Emergency Stop - Test: Troubleshooting

3512C Marine Engine TTG00001-UP(SEBP4537 - 29) - Documentation https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?retu...
Welcome: a3yn3412
Product: MARINE ENGINE
Model: 3512C MARINE ENGINE TTG
Configuration: 3512C Marine Engine TTG00001-UP
Troubleshooting
3500C Marine Propulsion Engines
Media Number -KENR5404-06 Publication Date -01/03/2014 Date Updated -26/10/2016
i02637229
Emergency Stop - Test

SMCS - 7332-038-SQ
System Operation Description:
When the local emergency stop switch on the control panel is depressed, the coils of relay "R4" and relay
"R4A" are energized. The contacts of relay "R4" keep the coils of relay "R4" and relay "R4A" energized until
the Engine Control Switch (ECS) is cycled to the OFF/RESET position. The contacts of relay "R4A"
energize the coils of relays "R2" and "R2A". When relays "R2" and "R2A" are energized, power is removed
from the engine's primary Electronic Control Module (ECM) and the engine's secondary ECM. The primary
ECM and the secondary ECM will power down. The injection signals to the injector solenoids will stop. The
emergency stop lamp on the control panel will illuminate.
The contact of relay "R4A" also supplies power to terminal 3 of the connector for the timer. When power is
applied to terminal 3 of the connector for the timer, the timer will activate. The timer outputs 24 VDC to
terminal 6 of the connector for the timer for 2.5 seconds. The 24 VDC from terminal 6 of the connector for
the timer is applied to the coil of the "Air Shutoff Switch (ASOS)". The contact of the "ASOS" energizes the
air shutoff solenoids. The timer will output voltage to the coil of the "ASOS" for approximately 2.5 seconds.
The "ASOS" will then deactivate and power is removed from the air shutoff solenoids. This prevents damage
to the air shutoff solenoids. A normally open switch at the air shutoff valves will close when the air shutoff
solenoid activates the air shutoff valve. The switch input to the ECM notifies the ECM that the air shutoff
valves are closed. The ECM will not send injection signals to the injector solenoids until the switch inputs
from the air shutoff valves indicate that the valves are open.
Relay "R3A" and relay "R3" are energized at the same time as the "ASOS" through terminal 3 of the diode
assembly. Terminal 3 of the diode assembly will energize relay "R3A" and relay "R3" for 2.5 seconds. The
relays "R3A" and "R3" will de-energize after 2.5 seconds. The overspeed indicator on the control panel will
illuminate for 2.5 seconds.
In order to start the engine after an emergency stop condition, the ECS must be turned to the OFF/RESET
position. This resets the ECM and the air shutoff timer. In addition to turning the ECS to the OFF/RESET
position, the operator must manually open the air shutoff valves before starting the engine.
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Illustration 1 g01322358
Typical example
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Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
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Terminal locations for the C-C17/F-C1 LH rigid harness connectors and the connectors G-C6/F-C2 for a LH Control panel
(Terminal 11) 24 VDC 120-BK(Black)
(Terminal 12) Emergency stop signal 354-BK(Black)
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Terminal locations for the P-C2/A-C91 connectors for the power distribution panel
(Terminal B) Emergency stop signal 354-BK(Black)
(Terminal E) 24 VDC 120-BK(Black)
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Terminal locations for the C-C1/E-C1 LH rigid harness connectors and the A-C1/E-C2 RH rigid harness connectors
(Terminal f) 24 VDC 120-BK(Black)
(Terminal m) Emergency stop signal 354-BK(Black)
Test Step 1. Inspect the Electrical Connectors and the Wiring
A. Turn the circuit breaker for the battery to the OFF position.
B. Turn the ECS to the OFF/RESET position.
C. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Check
the allen head screw on each of the ECM connectors for the proper torque. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for the correct torque values.
D. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with
the circuit.
E. Check the harness and the wiring for abrasion and for pinch points.
Expected Result:
All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free
of corrosion, of abrasion or of pinch points.
Results:
OK - The harness and wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the connectors are completely coupled.
STOP
Test Step 2. Test the Circuit for the Local Emergency Stop Switch
A. Turn the circuit breaker for the battery to the ON position.
B. Turn the ECS to the STOP position.
C. Activate the local emergency stop switch on the control panel.
D. Monitor the air shutoff solenoids.
E. Deactivate the local emergency stop switch.
Expected Result:
The air shutoff solenoids activated.
Results:
OK - The air shutoff solenoids activated correctly.
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Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting,
"Electrical Connectors - Inspect".
STOP
Not OK - The air shutoff solenoids failed to activate. Proceed to Test Step 3.
Test Step 3. Check for Voltage from the "ASOS" at the Connector P-C1 for the Power Distribution
Panel
A. Turn the ECS to the OFF/RESET position.
B. Remove wire G708-BK(Black) from terminal "I" of connector A-C90. Install a wire jumper into the
connector for wire G708-BK(Black).
C. Turn the ECS to the STOP position.
D. Activate the local emergency stop switch.
E. Monitor the voltage on the wire jumper in terminal I at connector A-C90 of the rigid harness. Refer to
Illustration 1 for a schematic of the circuit.
F. Activate the local emergency stop switch.
G. Return all wiring to the original configuration.
Expected Result:
The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.
Results:
OK - The voltage measures 24 ± 3 VDC for approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 7.
Not OK - The voltage did not measure 24 ± 3 VDC for approximately 2.5 seconds. Proceed to Test
Step 4.
Test Step 4. Test for Voltage to the Coil of Relay "R4A" at the Connector P-C2 for the Power
Distribution Panel
B. Remove wire 354-BK(Black) from terminal "B" of connector A-C91.
E. Monitor the voltage on wire 354 at connector A-C91 of the rigid harness.
F. Deactivate the local emergency stop switch.
G. Return all wiring to the original configuration.
Expected Result:
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The voltage measures 24 ± 3 VDC.
Results:
OK - The voltage measures 24 ± 3 VDC. The circuit is operating correctly to this point. Proceed to
Test Step 5.
Not OK - No voltage was measured. Proceed to Test Step 11.
Test Step 5. Test for Voltage at the Coil of the "ASOS"
B. The input to the coil of the "ASOS" is wire T708-BK(Black) from terminal 6 of the timer. Remove
wire T708-BK(Black) from the "ASOS".
C. Connect a voltmeter between wire T708-BK(Black) from the "ASOS" and the engine ground.
D. Turn the ECS to the STOP position.
E. Activate the local emergency stop switch.
F. Monitor the voltage on the voltmeter.
G. Deactivate the local emergency stop switch.
H. Return all wiring to the original configuration.
Expected Result:
Results:
correctly to this point. Proceed to Test Step 6.
Not OK - The voltage did not measure 24 ± 3 VDC. Proceed to Test Step 8.
Test Step 6. Check for Voltage from the "ASOS" to the Air Shutoff Solenoids
B. Disconnect wire G708-BK(Black) from the "ASOS".
C. Connect a voltmeter to the empty terminal on the "ASOS". Connect the other lead from the voltmeter
to engine ground.
H. Reconnect wire G708-BK(Black) to the "ASOS".
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Expected Result:
Results:
correctly to this point.
Repair: Repair the wire G708-BK(Black) between the "ASOS" and wire G708-BK(Black) on pin I at
connector P-C1 of the rigid harness.
STOP
Not OK - The voltage did not measure 24 ± 3 VDC for approximately 2.5 seconds.
Repair: Verify that 24 ± 3 VDC is present on wire K708-BK(Black) at the normally open contacts of
the "ASOS". If voltage is not present on wire K708-BK(Black), check the wire K708-BK(Black) and
the circuit breaker for the air shutoff for problems.
If voltage is present on the wire K708-BK(Black), check wire 220-BK(Black) on the coil of the
"ASOS" for continuity to the −Battery. If necessary, repair the wire or replace the wire. If wire 220-
BK(Black) is OK and voltage is present on wire K708-BK(Black), replace the "ASOS".
STOP
Test Step 7. Check the Voltage at the Connector for the Air Shutoff Solenoids
B. Disconnect the connector for the air shutoff solenoids. Disconnect the connector for the right and left
sides of the engine.
C. Connect a voltmeter between wire G708-BK(Black) on the connector for the air shutoff solenoid and
the engine ground.
H. Reconnect the connectors for the air shutoff solenoids.
Expected Result:
Results:
correctly to this point.
Repair: Check the wire H708-BK(Black) from terminal A of the connector for continuity to the
−Battery. If the wire H708-BK(Black) to the −Battery terminal is OK, replace the air shutoff solenoid.
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Verify that the circuit operates correctly.
If the wire H708-BK(Black) does not have continuity to the −Battery from terminal A of the
connector, check for continuity on wire H708-BK(Black) on pin H at connector P-C1/A-C90 of the
rigid harness to −Battery. If the wire H708-BK(Black) does not have continuity to the −Battery from
pin H at connector P-C1 of the rigid harness, verify that the breaker for the air shutoff is not tripped.
STOP
Not OK - The voltage did not measure 24 ± 3 VDC for approximately 2.5 seconds. System voltage
was not available at the solenoid connector.
Repair: There is a problem in the wiring between the connector for the air shutoff solenoids and wire
G708-BK(Black) on pin I at connector P-C1/A-C90 of the rigid harness. Repair the connectors or
wiring and/or replace the connectors or wiring.
STOP
Test Step 8. Check the Voltage at the Contact of Relay "R4A"
B. Disconnect wire T120-BK(Black) from terminal 87 of relay "R4A".
C. Connect a voltmeter between terminal 87 of relay "R4A" and the engine ground.
H. Turn the ECS to the OFF/RESET position.
I. Reconnect wire T120-BK(Black).
Expected Result:
Results:
OK - The voltage measures 24 ± 3 VDC. Proceed to Test Step 9.
Test Step 9. Check the Voltage at Terminal 6 of the Connector for the Timer
B. Disconnect wire T708-BK(Black) from terminal 6 of the connector for the timer.
C. Connect a voltmeter between terminal 6 of the connector for the timer and engine ground.
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H. Return all wiring to the original configuration.
Expected Result:
Results:
OK - The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.
Repair: Repair the wire T708-BK(Black) between the "ASOS" and terminal 6 of the timer.
STOP
Not OK - The voltage did not measure 24 ± 3 VDC for approximately 2.5 seconds.
Repair: Check for 24 ± 3 VDC on terminal 3 of the connector for the timer.
If voltage is not present on terminal 3, repair the wire T120-BK(Black) between terminal 87 of relay
"R4A" and terminal 3 of the connector for the timer.
If voltage is present on terminal 3 of the connector for the timer, verify that wire 220-BK(Black) on
terminal 2 of the connector for the timer has continuity to the −Battery. If wire 220-BK(Black) does
not have continuity to the −Battery, repair the wire.
Verify that 24 ± 3 VDC is present on terminal 1 of the connector for the timer. If 24 ± 3 VDC is not
present on terminal 1 of the connector for the timer, verify that the ECS is not in the "OFF/RESET"
position. Verify that the "MPD" breaker is not tripped. Check the normally closed contact of relay "R1"
for proper operation. Check the wire 120-BK(Black) between terminal 1 of the connector for the timer
and relay "R1" for damage. Check the wire A120-BK(Black) between relay "R1" and the "MPD"
breaker for damage. If necessary, repair the wires.
If the voltage is present on terminal 1 and 3 of the timer and wire 220-BK(Black) is OK, replace the
timer.
STOP
Test Step 10. Check the Voltage at the Coil of Relay "R4A"
B. Connect a voltmeter between wire 354-BK(Black) on terminal 86 of relay "R4A" and the engine
ground.
E. Monitor the voltage on the voltmeter.
F. Deactivate the local emergency stop switch.
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Expected Result:
Results:
OK - The voltage measures 24 ± 3 VDC.
Repair: Check wire 220-BK(Black) on the coil of the "R4A" relay for continuity to the −Battery. If
necessary, repair the wire or replace the wire.
Check for 24 ± 3 VDC on wire 120-BK(Black) on terminal 30 of relay "R4A". If 24 ± 3 VDC is not
present on wire 120-BK(Black), verify that the ECS is not in the "OFF/RESET" position. Verify that
the "MPD" breaker is not tripped. Check the normally closed contact of relay "R1" for proper
operation. Check the wire 120-BK(Black) between terminal 30 of the relay "R4A" and relay "R1" for
damage. Check the wire A120-BK(Black) between relay "R1" and the "MPD" breaker for damage. If
necessary, repair the wires.
If wire 220-BK(Black) is OK and voltage is present on wire 120-BK(Black) on terminal 30, replace
relay "R4A".
STOP
Not OK - The voltage did not measure 24 ± 3 VDC.
Repair: Repair the wire 354-BK(Black) between the coil of the "ASOS" and the connector P-C2/A-
C91 on the power distribution panel.
STOP
Test Step 11. Check the Voltage from the Local Emergency Stop Switch to Relay "R4A"
B. Disconnect wire 354-BK(Black) from the local emergency stop switch.
C. Connect a voltmeter to the empty terminal on the local emergency stop switch. Connect the other lead
from the voltmeter to engine ground.
H. Reconnect wire 354-BK(Black).
Expected Result:
Results:
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Repair: Repair the wire 354-BK(Black) between the local emergency stop switch and the wire 354-
BK(Black) on pin B at connector P-C2/A-C91 of the rigid harness. Refer to Illustration 1 for a
schematic of the circuit and the interconnecting connectors of the circuit.
STOP
Test Step 12. Check the Voltage to the Local Emergency Stop Switch
B. Connect a voltmeter between wire 120-BK(Black) on the local emergency stop switch and engine
ground.
D. Monitor the voltage on the voltmeter.
Expected Result:
Results:
Repair: Replace the local emergency stop switch.
STOP
Not OK - The voltage did not measure 24 ± 3 VDC.
Repair: Check the wire 120-BK(Black) on pin E at connector P-C2/A-C91 of the rigid harness
between the connector and the local emergency stop switch for damage. Refer to Illustration 1 for a
schematic of the circuit and the interconnecting connectors of the circuit.
Verify that the ECS is not in the "OFF/RESET" position. Verify that the "MPD" breaker is not tripped.
Check the normally closed contact of relay "R1" for proper operation. Check the wire A120-
BK(Black) between relay "R1" and the "MPD" breaker for damage. If necessary, repair the wires.
STOP
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Emergency Stop - Test: Troubleshooting

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3512C Marine Engine TTG00001-UP(SEBP4537 - 29) - Documentation https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?retu...

Emergency Stop - Test

System Operation Description:

Test Step 1. Inspect the Electrical Connectors and the Wiring

B. Turn the ECS to the OFF/RESET position.

OK - The harness and wiring appear to be OK. Proceed to Test Step 2.

Not OK - There is a problem in the connectors and/or wiring.

A. Turn the circuit breaker for the battery to the ON position.

B. Turn the ECS to the STOP position.

C. Activate the local emergency stop switch on the control panel.

D. Monitor the air shutoff solenoids.

E. Deactivate the local emergency stop switch.

The air shutoff solenoids activated.

OK - The air shutoff solenoids activated correctly.

A. Turn the ECS to the OFF/RESET position.

C. Turn the ECS to the STOP position.

D. Activate the local emergency stop switch.

F. Activate the local emergency stop switch.

G. Return all wiring to the original configuration.

The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.

A. Turn the ECS to the OFF/RESET position.

B. Remove wire 354-BK(Black) from terminal "B" of connector A-C91.

C. Turn the ECS to the STOP position.

D. Activate the local emergency stop switch.

F. Deactivate the local emergency stop switch.

G. Return all wiring to the original configuration.

The voltage measures 24 ± 3 VDC.

Not OK - No voltage was measured. Proceed to Test Step 11.

Test Step 5. Test for Voltage at the Coil of the "ASOS"

A. Turn the ECS to the OFF/RESET position.

D. Turn the ECS to the STOP position.

E. Activate the local emergency stop switch.

F. Monitor the voltage on the voltmeter.

G. Deactivate the local emergency stop switch.

H. Return all wiring to the original configuration.

The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.

A. Turn the ECS to the OFF/RESET position.

B. Disconnect wire G708-BK(Black) from the "ASOS".

D. Turn the ECS to the STOP position.

E. Activate the local emergency stop switch.

F. Monitor the voltage on the voltmeter.

G. Deactivate the local emergency stop switch.

H. Reconnect wire G708-BK(Black) to the "ASOS".

The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.

A. Turn the ECS to the OFF/RESET position.

D. Turn the ECS to the STOP position.

E. Activate the local emergency stop switch.

F. Monitor the voltage on the voltmeter.

G. Deactivate the local emergency stop switch.

H. Reconnect the connectors for the air shutoff solenoids.

The voltage measures 24 ± 3 VDC for approximately 2.5 seconds.

Verify that the circuit operates correctly.

Test Step 8. Check the Voltage at the Contact of Relay "R4A"

A. Turn the ECS to the OFF/RESET position.

B. Disconnect wire T120-BK(Black) from terminal 87 of relay "R4A".

D. Turn the ECS to the STOP position.

E. Activate the local emergency stop switch.

F. Monitor the voltage on the voltmeter.

G. Deactivate the local emergency stop switch.

H. Turn the ECS to the OFF/RESET position.

I. Reconnect wire T120-BK(Black).

The voltage measures 24 ± 3 VDC.

OK - The voltage measures 24 ± 3 VDC. Proceed to Test Step 9.