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Document

ID: IK0800226

Availability: ISIS, Bus ISIS, FleetISIS, Body

BuilderRevision: 7

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System: ELECTRICAL SYSTEM Created: 3/8/2010

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Modified: 6/8/2015

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Title : Accelerator Position Sensor/ Idle Validation Switch APS / IVS Diagnostics,

MaxxForce® equipped engine control systems

Applies To : This applies to all MaxxForce® equipped engines, 2007 to 2010 Model

Year MaxxForce® 5, 7 DT, 9 and 10 engines. Vehicles to include, but not limited to

CityStar�, DuraStar�, WorkStar®, TranStar�, BE,CE, RE and FE Buses, and

1552/1652 SC.

Change Log

Please refer to the change log text box below for recent changes to this article:

06/08/2014 ‐ Added SPN/FMI information based on feedback.06/08/2014 ‐ Added Change Log

Description

Two new APS sensors (Accelerator Position Sensor) have been developed and released for use with pre‐2010 emissions International Engines. The new sensors listed below contain "non‐contact" hall‐effect idle validation sensors. This replaces the open/closed IVS switches in the old sensors. As a result of this new design, the normal resistance measurements performed for the potentiometer and idle validation switch on the previous "contact' sensor are no longer applicable. A technician can continue to perform resistance measurement tests on the engine harness with the sensor unplugged (open circuit), but should rely solely

of 8IK0800226 Accelerator Position Sensor/ Idle Validation Switch APS / IVS Diagnostics, ...

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carla.nelson

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carla.nelson

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SB-10052686-3799

upon the voltage measurement tests, with a breakout harness installed, at the ECM and APS sensor, and the new sensor connected.

Symptoms

• APS/ IVS fault codes present• EGR valve, turbo actuator fault codes present• Engine speed restricted to idle• Erratic automatic transmission operation• Engine warning lights illuminated

Possible Diagnostic Trouble Codes

Fault SPN FMI Condition Possible Cause

1131 91 4 APS Signal Out‐of‐Range LOW• APS Signal Open or Shorted to Ground� VREF Circuit Open or Shorted to Ground• Failed Sensor

1132 91 3 APS Signal Out‐of‐Range HIGH� APS Signal Shorted to Power• Failed Sensor

1133 91 2 APS Signal In‐Range Fault• Circuit Fault• Failed Sensor

1134 91 7 APS / IVS Disagree� Circuit Fault• Failed Sensor

1135 558 11 IVS Fault� IVS Circuit Open or Shorted to Ground or Power• Failed Sensor

Parts Information

• Please refer to TSI 10‐08‐01 for parts details including cross reference information.

Diagnostics

There can be various conditions that can cause APS/IVS related issues. As with any performance related fault, a thorough description of the issue, from the operator is critical.

� Is the fault sensitive to road conditions, such as rough terrain, hills, etc?• Is the fault temperature sensitive?• Does the fault occur, when coming to a stop, or when accelerating or cruising?� Do any other faults occur at the same time, such as loss of dash cluster, or other in cab accessories?



� Are there other codes that can be attributed to this issue, such as loss of communication with the EGR Module / Turbo Actuator, or loss of ignition faults?

If any circuit issues are suspected, a thorough visual inspection of all circuitry for shorts, and opens is critical, as intermittent issues are usually caused by wiring faults. Any harness mounting points should be disassembled and inspected. Where harnesses pass by sharp edges, or possible points of abrasion, you should be inspect and repair if required. On MaxxForce® 7, DT, 9 and 10 engine equipped chassis' several common areas of contact and circuit damage has been noted (Please see the attached photos later in the document).

Whenever connector inspection has been performed, and tested satisfactory, always apply a light coating of dielectric grease upon reconnection, being careful to properly lock connectors.

If idle validation faults are an issue, testing of the ignition voltage supply to the sensor should be performed. On MaxxForce® DT, 9, and 10 series engines, the IVS ignition voltage supply originates at the output circuit of the EGR / Turbo actuator relay, located on the left side of the engine. It's routed through the 1702 Engine / Melrose connector, across the engine, and into the fuse panel in the cab. The circuit is fused, and then continues through the cab harness, the 1800 IP / DCM connector, and on to the APS / IVS sensor. Inspection of the terminals, at the EGR / Turbo actuator relay, for "spreading" and correct crimping is recommended as well as inspection of the fuse and circuitry to the pedal sensor.

The after treatment sensor harness mounting points at the transmission should be inspected for damage and repaired if necessary. These sensors share a common 5vref internal to the ECM and can affect the APS function.

Please see the photos below for some possible areas of wiring contact / damage.

On MaxxForce® 7 (V8) engines the harness coming from the 42pin connector might rub on the rear engine lift bracket or it might rub on the exhaust pipe. If necessary peel back the insulation to examine the wires closely.

MaxxForce 7 Wire Rub at Exhaust Pipe MaxxForce 7 Wire Rub at Exhaust Pipe

Below are photos that show the recommended harness routing if you find this harness rubbing on the rear engine lift bracket or the exhaust pipe.



MaxxForce 7 Harness routing away from lifting eye

MaxxForce 7 Harness routing away from exhaust pipe

On MaxxForce® 9,10 and DT (I6) engines the harness coming from the 42 pin connector might rub on the throttle valve, intake tube, washer bottle mounting bolt, or dipstick tube mounting bracket.

MaxxForce I6 Possible Rub Points MaxxForce I6 Possible Rub Points

MaxxForce I6 Possible Rub Points MaxxForce I6 Possible Rub Points



Component Function / Description

APS/IVS Circuit Operation

� The APS/IVS is integrated into one component and mounted on the pedal. The APS/IVS switch can be replaced without replacing the complete assembly.

APS

• The APS is a potentiometer sensor that is supplied with a 5 V reference voltage at Pin C from ECM Pin C‐63. The sensor is grounded at Pin B from ECM Pin C‐34. The sensor returns a variable voltage signal from Pin A to ECM Pin C‐33.

IVS

• The IVS is an ON / OFF switch that is supplied B+ on Pin F from the VIGN fuse. The switch sends and ON or OFF idle voltage signal from Pin D to ECM Pin C‐47.

APS Auto‐Calibration

• The ECM auto‐calibrates the APS signal every time the ignition key is turned on. The ECM "learns" the lowest and highest pedal positions allowing for maximum pedal sensitivity. When the key is turned off, this information is lost until the next key cycle where the process is repeated. No accelerator pedal adjustment is needed with this feature.

Fault Detection / Management

• When the key is on, the ECM continuously monitors the APS/IVS circuits for expected voltages. It also compares the APS and IVS signals for conflict. If a conflict occurs, the ECM will set a Diagnostic Trouble Code (DTC). Any malfunction of the APS/IVS sensor circuit will illuminate the amber engine lamp. If the ECM detects an APS signal Out of Range HIGH or LOW, the engine will ignore the APS signal and operate at low idle. If a disagreement in the state of IVS and APS is detected by the ECM and the ECM determines that it is an IVS fault, the ECM will only allow a maximum of 50% APS to be commanded. If the ECM cannot discern if it is an APS or IVS fault, the engine will be allowed to operate at low idle only.

Troubleshooting

NOTE:

When performing diagnostic tests, be sure to refer to the correct circuit diagram manuals, found in the Service Portal, for the vehicle you are working on.



ZTSE 4485A ‐ APS /IVS Breakout Tee

MaxxForce® 5, 7 DT, 9 and 10 General Circuit Diagram

Connector Voltage Checks (Disconnect sensor from harness. Connect breakout harness to chassis harness only. Turn ignition switch to ON. Use DMM to measure voltage.)

Test Points Specification Comments

A to Gnd 0 V If > 0.25V, signal is shorted to PWR.

B to Gnd 0 V If > 0.25 V, check for short to PWR.

C to Gnd 5 V

If > 5.5 V, check VREF for short to PWR.

If < 4.5 V, check VREF for OPEN or short to GND. Perform "Harness Resistance Checks"

D to Gnd 0 V If > 0.25 V, check for short to PWR. Perform "Harness Resistance Checks"

F to Gnd B+ If < B+, check for OPEN or blown fuse.



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(Turn ignition switch to OFF. Disconnect battery GND and 9260 GND connector. Connect breakout box and breakout harness. Leave ECM and sensor disconnected. Use DMM to measure resistance.)

Test Points Specification Comments

A to C‐33 < 5 ohms If > 5 ohms, check for APS signal circuit OPEN.

B to C‐34 < 5 ohms If > 5 ohms, Signal ground OPEN

C to C‐63 < 5 ohms If > 5 ohms, VREF wire OPEN.

D to C‐47 < 5 ohms If > 5 ohms, IVS signal circuit OPEN.

F to Fuse < 5 ohms If > 5 ohm, IVS power circuit OPEN.

Operational Voltage Checks (Check with breakout tee installed and APS/IVS sensor connected)

APS Test PointsAPS A or C‐48 to

ground

IVS Test PointsIVS D or C‐47 to

ground

Operational Signal Checks(Check with breakout box installed on ECM and Engine

Harness)

Position Voltage APS% Voltage APS% Comments

Low Idle 0.64 ‐ 0.66V 0 % 0 V 0 % IVS toggles just off idle.

High Idle 3.85 ‐ 4.00 V 100% 12 ± 1.5 V 100%

NOTE:

If all circuit and operational tests have been performed, and all wiring / components have been inspected and are deemed to be satisfactory, yet the issue is still unresolved, recommend opening a tech service case file for further diagnostic assistance.

Additional Related iKNow Documents

• IK0800392 ‐ APS Diagnostics by Engine

� IK0800218 ‐ Accelerator Position Sensor/Idle Validation Switch APS / IVS Diagnostics, 3‐Box equipped engine control systems

• IK0800219 ‐ DLC equipped vehicles Accelerator Position Sensor / Idle Validation Switch APS / IVS Diagnostics NavPak�, CEC equipped engine control systems

• IK0800223 ‐ DLCII equipped vehicles AcceIerator Position Sensor / Idle Validation Switch APS / IVS Diagnostics DLCII equipped engine control systems

• IK0800227 ‐ Accelerator Position Sensor / Idle Validation Switch APS / IVS Diagnostics MaxxForce® 11 and 13 engines

