INSULATION 4880910 - Caterpillar

Illustration 1 g00721817
System Schematic For kW Level OutputThe kW level output will be activated whenever the total power output of the generator exceed the setpoint P139. The kW level output is the connector contact 34 of the GSC+. This setpoint can be programmed from 0 to 110 percent of the rated power on the nameplate (setpoint P030). This setpoint can be programmed with a time delay from 0 to 120 seconds (setpoint P140). See System Operation, "Engine/Generator Programming OP5-0". Also, see System Operation, "Service Mode". Once the output is activated, the kW level output will be deactivated when the total power output of the generator drops below a programmed setpoint (setpoint P141). This setpoint is different from the activation setpoint. This setpoint can be programmed from 0 to 110 percent of the power rating on the nameplate of the generator. This setpoint can be programmed with a time delay from 0 to 120 seconds.When kW relay is disconnected from the GSC+, the voltage on the kW level output is approximately 5.0 DCV. When kW relay is connected to the GSC+, the voltage on the kW level output is approximately 0 volts. The kW level output is capable of drawing (sinking) approximately 100 mA. Documenting and troubleshooting any connections to this output is the responsibility of the customers and the dealers. The possible cause of a CID 0859 FMI 04 is a short to the "-battery" circuit of the kW level output.The GSC+ treats a CID 0859 FMI 04 as an alarm fault.Troubleshooting of this failure is straight forward. The FMI 04 defines the diagnostic code as a short to "B-". Use the following information in order to find the exact cause of the diagnostic code.
FMI information
system schematic of the kW level output
customer's documentation
dealer's documentationTest Step 1. CHECK THE GENERATOR SET CONTROL
Verify that the CID 0859 FMI 04 diagnostic code is active.
Disconnect the wire from contact 34 of the GSC+.Expected Result:The diagnostic code becomes inactive.Results:
OK - The diagnostic code changes to inactive. Proceed to test step 2.
NOT OK - The diagnostic code remains active. The GSC+ may have failed.Repair: It is unlikely that the GSC+ has failed. Exit this diagnostic code procedure and repeat the CID 0859 FMI 03 diagnostic code procedure again. If the cause of the failure is still unknown, then replace the GSC+.STOPTest Step 2. CHECK FOR A SHORT TO "B-" IN THE WIRING OF THE kW LEVEL OUTPUT
Shut down the genset.
Disconnect the "B-" terminal from the battery.
The wire remains disconnected from contact 34 of the GSC+.
Measure the resistance between the wire that was disconnected from contact 34 of the GSC+ and the "B-" terminal.Expected Result:The resistance is greater than 5000 ohms.Results:
OK - The resistance is greater than 5000 ohms. The resistance is correct.Repair: The failure is intermittent. The probable cause is a poor electrical connection. Check the wiring for damage and clean all connections. Exit this procedure and perform the CID 0859 FMI 04 procedure again. If no failure is found and the diagnostic code is