5/24/2018

BETT
( Basic Electrical Theory and Troubleshooting )

Electronic Control System Inputs

After completing this module, you

should be able to:

 Identify the different switch types and symbols for each

 Recognize the different sensor types
 Explain the role of the different sensors and interaction with the
ECM
 How to read and understand sensor readings

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Input Power
 Keyswitch and Unswitch battery
– The unswitched power supply provides power to some
circuits in the ECM that require power when the keyswitch is
off.
– The keyswitch controlled power is utilized for normal
operation

Sensors and
switches
 Sensor and switches provide input signals to the ECM. For
measuring pressures, temperatures and other parameters,
 sensor provide a voltage or resistance that is proportional to the
parameter being measured.
 Switches are used when a simple on/off signal is all that is
required.

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SENSORS
 Some sensors, called passive sensors, have only signal and return wires.
 Other sensors, called active sensors, have a 5 volt DC supply, signal and return
wires.
 Other sensors, such as the thermocouple type of exhaust gas temperature
sensor, and some speed sensors, create their own voltage
 The ECM contains an analog to digital (A/D) converter for each of these sensor
input circuits. The A/D converter takes the
 sensors analog input signal and converts it to a digital signal which the ECM can
then use to determine temperature, level and pressure.

Temperature Sensor
 Temperature Sensors used by Cummins are generally passive, variable
resistance sensors.
 These sensors contain a thermistor, a special type of resistor that has the
unique characteristic of decreasing resistance with an increase in
temperature

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Temperature Sensor

Variable Resistor Test

With AVO meter

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Variable Resistor
Test With INSITE 1 of 3

Variable Resistor
Test With INSITE 2 of 3

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Variable Resistor
Test With INSITE 3 of 3

Temperature Sensor

 Thermistor like the variable resistance sensors

 Thermocouple.

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Thermocouple

 A thermocouple sensor is made of two dissimilar metals joined together.

When heated, the one metal transfers electrons to the other metal. This
creates a voltage difference that the ECM detects. By using the tables
stored in the ECM, the detected voltage is converted into a temperature
measurement.

Checking
Thermocouple 1 of 2

 If the resistance reading is excessive it indicates that the two dissimilar metals
have separated.

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Checking
Thermocouple 2 of 2

 The ECM response method

– With the key on, or with the engine running, disconnect the sensor and short
the sensor connectors to observe changes in the INSITE readings. If the
readings in INSITE respond correctly, the ECM and associated circuitry is
working properly and the sensor is likely faulty.

Water-in-Fuel
Sensor ( WIF )
 water-in-fuel sensor, act as simple switches providing an on/off signal. When the
water in the bottom of the fuel filter reaches the contacts in the sensor, the water
completes the circuit between those contacts and causes the warning light to
illuminate.

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Water-in-Fuel Sensor ( WIF )

Checking 1 of 2

 If the fault code is for voltage above normal, the sensor is tested with an ohm
meter. A reading of greater than 100k ohms indicates the sensor is not shorted.

Water-in-Fuel Sensor ( WIF )

Checking 2 of 2

 If the fault code is for voltage below normal, the circuit response is
tested by disconnecting the sensor and checking the circuit If the active
fault code is for voltage above normal when the sensor is disconnected,
and changes to a code for voltage below normal when the sensor is
connected, the sensor is faulty

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Level Sensor

 coolant level sensors used on many Cummins engines, are capacitance

type sensors. The presence or absence of fluid between the plates of
the capacitor changes the conductivity between the plates. The change
in conductivity affects a circuit in the ECM which is interpreted by the
ECM as a change in fluid level.

Level Sensor
Checking
 Troubleshooting a level sensor fault code requires checking for the
proper supply voltage from the ECM, proper ground, and no short
circuits or opens in the wiring harness. If those three conditions test
okay, the sensor needs to be replaced. Newer ECMs allow for testing
the sensor by disconnecting the sensor and then shorting the sensor
supply wire to the signal wire in the harness.

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Level Sensor
Checking
 If the active fault code changes from a low voltage to a high voltage
when the sensor contacts are disconnected and then shorted, the circuit
is responding properly and the sensor must be bad.

Level Sensor
Checking
 If the active fault code changes from a low voltage to a high voltage
when the sensor contacts are disconnected and then shorted, the circuit
is responding properly and the sensor must be bad.

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Speed and Position

Sensors
Speed and position sensors provide input that the ECM uses to determine the engine
speed and the current engine position.
1. Variable reluctance (VR) also know as magnetic pickup sensors
2. Hall Effect sensors

Variable Reluctance (VR)

Variable reluctance (VR) also known as magnetic pickup sensors contain a fine
wire wrapped thousands of times around a magnetic
As pieces of ferrous metal, such as gear teeth, pass near the tip of the sensor,
the magnetic field is disturbed. This causes an A.C. voltage to be generated by the
sensor. The voltage and frequency from the sensor varies with the speed of the target
passing the sensor, the proximity of the target to the end of the sensor, and the
strength of the magnet in the sensor. The ECM can detect this voltage and determine
when gear teeth have passed. The change in frequency as speed changes is how the
ECM interprets an engine speed.

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Variable Reluctance (VR)

 The sensor used in some control systems is actually 2 separate coils or

sensors built into a common housing. This provides the engine with a
dedicated speed signal and an independent signal for the OEM to use
for other vehicle systems if desired.

Variable Reluctance (VR)

 Some ISB engines used a variable reluctance sensor with a third wire. While this
sensor might appear to be an active sensor, the schematic shown here indicates
that this is a passive sensor. The third wire is a shield to reduce radio frequency
interference (RFI) or electromagnetic interference (EMI).

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Variable Reluctance (VR)

Checking

 Ohm meter

Variable Reluctance (VR)

Checking

 Mechanical checks
– usually the gap between the end of the sensor and the gear
mechanical damage to the sensor and debris on the end of
the sensor.

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Hall Effect Sensor

Hall Effect sensors contain a piece of semiconductor material that changes

conductance in the presence of metal. This is called the "hall effect". These sensors
are basically proximity sensors and detect when metal is within 0.1 inch of the front of
the sensor. An integrated circuit inside the sensor generates a voltage signal to show
proximity.

Hall Effect Sensor

Checking
 Hall Effect sensors, such as this ISX crankshaft position sensor, can be tested
using a voltmeter and a breakout harness.
 Attach the meter to the sensor signal wires, not the 5 volt supply wire, and bar the
engine over by hand. The voltmeter reading should alternate between a high
reading, 4 to 5 volts, when the sensor is close to metal, and low, 0.5 to 2.3 volts,
when the sensor is not close to metal.

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Hall Effect Sensor

Checking Cont…

Pressure Sensor

 Pressure sensors on Cummins engines are typically active sensors. These

sensors have a 5 volt supply, a return or ground, and a signal wire. As the
pressure applied to the sensor changes, the voltage between the signal wire and
ground will vary within the range of approximately 4.5 volts to 0.5 volts.

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Pressure Sensors
Types
 Capacitance
 Crystal structure

Pressure Sensors
Capacitance Type
 The pressure sensor contains a disc that has the pressure to be measured on one side and
reference pressure on the other side. Pressure acting on the disc causes it to move toward or
away from a second metal disc. As the gap changes, the capacitance also changes. An integrated
circuit inside the pressure sensor converts the capacitance value into a voltage signal that is
proportional to the measured pressure.

 There’s two type of this sensor;

1. Gauge Sensor
2. Absolute Sensor

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Pressure Sensors
Capacitance Type
Gauge Pressure Sensor
It is vented by a hole in the sensor or through the stranded sensor wiring. The
pressure measured by these sensors depends on the atmospheric pressure just like
a mechanical pressure gauge.

Pressure Sensors
Capacitance Type
Absolute Pressure Sensor
An "absolute" pressure sensor has a vacuum on one side. This type of sensor
provides a signal representing the total actual pressure. This type of sensor reads
approximately 14.5 psi when it is sensing atmospheric pressure.

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Pressure Sensors
Crystal structure Type
 Some pressure sensors contain a crystal structure. Pressure compresses the
crystal creating a small voltage proportional to the amount of pressure. This is
known as the piezoelectric effect. With this type of sensor, the resistance can be
measured to verify proper operation. However, the resistance range is too large
to verify sensor calibration with a resistance check. The sensor calibration is
checked by comparing the reading in INSITE to the reading on a mechanical
gauge.
 Piezoelectric sensors are also used for combustion knock detection on some
engines.

Pressure Sensors
Checking
 With Volt meter
– Checking supply
– Checking signal

Simply uses the

pressure on one
side of the
restriction as the
reference for the
pressure on the
other side, hence
the differential

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Pressure Sensors
Checking
Notice that this circuit, like others shown in this training, contains resistors
built into the ECM. In this example, the 47k ohm resistor is a pull down
resistor. Its function is to ensure that the signal wire has a path to ground
inside the ECM,

Pressure Sensors
Checking
And a low voltage fault code will become active if the sensor is disconnected. Without
this resistor, even a small induced voltage on the signal wire could prevent an active
code.

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Pressure Sensors
Checking
Notice also that if the return wire develops an open, the circuit is still grounded
through the 47k ohm resistor. This causes an active high signal voltage code.

Pressure Sensors
Checking
Circuit response testing capability.
example: The fault code indicates that the voltage detected on the barometric
pressure sensor signal wire is too high.

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Pressure Sensors
Checking
 The first test is to check the 5 volt supply from the ECM. The procedure calls for a
check of code 386 (sensor supply voltage above normal). A code 386 would
indicate that the ECM is not supplying a proper 5 volt signal to several
 A visual inspection of connectors and connector pins is next. If these preliminary
checks are okay, the procedure calls for disconnecting the barometric pressure
sensor.

Pressure Sensors
Checking
 The first test is to check the 5 volt supply from the ECM. The procedure calls for a
check of code 386 (sensor supply voltage above normal). A code 386 would
indicate that the ECM is not supplying a proper 5 volt signal to several
 A visual inspection of connectors and connector pins is next. If these preliminary
checks are okay, the procedure calls for disconnecting the barometric pressure
sensor.

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Pressure Sensors
Checking
 With the key on for 30 seconds, check the fault codes. Since the sensor
is disconnected (no voltage on the wire) code 221 should become
inactive and code 222 (voltage below normal) should now be active. In
this example Code 221 remains active indicating the ECM is not
responding correctly.

Pressure Sensors
Checking
 The troubleshooting tree directs you to check and test pins and
connectors at the ECM.

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Pressure Sensors
Checking
 Then repeat the response test by disconnecting the engine harness from
the ECM.
 This eliminates any possibility of a wiring harness fault causing the
problem. When these steps are completed and the system still does not
respond properly, replace the ECM.

Calibration Error

The performance troubleshooting tree has provisions for testing sensors that may have failed in
range or gone out of calibration. If this type failure occurs, the ECM may not detect the problem or
set a code. In this situation, the sensor calibration can be checked by measuring the resistance or
voltage and comparing it to a table published in the service literature.
For example, the humidity reading displayed in INSITE is absolute humidity. Calculations based
on input from the humidity sensor, the intake manifold temperature and manifold pressure sensors
provide this absolute humidity . To check its calibration, the humidity sensor is monitored using
INSITE, while temperature and relative humidity are also noted.
Using a chart to correct for relative humidity, find the point where the temperature (vertical line)
meets the relative humidity (curved line). Follow the horizontal line to the scale on the right and
compare the absolute humidity with the absolute humidity reading in INSITE.

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Calibration Error

In this situation, the sensor calibration can be checked by measuring the resistance or voltage and
comparing it to a table published in the service literature.
For example, the humidity reading displayed in INSITE is absolute humidity. Calculations based
on input from the humidity sensor, the intake manifold temperature and manifold pressure sensors
provide this absolute humidity . To check its calibration, the humidity sensor is monitored using
INSITE, while temperature and relative humidity are also noted.
Using a chart to correct for relative humidity, find the point where the temperature (vertical line)
meets the relative humidity (curved line). Follow the horizontal line to the scale on the right and
compare the absolute humidity with the absolute humidity reading in INSITE.

Calibration Error
For example, the humidity reading displayed in INSITE is absolute humidity.
Calculations based on input from the humidity sensor, the intake manifold
temperature and manifold pressure sensors provide this absolute humidity . To check
its calibration, the humidity sensor is monitored using INSITE, while temperature and
relative humidity are also noted.
Using a chart to correct for relative humidity, find the point where the temperature
(vertical line) meets the relative humidity (curved line). Follow the horizontal line to
the scale on the right and compare the absolute humidity with the absolute humidity
reading in INSITE.

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Calibration Error
Using a chart to correct for relative humidity, find the point where the
temperature (vertical line) meets the relative humidity (curved line). Follow
the horizontal line to the scale on the right and compare the absolute
humidity with the absolute humidity reading in INSITE.

Combination Sensor

 Some sensors perform more than one function. An example is the

combination intake manifold pressure/temperature sensor used on some
ISX engines.

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Combination Sensor

 These sensors simply contain both units in one housing. Each portion of
the sensor operates the same as the individual units.

Combination Sensor
Checking
 Testing combination sensors is the same as testing the individual
sensors. Each portion of the sensor has its own fault codes and
troubleshooting trees.

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Accelerator Position
Sensor
The accelerator position sensor is another variable resistance three-wire sensor. However, the variable
resistor is a sliding contact type resistor connected to the accelerator pedal.
The accelerator not only contains a position sensor but may also have a idle validation switch incorporated
into it. This is a safety redundancy check to help ensure that the accelerator is not
malfunctioning.
The accelerator position sensor and the idle validation circuits work together. In the idle position: the switch
indicates to the ECM that the pedal is at idle, and the accelerator position signal to the ECM is low. The ECM
knows to ignore the accelerator position signal and provide the set idle speed for the engine.

Accelerator Position
Sensor
As the accelerator is depressed, the idle validation switch indicates off-
idle status to the ECM. At the same time, the accelerator voltage
increases. The ECM now uses the signal from the sensor to determine
the operator's desire for speed and power.

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Accelerator Position
Sensor Checking
 The accelerator position sensor, like other variable resistance sensors is
tested with an ohm meter.

Accelerator Position
Sensor Checking
 The idle validation switch is also tested with an ohm meter.

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Accelerator Position
Sensor Checking
 The accelerator position sensor and idle validation switch are also
displayed using the monitor function of INSITE.

Switches

 Switches connect and disconnect devices from circuits. There are a

number of different types of switches depending on the switch function.
 Switch elements include movable contacts that complete the circuit at
the stationary contacts.

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Switches

 Switches are categorized by the number of "poles" they have and

the type of "throw". Poles are the number of electrically
 independent switch contacts that are switched simultaneously.
Throw indicates the number of switch positions.

Switches

 The switch position can be either latched or

momentary. A latched switch maintains the switch
position when the switch is toggled, such as a cruise
control on/off switch.

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Switches

 A single pole-single throw switch controls one circuit and has two
positions, open and closed. Most on/off switches in the control system
are single pole single throw type switches.

Switches

 A single pole-double throw switch has three positions, two closed and
one open.
 This type of switch completes one of two circuit paths. A double throw
switch cannot make contact with both circuits at the
 A common single pole-double throw switch used on engine control
systems is the engine brake switch.

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Switches

Double Pole-Single Throw switch

 The switch "Pole" refers to the number of switches that will move
together.
 This double pole switch has two separate contacts in separate circuits.
With a double pole switch, when one switch is moved, the other switch
moves with it to either open or close the electrical path in the other
circuit.

Switches

 Switches can be energized mechanically, hydraulically, or pneumatically.

An example of a hydraulically activated switch includes a pressure
switch thatopens or closes when it senses a specific pressure. An
example of a pneumatically activated switch in an electronic engine
control system is a brake light switch.

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Switches

 For most control systems, when the switch is closed,

the supply voltage is pulled to its low level.
 This indicates the switch position to the ECM.

Switches

 When troubleshooting switches a continuity check across the

terminals can be used to verify if the switch is open or closed in
each position

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