Cylinder Performance Analyzer Tool Training Program Study Guide

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1 TMT CLASS COURSE CODE: D1202 FIRST EDITION, FEBRUARY 2012 Cylinder Performance Analyzer Tool Training Program Study Guide

3 Cylinder Performance Analyzer STUDY GUIDE 2012 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc. 1

4 STUDY GUIDE Cylinder Performance Analyzer Training Program TABLE OF CONTENTS Introduction MODULE 1: PURPOSE OF THE TOOL... 5 MODULE 2: COMPONENTS... 7 MODULE 3: TOOL INSTALLATION... 9 MODULE 4: TOOL INSTALLATION MODULE 5: RUNNING TESTS MODULE 6: ACCESSING SAVED DATA CONCLUSION 2

5 Cylinder Performance Analyzer INTRODUCTION INTRODUCTION Welcome to the Navistar training course for the Cylinder Performance Analyzer tool. This course will introduce you to the Cylinder Performance Analyzer tool, and the diagnostic and service procedures that must be followed when using the tool. OBJECTIVES Upon completion of this program you will be able to: Defi ne the purpose of the CPA Tool, identify the CPA Tool components, install and operate the CPA Tool and software, perform diagnostic tests using the CPA Tool, and interpret the diagnostic test results to identify the presence of one or more problem cylinders of an engine. Defi ne Purpose of CPA Tool Identify CPA Tool Components Install and Operate CPA Tool Perform Diagnostic Tests Using CPA Tool Interpret Diagnostic Results to Identify Problem Cylinder(s) MODULES This course consists of the following six modules: Purpose of the Tool, Components, Tool Installation, Software Operation, Running Tests, and Accessing Saved Data. 1. Purpose of the Tool 2. Components 3. Tool Installation 4. Software Operation 5. Running Tests 6. Accessing Saved Data 3

6 STUDY GUIDE Cylinder Performance Analyzer Diagnostic and Service Procedures NOTES 4

Cylinder Performance Analyzer MODULE 1 MODULE 1: PURPOSE OF THE TOOL Purpose of the Tool The Cylinder Performance Analyzer, or CPA, tool is intended to assist in

7 Cylinder Performance Analyzer MODULE 1 MODULE 1: PURPOSE OF THE TOOL Purpose of the Tool The Cylinder Performance Analyzer, or CPA, tool is intended to assist in the diagnosis of power cylinder defects by monitoring camshaft and crankshaft signals. Assists in Diagnostics Monitors Camshaft Signal Monitors Crankshaft Signal 5

8 STUDY GUIDE Cylinder Performance Analyzer Training Program NOTES 6

9 Cylinder Performance Analyzer MODULE 2 MODULE 2: COMPONENTS THE CYLINDER PERFORMANCE ANALYZER, OR CPA TOOL, IS A SENSITIVE AND SOPHISTICATED PIECE OF EQUIPMENT; ANY EXTERIOR DAMAGE MAY CAUSE ADVERSE AFFECTS TO THE FUNCTIONALITY OF THE TOOL AND CAUSE IMPROPER TEST RESULTS. Components The CPA tool has four components: USB Cable; Sensor Tee Harness for the Camshaft Position Sensor, or CMP; Sensor Tee Harness for the Crankshaft Position Sensor, or CKP; and the Cylinder Performance Analyzer. The CPA tool also requires the use of an Electronic Service Tool, or EST. 1. USB Cable 2. Tee Harness for the Camshaft Position Sensor (CMP) 3. Tee Harness for the Crankshaft Position Sensor (CKP) 4. Cylinder Performance Analyzer USB Cable The USB cable connects the Cylinder Performance Analyzer to the EST. Camshaft Sensor Tee Harness The Sensor Tee Harness for the CMP connects in-line between the sensor and engine harness to allow for signal capture. The Sensor Tee Harness for the CMP has yellow braiding near the connectors for easier identifi cation. Crankshaft Sensor Tee Harness The Sensor Tee Harness for the CKP connects in-line between the sensor and engine harness to allow for signal capture. Cylinder Performance Analyzer The Cylinder Performance Analyzer receives signals from both the camshaft and crankshaft position sensors and relays the information to the EST. Located on the front of the CPA case are two potentiometers that allow for signal adjustment when performing a signal check. 7

10 STUDY GUIDE Cylinder Performance Analyzer Training Program NOTES 8

Cylinder Performance Analyzer MODULE 3 MODULE 3: TOOL INSTALLATION Camshaft position sensor To install the

Next, plug the male end of the sensor Tee Harness into the CMP, and plug the female end into the engine

If the ECM loses connection with the CMP, the engine may stop running during the Full Load to Highway Speed

Pull the harness tight and use zip ties to keep it out of the way of the accessory belt and pulleys.

side of the vehicle. Plug the harness into the CAM SENSOR port of the CPA tool.

CRANKSHAFT POSITION SENSOR. Next, disconnect the Crankshaft Position Sensor.

loses connection with the CKP, the engine may stop running during the Full Load to Highway Speed test.

11 Cylinder Performance Analyzer MODULE 3 MODULE 3: TOOL INSTALLATION Camshaft position sensor To install the CPA tool on an engine, start by disconnecting the Camshaft Position Sensor. Next, plug the male end of the sensor Tee Harness into the CMP, and plug the female end into the engine wiring harness. Ensure a good connection by listening for a click when the connector is fully inserted. If the ECM loses connection with the CMP, the engine may stop running during the Full Load to Highway Speed test. Route the Sensor Tee Harness next to the front engine harness and up the driver s side of the engine. Pull the harness tight and use zip ties to keep it out of the way of the accessory belt and pulleys. Once secured, continue routing the sensor Tee Harness out of the engine compartment and to the driver s side of the vehicle. Plug the harness into the CAM SENSOR port of the CPA tool. IT MAY BE NECESSARY TO REMOVE THE ENGINE COVER OR DRIVERS SIDE QUARTER FENDER TO GAIN ACCESS TO THE CRANKSHAFT POSITION SENSOR. Next, disconnect the Crankshaft Position Sensor. Plug the male end of the Sensor Tee Harness into the CKP and the female end into the engine wiring harness. Ensure a good connection by listening for a click when the connector is fully inserted. If the ECM loses connection with the CKP, the engine may stop running during the Full Load to Highway Speed test. Route the harness out to the driver s side of the engine compartment and connect it to the CRANK SENSOR port of the CPA tool. 9

12 STUDY GUIDE Cylinder Performance Analyzer Diagnostic and Service Procedures NOTES 10

Cylinder Performance Analyzer MODULE 4 MODULE 4:

CPA tool is connected to the engine, connect the tool

WITH A VERSION OF SERVICEMAXX WHICH INCORPORATES THE

DROPDOWN AND SELECT CYLINDER PERFORMANCE ANALYZER.

open the Cylinder Performance Analyzer software by

navigating through Programs, Navistar, Engine

Engine Cylinder Performance Analyzer tab.

Manually enter the Base Engine Type, Engine Type,

VIN, ESN, Transmission Type, Horsepower Rating, Total

Name, Operator, and Customer Complaints.

follows the cursor with examples of information to be

The help tip strip can be disabled by checking the

13 Cylinder Performance Analyzer MODULE 4 MODULE 4: SOFTWARE OPERATION Software Operation Now that the CPA tool is connected to the engine, connect the tool to the EST and verify the light located near the USB port on the CPA tool is fl ashing. IF YOU ARE USING AN EASYTECH EST THAT IS EQUIPPED WITH A VERSION OF SERVICEMAXX WHICH INCORPORATES THE CPA TOOL, YOU WILL NEED TO START BY OPENING THE SERVICEMAXX SOFTWARE. ONCE SERVICEMAXX HAS BEEN OPENED, CLICK THE TESTS DROPDOWN AND SELECT CYLINDER PERFORMANCE ANALYZER. If you are using an older version of ServiceMaxx, open the Cylinder Performance Analyzer software by clicking on the Start menu from the desktop and navigating through Programs, Navistar, Engine Cylinder Performance Analyzer, and clicking on the Engine Cylinder Performance Analyzer tab. Next, enter the appropriate information into each of the dialog boxes. The time and date will automatically populate. Manually enter the Base Engine Type, Engine Type, Software Identifi cation, Engine Family Rating Code, VIN, ESN, Transmission Type, Horsepower Rating, Total Miles, Total Fuel Used, Total Engine Hours, Dealer Name, Operator, and Customer Complaints. While navigating the dialog box, a help tipstrip follows the cursor with examples of information to be entered in each fi eld. The help tip strip can be disabled by checking the Hide Help Tipstrip box. Click Proceed once all of the correct information has been input to the respective fi elds. If the fi elds are not completely fi lled in, a pop-up window will display the blank fi elds and will not allow the program to advance. 11

STUDY GUIDE Cylinder Performance Analyzer Diagnostic and Service Procedures MODULE 4: SOFTWARE OPERATION Software Operation This image identifi es all of the buttons and information that become

14 STUDY GUIDE Cylinder Performance Analyzer Diagnostic and Service Procedures MODULE 4: SOFTWARE OPERATION Software Operation This image identifi es all of the buttons and information that become active after advancing from the dialog box. These items are the: 1. Speed History Graph 2. Cylinder Graphic 3. CKP Signal 4. CMP Signal 5. Description of Test Results 6. Stop Test Button 7. Start Test Button 8. Autosave Box 9. Test List Dropdown 10. Information Table

Cylinder Performance Analyzer MODULE 4 MODULE 4: SOFTWARE OPERATION Mandatory Tests: Signal Check Hot Idle Full Load to Highway Speed Test

be performed using the CPA Tool. The categories are Mandatory Tests, Test as Per Customer Complaint, and Test as Per Tech Services Request.

The Cold Idle test is performed as Per Customer Complaint, and the User Defi ned test is performed as Per Tech Services Request.

This test must be completed before performing the Full Load to Highway Speed or User Defined tests.

15 Cylinder Performance Analyzer MODULE 4 MODULE 4: SOFTWARE OPERATION Mandatory Tests: Signal Check Hot Idle Full Load to Highway Speed Test as Per Customer Complaint: Cold Idle Test as Per Tech Services Request: User Defined Test List There are three categories of tests that can be performed using the CPA Tool. The categories are Mandatory Tests, Test as Per Customer Complaint, and Test as Per Tech Services Request. The Signal Check, Hot Idle test, and Full Load to Highway Speed test are all Mandatory Tests. The Cold Idle test is performed as Per Customer Complaint, and the User Defi ned test is performed as Per Tech Services Request. Signal Check Explanation The signal check will verify the signal from the CMP and CKP sensors while an engine is running. This test must be completed before performing the Full Load to Highway Speed or User Defined tests. Hot Idle Explanation The Hot Idle test is used to find faults associated with the combustion of each cylinder while an engine at operating temperature is running at idle speed. Full Load to Highway Speed Explanation The Full Load to Highway Speed test is used to determine power cylinder failure while an engine is under load. Cold Idle Explanation The Cold Idle test is used to determine power cylinder failure while a cold engine is running at idle speed. The vehicle must be allowed to cold soak before performing this test. 13

16 STUDY GUIDE Cylinder Performance Analyzer Training Program NOTES 14

Cylinder Performance Analyzer MODULE 5 MODULE 5: RUNNING TESTS Preliminary Steps The fi rst step taken before performing any tests with the CPA tool is starting the engine.

WHILE PERFORMING TESTS WITH THE CPA TOOL AND ITS SOFTWARE, UTILIZE THE BRIEF TEST DESCRIPTION BOX TO ADD ANY ADDITIONAL INFORMATION THAT MAY ASSIST TECHNICAL SERVICES.

17 Cylinder Performance Analyzer MODULE 5 MODULE 5: RUNNING TESTS Preliminary Steps The fi rst step taken before performing any tests with the CPA tool is starting the engine. Next, select which test is to be completed by using the Test List. WHILE PERFORMING TESTS WITH THE CPA TOOL AND ITS SOFTWARE, UTILIZE THE BRIEF TEST DESCRIPTION BOX TO ADD ANY ADDITIONAL INFORMATION THAT MAY ASSIST TECHNICAL SERVICES. THE DETAILED TEST DESCRIPTIONS/ TEST COMMENTS BOX SHOULD ALSO BE USED TO DESCRIBE ANY IMPORTANT OBSERVATIONS DURING THE TESTING. Signal Check Let s start by covering the Signal Check. With the engine running, select Signal Check from the Test List drop down menu. Ensure the Auto Save box is checked. Next, click the Start Test button. A dialog box will open and explain how to perform the test. Adjust the potentiometers all the way towards the positive symbol and follow the instructions in the dialog box. The test will auto stop and a pop-up screen will display the test results. The signal check results are only accepted for two days. After the two day period another signal check will need to be completed. Hot Idle Test Before performing the Hot Idle test, verify the engine coolant is at least 180 degrees Fahrenheit, or 82 degrees Celsius, and that the engine is running. Then, select the Hot Idle test from the Test List drop down menu. Ensure the Auto Save button is checked, and then click the Start Test button. Let the test run for approximately 30 seconds, then click the Stop Test button. Review the data in the summary box and the cylinder graphic to the right. Refer to the summary box for further instruction and required steps. Full Load to Highway Speed Test If possible, load the vehicle to 75% of its Gross Vehicle Weight Rating, or GVWR, before performing the Full Load to Highway Speed test. Once loaded, ensure the engine is running and then select the Full Load to highway speed test from the Test List drop down menu. Click the Start Test button and rapidly accelerate the vehicle up to highway speeds. The Full Load to highway speed test will automatically stop after the software has collected the appropriate data. Review the data in the summary box and the cylinder graphic to the right. Refer to the summary box for further instruction and required steps. 15

18 STUDY GUIDE Cylinder Performance Analyzer Training Program MODULE 5: RUNNING TESTS Cold Idle Test To properly identify certain customer complaints using the Cold Idle test, it may be required to let the vehicle sit outside over night. After ensuring the vehicle has been fully cold-soaked, start the engine and select the Cold Idle test from the drop down menu. Click the Start Test button and run the test for approximately 30 seconds. After the allotted time has elapsed, press the Stop Test button. Review the data in the summary box and the cylinder graphic to the right. Refer to the summary box for further instruction and required steps. User Defined The User Defi ned test is not used during normal diagnostics. Rather, this test is only to be performed when instructed by, and with the assistance of, technical services. Interpret Test Data At the end of each test, the data collected will display in several different areas. The speed history graph will display the fl uctuations in engine speed in a line style graph. The cylinder graphic will display either the color red, green, or blue in some or all of the represented cylinders. Red indicates a power cylinder with a defect, Green indicates no defect found, and Blue indicates high speed fl uctuation with no defect found. High speed fl uctuation does not designate a cylinder defect. If the Hot Idle and Full Load to Highway Speed tests indicate high speed fl uctuation, check the ECM for calibration updates. If the ECM calibration is current and the problem persists, contact technical services for further assistance. 16

19 Cylinder Performance Analyzer MODULE 5 NOTES 17

Saved Data To access previously saved data stored

20 STUDY GUIDE Cylinder Performance Analyzer Training Program MODULE 6: ACCESSING SAVED DATA Accessing Saved Data To access previously saved data stored by the Cylinder Performance Analyzer, double click the My Computer icon on the desktop. Select the C: drive and double click the Engine Cylinder Performance Analyzer folder. All auto-saved data from the Cylinder Performance Analyzer can be found here. 18

21 Cylinder Performance Analyzer MODULE 6 NOTES 19

22 Cylinder Performance Analyzer STUDY GUIDE

2010 EPA 2013 HD-OBD N9 and N10 with SCR Diagnostics for Technicians. Study Guide. Course Code: 8448

2010 EPA 2013 HD-OBD N9 and N10 with SCR Diagnostics for Technicians Study Guide Course Code: 8448 1 2010 EPA 2013 HD-OBD N9 and N10 with SCR Diagnostics for technicians Study Guide 2014 Navistar, Inc.