Rules for safe work

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? Relieve all pressure in the systems of air, oil , fuel, and cooling before
removing or disconnecting any lines , fittings or related parts. Be alert for
possible pressure when disconnecting any device that uses a system pressure. No
pressure check for leaks with your hands. The fuel oil or high pressure can cause
personal injury.
? To reduce the possibility of suffocation and freezing , wear protective clothing
and ONLY disconnect liquid line refrigerant ( Freon ) in a well ventilated area .
? To protect the environment, coolant systems should be emptied and filled using
equipment properly to prevent the release of refrigerant ( fluorocarbon ) in the
atmosphere . Federal law requires the capture and recycling of refrigerant.
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? To reduce the possibility of personal injury , use a hoist or get assistance when
lifting components weighing 23 kg [50 lb] or more. Make sure all lifting devices
such as chains, hooks, or slings are in good condition and are the correct
capacity. Be sure to place the hooks correctly. Always use a spreader bar when
needed. Lifting hooks must not be loaded laterally .
? The corrosion inhibitor , a component of SCA and lubricating oil , containing
alkali. Do not let the substance in your eyes . Avoid prolonged or repeated skin
contact. Do not swallow. After contact with skin, wash immediately with soap and
water. In case of contact with eyes , rinse immediately with plenty of water for at
least 15 minutes. CALL A PHYSICIAN IMMEDIATELY . KEEP OUT OF REACH OF CHILDREN.
Rules for safe work
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? The Nafta and methyl ethyl ketone (MEK ) are flammable and should be used with
caution. Follow the manufacturer's instructions to provide complete safety when
using these materials. KEEP OUT OF REACH OF CHILDREN.
? To reduce the possibility of burns, be alert for hot parts on products that have
been recently disconnected , exhaust gas flow , and hot fluids in lines , tubes,
and magazines.
? Always use tools that are in good condition . Make sure you understand how to use
them before performing any service work. Use ONLY genuine Cummins parts Cummins
ReCon � � or replacement.
? Always use the same part number screw (or equivalent) when replacing screws. Do
not use a screw lower quality if replacements are needed .
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? When necessary , removal or replacement of any rotary guard covering , steering
components , and / or bands should only be performed by a trained technician.
Before removing any stores shut off the engine and should isolate any starter. All
screws should be replaced by readjusting guards .
? Do not make any repair when fatigued or after consuming alcohol or drugs that may
affect performance.
? Some state and federal agencies in the United States has determined that used
engine oil can be carcinogenic and can cause reproductive toxicity. Avoid
inhalation of vapor , ingestion , and prolonged contact with used motor oil.
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? Do not connect jumper cables or battery power to any control wiring on or
governor . This can cause electrical damage to the ignition or the governor.
? Always tighten the screws and fuel connections to the required specifications.
The overtighten or poor clamping may allow leakage . This is critical for systems
of natural gas and liquefied petroleum gas and air .
? Always test for fuel leaks as indicated , as the odorant can fade.
? Close the manual fuel before performing maintenance and repairs valves, and when
storing the vehicle inside .
Rules for safe work
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Introduction What is CENSE ?
CENSE is a system
monitoring , consisting of a
module (ECM ) that is installed
by Cummins ( high
power ) and a set of
sensors. There motors
or industrial applications
construction, which they bring to
series such as the QSK60 and
QSK78 . In other motors is
optional , such as : K2000E
( KTTA50 ) , K1500 ( KTTA38 ) and
the QST30 .
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Sensors CENSE
? CENSE provides a large number of sensors located throughout the engine , amongst
which are:
? Pressure Sensors
? Temperature Sensors
? Level Sensors
Speed ??sensors ?
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Objective CENSE
? CENSE is responsible for monitoring the engine parameters in real time , thus can
alert the operator of a malfunction in the engine . On the other hand , is a CENSE
store this information, which can be downloaded using the INSITE CENSE software and
can be used for various purposes.
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Using these data
? The data collected can be used to :
? Determine the status of the operation frequency
? Identify frequent load cycles
? Determine the need to repair motor
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Operation of the lamp panel
? CENSE is responsible for operating the lighting system . Three lights are the
tools available to the system and indicating different levels of failures . When
contact occurs , check CENSE makes these lights lighting the three and then turning
them off ( unless there is a fault )
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OEM lights . Example Komatsu 930 E2
Red : Protection Engine . Level 1
Yellow: Caution . Level 2
Blue: Maintenance . Level 3
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Storage of information
? CENSE can store fault through a fault code . They can be active or inactive. An
inactive fault is that historic failure , a problem that was solved by a repair or
accidentally. An active fault is one that is present in real time
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additional purposes
? Security have constant monitoring and is freely available
? The ability to diagnose incidents
? Perform predictive maintenance
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INSITE CENSE
? To ensure the INSITE tool , it is necessary to have a finished engine electrical
systems knowledge , this is the location of the module and connectors, able to
interpret an electrical diagram , explain the operation of sensors , in addition to
its location and have a management -level PC user.
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memory CENSE
? CENSE memory is made up of 512 KB 2 chips , one for storing data and other trend
data to record the fault codes , parameter data and application data
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Specifications for CENSE
? CENSE works with 24 volts, within the range of 16 volts to 32 volts, from -40 � C
to 105 � C
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Contact in On - No boot
? Giving CENSE contact on for a short time 3 cabin lights . After these are turned
off unless the system has found a fault .
? CENSE requires RPM signal
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Start signals
? To CENSE the engine is in start condition when receiving signals from magnetic
pick up sensor and oil pressure prefilter .
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Displays connection and disconnection
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INSITE windows CENSE
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Initial State of INSITE CENSE
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Program Settings
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Program Settings
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INSITE configuration
? Save Job Data : This option ensures that each time a connection is made , a job
is stored on the PC under a name
? Automatically Load Trend Data : This option automatically download data from one
trend CENSE this while connected to a real connection settings INSITE . Depending
on the amount of information stored in the CENSE , this can take 10 minutes to
reach
? Automatically Load Data Fault : Allows automatically download fault codes and
snapshots
? Purge Option. Deletes information CENSE INSITE program in a retention period and
finally a total reset of the information
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Setting units of measure
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? This screen is typical when a connection is established with a module . Always be
helpful to identify the work that you want to download . Not be placed more than 8
characters in the space where Job Number says . Notice that in most cases the data
of the vehicle and the engine are automatically viewed on this screen. This
information, if required, can be changed from this place
Starting a job
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Login screen
? When the ECM connection is established automatically monitor the faults and icons
are enabled. Also appearing the adjustement and View access
II.C�digos Module Fault
EDGAR VILELA
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This module will explore :
? Access trouble codes
? Definition and process of snapshots
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Access trouble codes
? There are two access points to see the fault codes , as seen in Figure
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Snapshots of a fault code
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Screen snapshots of a
In theory , the role of
snapshots of a module CENSE
captures 150 pictures before
that the fault is registered ,
a second, of all
parameters available from
motor, it is known that
prefault name . in the
time of failure , is atfault
1 photos and capture all 1 photo
second parameters
30 seconds after
whose name is postfault .
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Process snapshots
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inactivate
? Allows inactivate failure after complete repair. If the fault persists , it may
not be activated
III.Monitoreo module in real time. Monitoring techniques
EDGAR VILELA
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This module will explore :
? Access to real-time monitoring
? Option parameter storage
? Graphical monitor
? Textual monitor
? Data logger
? Adapting a technique of monitoring return
? Excel
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Access to monitoring
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Option parameter storage
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Graphical Monitor
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monitoring plotted
? You can select all the parameters of an ECM available to perform this
monitoring . This form of monitoring may be reproduced by using graphical playback
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Textual Monitor. abstract
? Represent the same way to perform monitoring . Where they can be monitored a
total of 16 parameters in real time under way record and view
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textual Monitor
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Data Logger
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Data Logger. abstract
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Storage monitoring
? The monitoring done by default are stored in a folder called Log. However, the
storage of information can be performed in any folder on a PC. It is noteworthy
that this information will be seen in an Excel spreadsheet .
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Monitoring the temperature of exhaust
? The exhaust temperatures can be monitored in real time and stored in numerical
and graphical form .
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Viewing a monitoring technique in Excel
? Files created using a technique of monitoring are stored in the default log
folder. The files are viewed in this folder with a. RTD (real time data) . In some
cases get to choose the program to open the Excel file. RTD
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Adapted from a monitoring technique to form
Excel
So is it a template. RTD
then be opened using
Excel . Select column
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Adapted from a monitoring technique to form
Excel
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Adapted from a monitoring technique to form
Excel
The windows should be selected following the
Lash tab and comma, and then give following
finalize
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Adapting a technique for monitoring
Excel spreadsheet
? As can be seen , the new way that takes the Excel file is manageable , given that
it has a value in each cell. Note that in case of a simulator monitoring values ??
appear enclosed in brackets. If you want to make a graph , you must remove the
brackets. Should be a real monitoring, and the value automatically appear to the
right of the cell, you can proceed with the graph.
Module IV. Settings
EDGAR VILELA
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This module will explore :
? Set realtime ECM
Adjusting the Monitor ? Maintenance
? Setting the trend data
? Setting the nameplate
Cense ? Data Reset
? Definition
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Setting the Real Time ECM
? This function allows to know the current schedule CENSE ECM . This schedule may
be adjusted manually or synchronize your PC time with daylight ECM . It is
important to confirm that the PC is the schedule according to the real time.
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Adjusting the Monitor maintenance
? This option enables fault codes to alert the operator of maintenances to be
performed to cooling systems , lubrication system and fuel system. The function
allows you to enter the specific times to activate the relevant fault codes .
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Setting the Trend Data
? The trend Data, Historical information is stored by the ECM of all parameters
available . This information is stored on a chip that has a capacity of 512 KB .
Depending on the number of chosen parameters and sampling time , the Trend Maximun
Length , defined as the time that it took to saturate the ECM will define the chips
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Setting the Trend Data
? The Change deploys a window that lets you select the condition of the engine
where the engine parameters will be stored option . These conditions are:
? At Rated: Motor full load condition
? Running : Motor is been running
? Warm : Motor with temperature.
? By default, the Keyswitch On option always active , ie , it is a non-conforming
condition.
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Setting the nameplate
? This function allows data related to : Customer , Motor and Equipment. We
recommend keeping the data correctly entered here . This can be done when an ECM is
new or when an ECM comes from another computer
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Data reset Cense simulator
? The following information may be removed from CENSE this place while it is
connected :
? Engine start log
� Duty cycle and fuel consumation
� Fault Codes
� Trend Data
� Maintenance of coolant
� Maintenance of fuel
� Maintenance of oil
� Short term 1
� Short term 2
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Data Cense real connection reset
The following information may be removed from CENSE this place while it is
connected :
� Engine start log
� Duty cycle and fuel consumation
� Data reset Cense real connection
� Fault Codes
� Trend Data
� Maintenance of coolant
� Maintenance of fuel
� Maintenance of oil
� Short term 1
? Short term 2
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Definition
? Engine start log: log of engine stops and arrests . Additionally you can
appreciate the hours that the engine remained running and the hours that an engine
was stopped .
? Short term 1 and 2 are defined as the short time in which the sampling takes
Cense : fuel consumption , load factor, factor and duty cycles RPM or load.
Generally these times are 500 hours , but can be set to 999 . This information can
be erased from Cense Data Reset.
? Long Term is defined as the length of time , ie , from an ECM was put into
service. Stores the same information as short term , but in a longer period . This
information will NOT be removed if not by a recalibration of different base.
Module V. Ver. View
EDGAR VILELA
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This module will explore :
? Facts faults. Fault Data
? Registration of motor starts . Engine start logs
? Engine Hourmeter
? engine data plate . System ID and CENSE data plate
? Trend data. Trend data
? Load cycle and fuel consumption ( Duty cycle and fuel consumption )
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Fault data
? This option has a direct access from the equipment shown in the photo and it was
previously explained .
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Registration of motor starts . Engine
Log start
Registration of starts of an engine allows you to view the recording of starts and
stops the engine has had , indicating the date and time that the engine remained
running or stopped. This feature is important when a major engine failure is
detected and if this is stopped promptly.
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Engine Hour Meter
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Nameplate motor ( System ID and CENSE data
plate)
In this window you can find information about : CENSE , such as Part No. Engine, as
the serial number of the OEM engine , as equipment model calibration , calibrate
the ECM has incorporated
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Trend data
? This window allows you to download , delete, and update data set if ECM is
connected to one trend . The load Up option allows data download a trend and if
connected and already downloaded , this option can be updated this feature
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Charge cycle fuel consumption ( Duty cycle and fuel consumption )
? This window allows you to view information stored in the ECM and that has to do
with the cycles of engine load and average fuel consumption used in various
intervals. For Example:
? Long term , that information is the life of the motor ( can not be reset )
? Short Term 1 , 500-hour interval
? Short Term 2 , another interval of 500 hours. In both cases, this information can
be reset from CENSE data resert
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Charge cycle fuel consumption ( Duty cycle and fuel consumption ) . Summary
From this option you can see the average load factor and speed factor in the long
term and short term 1 and 2.
The average load factor from last 25 hours also available . This information can be
viewed in graphical form , as shown.
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Charge cycle fuel consumption ( Duty cycle and fuel consumption ) . Summary
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Fault information system (FIS ) . The Library
INSITE CENSE
The library CENSE INSITE provides information for various types of Cummins engines
that can lead this monitoring system.
It can also be accessed from the disk C , Intelect , and see the folder CENSE HLP
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Access 1.
There are 2 ways to access the library you have in INSITE CENSE .
The first is achieved when it is connected to a particular ECM . The library will
be found only engine in question.
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Access 2 .
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System Resources
? This feature allows you to observe the state of the ECM CENSE memories . Memories
are observed :
? Percentage of saturation fault log. In the shown case reaches 92%
? Percentage of saturation trend data. In the shown case reaches 99% , which means
that this memory is virtually taken over . The ECM , should reach this end , stop
storing information
Module VI. Herramientas.Tools
EDGAR VILELA
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This module will explore :
? Know the procedures that exist to download information from a Cense ECM
? How to do a safe procedure for downloading the data trend .
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Tools. Data Extraction
This function enables a process of rapid connection in which you can create a job ,
download fault codes and their snapshots, download the trend data and if this
option is chosen , you can also reset the data trend
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First option: Data Extraction ...
There are methods to quickly download fault codes and trend data. In case you want
to clear the trend data , it is only accepted if a train click download data blocks
. The next slide shows the image each time you start a job with the difference of
the last two options appears .
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Tools. Data Extraction
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Data Extraction ...
? After Reset Function Extraction data , selects the option to either erase fault
codes or trend data. Note that if you do not select the Retrieve Trend log
function, not delete the data train . After giving OK , start downloading the
information upon completion, the program will automatically disconnect
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Second Option : Establishing connection
? As explained above, contact a Cense ECM upon user option settings option and
select automatic download of trend data. The time it takes to download the
information depends on the amount of information stored on the train this data, .
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Second Option : Establishing connection
Once accredited discharge trend data ( viewing this information view) proceed to
close the job. The fact reset from this work , erase the information from 2
sources, the ECM and the PC. Start a new job. Go to CENSE Data Reset, and then
select Data Trend give OK .
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Second Option : Establishing connection
? The following message appears : "You're upgraded to the module . After deleting
the data from the storage module , change information changes saved in this work.
Your want to continue? " .
? This post gives clear warning that the information will be erased from ECM and
PC. But as was shown in the previous slide , the download was already done in a
previous work
Module VII. Export to Excel spreadsheets Procedures
EDGAR VILELA
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This module will explore :
? Procedure to take snapshots or trend data to Excel spreadsheet
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Procedure to take snapshots or trend data to Excel spreadsheet
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Procedure to take snapshots or trend data to Excel spreadsheet
It should make a trend data and shall separate snapshot in return, not to mess up
the template. Thus , click engine faults / Snapshot Data and repeating the process
again, click only on trend data.
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Procedure to take snapshots or trend data to Excel spreadsheet
1.Se should open a downloaded INSITE CENSE work .
2.Se confirm that this work should have fault codes and snapshots, along with trend
data
Three . Go to JOB 4 . Go to Export . This shows three alternatives. May . Select
Export Job to ASCII 6. A window in which to indicate where the information was
stored , if on the same PC or an external storage device , such as a PEN drive 7 is
displayed. The window shown below , has a choice : to export trouble codes along
with snapshots or export data , both the trend Excel spreadsheet . It is
recommended to do a procedure and then the other. 8. Finally finiched exporting
(export completed ) 9 window unfolds . In most cases , the work , where one chooses
to keep them separate , is by default in the folder usrdata .
Module VIII. Export and import procedure works .
EDGAR VILELA
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This module will explore :
? To export work in INSITE CENSE
? Procedure to import work in INSITE CENSE
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Exporting Jobs
This method allows information sharing between different users and allow discuss
the same work
Select the storage location of this export. Usually privileges a PEN drive or a
specific place within the hard drive C. Failure to choosing a location , the
default file is stored in Export
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Exporting Jobs
Here you must select the work you want to export. Note the marked option : Remove
jobs after export: remove work after export , this is a cut paste.
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Importing Jobs
After exporting a
particular job, this
stay with the name
assigned and extension. EXP .
This file will be recognized
only by INSITE
CENSE . It must be ensured
that the imported file has
the. EXP and is
extracted from some of the
Memories PC.
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Importing Jobs
? After this screen , where you must choose the jobs they want or be imported
appears .
? The following message appears if you are importing a job that was already
downloaded : One of the jobs that these imported has the same name as a work that
is already in the system. Enter a new name for the job and press OK or press SKIP (
skip ) not to import this work
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Module IX . SPN.Corrupted Codes Codes
EDGAR VILELA
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This module will explore :
? Definition of concepts such as ghosts and corrupt codes codes.
? How to visualize code corrupt
? Identifying corrupt codes
? Procedures to solve problems related to these codes.
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Definition of concepts
That is the ghost code?
The ghost code is called when the truck or other equipment accuses one
EP Red code (engine protection) , and Quantum Cense or not there is a
this code to justify the appearance of the red light.
When should see corrupt codes?
Every time the phantom code failure occurs , or when there
doubt with the proper functioning of the ECM Cense .
What should I do in the presence of one of these codes ?
List will be handed to the fault codes and what to do in each
one.
If a corrupt four codes are present in the ECM
I can recalibrate and try again?
NO .
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Viewing SPN
See the procedure to export to Excel error codes ( see module
VII )
Open the file and go to the bottom of the page where you will find a summary of
deployed code , this is where to seek codes provided in this document .
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List of fault codes PCDT
10196 ? Power interruption . See fault tree
? Exception 10098 Ram corrupted storage in BB . Replace the ECM
10099 ? Power / Cal / FAULTLOG in BB ram corrupted . Replace the ECM
10094 ? Module power reset . See fault tree
? 10183 Miscellaneous corrupted pool . Replace the ECM
10185 ? Backup corrupted memory pool . Replace the ECM
10093 ? External Watchdog reset . See fault tree
? 10193 RS422 data link communication failure . See fault tree
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Fault code 10196 Power interruption
Fault code 10196 Power interruption .
This code is lost every time you are active and resets the
power to the ECM Cense . At that time the ECM is
reset alarm turning on the lights when the truck was
movement causing the ghost code.
Browse:
Cummins harness these fuses must be in good condition and
firm in their contacts.
Should review and measure continuity in the grounding harness
with reference to the battery, clean connections and improve
condition.
You must ensure the correct supply voltage of the OEM
to the engine (key switch and unswitch )
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10093 external watchdog reset
10093 external watchdog reset .
This code each time the power is turned interruption is activated
a consequence of this code should therefore use the same
methodology for code 10196
Browse:
Cummins harness these fuses must be in good condition and
firm in their contacts.
Should review and measure continuity in the grounding harness
with reference to the battery, clean connections and improve
condition.
You must ensure the correct supply voltage of the OEM
to the engine (key switch and unswitch )
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10193 RS422 data link communication failure
10193 RS422 data link communication failure .
This code every time you communication error occurs Dispacht device activates it
was found that at times the interface has to transmit Dispacht Cummins fault codes
failed and allows activation of this code.
This code when found has been activated many times allows the ecm restart alarm
turning on the lights when the truck is in motion causing the ghost code.
Browse:
Check the program Cense the RS422 communication option with this ticket
Check a corresponding output RS422 communication port from the ecm Voltages .