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Generator Output Power Sensor
Generator Output Power Sensor
Shutdown SIS
Previous Screen
Troubleshooting
G3516B Engines
Media Number -RENR2270-08 Publication Date -01/09/2012 Date Updated -04/09/2012
i04782454
The ECM monitors the generator output power in order to control the air/fuel ratio. The ECM uses a load
signal from one of the following sources in order to monitor the generator output power:
Wattmeter
The PLC and the wattmeter are also called power sensors.
Only one load signal is connected to the ECM. If the generator is equipped with the EMCP II+, the ECM
receives the load signal from the Generator Set Control + (GSC+). The load signal is sent via the Cat Data
Link. If the generator is not equipped with the EMCP II+, the ECM receives the load signal from a power
sensor via terminal J1-25. The load signal from the power sensor is an analog voltage. The load signal
increases from 0 VDC to 4.8 VDC as the generator output increases to the maximum output.
On powerup, the ECM will start requesting information on the generator load from the GSC+ via the Cat
Data Link. If 2 seconds elapse and the ECM does not receive a response from the GSC+, the ECM looks
for a signal on terminal J1-25. If there is no load signal on terminal J1-25, the ECM will generate a 1719-03
diagnostic code. If the engine is running, the engine will shut down.
A 1719-03 diagnostic code is also generated if the voltage on terminal J1-25 ever exceeds 4.8 VDC. If the
engine is running, the engine will shut down.
This code only applies to engines that are equipped with a power sensor.
If the engine load is greater than 20 percent and the voltage on terminal J1-25 is less than 0.2 VDC, the
ECM will generate a 1719-04 diagnostic code. If the engine is running, the engine will shut down.
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This code only applies to engines that are equipped with the EMCP II+.
The ECM calculates two values that represent the engine load. One value is calculated by using the
information on the generator load from the GSC+. The other value is calculated from the following inputs:
Other factors
The ECM compares the two values. If the value that is calculated by using the information from the GSC+
is not within 20 percent of the other value, the ECM will generate a 1719-12 diagnostic code. If the engine
is running, the engine will shut down.
Illustration 1 g02891079
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Only one input is used. The input that is used depends on the generator configuration.
Illustration 2 g01076153
Terminal box
A. Set the engine control to the OFF/RESET mode. Switch 16 amp circuit breaker (2) to the OFF
position.
Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
J1/P1 connectors
Wiring and the connections between the generator output power sensor and the ECM
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a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 1
Nm (55 9 lb in).
Illustration 3 g02891458
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Illustration 4 g02891476
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the
generator output power sensor.
c. Check the harness and wiring for abrasion and for pinch points between the generator output
power sensor and the ECM.
Expected Result:
All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.
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STOP
A. Connect the Cat Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting,
"Electronic Service Tools".
B. Start the engine and run the engine. Attempt to apply at least a 30 percent load to the generator.
C. Observe the "Active Diagnostic" screen on Cat ET. Allow a minimum of 30 seconds for any codes to
activate. Look for these codes:
1719-03
1719-04
1719-12
Expected Result:
There are no active codes for the generator output power sensor.
Results:
No active codes - There are no active codes for the generator output power sensor. There may be a
logged code for the generator output power sensor.
Repair: If there is a logged code for the generator output power sensor, there may be a problem with
the wiring and/or a connector. Refer to Troubleshooting, "Inspecting Electrical Connectors".
STOP
Active 1719-03 code - There is an active 1719-03 code. If the generator is equipped with EMCP II+,
proceed to Test Step 7. Otherwise, proceed to Test Step 5.
Active 1719-04 code - There is an active 1719-04 code. Proceed to Test Step 3.
Active 1719-12 code - There is an active 1719-12 code. Proceed to Test Step 9.
Test Step 3. Check the "Load Signal" Wiring for a Short Circuit
C. Check for continuity between P1-25 and all the other terminals on the P1 connector.
Expected Result:
Results:
OK - Each continuity check indicates an open circuit. The "load signal" wiring does not have a short
circuit. Proceed to Test Step 4.
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Repair: The problem may be between the P1 connector and the J9 connector. Alternatively, the
problem may be between the P9 connector and the power sensor.Repair the harness or the
connection, when possible. Replace parts, if necessary. Verify that the problem is resolved.
STOP
Note: A potentiometer may be installed in the "load signal" wiring. A high resistance reading may be
caused by the potentiometer.
A. Check the continuity of the wire between P1-25 and the power sensor.
Expected Result:
Results:
OK - The "load signal" wiring has continuity. Reconnect the P1 connector. Reconnect the "load
signal" wires to the power sensor. Be sure to observe the correct polarity. Proceed to Test Step 6.
Not OK - The "load signal" wiring has an open circuit. The open circuit may be in a wire, in a
connector, or in the potentiometer.
Repair: Repair the component, when possible. Replace parts, if necessary. Verify that the original
problem is resolved.
STOP
Test Step 5. Check the "Load Signal +" Wire for a Short Circuit
A. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.
C. Disconnect the "load signal +" wire from the power sensor.
D. Check for continuity between P1-25 and all the other terminals on the P1 connector.
Expected Result:
Results:
OK - Each continuity check indicates an open circuit. The "load signal +" wire does not have a short
circuit.
Repair: Reconnect the P1 connector. Reconnect the "load signal +" wire to the power sensor.
Not OK - At least one continuity check indicates a short circuit. There is a short circuit in a harness
or in a connector.
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Repair: The problem may be between the P1 connector and the J9 connector. Alternatively, the
problem may be between the P9 connector and the generator output power sensor.Repair the harness
or the connection, when possible. Replace parts, if necessary. Verify that the problem is resolved.
STOP
Test Step 6. Check the Power Sensor, the Potential Transformers, and the Current Transformers
Verify that the power sensor, the potential transformers, and the current transformers are operating
correctly. Refer to the appropriate service literature for the components.
Expected Result:
Results:
Repair: Repair the component, when possible. Replace the component, if necessary. Verify that the
original problem is resolved.
STOP
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
C. Disconnect the wiring for the Cat Data Link from the GSC+.
E. Measure the resistance between the points that are listed in Table 1. During each measurement,
wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the
wires near each of the connectors.
Table 1
Resistance Measurements for the Cat Data Link
Connector and Terminal Connector and Terminal
P1-8 Terminal 19 on the GSC+
P1-9 Terminal 20 on the GSC+
P1-8 Ground strap for the ECM
P1-9 Ground strap for the ECM
Expected Result:
Each check of the resistance between the terminals is less than five Ohms.
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Each check of the resistance between a terminal and the ground strap is greater than 20,000 Ohms.
Results:
OK - Each check of the resistance for the Cat Data Link is within the specification. The wiring for
the Cat Data Link appears to be OK.
1. Reconnect the wiring to the GSC+. Be sure to connect each wire to the appropriate terminal.
Not OK - At least one check of the resistance for the Cat Data Link is incorrect. There is a problem
with the wiring for the Cat Data Link.
Repair: Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify
that the original problem is resolved.
STOP
Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the EMCP II+.
Expected Result:
Results:
Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify that
the original problem is resolved.
STOP
Verify that the value of the "Fuel Quality" parameter is correct. Use the value that is obtained from the
Caterpillar Software, LEKQ6378, "Methane Number Program".
Expected Result:
Results:
OK - The value of the "Fuel Quality" parameter is correct. Proceed to Test Step 10.
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Repair: Enter the correct value for the parameter. Verify that the original problem is resolved.
STOP
Test Step 10. Check the Sensors for the Air Inlet Manifold
B. Connect a pressure gauge and a temperature sensor to the air inlet manifold.
C. View the Status Group 1 on Cat ET. Compare the values on the instruments with the following
parameters:
Expected Result:
Results:
Repair: Replace the appropriate sensor. Verify that the original problem is resolved.
STOP
Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the EMCP II+.
Expected Result:
Results:
Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify that
the original problem is resolved.
STOP
Test Step 12. Verify that the Output Power Reading is Correct
Operate the generator at various loads. Verify that the value of the "Generator Real kW" parameter in
Status Group 1 is within 1 percent of the generator output power.
Expected Result:
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Results:
OK - The value of the "Generator Real kW" parameter is correct. Proceed to Test Step 13.
STOP
It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem
is not resolved, temporarily install a new ECM. Refer to Troubleshooting, "Replacing the ECM".
Expected Result:
Results:
Repair: Install the original ECM and verify that the problem returns. If the new ECM operates
correctly and the original ECM does not operate correctly, replace the ECM. Before you replace the
ECM, consult the ECM Hotline.
STOP
Repair: Reinstall the original ECM. Consult with Caterpillar customer service for large gas engines.
STOP
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