02/11/2025 Generator Output Power - Test (KENR9738-05)

SMCS - 1439, 4450, 4490 i10447979

System Operation Description:

PSP
Use this procedure to troubleshoot a suspected problem with the circuit that is for the speed

202 -000
control. Use this procedure if one of the diagnostic codes in Table 1 is active or easily repeated.

5 D
06: /10/ E7C8
Table 1

CDL Code and

KE 3 2 1
Diagnostic Codes Table

:35 5 System

NR +
Conditions which Generate this Code

© 2 97 06:3
Description Response

025 38 0
1719-3
Generator Output Power The volt power supply is above normal for two The code is

Cat
Sensor : Voltage Above seconds. logged.
Normal The alarm

1719-9 erp
The Electronic Control Module (ECM) has lost the
output is

illa
Generator Output Power last four messages that were expected from the
activated.

r In
The shutdown
Sensor : Abnormal generator output power sensor over the Cat data
output is

c
Update Rate link.

1719-12
The generator output power sensor has reported
activated.
The engine is .
Generator Output Power shut down.
that an internal fault has occurred.
Sensor : Failure

The control system monitors the generator's output power to accurately control the air/fuel ratio.
The control system uses a load signal from one of the following sources to monitor the
generator's output power:

Electronic Modular Control Panel II+ (EMCP II+)

Programmable Logic Controller (PLC)

Wattmeter

The PLC and the wattmeter are also called power sensors.

If the generator is equipped with the EMCP II+, the Electronic Control Module (ECM) receives the
load signal from the Generator Set Control + (GSC+) 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's output increases to the maximum output.
On powerup, the ECM requests information on the generator's load from the GSC+ via the Cat
Data Link. If two seconds elapse and the ECM does not receive a response from the GSC+, the
ECM assumes that a load signal will appear on terminal J1-25 when the engine is at rated speed
and the calculated load is greater than 30 percent. The ECM generates a 1719-3 code if the
following conditions exist:

The engine is at rated speed.

The calculated load is greater than 30 percent.

A load signal is not present on terminal J1-25.

Illustration 1 g01325176

Schematic of the power sensor's input with EMCP II+

For the actual wiring, refer to the generator's schematic diagram.

Illustration 2 g01325177

Schematic of the wiring for the load signal.

For the actual wiring, refer to the generator's schematic diagram. The potentiometer is optional. For further

information, refer to Troubleshooting, "Ganerator Output Power Sensor - Set".

Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND WIRING

A. Remove the electrical power from the engine.

Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".

B. Thoroughly inspect the following components:

J1/P1 connectors

J6/P6 connectors

The wiring and the connections between the ECM and the GSC+ (if equipped)

The wiring and the connections between the electronic control module and the power
sensor (if equipped)

a. Check the torque of the allen head screw for the ECM connectors.

b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit
for the power sensor.

c. Check the harness and wiring for abrasion and for pinch points between the power
sensor and the electronic control module.

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.
Repair: Perform the necessary repairs and/or replace parts, if necessary.

STOP

Test Step 2. CHECK FOR A DIAGNOSTIC CODE

A. Connect Caterpillar 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:

1719-3

1719-9

1719-12

D. Stop the engine.

Expected Result:

There are no active codes for the generator output power sensor.

Results:

OK - 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, "Electrical Connectors
- Inspect".

STOP

Not OK - There is an active 1719-3 code. Proceed to Test Step 3 .

Not OK - There is an active 1719-9 code. Proceed to Test Step 6 .

Not OK - There is an active 1719-12 code. Proceed to Test Step 7 .

Test Step 3. CHECK THE "LOAD SIGNAL" WIRING FOR A SHORT CIRCUIT

A. Disconnect the P1 connector.

B. Disconnect the "load signal" wires from the power sensor.

C. Check for continuity between P1-25 and all the other terminals on the P1 connector.

D. Check for continuity between P1-19 and all the other terminals on the P1 connector.

Expected Result:

Each continuity check indicates an open circuit.

Results:

OK - Each continuity check indicates an open circuit. The "load signal" wiring does not have
a short circuit.
 Repair: Connect the P1 connector and the P3 connector. Connect the "load signal" wires to
the power sensor. Be sure to observe the correct polarity.

Proceed to Test Step 4 .

Not OK - At least one continuity check indicates a short circuit.
Repair: Repair the harness or the connection, when possible. Replace parts, if necessary.
Verify that the problem is resolved.

STOP

Test Step 4. CHECK THE "LOAD SIGNAL" WIRING FOR CONTINUITY

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 wiring between P1-25 and the power sensor.

B. Check the continuity of the wiring between P3-16 and the power sensor.

C. Check the continuity of the wiring between P1-19 and the power sensor.

D. Check the continuity of the wiring between P3-3 and the power sensor.

Expected Result:

The "load signal" wiring has continuity.

Results:

OK - The "load signal" wiring has continuity. Proceed to Test Step 5 .

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 (if equipped).
Repair: Repair the component, when possible. Replace parts, if necessary. Verify that the
original problem is resolved.

STOP

Test Step 5. 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:

The components are operating correctly.

Results:
 OK - The components are operating correctly. Proceed to Test Step 12 .

Not OK - At least one of the components is not operating correctly.

Repair: Repair the component, when possible. Replace the component, if necessary. Verify
that the original problem is resolved.

STOP

Test Step 6. CHECK THE CONTINUITY OF THE CAT DATA LINK

A. Disconnect Cat ET from the service tool connector.

B. Disconnect the wiring for the Cat Data Link from the GSC+.

C. Disconnect the P1 connector from the ECM.

D. Measure the resistance between the points that are listed in Table 2 . 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 2

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.

Each check of the resistance between the terminals and the ground strap is greater than five
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.
Repair: Perform the following procedure:

1. Connect the wiring to the GSC+. Be sure to connect each wire to the appropriate
terminal.
 2. Connect the P1 connector.

Proceed to Test Step 7 .

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

Test Step 7. CHECK THE GSC+

Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the
EMCP II+.

Expected Result:

The GSC+ is operating correctly.

Results:

OK - The GSC+ is operating correctly. Proceed to Test Step 8 .

Not OK - The GSC+ is not operating correctly.

Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify
that the original problem is resolved.

STOP

Test Step 8. CHECK THE "FUEL QUALITY" PARAMETER

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:

The value of the "Fuel Quality" parameter is correct.

Results:

OK - The value of the "Fuel Quality" parameter is correct. Proceed to Test Step 9 .

Not OK - The value of the "Fuel Quality" parameter is not correct.

Repair: Enter the correct value for the parameter. Verify that the original problem is resolved.

STOP

Test Step 9. CHECK THE SENSORS FOR THE AIR INLET MANIFOLD

A. If the engine is running, stop the engine.

 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:

"Inlet manifold air pressure (abs)"

"Inlet air temperature"

Expected Result:

The values of the parameters are correct.

Results:

OK - The values of the parameters are correct. Proceed to Test Step 10 .

Not OK - One or both of the values of the parameters are incorrect.

Repair: Replace the appropriate sensor. Verify that the original problem is resolved.

STOP

Test Step 10. CHECK THE GSC+

Verify that the GSC+ is operating correctly. Refer to the appropriate service literature for the
EMCP II+.

Expected Result:

The GSC+ is operating correctly.

Results:

OK - The GSC+ is operating correctly. Proceed to Test Step 11 .

Not OK - The GSC+ is not operating correctly.

Repair: Repair the GSC+. Refer to the appropriate service literature for the EMCP II+. Verify
that the original problem is resolved.

STOP

Test Step 11. 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 one percent of the generator's output power.

Expected Result:

The value of the "Generator Real kW" parameter is correct.

Results:

OK - The value of the "Generator Real kW" parameter is correct. Proceed to Test Step 12 .

Not OK - The value of the "Generator Real kW" parameter is incorrect.

Repair: Refer to Troubleshooting, "Generator Output Power Readings Do Not Match".

STOP

Test Step 12. CHECK THE ELECTRONIC CONTROL MODULE

Temporarily install a new electronic control module. Refer to Troubleshooting, "ECM - Replace".

Expected Result:

The problem is resolved when a new electronic control module is installed.

Results:

OK - The problem is resolved when a new electronic control module is installed.

Repair: Install the original electronic control module and verify that the problem returns. If
the new electronic control module operates correctly and the original electronic control
module does not operate correctly, replace the electronic control module.

STOP

Not OK - The problem is not resolved when a new electronic control module is installed.
Repair: Install the original electronic control module. Consult with Caterpillar customer
service for large gas engines.

STOP

PSP-000DE7C8
2025/10/15
06:32:12+06:30
i03662112
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