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Principles of the Control System of Price Quotation Inquiry for Generator Leasing and Leasing in Ningbo Area, Zhejiang Province


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Resistance check

note

When servicing electrical connectors, to prevent the pins from expanding and damaging the connectors, you must use the correct leads and / or Cummins® approved circuit test tools.

If INSITE ™ service software is available, monitor the switch circuit for proper operation. Otherwise, follow the troubleshooting and troubleshooting steps in this section.

Disconnect the original equipment manufacturer (OEM) harness from the Cummins Electronic Control Module (ECM).

Plug the test lead into the remote throttle switch signal contact on the OEM harness connector and connect it to the multimeter test lead. Ground another test lead to the Cummins ISB5.9 G CM2180 engine block. Turn the remote throttle switch to the ON position. The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, check if the remote throttle switch signal wire is open. Refer to the OEM Troubleshooting Manual.

If the resistance value meets the technical specifications, you must check whether the remote throttle switch signal wire is short-circuited to ground, whether the terminal is short-circuited between terminals, and whether it is short-circuited to an external power source.

Check for short to ground

When checking for a short circuit, disconnect the OEM wiring harness connector from the ECM and disconnect the OEM wiring harness from the remote throttle switch to isolate the remote throttle switch circuit.

Adjust the multimeter to measure the resistance. Plug the test lead into the remote throttle switch signal lead on the OEM harness connector and connect it to the multimeter test lead. Use another multimeter test lead to contact the Cummins ISB5.9 G CM2180 engine block to ground. Measure resistance.

The multimeter must show an open circuit (100K ohms or greater). If the circuit is not open and the switch has been previously checked, there is a short to ground in the remote throttle switch circuit.

Repair or replace the wires connected to the remote throttle switch signal. Refer to the OEM Troubleshooting Manual.

Check for shorts between the pins

Turn the remote throttle switch to the OFF position. Plug the test lead into the remote throttle switch signal lead on the OEM harness connector.

Connect the test leads to the multimeter test lead. Plug another test lead from the multimeter connected to the test leads into the switch circuit lead on the OEM harness connector. Measure resistance.

The multimeter must show an open circuit (100K ohms or greater).

Remove the test leads from the remote throttle switch signal leads and check all other contact pins. The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open and the switch has been previously checked, there is a short circuit between the remote throttle switch signal stylus and any stylus showing a closed circuit.

Repair or replace the wires in the OEM harness. Refer to steps 019-071.

Check for short to external power

Turn the vehicle key switch to the ON position. Set the remote throttle switch to the ON position. Set up your multimeter to measure DC voltage (VDC). Plug the test lead into the remote throttle switch signal lead and connect it to the multimeter test lead. Use another multimeter test lead to contact the Cummins ISB5.9 G CM2180 engine block to ground. Measure the voltage. The voltage must be 1.5 volts or less.

If the voltage is incorrect, there is an external power source connected to the circuit, or there is a short circuit between the remote throttle switch circuit and the live wires in the OEM harness. Repair or replace OEM wiring harness. Refer to steps 019-071.

Cummins ISB5.9 G CM2180 engine knock sensor removal

Note: Cummins ISB5.9 G CM2180 engine is equipped with two knock sensors. Use the following steps to understand the exact location on the Cummins ISB5.9 G CM2180 engine. Refer to steps 100-002 in Section E.

Disconnect the wiring harness from the sensor.

Remove the sensor from the Cummins ISB5.9 G CM2180 engine.

installation

Note: Washers should not be used when mounting the sensor. Double head studs can be secured with thread compound.

Install the sensor in the correct position on the block or head.

Torque: 20 nm [177 in-lb]

Harness to connect sensors. You should hear a click when the connection is complete.

Cummins ISB5.9 G CM2180 engine exhaust back pressure sensor

Disassembly

Disconnect the wiring harness from the sensor.

Remove the sensor from the Cummins ISB5.9 G CM2180 engine.

installation

Check and make sure the sensor has an o-ring.

Install the sensor.

Harness to connect sensors. When the connection is complete, you will hear a click.

Torque: 11 nm [97 in-lb]

Cummins ISB5.9 G CM2180 engine mixer inlet pressure sensor circuit

Resistance check

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the mixer inlet pressure sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the mixer inlet pressure in the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector +5 VDC power stylus (2) and the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the power leads.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-202 in Section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the mixer inlet pressure circuit stylus of the Cummins ISB5.9 G CM2180 engine harness ECM connector 2 and the corresponding stylus of the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the return wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-202 in Section 19.

Refer to steps 019-204 in Section 19.

Check for short to ground

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the mixer inlet pressure sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the mixer inlet pressure circuit stylus of the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector and the Cummins ISB5.9 G CM2180 engine block ground terminal.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the return wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the mixer inlet pressure of the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector +5 VDC power stylus (2) and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the power leads.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the mixer inlet pressure sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the mixer inlet pressure of the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector +5 VDC power stylus (2) and all the pins of the Cummins ISB5.9 G CM2180 engine harness ECM No. 1 connector.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance value between the contact pins of the mixer inlet pressure circuit of the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector and all the pins of the Cummins ISB5.9 G CM2180 engine harness ECM No. 1 connector.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine heated oxygen sensor circuit

Resistance check

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the ECM power connector. Disconnect the 31-pin Cummins ISB5.9 G CM2180 engine harness connector from the 31-pin OEM harness connector. Disconnect the heated oxygen sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the heated (+) signal stylus of the Cummins ISB5.9 G CM2180 engine harness 31-pin connector and the corresponding stylus of the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the heated oxygen sensor heater (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-203 in Section 19.

Refer to steps 019-208 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the negative (-) stylus of the heated oxygen sensor of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding stylus of the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the heated oxygen sensor (-) wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-203 in Section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for short to ground

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the ECM power connector. Disconnect the 31-pin Cummins ISB5.9 G CM2180 engine harness connector from the 31-pin OEM harness connector. Disconnect the heated oxygen sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) stylus of the heated oxygen sensor of the 31-pin connector of the Cummins ISB5.9 G CM2180 engine harness and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the heated oxygen sensor heater (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-208 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the positive (+) stylus of the heated oxygen sensor of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

When checking both signal lines, the multimeter must show open (100 kohm or greater).

If the circuit is not open, there is a short to ground in the heated oxygen sensor heater (-) wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the ECM power connector. Disconnect the 31-pin Cummins ISB5.9 G CM2180 engine harness connector from the 31-pin OEM harness connector. Disconnect the heated oxygen sensor from the Cummins ISB5.9 G CM2180 engine harness.

Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) stylus of the heated oxygen sensor of the 31-pin connector of the Cummins ISB5.9 G CM2180 engine harness and all other styluses of the Cummins ISB5.9 G CM2180 engine harness 1 and 2.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-208 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the negative (-) stylus of the heated oxygen sensor of Cummins ISB5.9 G CM2180 engine harness ECM connector and all other pins of this connector and all the stylus of Cummins ISB5.9 G CM2180 engine harness ECM connector 2. Between the resistance values.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine gas mass flow sensor circuit

Resistance check

Equipped with transformer

Disconnect the Cummins ISB5.9 G CM2180 engine harness Cummins Electronic Control Module (ECM) connector 1 from the ECM. Disconnect the transformer from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the gas mass flow sensor signal stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness transformer connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the sensor signal wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-220 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance from the transformer circuit stylus in the Cummins ISB5.9 G CM2180 engine harness to the cylinder ground.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the transformer return wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-220 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness 31-pin connector from the OEM harness.

Disconnect the transformer from the Cummins ISB5.9 G CM2180 engine harness.

Measure the resistance from the transformer +12 VDC power contacts in the 31-pin connector to the corresponding contacts in the Cummins ISB5.9 G CM2180 engine harness transformer connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the +12 VDC wire of the transformer power supply.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-220 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness from the transformer.

Disconnect the transformer from the gas mass flow sensor. Set up your multimeter to measure resistance.

Measure the resistance from the gas mass flow sensor signal stylus on the sensor connector to the signal stylus on the transformer connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the gas mass flow signal lead.

Repair or replace the transformer.

Refer to steps 019-218 in Section 19.

Refer to steps 019-439 in Section 19.

Measure the resistance from the gas mass flow sensor circuit stylus on the sensor connector to the circuit stylus on the transformer connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the gas mass flow circuit conductor.

Repair or replace the transformer.

Refer to steps 019-218 in Section 19.

Refer to steps 019-439 in Section 19.

Without transformer

Disconnect the Cummins ISB5.9 G CM2180 engine harness Cummins Electronic Control Module (ECM) connector 1 from the ECM. Disconnect the gas mass flow sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the Cummins ISB5.9 G CM2180 engine harness ECM No. 1 connector to the gas mass flow sensor supply voltage +12 VDC stylus to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the sensor supply voltage +12 VDC wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-220 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance from the gas mass flow sensor circuit stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in any of the gas mass flow sensor circuit wires.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-220 in Section 19.

Refer to steps 019-043 in Section 19.

Check for short to ground

Equipped with transformer

Disconnect the Cummins ISB5.9 G CM2180 engine harness 31-pin connector from the OEM harness. Disconnect the sensor power transformer connector from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the sensor power transformer supply voltage +12 VDC contact pin in the Cummins ISB5.9 G CM2180 engine harness 31-pin connector to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the +12 VDC wire of the sensor power transformer.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM.

Measure the resistance from the gas mass flow sensor signal stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the signal wire of the gas mass flow sensor.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Without transformer

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the gas mass flow sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the Cummins ISB5.9 G CM2180 engine harness ECM connector to the gas mass flow sensor supply voltage +12 VDC stylus to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the sensor supply voltage +12 VDC wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance from the gas mass flow sensor circuit stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the gas mass flow sensor circuit lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Equipped with transformer

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the sensor power transformer connector from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the gas mass flow sensor signal pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to all other pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the gas mass flow sensor signal pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to all the pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 2.

The multimeter must show that all contacts are open (100K ohms or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness 31-pin connector from the OEM harness.

Disconnect the transformer from the Cummins ISB5.9 G CM2180 engine.

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors.

Set up your multimeter to measure resistance.

Measure the resistance from the transformer +12 VDC power contacts in the 31-pin connector to all other contacts in the 31-pin connector.

The multimeter must show that all contacts are open (100K ohms or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness 31-pin connector from the OEM harness.

Disconnect the transformer from the Cummins ISB5.9 G CM2180 engine.

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors.

Set up your multimeter to measure resistance.

Measure the resistance between the transformer +12 VDC power contacts in the 31-pin connector and all other contacts in Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors.

The multimeter must show that all contacts are open (100K ohms or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness from the transformer.

Disconnect the transformer from the gas mass flow sensor. Set up your multimeter to measure resistance.

Measure the resistance from the gas mass flow sensor signal stylus on the sensor connector to the signal stylus on the sensor converter.

The multimeter must show that all contacts are open (100 kohm or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace the transformer.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance from the gas mass flow sensor +12 VDC power contacts on the sensor connector to all other contacts on the sensor converter.

The multimeter must show that all contacts are open (100 kohm or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace the transformer.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Without transformer

Disconnect Cummins ISB5.9 G CM2180 engine harness ECM No. 1 and No. 2 connectors from the ECM. Disconnect the gas mass flow sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between all gas probes in Cummins ISB5.9 G CM2180 engine harness ECM connector 1 +12 VDC stylus to all other pins in Cummins ISB5.9 G CM2180 engine harness ECM connector 1 .

Repeat check the resistance from the gas mass flow sensor circuit stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to all other pins in the connector.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between all gas probes in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 +12 VDC contact pins to all the pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 2.

Repeat the check of the resistance from the gas mass flow sensor circuit contacts in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to all the pins in the Cummins ISB5.9 G CM2180 engine harness ECM connector 2.

The multimeter must show that all contacts are open (100K ohms or higher).

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine fuel control valve circuit

Resistance check

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the fuel control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding contact pin of the Cummins ISB5.9 G CM2180 engine harness valve connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the fuel control valve (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance between the negative (-) stylus of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding stylus of the Cummins ISB5.9 G CM2180 engine harness valve connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the fuel control valve (-) lead. Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Check for short to ground

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the fuel control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the fuel control valve (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance between the negative (-) contact pin of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the fuel control valve (-) lead. Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM # 1 connector and power connector from the ECM. Disconnect the fuel control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and all other contacts of the connector.

Repeat the stylus-to-stylus check from the negative (-) stylus of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector No. 1 to all other pins of this connector.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance between the positive (+) stylus of the fuel control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and all the studs of the Cummins ISB5.9 G CM2180 engine harness ECM power connector.

Repeat the stylus to stylus check for all other styluses from the fuel control valve negative (-) stylus of the Cummins ISB5.9 G CM2180 engine harness ECM connector to the Cummins ISB5.9 G CM2180 engine harness ECM connector.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine wastegate control valve circuit

Resistance check

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the wastegate control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the wastegate control valve in the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding contact pin in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the exhaust bypass control (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the positive (-) contact pin of the wastegate control valve in the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the exhaust bypass control (-) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for short to ground

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the wastegate control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the wastegate control valve in the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding contact pin in the Cummins ISB5.9 G CM2180 engine harness valve connector.

The multimeter must be displayed as closed (10 kohms or less).

If the circuit is not closed, there is an open circuit in the exhaust bypass control (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the positive (-) contact pin of the wastegate control valve in the Cummins ISB5.9 G CM2180 engine harness ECM connector and the corresponding contact pin in the Cummins ISB5.9 G CM2180 engine valve connector.

The multimeter must be displayed as closed (10 kohms or less).

If the circuit is not closed, there is an open circuit in the exhaust bypass control (-) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the wastegate control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pin of the exhaust bypass control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the Cummins ISB5.9 G CM2180 engine block ground terminal.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the exhaust bypass control (+) lead.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 Engine Harness ECM Connector Cummins ISB5.9 G CM2180 Engine Harness ECM Connector Negative (-) Stray Bypass Control Valve Negative (-) in Stylus and Cummins ISB5.9 G CM2180 Engine Block The resistance value between the ground terminals.

The multimeter must show that all contacts are open (100K ohms or higher).

If the circuit is not open, there is a short to ground in the positive (-) lead of the wastegate control valve.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connectors 1, 2 and ECM power connector from the ECM. Disconnect the wastegate control valve from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance between the positive (+) contact pins of the exhaust bypass control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 and all other contact pins of the connector.

Repeat the check between the negative (-) contact pin of the exhaust bypass control valve of the Cummins ISB5.9 G CM2180 engine harness ECM No. 1 connector and all other contact pins of this connector.

Measure the resistance between the positive (+) contact pins of the exhaust bypass control valve of the Cummins ISB5.9 G CM2180 engine harness ECM connector and all the contacts of the Cummins ISB5.9 G CM2180 engine harness ECM power connector.

The multimeter must show that all contacts are open (100 kohm or higher).

If the circuit is not open, there is a short circuit between the contact pins used.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine intake manifold absolute pressure and temperature sensor circuit

Resistance check

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the intake manifold absolute pressure and temperature sensors from the Cummins ISB5.9 G CM2180 engine harness. Disconnect the oil pressure / temperature sensor from the Cummins ISB5.9 G CM2180 engine harness.

Set up your multimeter to measure resistance.

Measure the resistance between the intake manifold absolute pressure in the Cummins ISB5.9 G CM2180 engine harness ECM connector + 5 VDC power stylus and the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector. Repeatedly measure the resistance between the pressure signal stylus of the ECM connector and the corresponding stylus in the sensor harness connector.

During the resistance check, the multimeter must display a reading of 10 ohms or less (closed circuit). If the circuit is not closed, repair or replace the Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the temperature signal stylus of the ECM connector and the corresponding stylus in the sensor harness connector. Repeatedly measure the resistance between the pressure / temperature loop stylus of the ECM connector and the corresponding stylus in the sensor harness connector.

In both resistance checks, the multimeter must display a reading of 10 ohms or less (closed circuit). If the circuit is not closed, repair or replace the Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-205 in section 19.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for short to ground

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM.

Disconnect the intake manifold absolute pressure and temperature sensors from the Cummins ISB5.9 G CM2180 engine harness.

Set up your multimeter to measure resistance.

Measure the resistance between the pressure signal stylus of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the ground terminal of the Cummins ISB5.9 G CM2180 engine block. Repeat the short-to-ground check between the temperature signal stylus of the Cummins ISB5.9 G CM2180 engine harness ECM connector and the ground terminal of the Cummins ISB5.9 G CM2180 engine block.

During the two short-to-ground checks, the multimeter must display a reading of 100 kohms or greater (open circuit). If the circuit is not open, repair or replace the Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect the two Cummins ISB5.9 G CM2180 engine harness ECM connectors from the ECM.

Disconnect the ECM power connector.

Disconnect the intake manifold absolute pressure and temperature sensors from the Cummins ISB5.9 G CM2180 engine harness.

Set up your multimeter to measure resistance.

Measure the resistance from the pressure signal stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to all other pins in the connector 1. Repeat the check between the stylus from the temperature signal stylus to all other styluses in the connector and from the pressure / temperature circuit stylus to all other styluses in the connector.

Multimeter measurements show that resistance readings between all styluses must be 100 kohms or greater (open circuit). If the circuit is not open, there is a short circuit between the stylus under test.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Measure the resistance between the pressure signal contacts in the Cummins ISB5.9 G CM2180 engine harness ECM No. 1 connector to all the pins in the Cummins ISB5.9 G CM2180 engine harness ECM No. 2 connector. Repeat from stylus of temperature signal in ECM connector No. 1 to all stylus in ECM connector No. 2 and from pressure / temperature circuit stylus in ECM connector No. 1 to all stylus in ECM connector No. 2 Check the resistance between times.

Multimeter measurements show that resistance readings between all styluses must be 100 kohms or greater (open circuit). If the circuit is not open, there is a short circuit between the stylus under test.

Repair or replace Cummins ISB5.9 G CM2180 engine harness.

Refer to steps 019-204 in Section 19.

Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine humidity sensor

Disassembly

Turn the locking tab to the side.

Push the button toward the rear of the connector and remove it from the sensor.

Remove the sensor from the mixer inlet elbow.

installation

Verify that the new sensor has an O-ring on the sealing surface of the inlet manifold with the mixer.

Lubricate the o-ring.

Install the sensor into the mixer inlet elbow.

Torque: 14 nm [124 in-lb]

Push the connector until it locks.

Turn the locking tab to the locked position.

Cummins ISB5.9 G CM2180 engine humidity sensor circuit

Resistance check

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the humidity sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the humidity sensor +5 VDC power stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the power leads.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance from the humidity sensor circuit stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must be shown as closed (10 ohms or less).

If the circuit is not closed, there is an open circuit in the return wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance from the humidity sensor signal stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the corresponding stylus in the Cummins ISB5.9 G CM2180 engine harness sensor connector.

The multimeter must show closed circuit (10 ohms or less) during both inspections.

As long as one circuit is not closed, there is an open circuit in the signal wire under test.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Check for short to ground

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 from the ECM. Disconnect the humidity sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure the resistance from the humidity sensor circuit stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the return wire.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance from the humidity sensor signal stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector 1 to the Cummins ISB5.9 G CM2180 engine block ground.

When checking both signal lines, the multimeter must show open (100 kohm or greater).

If the circuit is not open, there is a short to ground in the signal wire under test.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Measure the resistance from the humidity sensor +5 VDC power stylus in the Cummins ISB5.9 G CM2180 engine harness ECM connector to the Cummins ISB5.9 G CM2180 engine block ground.

The multimeter must show an open circuit (100K ohms or greater).

If the circuit is not open, there is a short to ground in the power leads.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Check for shorts between the pins

Disconnect the Cummins ISB5.9 G CM2180 engine harness ECM # 1 connector and power connector from the ECM. Disconnect the humidity sensor from the Cummins ISB5.9 G CM2180 engine harness. Set up your multimeter to measure resistance.

Measure from the humidity sensor signal stylus in Cummins ISB5.9 G CM2180 engine harness ECM connector to all other styluses in this connector and all stylus in Cummins ISB5.9 G CM2180 engine harness ECM power connector resistance.

The multimeter must show that all contacts are open.

If, during any inspection between styluses, there is no open circuit, then there is a short circuit between the styluses tested.

Repair or replace Cummins ISB5.9 G CM2180 engine harness. Refer to steps 019-043 in Section 19.

Cummins ISB5.9 G CM2180 engine electrical parts connector and stylus inspection

Overview

The following checks should be performed on all parts, connectors or harness connectors to ensure that there are no damaged contact pins.

Diagnose intermittent and current non-current circuit faults. Refer to steps 019-362 in Section 19.

Check if you can continue to use

When disconnecting the connector during troubleshooting, always check for loose connectors (gently pull the wires on the back of the connector) and check the stylus to make sure they are not the cause of the poor connection. Pay attention to whether the stylus is bent, corroded, and retracted.

Moisture inside the connector

Moisture in the joints can cause system performance problems. Moisture in joints is often difficult to see. If moisture is suspected, you must use contact cleaner part number 3824510 on the connector to dry the connector. You can also use a hot air gun, but keep it in a low heat setting so that the connectors or wires are not damaged.

NOTE: Do not blow compressed air into the electronic control unit ports or connectors. Due to condensation, compressed air may contain moisture.

Bent or enlarged stylus

Check the positive terminal of the connector. If the terminals are bent, these terminals will be difficult to plug into the other side of the connector; or if the male terminals are enlarged, that is, protruding or flattened, and they are too large to be plugged into the other side of the connector, they must be replaced needle. For faulty special connectors, refer to the connector repair section.

Stylus corrosion

Check whether the male and female terminals are corroded. Corrosion can cause poor electrical connections in the connector. If there is significant corrosion on the stylus, they must be replaced. For faulty special connectors, see the section on connector repair.

Stylus indentation

Check the male and female terminals of the stylus to see if they are retracted into the connector so that they are not touching each other. For repair, press the contact pin into the connector body from the back of the connector. Make sure the terminals are locked in place. If the terminal cannot be locked in place, it needs to be replaced. For faulty special connectors, see the section on connector repair.

Cummins ISB5.9 G CM2180 engine non-active or intermittent fault code

Overview

This step is designed to diagnose intermittent and current non-current circuit faults. This step is also suitable for diagnosing circuit-related fault codes with high non-current counts.

If there are multiple fault codes, use the electrical wiring diagram to check for common sensor power and ground circuits that may be shared by sensors, actuators, and switches. Pressure sensors may share a common 5 volt power and ground circuit. The temperature sensor and actuator may share a common ground circuit. If there is an intermittent connection in any of the sensor circuits or ground circuits, the fault codes associated with all of these sensors may become high frequency counts of current or non-active fault codes.

If there is a trigger condition for a fault code, and then that condition no longer occurs, an inactive fault code will be generated. If the condition is intermittent, there may be multiple non-current counts for a particular DTC. If there are more than 10 non-current counts, the fault code should be diagnosed and eliminated according to the current fault code. Diagnostic priority should be given to fault codes related to Cummins ISB5.9 G CM2180 engine performance components such as turbochargers, EGR valves, or any system-related fault codes.

Initial inspection

Ask the operator and determine the Cummins ISB5.9 G CM2180 engine operation at the time of the failure and the symptoms when the failure becomes current.

Determine if recent repairs or maintenance may be associated with intermittent conditions.

Refer to the "Overhaul Tips" section of the fault code diagnostic tree. Overhaul tips will provide additional troubleshooting information and will list possible causes of the fault code.

Verify that the Cummins Electronic Control Module (ECM) calibration is correct. Check the calibration version history on QuickServe® Online for revisions applicable to the ECM storage calibration. If necessary, recalibrate the ECM. Cummins ISB5.9 G CM2180 engine under repair, corresponding fault judgment and troubleshooting manual, step 19-032 (ECM calibration code) in Section 19.

Disconnect sensors or actuators related to intermittent conditions.

Check the wiring harness and connectors for the following:

Loose connector (pull the wire lightly after the connector)

Stylus corrosion

Bent or broken stylus

Stylus retracted or extended

Moisture inside or on joint

Dirt or debris in or on the stylus of the connector

Missing or damaged joint seal

Damaged wire insulation

Joint housing break

Damaged connector

Stylus wear (careful visual inspection)

The ground is dirty, the surface is painted, corroded or loose.

Thoroughly inspect the wiring harness between the suspected component and the ECM connector. Check the strain relief on the wire harness for proper operation.

The black powder found inside the connector is a sign that the stylus may be abraded. Clean the contacts of the stylus and reconnect the connector.

Disconnect the wire harness connector from the ECM. Check the ECM connector for the following conditions:

Loose connector (pull the wire lightly after the connector)

Stylus corrosion

Bent or broken stylus

Stylus retracted or extended

Moisture inside or on joint

Dirt or debris in or on the stylus of the connector

Missing or damaged joint seal

Damaged wire insulation

Joint housing break

Damaged connector

Stylus wear (careful visual inspection)

The ground is dirty, the surface is painted, corroded or loose.

Clean the connectors of the part in question and clear the fault code.

Harness shake test

Connect to INSITE ™ and open the Data Monitor / Logger feature. Monitor the sensor signal voltage of the corresponding sensor. The actual value of the sensor or component is also monitored.

Start with the problematic part first, then the wiring harness to the ECM, twist, bend, and pull each wiring harness slightly between and between the connections.

The sensor signal voltage displayed by INSITE ™ should remain stable while performing the harness shake test. Typical readings should be between 0.5 and 5.12 volts.

NOTE: This step can also be used to check if the leads of the switch are loose or damaged. INSITE ™ can be used to monitor the status of the switch. When performing the harness shake test, pay attention to whether the switch status has changed.

If the fault code becomes active, non-current count increases, sensor signal voltage fluctuations, or the state of the switch changes, it indicates a loose connection or damaged wire. Refer to steps 019–361 for component connector and stylus inspection, and check the stylus of the defective connector. Repair or replace if necessary.

Note: The ECM cannot change the status of switches and faults immediately. The ECM reading will not change until the harness is slightly twisted for 10-15 seconds. Attempting to monitor too many parameters with INSITE ™ at one time will slow down the update rate on the screen. Keep the number of parameters monitored with INSITE ™ to a minimum to increase the update rate.

Start the Cummins ISB5.9 G CM2180 engine.

Cummins ISB5.9 G CM2180 engine is connected to INSITE ™ to enable the Data Monitor / Logger feature. Monitor the sensor signal voltage of the corresponding sensor. The actual value of the sensor or component is also monitored.

The sensor signal voltage displayed by INSITE ™ should remain stable while performing the harness shake test. Typical readings should be between 0.5 and 5.12 volts.

At the same time, slightly bend, twist and pull the connection and the harness between the connections.

If the sensor signal voltage is out of range or fluctuates during the test, it means that the connection is loose or the wire is damaged somewhere. Check the stylus of the defective connector.

Ground circuit check

Check for poor battery grounding and chassis grounding. Pull the ground wire or cable forcibly and check if the connection is loose. Check the following grounds to make sure they are tightly connected, clean, and on unpainted surfaces:

Cummins ISB5.9 G CM2180 engine block ground

Grounding of chassis (or frame stringer)

ECM ground

Charger and starter motor negative terminal

When performing this step, check if the fault code has become functional or the non-current count has increased. If the above phenomenon occurs, it means that the joint is loose or the wire is damaged somewhere. Disconnect and clean the ground cable and ground surface, then reconnect. If necessary, repair or replace ground cables or wires.

Measure the resistance between the battery negative (-) terminal and the following:

ECM housing (clean, unpainted surface)

Cummins ISB5.9 G CM2180 engine block (clean, unpainted surface)

Starting motor negative (-) terminal

Charger negative (-) terminal

Fireproof partition ground terminal

Cab ground (dashboard switch, public ground)

Vehicle frame stringer.

All measured resistance values should be less than 1 ohm. If the resistance is greater than 1 ohm, clean the ground cable and ground surface, then reconnect. If necessary, repair or replace ground cables or wires.

Note: For how to use the multimeter correctly, refer to steps 019–359 “Using the Universal Multimeter”.

Voltage check

This test must be performed with the actuator connected to the wire harness.

When disconnecting the sensor or actuator from the wire harness, measure the voltage at the Cummins ISB5.9 G CM2180 engine harness connector.

Connect the sensor or actuator to the wiring harness and measure the voltage when all parts are connected. When performing an inspection, connect a tapped cable or back test probe between the connector and the multimeter's test lead.

The voltage to the part should be within 0.5 volts of the initial measured voltage. If the voltage drop is greater than 0.5 volts, check for intermittent connections between the actuator and the ECM, open wires, or corroded relay connections.

Sensor accuracy check

When the sensor circuit is open to high or low voltage, the sensor value will lock to a default value when the fault code becomes active. The default value is usually set to a value within the standard operating range of the sensor. When the sensor value is monitored with the service software, the sensor reading will show the correct value even if the fault code becomes active. Some typical global default sensor values are as follows:

Cummins ISB5.9 G CM2180 engine coolant temperature = 104.4 ° C [219.9 ° F]

Intake manifold temperature = 21.3 ° C [70.3 ° F]

Intake manifold pressure = 2.4 kpa [0.7 inHg]

EGR temperature = 37.8 ° C [100 ° F]

Cummins ISB5.9 G CM2180 engine oil pressure = 73.1 kPa [10.6 psi]

Note that the value displayed by the service software may be a default sensor reading when diagnosing intermittent circuit fault codes. When diagnosing intermittent circuit fault codes, always use the sensor signal voltage measurement.

For further investigation, use the Data Monitor / Logger feature of INSITE ™ to monitor the input and output of the running Cummins ISB5.9 G CM2180 engine and record the data in a log file. The logging feature in INSITE ™ allows information to be recorded during intermittent events and can be reviewed later.

Cummins ISB5.9 G CM2180 engine camshaft position sensor

Disassembly

Disconnect the sensor from the Cummins ISB5.9 G CM2180 engine harness. Turn the locking tab to the side. Push the button toward the rear of the connector and remove the connector from the sensor.

Remove the screws that secure the sensor to the cylinder.

Remove the sensor from the installation position.

Check if you can continue to use

Inspect the camshaft position sensor and the speed signal wheel for debris, cracks, or damage.

If there is debris on the camshaft position sensor, clean the sensor.

If the sensor is chipped, cracked, crushed, or damaged, replace the sensor with a new one.

installation

Install a new o-ring on the sensor.

Apply clean Cummins ISB5.9 G CM2180 engine oil to O-rings.

Install the new sensor in the fixing hole.

Install and tighten the screws.

Torque: 10 nm [89 in-lb]

Connect the sensor to the Cummins ISB5.9 G CM2180 engine harness.

Slide the locking tab aside to lock the connector to the sensor.

Cummins ISB5.9 G CM2180 engine crankshaft position sensor

Disassembly

Disconnect the sensor from the Cummins ISB5.9 G CM2180 engine harness. Turn the locking tab to the side. Push the button toward the rear of the connector and remove the connector from the sensor.

Remove the screws that secure the sensor to the cylinder.

Remove the sensor from the installation position.

Check if you can continue to use

Check the Cummins ISB5.9 G CM2180 engine speed sensor for debris or cracks.

If debris is on the sensor, clean the sensor.

If the sensor is chipped, cracked, or damaged, replace it with a new one.

installation

Install a new o-ring on the sensor.

Apply clean Cummins ISB5.9 G CM2180 engine oil to O-rings.

Install the new sensor in the fixing hole.

Install and tighten the screws.

Torque: 25 nm [221 in-lb]

Connect the sensor to the Cummins ISB5.9 G CM2180 engine harness.

Slide the locking tab aside to lock the connector to the sensor.

Cummins ISB5.9 G CM2180 engine fan control switch

Overview

The fan control switch circuit signals the operator that the Cummins ISB5.9 G CM2180 engine fan is engaged. Fan on and off circuits include fan control switch signals, switch circuits, and OEM toggle switches installed in the cab. This circuit is considered "fail-safe", which means that when the circuit is open, the ECM will engage the Cummins ISB5.9 G CM2180 engine fan.

NOTE: This step is valid only when the fan control switch is connected to the ECM and the manual fan switch feature is enabled in the ECM. If the fan control switch is connected in series with the fan control relay, the ECM can record the fan circuit failure during normal operation. Before performing this step, verify that the circuit is connected properly.

Resistance check

If INSITE ™ is available, it can be used to monitor whether the fan control switch is working properly. If it does not work properly, follow the troubleshooting and troubleshooting steps in this section.

Determine the position of the fan control switch. Label these wires with switch positions or wire numbers. Remove the electrical connector from the switch. Adjust the multimeter to measure the resistance. Touch a test lead of the multimeter to one terminal of the switch. Touch another multimeter test lead to the other terminal of the switch.

Turn the switch to the "ON" position and measure the resistance value. The multimeter must show an open circuit (100 kohm or greater). If the circuit is not open, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual.

Set the switch to the OFF position and measure the resistance. The multimeter must show closed circuit (10 ohms or less). If the circuit is not closed, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual. If the resistance value is correct, you must check whether the switch still has a short to ground.


Check for short to ground

Touch a test lead of the multimeter to one of the terminals of the switch. The other test lead touches the ground terminal of the chassis. Turn the switch to the "OFF" position and measure the resistance value. The multimeter must show an open circuit (100 kohm or greater). If the circuit is not open, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual. If the switch passes all the previous checks, the circuit must be checked for open circuits, shorts to ground, shorts between contacts, and shorts to external power.

Cummins ISB5.9 G CM2180 engine fan control switch circuit

Resistance check

note

When servicing electrical connectors, to prevent the pins from expanding and damaging the connectors, you must use the correct leads and / or Cummins® approved circuit test tools.

If INSITE ™ service software is available, monitor the fan control switch circuit for proper operation. Otherwise, follow the troubleshooting and troubleshooting steps in this section.

Disconnect the original equipment manufacturer (OEM) harness connector from the Cummins Electronic Control Module (ECM). Insert a test lead into the switch circuit contact pin on the OEM harness connector, and connect the alligator clip to the multimeter test lead. Insert the other wire into the fan control switch signal contact pin on the OEM harness connector, and then connect the alligator clip to the other test lead of the multimeter.

Set the fan control switch to the off position. The multimeter must be shown as closed (10 ohms or less). If the circuit is not closed and the switch has been checked previously, check the fan control switch, switch loop wires, and fan control switch signal wires for open circuits. For repair procedures, refer to the OEM troubleshooting and troubleshooting manual. If the resistance meets the technical specifications, you must check the fan control switch, the negative (-) wire of the switch circuit, and the fan control signal wire for short-circuit to ground, short-to-contact pins, and short-circuit to external power.

Check for short to ground

When checking for electrical shorts, disconnect the OEM wiring harness from the ECM and fan control switch to isolate the fan control circuit. Disconnect clutch position switch / Cummins ISB5.9 G CM2180 engine protection override switch and accelerator pedal assembly. Turn all cab panel switches off or to the neutral position. Use the trailer brake manual valve to adjust the service brake.

Adjust the multimeter to measure the resistance. Insert the test lead into the fan control switch signal contact on the OEM harness connector and connect it to the multimeter test lead. Ground the other test lead of the multimeter to the Cummins ISB5.9 G CM2180 engine block. Measure resistance.

The multimeter must show an open circuit (100K ohms or greater). If the circuit is not open and the switch has been previously checked, there is a short to ground in the fan control switch circuit. According to the vehicle manufacturer's procedures, repair or replace the wires connected to the fan control switch signal contacts on the OEM harness.

Check for shorts between the pins

Set the switch according to the previous section to isolate the fan control switch circuit. Turn the fan control switch to the on position. Insert the wire into the fan control switch signal contact. Connect the multimeter with an alligator clip. Insert another wire into the switch circuit contact pin and measure the resistance. The multimeter must show an open circuit (100K ohms or greater).

Remove the wires from the fan control switch signal contacts and check all other contacts. Measure resistance. The multimeter must show an open circuit (100K ohms or greater). If the circuit is not open and the switch has been previously checked, there is a short circuit between the fan control switch circuit and any contact pins that appear to be closed. Repair or replace the wires in the OEM harness. Refer to steps 019-071.

Check for short to external power

Turn the key switch to the ON position. Set the fan control switch to the off position. Adjust the multimeter to measure VDC (direct voltage). Insert the test lead into the fan control switch signal contact pin and connect it to the multimeter test lead. Ground the other test lead of the multimeter to the Cummins ISB5.9 G CM2180 engine block. Measure the voltage. The voltage must be 1.5 VDC or less.

If the voltage is incorrect, an external power source is connected to the circuit, or the fan control switch circuit is shorted to a live wire in the OEM harness. Remove the power supply or follow the vehicle manufacturer's steps to repair the wires in the OEM harness.

Connect all parts after the repair is completed.

Note: If the fan control switch circuit passes all the tests above, it functions normally.

Cummins ISB5.9 G CM2180 engine maximum speed switch

Overview

The maximum Cummins ISB5.9 G CM2180 engine speed switch is an OEM-installed switch that allows the driver to select a lower, programmable maximum Cummins ISB5.9 G CM2180 engine speed. Certain applications such as the use of hydraulic systems may require protection to avoid overspeed situations. The operator can toggle this switch to limit the maximum Cummins ISB5.9 G CM2180 engine speed to a lower value where the hydraulic system can work safely.

Note: The switch is programmable, which means that the speed limit position and normal position can be either on or off depending on the configuration. Determine what configuration the particular switch is in, and adjust troubleshooting and troubleshooting criteria before deciding that the switch has failed.

Resistance check

If INSITE ™ is available, monitor the maximum Cummins ISB5.9 G CM2180 engine speed switch for normal operation. Otherwise, follow the troubleshooting and troubleshooting steps in this section.

Find the maximum Cummins ISB5.9 G CM2180 engine speed switch. Label these wires with switch positions or wire numbers. Remove the electrical connector from the switch. Adjust the multimeter to measure the resistance. Touch a test lead of the multimeter to one terminal of the switch. Touch another multimeter test lead to the other terminal of the switch.

Set the switch to the on position and measure the resistance. The multimeter must show an open circuit (100 kohm or greater). If the circuit is not open, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual.

Set the switch to the off position and measure the resistance. The multimeter must show closed circuit (10 ohms or less). If the circuit is not closed, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual. If the resistance value is correct, you must check whether the switch still has a short to ground.

Check for short to ground

Touch a test lead of the multimeter to one of the terminals of the switch. The other test lead touches the ground terminal of the chassis. Turn the switch to the off position and measure the resistance. The multimeter must show an open circuit (100 kohm or greater). If the circuit is not open, the switch is faulty. For replacement procedures, refer to the OEM troubleshooting and troubleshooting manual. If the switch passes all the previous checks, the circuit must be checked for open circuits, shorts to ground, shorts between contacts and shorts to external power.

Cummins ISB5.9 G CM2180 engine speed switch circuit

Resistance check

note

When servicing electrical connectors, to prevent the pins from expanding and damaging the connectors, you must use the correct leads and / or Cummins® approved circuit test tools.

If INSITE ™ service software is available, monitor the maximum Cummins ISB5.9 G CM2180 engine speed switch circuit for proper operation. Otherwise, follow the troubleshooting and troubleshooting steps in this section.

Disconnect the original equipment manufacturer (OEM) harness connector from the Cummins Electronic Control Module (ECM). Insert a test lead into the switch circuit contact pin on the OEM harness connector and connect the alligator clip to the multimeter test lead. Plug another wire into the largest Cummins ISB5.9 G CM2180 engine speed switch signal contact pin on the OEM harness connector and connect the alligator clip to another multimeter test lead.

Note: The maximum Cummins ISB5.9 G CM2180 engine speed switch can be programmed by the OEM. Depending on the OEM-programmed switch, the open or closed position of the switch can indicate either "normal" or "speed limit". Before continuing troubleshooting, refer to the OEM Troubleshooting and Troubleshooting Manual to determine how to program the switch and use the appropriate switch failure criteria for troubleshooting.

Turn the maximum Cummins ISB5.9 G CM2180 engine speed switch to the normal position. The multimeter must be shown as closed (10 ohms or less). If the circuit is not closed and the switch has been previously checked, check the switch circuit wires and the maximum Cummins ISB5.9 G CM2180 engine speed switch signal wire for open circuits. For repair procedures, refer to the OEM troubleshooting and troubleshooting manual. If the resistance meets the technical specifications, the switch circuit wires and the maximum Cummins ISB5.9 G CM2180 engine speed switch signal wire must be checked for short-circuit to ground, short-to-contact pins, and short-circuit to external power.


Check for short to ground

当检查是否电气短路时,从ECM 上断开OEM 线束,然后从最大康明斯ISB5.9 G CM2180 发动机转速开关上断开OEM 线束,以便隔离最大康明斯ISB5.9 G CM2180 发动机转速开关电路。断开离合器踏板位置开关/康明斯ISB5.9 G CM2180 发动机保护取消开关和油门踏板总成开关。将所有驾驶室面板开关关闭或转到中间位置。使用挂车制动器手动阀调节行车制动器。

调整万用表以便测量电阻。将一根测试导线插入OEM 线束接头上的最大康明斯ISB5.9 G CM2180 发动机转速开关信号触针,然后将其连接到一支万用表表笔。使万用表的另一根表笔接触康明斯ISB5.9 G CM2180 发动机缸体接地。

测量电阻。万用表必须显示开路(100K 欧姆或更大)。如果电路不是开路,而且先前已检查过开关,则在最大康明斯ISB5.9 G CM2180 发动机转速开关电路中存在对地短路。

根据车辆制造商的步骤,维修或更换与OEM 线束上的最大康明斯ISB5.9 G CM2180 发动机转速开关信号触针连接的导线。

检查触针之间是否短路

根据上节内容设置开关以隔离最大康明斯ISB5.9 G CM2180 发动机转速开关电路。将最大康明斯ISB5.9 G CM2180 发动机转速开关置于正常位置。将导线插入最大康明斯ISB5.9 G CM2180 发动机转速开关信号触针。用鳄鱼夹连接万用表。将另一根导线插入开关回路触针,然后测量电阻。万用表必须显示开路(100K 欧姆或更大)。

从最大康明斯ISB5.9 G CM2180 发动机转速开关信号触针拆下导线,然后检查所有其它触针。测量电阻。万用表必须显示开路(100K 欧姆或更大)。如果电路不是开路,而且先前已检查过此开关,则手动风扇开关电路与任何显示为闭路的触针之间存在短路。

维修或更换OEM 线束中的导线。参考步骤019-071。

检查是否对外部电源短路

将钥匙开关转到ON(接通)位置。将最大康明斯ISB5.9 G CM2180 发动机转速开关置于正常位置。调整万用表以便测量VDC(直流电压)。将一根测试导线插入最大康明斯ISB5.9 G CM2180 发动机转速开关信号触针,然后将其连接到一支万用表表笔。使万用表的另一根表笔接触康明斯ISB5.9 G CM2180 发动机缸体接地。测量电压。电压必须为1.5 VDC 或更小。

如果电压不正确,存在与电路连接的外部电源,或者在最大康明斯ISB5.9 G CM2180 发动机速度开关电路和OEM 线束的带电导线之间短路。

拆下电源或根据《OEM 故障诊断及排除手册》修理OEM 线束中的导线。维修完成后将所有部件连接好。

注: 如果最大康明斯ISB5.9 G CM2180 发动机速度开关电路通过了上面的所有测试,则其功能正常。

  The types of generator sets leased by Ningbo Rixin Power Technology Co., Ltd. are: 
  ◆ Open Cummins diesel generator: ordinary generator set, suitable for customers who have a power house or full of rainproof facilities.  Disadvantages of open-type generator set rental: ● It is louder than the silent type generator set and is not suitable for use in environmental conditions requiring very low noise; ● It cannot be used outdoors in rainy or snowy days. 
  ◆ Anti-speaker Cummins diesel generator: Silent unit, ● Suitable for places with strict requirements on environmental noise, such as large concerts, exhibition halls, urban subway construction, etc. The noise is generally 75 decibels, and the ultra-quiet type is 60 decibels Within.  Disadvantages of silent generator leasing: ● The unit itself is heavier than the open type unit, and the long-distance transportation cost is high.  ● Not suitable for use in high temperature environments.  ● Not affected by weather, can be used outdoors in rainy or snowy days. 
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  ◆ Cummins diesel generator set with fuel tank: suitable for short-term or temporary rental customers. 
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  Rental of medium-power Cummins generator sets: 300-900KW units. 
  Rental of high-power Cummins generator sets: 1000-1600KW units. 
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  We can minimize your losses due to power failure 
  Ningbo Rixin Power Technology Co., Ltd. Leasing Service Center has brand new used and reliable diesel generator sets.  Before you arrive at the site, follow the strict procedures to maintain the generator set to ensure that you will arrive at your leased site with the most productive and reliable power equipment.  Convenient and flexible leasing methods, which can provide you with long-term, short-term and temporary electricity leasing services. There are several types of leasing methods for users to choose from: 
  1. Our company is responsible for the power generation service. We will send a special person to the site to generate electricity for users, and send operating technicians to implement monitoring. 
  2. Our company provides power generation equipment, is responsible for the installation and operation of power generation equipment, supplies power generation equipment supplies such as cables, parallel cabinets, ATS conversion cabinets, etc. Party A can provide the venue. 
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  ◆ Try before you buy: Maybe you are considering buying a certain generator set equipment and also want to try whether it is suitable for you before buying.  Rixing Power Technology Rental Service Center is fully equipped. What could be more suitable than renting a similar machine for trial use with us? 
  ◆ Complement your core needs: Your power needs are always changing, and you also need to keep up with customer needs.  Maybe sometimes you don't have the power equipment you need to get the job done, but this is exactly what we have.  Trust Rixing Power Technology Leasing Service Center, we will quickly provide you with the power equipment you need to complete your work. 
  ◆ Responsive service: Our technically proficient team can provide you with consultation on the lease and use of diesel generator sets.  We will strive to be your trusted leasing company and service provider to make your production easier.  Just a call and we'll troubleshoot for you. 
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