FREE Cummins INSITE Software: Switch and Sensor Intermittent Connection Test on CUMMINS Engines

Switch and Sensor Intermittent Connection Test

Figure 1.1 - ECM Diagnostic Tests

#About

The Switch and Sensor Intermittent Connection Test is designed to aid in the identification of intermittent wiring connection problems that are difficult to locate. This test displays switch and sensor values as read from the ECM. Up to five switches or five sensors may be tested at one time. Once the test is started, it will display a bar graph showing the current value of each selected switch or sensor. While the test is running, wires can be gently twisted, bent, and pulled. As changes to the switch or sensor values occur, they are displayed on the test screen.

#Initial Condition

→Vehicle stationary (if applicable)

→Engine off

→Attempt to recreate the conditions present when the issue was originally observed. (For example, engine speed, engine temperature, and vehicle speed).

#To Perform the Test

1). Open Cummins INSITE and connect to diagnostic port on the Engine. Read More: How to Connecting CUMMINS Engines using Cummins INSITE Software.

2). Select Switch and Sensor Intermittent Connection Test from the ECM Diagnostic Tests window (refer to Figure 1.1 above), and then select Next.

Figure 1.2 - Switch and Sensor Intermittent Connection Test

3). Select up to five switch or sensor connections to be tested, then select Next.

NOTE: Only switches or sensors can be tested at one time, not both.

(a). Sensor Setting - Enable Sensor Selection (Up to 5)

Figure 1.3 - Enable Sensor Selection

→The test will display the name of each sensor selected. It will then determine an initial value for each selected sensor and display that value in the Baseline column.

→If necessary, adjust the Voltage Range before starting the test by using the up and down controls. The Voltage Range is added and subtracted from the baseline value to define the Out of Range limits on the graph. It can be adjusted depending upon the sensitivity required for the monitored sensor.

Figure 1.4 - Baseline (3.56V)

→Select Start.

Figure 1.5 - Current (Min/ Max 3.56V)

→Beginning as close to the tested sensor as possible and working back through the harness to the ECM, gently twist, bend and pull on the wire and connections.

→Changes to the sensor value will be displayed as they occur. The numeric value of each sensor will be continuously updated in the Current column as the test is running. The bar graph will display this value as well. If the sensor value goes outside of the voltage range, the graph's bar will change from green to red. The largest changes in voltage will be displayed in the Min and Max columns as well as on the bar graph.

Figure 1.6 - Out of Range (5.00V)

→Select Stop to freeze the values on the screen.

→Select Start again to reinitialize the screen and continue testing or select Back to return to the previous screen.

→Select Back again to close the test.

(b). Switch Setting - Enable Switch Selection (Up to 5)

Figure 1.7 - Enable Switch Selection

→The test will display the name of each switch selected. It will then read the initial status of the switch from the ECM, and display that status in the Baseline column.

Figure 1.8 - Baseline (Low)

→Select Start.

Figure 1.9 - Current (Low)

→Beginning as close to the tested switch as possible and working back through the harness to the ECM, gently twist, bend and pull on the wire and connections. Changes to the switches status will be displayed as they occur. These changes are displayed in the Current column as well as the bar graph.

Figure 2.1 - Out of Range (Good)

→Select Stop to freeze the values on the screen.

→If necessary, select Start again to reinitialize the test screen and continue testing.

→When finished, select Back to return to the previous screen.

→Select Back again to close the test.

#Additional Information

• If monitoring sensors, the Out of Range limits can be changed from the default value before starting the test.
• The maximum and minimum values are indicated on the screen. The values can be viewed by placing the mouse over the indication.
• The fewer parameters that are being monitored, the faster the sample rate.
• This test will be affected by fluctuations from valid sensor data. This will be especially true if the engine is running. For example, a truck that is cooling down will show exhaust temperature voltages changing even if the wiring is good.
• Wiring issues are normally indicated by rapid Voltage changes.
• If unable to recreate an intermittent issue while stationary, re-perform this test while operating the machine.

Read More:

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