The document describes troubleshooting a generator output power sensor input test for an engine. It provides details on the system operation and how an open or short circuit in the sensor could cause issues. The troubleshooting procedure involves inspecting connectors and wiring, checking continuity between components, testing for shorts, and measuring the sensor voltage to diagnose potential problems. The goal is to correct any issues with the sensor or wiring that could degrade the engine's response to load changes or cause turbocharger damage.
The document describes troubleshooting a generator output power sensor input test for an engine. It provides details on the system operation and how an open or short circuit in the sensor could cause issues. The troubleshooting procedure involves inspecting connectors and wiring, checking continuity between components, testing for shorts, and measuring the sensor voltage to diagnose potential problems. The goal is to correct any issues with the sensor or wiring that could degrade the engine's response to load changes or cause turbocharger damage.
The document describes troubleshooting a generator output power sensor input test for an engine. It provides details on the system operation and how an open or short circuit in the sensor could cause issues. The troubleshooting procedure involves inspecting connectors and wiring, checking continuity between components, testing for shorts, and measuring the sensor voltage to diagnose potential problems. The goal is to correct any issues with the sensor or wiring that could degrade the engine's response to load changes or cause turbocharger damage.
The document describes troubleshooting a generator output power sensor input test for an engine. It provides details on the system operation and how an open or short circuit in the sensor could cause issues. The troubleshooting procedure involves inspecting connectors and wiring, checking continuity between components, testing for shorts, and measuring the sensor voltage to diagnose potential problems. The goal is to correct any issues with the sensor or wiring that could degrade the engine's response to load changes or cause turbocharger damage.
Figure P-530.1: Generator Output Power Sensor Schematic J10 P10 2 1 25 3 Generator Output Power Sensor Input Analog Return J1 P1 12 11 10 9 8 7 6 5 4 3 Watt- meter L3 L2 L1 N E F Generator NOTE: Refer to the Electrical System Schematic Terminal Box X J9 ECM
The G3516B Engine utilizes a Generator Output Power Sensor with a 0-5 VDC Output Signal that is inputted to the ECM. This Kilowatt value is displayed as the Generator Total Real Power parameter on the ET Status Screen. The ECM uses the Kilowatt Sensor signal to determine when to open the Turbo Surge Bypass Valve. Refer to Section 2: Generator Output Power Sensor Scale Factor and Section 2: Generator Output Power Sensor Offset.
A rapid drop in the output power of the generator can cause the turbochargers to surge. Surging can damage the turbochargers. The ECM responds to a rapid drop in the signal voltage from the generator output power sensor by taking the following actions:
The ECM commands the Fuel Metering Module to reduce the fuel flow of the engine. The ECM activates the solenoids for the Turbocharger Compressor Bypass Valves. The ECM adjusts the Throttle Actuator in order to reduce the amount of pressure in the inlet manifold.
Use this procedure to troubleshoot Open or Short circuit diagnostic codes for the KW Power Input to the ECM. The ECM reads the voltage level at Connector J1/P1 terminal-25.
NOTE: Logged Diagnostic Codes provide an historical record. Before you begin this procedure, use ET to print the logged codes to a file.
NOTE: The most likely causes of the Diagnostic Code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with the ECM.
NOTE: The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Generator Output Power Sensor Input 25 Analog Return 3 Note: Refer to the Electrical System Schematic. P-530 P-530 G3516B Engine (Preliminary 16JUL02) 5- Troubleshooting 174 Diagnostic Codes CID-FMI Conditions which generate this code: System Response: Troubleshooting 1719-03 Generator Output Power Sensor open/short to +batt
The Generator Output Power Sensor Input signal to the ECM is greater than 4.8 VDC for at least 5 seconds, indicating an open circuit or short to a positive voltage source. The response of the engine to a drop in load will be degraded. The turbo surge protection will be deactivated. Rapid drops in load could lead to a turbo surge, which could lead to an early turbo failure.
Engine monitoring for the Turbocharger Surge is disabled. The alarm output is activated and the code is logged.
This diagnostic code remains Active until the Engine Mode Switch is turned to the OFF/RESET position.
Proceed with P-530: Generator Output Power Sensor Input Test 1719-04 Generator Output Power Sensor short to ground
The Generator Output Power Sensor Input signal to the ECM is less than 0.2 VDC for at least 5 seconds, indicating a short to ground. The response of the engine to a drop in load will be degraded. The turbo surge protection will be deactivated. Rapid drops in load could lead to a turbo surge, which could lead to an early turbo failure.
Engine monitoring for the Turbocharger Surge is disabled. The alarm output is activated and the code is logged.
This diagnostic code remains Active until the Engine Mode Switch is turned to the OFF/RESET position.
Proceed with P-530: Generator Output Power Sensor Input Test P-530 P-530 G3516B Engine (Preliminary 16JUL02) 5- Troubleshooting 175 Functional Test TEST STEP RESULT DIAGNOSIS/ACTION Step 1: Inspect Electrical Connectors And Wiring Turn the Engine Mode Switch to the OFF/RESET position and then switch the 16 amp Circuit Breaker for the ECM OFF. Thoroughly inspect ECM Connector J1/P1, Terminal Box Connectors J9/P9, J10/P10 and the Generator Output Power Sensor Input wiring/connectors between the ECM and the device that supplies the Generator Output Power Sensor Input Signal. Refer to P-501: Inspecting Electrical Connectors for details. Perform a 45 N (10 pound) pull test on each of the wires associated with the Generator Output Power Sensor Input circuit. Refer to the Electrical System Schematic. Check ECM Connector (Allen screw) for proper torque 6.0 Nm (4.4 lb-ft). Check the harness and wiring for abrasion and pinch points between the device that supplies the Generator Output Power Sensor Input Signal and the ECM.
See Figure P-530.1
All connectors/pins/sockets should be completely mated/inserted, and the harness/wiring should be free of corrosion, abrasion or pinch points.
OK
NOT OK
Proceed to next step.
Repair or replace the harness as necessary. STOP. Step 2: Check The Wiring Continuity Between The ECM and The Generator Output Power Sensor Device Turn the Engine Mode Switch to the OFF/RESET position and then switch the 16 amp Circuit Breaker for the ECM OFF. Disconnect the ECM J1/P1 Connector. Remove the Generator Output Power Sensor Device signal circuit wires from terminals 1 (+) and 2 (-). Using an Ohmmeter, measure the circuit continuity of the wire between P1-25 and the other end of the wire at the Generator Output Power Sensor Device terminal 1 (+). Using an Ohmmeter, measure the circuit continuity of the wire between P1-3 and the other end of the wire at the Generator Output Power Sensor Device terminal 2 (-).
See Figure P-530.1
In both cases the circuit continuity should check good.
NOT OK
OK
Locate and repair the open circuit condition and recheck the circuit for correct function. STOP.
Proceed to next step. P-530 P-530 G3516B Engine (Preliminary 16JUL02) 5- Troubleshooting 176
TEST STEP RESULT DIAGNOSIS/ACTION Step 3: Check The Wiring For Shorts To Ground Between The ECM and The Generator Output Power Sensor Device Turn the Engine Mode Switch to the OFF/RESET position and then switch the 16 amp Circuit Breaker for the ECM OFF. Disconnect the ECM J1/P1 Connector. Remove the Generator Output Power Sensor Device signal circuit wires from terminals 1 (+) and 2 (-). Using an Ohmmeter, measure the circuit resistance of the (+) wire between P1-25 and the ECM Ground Strap.
See Figure P-530.1
The circuit resistance should be infinite.
OK
NOT OK
Locate and repair the short circuit condition and recheck the circuit for correct function. STOP.
Proceed to next step. Step 4: Measure The Signal Voltage Between The ECM And The Generator Output Power Sensor Device Turn the Engine Mode Switch to the OFF/RESET position and then switch the 16 amp Circuit Breaker for the ECM OFF. Reconnect the ECM J1/P1 Connector. Reconnect the signal circuit wires to terminals 1 (+) and 2 (-) of the Generator Output Power Sensor Device. Switch the 16 amp Circuit Breaker for the ECM ON. Then turn the Engine Mode Switch to the STOP position. Start the engine and run the engine with a known load value. (For example, 500 kw.) Using a Multimeter and Signal Reading Probes (CAT P/N 7X1710), measure the Signal Voltage at the ECM between Terminals P1-25 and P1-3.
See Figure P-530.1
The measured voltage should correspond to the manufactures specifications for the Generator Output Power Sensor Device.
OK
NOT OK
The voltage measured from Generator Output Power Sensor Device has checked OK. The ECM does not read the voltage correctly. Replace the ECM. Refer to Section 2: Replacing the ECM with a new ECM BEFORE replacing the ECM. STOP.
The voltage measured from Generator Output Power Sensor Device is not correct. Replace the Generator Output Power Sensor Device. Recheck the circuit for correct function. STOP.