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
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.
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
Temperature Sensor
Variable Resistor Test
With AVO meter
Variable Resistor
Test With INSITE 1 of 3
Variable Resistor
Test With INSITE 2 of 3
Variable Resistor
Test With INSITE 3 of 3
Temperature Sensor
Thermistor like the variable resistance sensors
Thermocouple.
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.
Pressure Sensors
Types
Capacitance
Crystal structure
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
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.
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.
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.
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.
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.
Hall Effect Sensor
Checking Cont…
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.
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
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.
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.
1
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.
2
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.
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.
