P-530 P-530

G3516B Engine (Preliminary 16JUL02) 5- Troubleshooting 172

P-530: GENERATOR OUTPUT POWER SENSOR INPUT TEST

System Operation

























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.

P-530 P-530
G3516B Engine (Preliminary 16JUL02) 5- Troubleshooting 173
Figure P-530.2: ECM Connector Terminal Locations























Wire Side
Terminal Side
1 2 3 4 5 6 8 9 10 11 12 13
14
24
40
48
58 59 60 61 62 63 65 66 67 68 69 70
23
31
47
57
36
>PEI<
58 59 60 61 62 63 65 66 67 68 69 70
13
ECM Connector P1
64
48 49 50 51 52 53 54 55 56 57
40 41 42 43
32 33 34 35
24 25 26 27
44 45 46 47
36 37 38 39
28 29 30 31
14 15 16 17 18 19 20 21 22 23
1 2 3 4 5 6 7 8 9 10 11 12

Function Pin Location

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.