2 ECM#2 ECM

#3 P.M.#3 P.M.


#1 POWER

+ Battery

- Battery

#1 POWER

+ Battery

- Battery


#6 Good Injectors

#7 IAPCV


#6 Good Injectors

#7 IAPCV

A HEUI engine needs seven electronic components to start:

1. Positive and negative battery no power, no start

2. Functional ECM main control

3. A personality module must have the software

4. Parameters theft deterrent, typically, if communicating with theECM the top four are good.

5. Speed/Timing sensor ECM must see engine speed while cranking.

6. Injectors properly functioning injector solenoids (click test)

7. Injection Actuation Pressure Control Valve controls the correct

pressure for starting (min. psi 3126 725, 3126B/E 870).


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Slide # 190

Gather information

The Diagnostic ProcessThe Diagnostic Process

Gather information Driver Questionnaire

Questionnaire response

Performance effect of active diagnostic codes

Check the repair history

What happened, in what order

Gather information Driver Questionnaire

Questionnaire response

Performance effect of active diagnostic codes

Check the repair history

What happened, in what order

Discuss the information gathering process. This can be a key in

troubleshooting. Typically, the more information that is gathered, the

better the chances of solving the complaint.

The information listed here assists fact finding:

- Driver Questionnare

- Questionnare response

- Performance effect of active diagnostic codes

- The repair history

- Order of occurrence

Note: See Electronic troubleshooting Guide SENR5582 as a reference.


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Slide # 191

Verification


Verify operational problems Is the complaint due to misunderstanding of

parameters

Is the complaint due to a change of parameters

Is the engine performing as expected Is the problem repeatable

Verify operational problems Is the complaint due to misunderstanding of

parameters

Is the complaint due to a change of parameters

Is the engine performing as expected Is the problem repeatable

Once the information has been gathered, try to repeat the problem.

Some complaints are due to misunderstandings or a parameter that has

been changed. For instance, if a new or different driver is operating a

unit with gear-down protection programmed. (Gear Down Protection

allows a setting of an engine rpm limit for the higher gears that ensures

cruising speed can only be reached in top gear). This may generate a

performance complaint because the operator is not use to the rpm

limiting with his other truck.


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Slide # 192

Active codes


Determine probable causes Repair ACTIVE diagnostic codes first

What subsystem could cause the problem

What subsystem does the troubleshooting guide

suggest

Determine probable causes Repair ACTIVE diagnostic codes first

What subsystem could cause the problem

What subsystem does the troubleshooting guide

suggest

An active diagnostic code may be the reason for a complaint. Active

diagnostic codes should be troubleshot and repaired first. Troubleshoot

active codes with the appropriate Electronic Troubleshooting Guide.

Follow step by step in the guide. Do NOT skip steps.


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Slide # 193

Narrow list

Logged codes

Status screen


Narrow the list of causes Use driver information

Check LOGGED diagnostic codes

Check STATUS SCREENS

If more than one symptom, look for commoncauses

Avoid PRE-CONCEIVED IDEAS

Narrow the list of causes Use driver information

Check LOGGED diagnostic codes

Check STATUS SCREENS

If more than one symptom, look for commoncauses

Avoid PRE-CONCEIVED IDEAS

It is important in the troubleshooting procedure to shrink the list of

causes. We can narrow the list by using driver information, verifying

logged codes, and checking the status screens.

If there are no active codes, check the logged codes that could be

causing the symptom or complaint.

In addition, the status screen may assist in the troubleshooting

procedure. Verify that temperatures and pressures are correct for key

on, engine off. For example, if the fuel temperature in the status screen

shows 200 + degrees F with the key on, engine off, and the engine has

not been running, there could be a polarity problem. (wires are

swapped). The temperature of the fuel should be approximately the

ambient temperature. In this example, it is possible to have a

performance complaint.


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Commons

Pre-conceived

ideas

If there is more than one problem, investigate for common causes such

as, common wires, grounding studs and the ECM.

Stay away from Pre-Conceived Ideas. Do Not make any conclusions

until all the facts have been gathered.


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Slide # 194

Basics of

electronic t/s


Test subsystems Use procedure in manual

Connector checks are extremely important

Check every pin, socket, and wire

Test subsystems Use procedure in manual

Connector checks are extremely important

Check every pin, socket, and wire

The most common starting point for troubleshooting all electronics are

the connectors. It is extremely important to check every pin, socket,

and wire.

Perform 10 pound pull test on each of the wires associated with the

component.

All connectors/pins/sockets should be completely mated/inserted, and

the harness/wiring should be free of corrosion, abrasion, or pinch points.

Refer to SENR5582 and PB-10: Inspecting Electrical Connectors.


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Slide # 195

Troubleshooting ManualTroubleshooting Manual

Electronic system overview

Programming parameters

Troubleshooting without a diagnostic code

Troubleshooting with a diagnostic code

(functional tests)

Diagnostic code listing



Troubleshooting without a diagnostic code

Troubleshooting with a diagnostic code

(functional tests)


The troubleshooting guide contains the following.

- Electronic system overview

- Programming parameters

- Troubleshooting without a diagnostic code

- Troubleshooting with a diagnostic code- Diagnostic code listing


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Slide # 196



Brief explanation of component operation

Component diagrams

Sensor and connector locations

Engine and vehicle wiring harness diagrams Service tools


Brief explanation of component operation

Component diagrams

Sensor and connector locations

Engine and vehicle wiring harness diagrams Service tools

Briefly walk through the troubleshooting guide. Pointing out the

bulleted items and their locations.


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Slide # 197



Overview of parameters

Customer and factory passwords

Programming a new ECM

Programming or changing a personality module How to use ECM information


Overview of parameters

Customer and factory passwords

Programming a new ECM

Programming or changing a personality module How to use ECM information

Additionally, point out the locations in the guide for the following:

- Overview of parameters

- Customer and factory passwords

- Programming a new ECM

- Programming or changing a P/M- Using ECM information


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Slide # 198


Troubleshooting without a diagnostic code Section designation

General description of symptom

Page number to begin troubleshooting procedure

Example: PA-19: Engine cranks, but will not start . Page 65

Troubleshooting without a diagnostic code Section designation

General description of symptom

Page number to begin troubleshooting procedure

Example: PA-19: Engine cranks, but will not start . Page 65

Using the Troubleshooting Manual (SENR5582), (Table of Contents)

use the example of PA-19, Engine cranks, but wont start, on page 65.

PA-19 = Section designation

Engine cranks, but wont start = description of symptom

page 65 = starting page for Troubleshooting steps


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Slide # 199


Troubleshooting with a diagnostic code(functional tests)

Section designation

General description of subsystems and circuits

Page number to begin troubleshooting procedure Example:

PC-31: Engine speed/timing circuit test . Page 233

Troubleshooting with a diagnostic code(functional tests)

Section designation

General description of subsystems and circuits


PC-31: Engine speed/timing circuit test . Page 233

Again, discuss area in Table of Contents. Use the example PC-31:

Engine speed/timimg circuit test on page 233.


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Slide # 200



Diagnostic code

Code description

Flash code


232-04: 5 volt supply below normal (21) . Page 265


Diagnostic code

Code description

Flash code


232-04: 5 volt supply below normal (21) . Page 265

Briefly mention slide items. Reference 232-04 dianostic code.


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Slide # 201


Troubleshooting Without a diagnostic code Step by step elimination of all systems that could

cause symptom

Troubleshooting with a diagnostic code orfunctional tests Beginning of section on a specific subsystem

Begins with System operation overview

Diagnostic code listing Step 1 for that item

Troubleshooting Without a diagnostic code Step by step elimination of all systems that could

cause symptom

Troubleshooting with a diagnostic code orfunctional tests Beginning of section on a specific subsystem

Begins with System operation overview

Diagnostic code listing Step 1 for that item

When troubleshooting without a code, the Troubleshooting Manual

provides step by step information to eliminate all of the systems that

cause specific symptoms.

When troubleshooting with a daignostic code, the manual provides a

brief system operation explanation before the troubleshooting steps.


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Slide # 202

Engine Cranks, But Will

Not Start


Not Start

Troubleshooting Without a diagnostic code

A-19 page 65

Probable root causes Connect an electronic service tool

Will the ECM communicate

Electrical connection to injectors

Engine speed/timing signal

Incorrect engine software

Theft deterrent active

Troubleshooting Without a diagnostic code

A-19 page 65

Probable root causes Connect an electronic service tool

Will the ECM communicate

Electrical connection to injectors

Engine speed/timing signal

Incorrect engine software

Theft deterrent active

3406E3406E

As mentioned, this is the list of probable root causes. All of these

could cause an engine cranks, but wont start problem. Ruling out

these causes one by one should provide insight to the electronic

problem. Typically, the manuals will have some non-electronic causes

listed toward the end.


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Slide # 203

EUI has 6EUI has 6

#2 ECM#2 ECM

#3 P.M.#3 P.M.


#1 POWER

+ Battery

- Battery

#1 POWER

+ Battery

- Battery


#6 Good Injectors


#6 Good Injectors


Not Start


Not Start

Example 1 3406E ADEM IIExample 1 3406E ADEM II

Not an electronic problemNot an electronic problem

In our first example for an EUI engine, 6 components are needed to

start. We can systematically rule out the electronic components one by

one.

1. We can check for power to the ECM.

2. ECM communicates

3. If the ECM communicates P/M is programmed

4. Check for theft deterrent

5. See engine speed

6. Click test

If all the above is OK, the electronics are not preventing the engine

from starting. Move on to fuel/air etc


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Slide # 204

EUI has 6EUI has 6

#2 ECM#2 ECM

#3 P.M.#3 P.M.


#1 POWER

+ Battery

- Battery

#1 POWER

+ Battery

- Battery


#6 Good Injectors


#6 Good Injectors


Not Start


Not Start

Example 2 3406E ADEM IIExample 2 3406E ADEM II

No speedNo speed

In our second example, the ECM is NOT receiving an engine speed

signal.


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Slide # 205

No engine speed


Not Start


Not Start Find no speed or

Have code 190-02 loss of engine RPM signal

Refer to SENR5582-06, page 233 or 234 (PC-31)

Page 233 is systems operation

Read several steps to get directional guidance

Step 1 - Check all connectors, pins, & socketsStep 2 - Check for active code

Step 3 - Connect service tool

Find no speed or

Have code 190-02 loss of engine RPM signal

Refer to SENR5582-06, page 233 or 234 (PC-31)

Page 233 is systems operation

Read several steps to get directional guidance

Step 1 - Check all connectors, pins, & socketsStep 2 - Check for active code

Step 3 - Connect service tool

With no engine speed signal or 190-02 diagnostic code, refer to PC-31.

It may help to first read the outlined steps. This can familarize yourself

and create a better understanding of the procedures. Make sure to

follow the steps.

Note: Example two fits more appropriately in troubleshooting without a

diagnostic code - Engine Cranks and Wont Start. Step 6 in the

troubleshooting guide refers to PC-31


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Slide # 206

3 pin breakout


Not Start


Not Start Step 4 Install a 3 - pin breakout T at the harness side

of the sensor connector, J9 only

Step 4 Install a 3 - pin breakout T at the harness side

of the sensor connector, J9 only

Speed timing sensorSpeed timing sensor

A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

A

B

C

A

B

C

A

B

C

A

B

C

Install a 3 pin breakout T at the harness side of the sensor connector, J9

ONLY.


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Slide # 207

Measure voltage

pin A to pin B


Not Start


Not Start Step 4 Measure voltage at J9 pin A, with

reference to J9 pin B

Step 4 Measure voltage at J9 pin A, with

reference to J9 pin B


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

A

B

C

A

B

C

A

B

C

A

B

C

Once the breakout T is installed, measure the voltage at J9 pin A (+V

Engine Speed/Timing) with reference to J9 pin B (Engine Speed/Timing

Common) with the sensor disconnected.


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Slide # 208


Not Start


Not Start Step 4 Is voltage between 11.5 and 13.5 volts DC Step 4 Is voltage between 11.5 and 13.5 volts DC


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

+ 13.32 v+ 13.32 v

A

B

C

A

B

C

A

B

C

A

B

C

YESYES

Sensor is

receiving the

correct voltage

Sensor is

receiving the

correct voltage

The voltage should be between 11.5 and 13.5 volts DC. It is 13.32

volts, move on to the next step.


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Slide # 209

Connect sensor

side


Not Start


Not Start Step 5 Connect sensor to the breakout T Step 5 Connect sensor to the breakout T


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

A

B

C

A

B

C

A

B

C

A

B

C

Now connect the sensor to the breakout T.


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Slide # 210

Measure voltage


Not Start


Not Start Step 5 Measure the voltage at pin A with reference to

pin B

Step 5 Measure the voltage at pin A with reference to

pin B


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

A

B

C

A

B

C

A

B

C

A

B

C

Measure the voltage at J9 pin A (+V Engine Speed/Timing) with

reference to J9 pin B (Engine Speed/Timing Common).

Is the voltage still between 11.5 and 13.5 volts DC?


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Slide # 211

Between 11.5 &

13.5v? Yes


Not Start


Not Start Step 5 Is the voltage still between 11.5 and 13.5 volts Step 5 Is the voltage still between 11.5 and 13.5 volts


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

+ 12.75 v+ 12.75 v

A

B

C

A

B

C

A

B

C

A

B

C

YESYES

The sensor is receiving the

correct voltage

The sensor is receiving the

correct voltage

Is the voltage still between 11.5 and 13.5 volts? Yes, the sensor is

receiving the correct voltage. Move to the next step.


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Slide # 212

Remove signal

wire harness side


Not Start


Not Start Step 6 Remove the signal wire (pin C) from the engine

harness connector J9 to isolate the sensor signal wire

Step 6 Remove the signal wire (pin C) from the engine

harness connector J9 to isolate the sensor signal wire


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

A

B

C

A

B

C

A

B

C

A

B

C

Remove the signal wire (pin C) from the engine harness connector J9 to

isolate the sensor signal wire.


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Slide # 213

Measure voltage C

to B


Not Start


Not Start Step 6 Measure the voltage from breakout pin-C to

breakout pin-B, before and while cranking

Step 6 Measure the voltage from breakout pin-C to

breakout pin-B, before and while cranking


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

A

B

C

A

B

C

A

B

C

A

B

C

Measure the voltage from the breakout T, pin C to pin B. Do this before

and while cranking.


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Slide # 214

Voltage less than 2

or greater than

10?


Not Start


Not Start Step 6 Is the voltage less than 2.0 volts DC or more

than 10.0 volts with key on, before cranking

Step 6 Is the voltage less than 2.0 volts DC or more

than 10.0 volts with key on, before cranking


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

+ .162v+ .162v

A

B

C

A

B

C

A

B

C

A

B

C

Is the voltage less than 2.0 volts DC or more than 10.0 volts with key

on, before cranking?

< 2 volts indicates the sensor is not aligned with a gear tooth.

> 10 volts indicates the sensor is aligned with a gear tooth.


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Slide # 215

During cranking 2

to 9v?


Not Start


Not Start Step 6 During cranking is the voltage between 2.0

volts DC and 9.0 volts DC

Step 6 During cranking is the voltage between 2.0

volts DC and 9.0 volts DC


A

B

C

A

B

CECMECM

A

B

C

A

B

C

P9 J9

+ V

Com

+ .162 v+ .162 v

A

B

C

A

B

C

A

B

C

A

B

C

NONO

There is no output signal

or it is out of limits

There is no output signal

or it is out of limits

During cranking is the voltage between 2.0 volts DC and 9.0 volts DC?

No.

This means there is no output signal or it is out of limits.


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Slide # 216

Remove sensor,

check sliphead

Speed Timing SensorSpeed Timing Sensor

Position the timing wheel in a place not

allowing the slip head to fill a slot

Position the timing wheel in a place not

allowing the slip head to fill a slot

Step 7

Remove the existing

speed/timing sensor

Pull the slip head out

Reinstall the

speed/timing sensor

Remove the Engine Speed/Timing Sensor. If the slip head is in, pull it

out. Reinstall the Speed/Timing Sensor. The engine should start.

NOTE: Position the timing wheel (by turning the crankshaft) in a place

to not allow the slip head to fill a timing wheel slot. Damage to the slip

head or engine could occur if the procedure is not followed.


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Slide # 217

ADEM II

component

diagram

ADEM II Component DiagramADEM II Component Diagram

This is an overview of the Component Diagram. The yellow harness

indicates Caterpillar components, and the gray harness indicates the

OEM components.

Pick a few components, and briefly mention their functionality.


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Slide # 218

5 volt sensors

Supply & common

are shared

Oil PressureOil Pressure

ECMECM

DiagnosticDiagnostic

ToolToolFuel TempFuel Temp

Boost PressureBoost Pressure

Coolant TempCoolant Temp

SignalSignal

+ 5V+ 5V

GroundGround

Data linkData link

5 volt Active Sensors5 volt Active Sensors

(36) +5v(36) +5v

(30) Sensor common(30) Sensor common

(8) Oil pressure(8) Oil pressure

(3) Fuel Temp(3) Fuel Temp

(23) Boost pressure(23) Boost pressure

(14) Coolant Temp(14) Coolant Temp

3176B, C-10,C-12, & 3406E

3176B, C-10,

C-12, & 3406E

Review of the 5 volt active sensors. Shown are the sensors, their

respective wires and connectors. Additionally, the ECM, Data link, and

Diagnostic Tool are shown.

The 5 volt supply and common are shared. However, each sensor has

its own signal wire.

A supply

B common

C - signal


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Slide # 219

Diagnostic CodesDiagnostic Codes


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Slide # 220

SAE Society of

Automotive

Engineers, PID

FMI


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110

03 = Open 04 = Short03 = Open 04 = Short

Data linkData link

Diagnostic CodesDiagnostic CodesAA

BB

CC

The diagnostic codes on the left are Society of Automotive Engineers

(SAE). They are standard for all engine manufactures. They can be

referred to as Parameter Identifier (PID) numbers.

For example, 100 is an oil pressure indication.

Also, Failure Mode Identifier (FMI) codes are SAE standards. Theyfollow the PID number.

For example, a 03 would indicate an open circuit. A 04 is a short

circuit.


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Slide # 221

Boost open diag

code 102-03


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

102 03102 03

Lets look at an example if an open circuit was to occur with the boost

sensor signal wire. A 102-03 (boost pressure sensor open circuit)

should be indicated with a diagnostic tool.


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Slide # 222

Short between A &

B


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

232 04232 04

A shorted to BA shorted to B

Now lets look at a different scenario. The open remains in place,

however, a short is created between the A and B wire on the oil pressure

sensor connector. What code would appear?

A 232-04 ( 5 volt supply below normal ).


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Slide # 223

Unplug sensor

connectors one at

a time


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link

TroubleshootingTroubleshootingAA

BB

CC

232 04232 04

UnplugUnplug


After steps 1 5 in the troubleshooting manual have been competed,

start disconnecting individual +5 volt sensor connectors. Does

disconnecting a specific sensor cause the +5 volt diagnostic code to

change to all opens?

In this example, we start by unplugging the coolant temperature sensor

connector, but the code remains a 232-04.


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Slide # 224


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

232 04232 04

UnplugUnplug

UnplugUnplug


Unplug the boost pressure sensor connector, and the code is still a 232-

04.


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Slide # 225


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

232 04232 04

UnplugUnplug

UnplugUnplug

UnplugUnplug


Unplug the fuel temperature sensor connnector. The code remains a

232-04. Continue...


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Slide # 226

Open, corrosion or

bad sensor

Step 1 importance


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

100-03

174-03

102-03

110-03

100-03

174-03

102-03

110-03

UnplugUnplug

UnplugUnplug

UnplugUnplug

UnplugUnplugA shorted to BA shorted to B

At this point, disconnecting the oil pressure sensor connector creates all

opens. Connect the sensor suspected of causing the problem (oil

pressure sensor). Does the problem reoccur? Yes, could be corrosion

within the sensor connector or a bad sensor.

Note: Corrosion should have been found by throughly inspecting the

connectors in step 1.


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Slide # 227

T/S the boost open


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link


BB

CC

102 03102 03

Once the 232-04 is corrected connect the sensors. The 102-03 boost

pressure sensor open circuit should return. We would then troubleshoot

the boost pressure sensor open circuit.


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Slide # 228


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link

TroubleshootingTroubleshooting

232 04232 04

AA

BB

CC

Heres another example of a 232-04.


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Slide # 229

Unplug all, wiring

harness back to

ECM

Disconnect J2/P2

measure

resistance pin 36

to other sockets

Should find

resistance

between 36 & 30

less than 20 ohms,

shorted harness


ECMECM


ToolTool

100100

Fuel TempFuel Temp



SignalSignal

+ 5V+ 5V

GroundGround

174174

102102

110110


Data linkData link

TroubleshootingTroubleshooting

232 04232 04

UnplugUnplug

UnplugUnplug

UnplugUnplug

UnplugUnplug

?

AA

BB

CC


We unplug all the sensors and still have the 232-04 diagnostic code. We

have confirmed the problem exists from the wiring harness connectors

back to the ECM.

(Step 7) At this point, disconnect the engine harness connector J2/P2.

Leave the sensor connectors unplugged as well. Measure pin 36 (+ 5v)

to each of the remaining pins/sockets. Multimeter resistance range

should be closest to, but not less than 20 ohms. (Wiggle the harness

during measurement to reveal any intermittent short condition).

In this case, the resistance between pin/socket 36 and pin/socket 30

should read less than 20 ohms. This would indicate a short in the

engine wiring harness. We would replace the engine wiring harness or

make the necessary repairs.


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Slide # 230


ECMECM

Any 3 wire,Any 3 wire,

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

CommonCommon

Sensor SignalSensor Signal SignalSignal

GroundGround

ECM - BatteryECM - Battery

ECM + BatteryECM + Battery

Any 3 wire, 5 volt pressure or temperature sensor requires a supply

voltage of 5 v +/-0.25 volts. It requires a common/ground, (NOT a

battery ground). The last requirement is the sensor signal to the ECM.


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Slide # 231

C wire, analog

scale

C Wire Signal Output VoltageC Wire Signal Output Voltage

5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short

2.5 volts = 60 PSI2.5 volts = 60 PSIPSIPSI

- 04

Short

- 04

Short

This is a slide showing the C wire signal output voltage for an oil

pressure sensor. This is called an analog sensor scale. Sensors convert

actual temperatures or pressures to an electrical signal.

In the example:

The good range would be between approximately 0.5 v to 4.5 volts

and 0 to 120 psi of oil pressure. Below 0.5 volts and above 4.5 volts

would be a short.

0 psi = 0.5 volts

60 psi = 2.5 volts

120 psi = 4.5 volts


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Slide # 232

B to C short high

or low?


ECMECM

AnyAny

3 wire3 wire

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

CommonCommon


GroundGround



B to C shortB to C short

What happens if a short occurs between the common and signal wire?

Will it short low or high? Next slide...


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Slide # 233

Shorts low

Defaults to 87 psi

& DIAG


5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short


- 04

Short

- 04

Short

XX

Code 100-04Code 100-04

B to C shortB to C short

It will short below 0.5 volts because the signal voltage is being drawn

down by the short to ground. The diagnostic code would be 100-04.

- Electronic system response would set the oil pressure to 87 psi.

- ET will indicate approximately 87 psi while the diagnostic code is

active and DIAG will be displayed on the status screen.

- This diagnostic code does not affect engine response.


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Slide # 234

A to C short?


ECMECM

AnyAny

3 wire3 wire

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

CommonCommon


GroundGround



C to A shortC to A short

What happens if the sensor signal wire is shorted to the 5 volt supply?


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Slide # 235

Short high

Defaults to 87 psi

& DIAG


5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short


- 04

Short

- 04

Short

XX

100-04100-04

C to A shortC to A short

The signal voltage will be above acceptable limits and trigger a 100-04

diagnostic code.

The electronic system response will set the oil pressure to 87 psi.

ET will indicate approximately 87 psi while the diagnostic code is

active and DIAG will be displayed on the status screen.

This diagnostic code does not affect engine response.


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Slide # 236

Code for C

open? PID-03


ECMECM

AnyAny

3 wire3 wire

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

CommonCommon


GroundGround



C OpenC Open What code?What code? PID # and -03PID # and -03

What code will be seen with a signal wire or C open? The

appropriate PID number and - 03. The oil pressure PID number is 100.

So, the diagnostic code would be 100-03.

What is the voltage from B to C when the C wire is opened?


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Slide # 237

Chart shows 0, but

we have pull-up

voltage


5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short


- 04

Short

- 04

Short

Looking at this chart, the C to B voltage could not be 0V, that would

trigger an 04 Short code. The voltage from C to B with B referenced

as ground is called the 5V sensors pull-up voltage. When checking

for this voltage an ADEM II or ADEM III ECM will be approximately

6V DC. Pull-Up Voltage is commonly used in the electronic industry

and this is also how other competitive and automotive sensor faults are

diagnosed.


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Slide # 238

ECMs power

supply


100 volt DC EUI100 volt DC EUI

13.2 v speed timing sensor13.2 v speed timing sensor

8 v throttle position sensor8 v throttle position sensor

6.4 v pull up6.4 v pull up

5 v sensor supply5 v sensor supplyA

B

C

A

B

C Micro-processorMicro-processor

Battery +

Battery -

Battery +

Battery -

How is pull-up voltage produced? An overall explanation of the ECMs

power supply is shown here.

First the ECM must receive battery voltage, this may be 12 or 24VDC.

12 for on-highway trucks and typically 24 V for everything else. The

ECM uses a switching Power Supply to produce about a 100VDC

supply voltage. This 100VDC supply is used to power the

Mechanically or Hydraulically actuated EUIs. The 100V supply isregulated down to 13.2 volts which is for the Speed Timing Sensor.

Then, an 8V supply is produced for the TPS. (On 3500B engines there

is also a right and left exhaust gas temp sensor which is powered by

8VDC). From the 8V DC supply a 6.25 or 6.4 volt supply is provided,

and then a 5 volt dc supply. The 6.25 or 6.4 supply is not shown on

schematics because it is not brought outside the ECM like the other

supply voltages.


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C wire open

causes the

voltage to float to

6.25v

Technician

awareness

Verified ECM &

wiring to sensor

connector good

As the slide shows, there is a pull-up resistor shown in green. It runs

from the pull-up supply to the sensor signal line internal to the ECM.

The ECM microprocessor monitors the sensor signal line and

annunciates the proper temperature, pressure or fault code depending on

the voltage it receives. When the C wire is open, the voltage on the Cwire will float up to the pull-up voltage which in this case is

approximately 6.25V, and the ECM microprocessor will indicate an 03

code for that sensor as a result. There would be a separate pull-up

resistor for each 5 volt sensor.

The main reason for explaining this is so a technician is not surprised if

he uses a voltmeter and measures this 6+ volt dc level. If someone did

not know this was normal, they may think they have a bad ECM.

Also, if the sensor is unplugged and the pull-up voltage can be read

from C to B, then the following things have been verified: The ECM is

powered, it is producing the pull-up voltage, AND the B to C wiring

from the ECM to the sensor connector on the engine harness is okay.

Note: This does not verify that the A wire is OK.


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Slide # 239

B & C swapped at

connector - No

code


ECMECM

AnyAny

3 wire3 wire

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

SignalSignal

GroundGround



B to C swapB to C swap

What code?What code? No codeNo code

What code is triggered if the common and signal wires are swapped at

the connector? No code.

The voltage is floatingbecause the ground has been lost.


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Slide # 240

Status screen


5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short


- 04

Short

- 04

Short

B to C swapB to C swap

Look at status

screen low oil

pressure or

temp etc.

Look at status

screen low oil

pressure or

temp etc.

What may be helpful is viewing the status screen. With or without the

engine running the status screen may indicate an incorrect pressure or a

temperature, depending on the type ECM software involved.

In this example the voltage floated to 1.0 volt, which equals 20 psi.

Note: Could be a shutdown scenario because the ECM is seeing low

oil pressure .


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Slide # 241

A & C swapped -

No code


ECMECM

AnyAny

3 wire3 wire

5 volt5 volt

PressurePressure

or temp.or temp.

sensorsensor

AA

BB

CC

5 V + 0.25 V5 V + 0.25 V +5 volt+5 volt

SignalSignal

GroundGround



A to C swapA to C swap

What code?What code? No codeNo code

AA

BB

CC

What code will be produced by a swapped A and C wire at the

connector?

There may not be any code. It depends on the sensor and how the

program is written for the ECM to interpret the voltage read. On the

3176B, with the boost pressure sensor A & C wires swapped, the

voltage from C to B is 4.98v. This gives a 102-00 code, which is

Boost Pressure Sensor Stuck High.


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Slide # 242

Voltage floats

high, 120 psi

engine running or

not


5.0V5.0V4.54.54.04.03.53.53.03.02.52.52.02.01.51.51.01.00.50.50 Volt0 Volt

00

2020

4040

6060

8080

100100

120120- 04 Short- 04 Short

- 04

Short

- 04

Short


- 04

Short

- 04

Short A to C swapA to C swap

Look at status

screen High oil

pressure or

temp etc.

Look at status

screen High oil

pressure or

temp etc.

The chart shows by swapping A and C the voltage floats high.

Therefore, the ECM interprets the high voltage to high pressure. Since

this would not generate a code, where could we possibly see this?

The status screen. On the chart, pressure appears to be 120 psi. This

pressure would be there regardless if the engine was running or not.


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Slide # 243

Electronics ClassElectronics Class

Questions so

far?

Questions so

far?


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Lesson Plan 17 - Troubleshooting Lab (Broken Engines)

Objectives:

The student will be able to, with the help of his classmates, properly diagnose,

troubleshoot, and repair the electronic operating engines.

Literature Needed:

Broken engine lab sheet

Hardware Needed:

ET/ECAP comm adapter/cablesTool Boxes

VOM

3126B, 3406E, 3176B, 3406C engines

Time Required:

6.25 Hours

Tasks Required by Instructor to Meet Objectives:1. The instructor will make the necesary faults (bugs) before class startup. They are

as follows:

General: unplug comm adapter at each station.

3176B:

1). Battery Cable Disconnected, 2). Run Engine Out Of Fuel, 3). Personality Module

Loose, 4). Intake Man. Air Temp. Sensor Wires B & C Switched At Harness,

5). 12 Pin Bulkhead Connector Loose At Valve Cover Base, 6). Injector Wire #5

& 6 Under Valve Cover Loose, 7). Fuel Temp Sensor, Wires A & C Switched At

Sensor, 8). Atmospheric Pressure Sensor B & C switched

3406E:

1). Battery Cable Disconnected, 2). ESTS Tip Pushed In, 3). ESTS (A) Wire Loose

On Harness Side Of Connector, 4). Oil Pressure Sensor Wire Cut - pigtail, 5).

number 1 & 6 Injector Wires Switched at The Bulkhead Connector Both Gray

Wires, 6). Atmospheric Pressure Sensor A to BFly Wire on harness side of the

connector, 7). Injector harness swap # 5 & 6 under valve cover.


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PEEC:

1). Battery Cable Disconnected, 2). Wire #1 At 40 Pin OEM Connecter Loose, 3). 9

Pin ATA & 9 Pin Transducer Connectors Switched, 4). Green Wire "A" In 9Transducer Switched To Hole "F", 5). Shutoff Solenoid Black "A" Wire In The

"C" Hole Solenoid Side, 6). BTM Wire "A" Loose, 7). TPS Sensor Connector

Loose, 9). TPS Sensor Wire "C" Wire Loose On Harness Side.

3126B:

1). Battery Cable Disconnected, 2).Emergency Stop - Pushed In, 3). Emergency Stop

- Loose Wire, 4). Crank Relay Connector Loose, 5). ATA (9) Pin - (H) Wire In

(G) Hole, 6). IAPCV purple wire (62) loose at the ECM, 8). TPS Sensor - (A)

Wire Cut, 9). IAP sensor C wire cut on pigtail.

2. Review the complaints with the students before going to the lab.

3. Explain there may be additional problems due to experiment troubleshooting.

4. Answer any questions


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In completing this lab, you will practice the following skills, on several different engines:

1. Troubleshoot for complaints or problems like the following:

- Engine will not crank

- Cannot communicate with ECM- Engine cranks, but will not start

- Engine starts but idles only

- Engine has active codes, such as short or open circuits

- Engine has low power

- Engine has rough idle

2. Inspect connectors via "10 pound pull test".

3. Disassemble, inspect, and reassemble Deutsch DT and/or HD Connectors.

4. Use a Multi-Meter to check voltage and/or continuity5. Use Caterpillar ET (Electronic Technician) to:

- Find and print information

- Monitor status screens

- Retrieve active diagnostic codes

- Retrieve (and clear) logged diagnostic codes

- Perform diagnostic tests

Instructions

1. Fill in the work order for each engine that you repair (or attempt to repair).

2. Check coolant and oil levels before attempting to start the engine.

3. Use the diagnostic procedure - don't simply look for visual "bugs". Remember that these

are simulated problems, which may not be quite so obvious as the "real life" situations

that they represent.

4. Work from the worst problem to the least drastic, in order to find everything that is

wrong.

5. If you need parts, see the instructor.

6. You should be able to do all repairs with the same tooling that was available to you in theUnbroken Engines Lab performed earlier. All necessary diagnostic tooling is available,

but is unhooked from the engines.

7. When you think you are finished, bring the work order to the instructor. Explain the

symptoms you discovered, the cause of those symptoms, and the steps you took to

correct the problem(s).

8. You have not completed the lab until all codes and symptoms are gone, to the instructor's

satisfaction.

9. When the instructor is satisfied that you have fixed the engine completely, he will tell

you whether or not you need to re-bug it for the next team.

SEGQ4031 - 333 - Lab Sheet - Broken Engines

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10. Be safe -- If you are not sure about something, ask before doing it!

Work Order Number: 0001

Engine Model: 3126B

Engine Serial Number: 7AS00570Mileage or Hours: 13,500 mi.

Customer Name: Bilge Beer Distribution Inc.

Date Needed: Today -- A.S.A.P

Complaint:

Engine died while idling, and would not crank when the driver tried to restart it. Had to

be towed into the shop.

Technician(s): _______________________________________________________

Time Assigned: ______________ a.m. p.m. (circle)Time Completed:______________ a.m. p.m. (circle)

Oil Level:

_ O.K.

_ Low: Amount added _________

Coolant Level:

_ O.K._ Low: Amount added _________

Problem Statement: ______________________________________________________

______________________________________________________

Corrective Action: ______________________________________________________

______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


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______________________________________________________


______________________________________________________

Result: ____________________________________________________________________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________

Corrective Action: ____________________________________________________________________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


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Engine Model: 3406E

Engine Serial Number: 5EK00081

Mileage or Hours: 275,000 mi.

Customer Name: E-Z Haulers Inc.Date Needed: Today -- A.S.A.P

Complaint:

This cross country heavy hauler was brought in by the yard man, on the hook.

Engine began running rough while traveling down the road, then died. Engine

cranks, but will not restart. Driver complained that engine was low on power

before it died.

Technician(s): _______________________________________________________

Time Assigned: ______________ a.m. p.m. (circle)

Time Completed:______________ a.m. p.m. (circle)

Oil Level:

_ O.K.


Coolant Level:

_ O.K.



______________________________________________________Corrective Action: ______________________________________________________

______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


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______________________________________________________


______________________________________________________


______________________________________________________Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


______________________________________________________Corrective Action: ______________________________________________________

______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


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Work Order Number:0003

Engine Model: 3406C PEEC

Engine Serial Number: 4CK00010

Mileage or Hours: 300,000 miles + unknown hours

Customer Name: Frels Cattle RanchDate Needed: Today -- A.S.A.P

Complaint: Low power / poor response.

Background information: This is a salvaged engine from a wrecked highway truck. The

truck had 300,000 miles on it when it was in a bad accident. Rancher Frels bought the

engine and made it into a water pumper for the feed lot 2 years ago. He said it had been

working fine till yesterday. Gomer and his apprentice on 3rd shift already worked on it

for two hours last night, but couldn't find the problem. They had to go on an emergency

call. They said they put it "pretty much back the way they found it".

Technician(s): _______________________________________________________



Oil Level:

_ O.K.


Coolant Level:

_ O.K.



______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________


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Result: ______________________________________________________

______________________________________________________


______________________________________________________

Corrective Action: ____________________________________________________________________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________

Problem Statement: ____________________________________________________________________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


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Engine Model: 3176B

Engine Serial Number: 9CK00639

Mileage or Hours: 185,000 mi.

Customer Name: Roadburner Trucking Inc.Date Needed: Urgent - stranded along the road

Complaint:

Driver was on her normal daily run between Chicago and St. Louis. The engine had a

speed burp, then died. She coasted onto the shoulder.

Now it cranks but won't start. It must have active codes, because she said the light is

flashing.

It was in the shop last week, for a low power complaint. Gomer couldn't find anything

wrong.

Technician(s): _______________________________________________________



Oil Level:

_ O.K.


Coolant Level:

_ O.K.



______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________



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______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________Problem Statement: ______________________________________________________

______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________


______________________________________________________


______________________________________________________Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


______________________________________________________


______________________________________________________

Result: ______________________________________________________

______________________________________________________


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Lesson Plan 18 - Final Exam

Objectives:

The student will take a final exam to gauge the learning and comprehension level of

the courses material. The student must obtain at least 70% accuracy on this exam to

complete course requirements.

Literature Needed:

Final Test

Course Evaluation

Hardware Needed:

None

Time Required:

.75 Hour

Tasks Required by Instructor to Meet Objectives:

1. Ask the students for questions regarding material covered during the course.

2. Answer all questions using reference material. Be sure the students follow along intheir reference material while the question is answered.

3. Administer the Final Test

4. Review the Final Test, again using reference material to answer questions.

5. Ask the students to fill out the Course Evaluation Form.


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Lesson Plan 18 - Final Exam

Select the best answer:

1. Battery power is required by this type of engine/s to start:

A. PEEC

B. HEUI

C. EUI

D. All of the above

2. If the Theft Deterrent is programmed to Yes it will NOT prevent the engine from

starting:

A. True

B. False

3. The 3126B requires a minimum of _______ psi actuation pressure for the engine to

start:

A. 755

B. 870

C. 1000

D. 4000

4. If the 3406E throttle position sensor is not calibrated the engine will NOT start:

A. True

B. False

SEGQ4031 - 343 - Final Exam

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5. The (ET ) Speedometer and Tachometer Special Test verifies if the _______ is

driving those gauges.

A. steering wheel

B. Speed / Timing sensorC. ECM

D. air temperature

6. ____________ codes should be repaired immediately:

A. Inactive

B. Logged

C. OutputD. Active

7. A __________ should always be used for testing the Cooling Fan Output driver:

A. wire

B. test lamp

C. wrench

D. VOM

8. The PM provides the ECM instructions with a _______________.

A. software program

B. sensor signal

C. battery

D. microprocessor

9. An Active Diagnostic Code of 27 is related to ____________.

A. nothing

B. flashing

C. temperature sensor

D. camshaft


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10. A FMI code of 04 indicates____________:

A. the engine is fine

B. a short circuit

C. an open circuit

D. the tire pressure is low

11. A 10 lb. pull t

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