Marine Multi-Station Control System Caterpillar

Note: This test is only for the data link failures that occur on the control station data link.

There is a loss of communications with the active control station. The power train control processor (PCP) and the active control station do not communicate.

Note: The PCP and the active control station communicate on the dedicated data link for the control station.

Troubleshooting:

If the active control station is the master control station, ET will display a CID 1816 FMI 09 code. In this case, go to the CID 1816 FMI 09 diagnostic test.

Test Step 1. DETERMINE THE CONTROL STATION.

1. Determine if the active station is one of the stations on the control station data link.

2. Determine if the vessel is equipped with one control station and one master control station.

Expected Result:

The vessel is equipped with 2 stations (1 Master Station and 1 Control Station).

Results:

• YES - The vessel is equipped with one control station and one master control station. Go to Test Step 2.

• NO - The vessel is equipped with 3 or more stations. Go to Test Step 9.

Test Step 2. CHECK THE ELECTRICAL CONNECTIONS AND WIRING.

1. Ensure that the keyswitch is OFF.

2. Inspect the ICH or CSP data link cable for the following conditions:

   • Corrosion

   • Abrasion

   • Pinch points

   • Incorrect attachment

Expected Result:

All harnesses are in good condition.

Results:

• OK - All harnesses are in good condition. Go to Test Step 3.

• NOT OK - All harnesses are not in good condition.

  Repair: Repair the harnesses or replace the harnesses.

  After the repair, verify that the diagnostic code is NOT active.

  STOP

Test Step 3. VERIFY THAT THE CABLE IS CORRECT.

Illustration 1	g03325937

1. Use a DVM in order to verify the correct cable pinout. Refer to Illustration 1. Refer to Table 1.
   Show/hide table

   Table 1

   Circuit Name	Pin Number on the PCP Connector	Pin Number on the Master Control Station Connector
   +Battery	1	11
   -Battery	2	12
   CAN data link +	3	7
   CAN data link -	4	8
   CAN Shield	5	9
   Station Lockout	8	10

2. Ensure that the CAN termination loop jumpers are installed at each end of the cable.

3. Measure the resistance from pin 6 on the PCP connector to pin 7 on the PCP connector.

4. Measure the resistance from pin 5 on the control station connector to pin 6 on the control station connector.

Expected Result:

The resistance is less that 10 Ohms for all readings.

Results:

• OK - The resistance is less that 10 Ohms. Go to Test Step 4.

• NOT OK - The resistance IS NOT less that 10 Ohms.

  Repair: Repair the cable or replace the cable.

  After the repair, verify that the diagnostic code is NOT active.

  STOP

Test Step 4. VERIFY THE CORRECT NUMBER OF TERMINATING RESISTORS.

Verify that there is NO terminating resistor that is connected at the control station or the PCP. The terminating resistors for the data link for the control station are located in the hardware for the control station and inside the PCP.

NO terminating resistors should be connected to the data link for the control station.

Expected Result:

No terminating resistors are connected to the data link for the control station.

Results:

• OK - No terminating resistors are connected to the data link for the control station. Go to Test Step 5.

• NOT OK - One or more terminating resistor is connected to the data link for the control station. Remove the terminating resistors.

  STOP

Test Step 5. MEASURE THE VOLTAGE AT THE CONTROL STATION.

1. Ensure that the keyswitch is OFF.

2. Measure the voltage and record the voltage at the batteries.

3. Disconnect the 8-pin data link cable from the ICH or the CSP.

4. Turn the keyswitch ON.

5. Use a digital volt meter (DVM) in order to measure the voltage between pin 1 and pin 2 on the 8-pin data link cable.

Expected Result:

The voltage is equal to the measured battery voltage minus 2 V.

Results:

• OK - The voltage is equal to the measured battery voltage minus 2 V. Go to Test Step 7.

• NOT OK - The voltage is 0 VDC. Repair the harness or replace the harness. Exit this procedure. Perform this procedure again.

  STOP

• NOT OK - The voltage IS NOT equal to the measured battery voltage minus 2 V. Go to Test Step 6.

Test Step 6. VERIFY THE VOLTAGE AT THE DATA LINK CONNECTOR FOR THE PCP CONTROL STATION.

1. Turn the keyswitch OFF.

2. Disconnect the 8-pin data link cable from the control station connector on the PCP.

3. Turn the keyswitch ON.

4. Use a DVM in order to measure the voltage between pin 11 and pin 12 on the 12-pin connector.

Expected Result:

The voltage is equal to the measured battery voltage minus 2 V.

Results:

• OK - The voltage is equal to the measured battery voltage minus 2 V.

  Repair: Replace the cable.

  After the repair, verify that the diagnostic code is NOT active.

  STOP

• NOT OK - The voltage IS NOT equal to the measured battery voltage minus 2 V.

  Repair: Go to the Special Instruction, REHS0354, "Charging System Troubleshooting".

  STOP

Test Step 7. MEASURE THE RESISTANCE THROUGH THE DATA LINK CABLE FOR THE CONTROL STATION (SHORT CIRCUIT TEST).

1. Turn the keyswitch OFF.

2. Disconnect the harness from the control station ICH or the CSP.

3. Disconnect the data link for the control station from the PCP.

4. Measure the resistance between pin 3 (CAN+) and pin 4 (CAN -) on the 8-pin connector. Wiggle the harness during the measurement in order to reveal an intermittent condition.

5. Continue to test with the combinations of pins that are listed in Table 2.

Expected Result:

The resistances are greater than 20000 Ohms.

Results:

• OK - The resistances are greater than 20000 Ohms. Go to Test Step 8.

• NOT OK - The resistances ARE NOT greater than 20000 Ohms.

  Repair: Replace the cable.

  After the repair, verify that the diagnostic code is NOT active.

  STOP

Test Step 8. MEASURE THE RESISTANCE THROUGH THE DATA LINK CABLE FOR THE CONTROL STATION (OPEN CIRCUIT TEST).

Show/hide table

Illustration 2	g01033023
Service tool is to be supplied by the customer.

1. Turn the keyswitch OFF.

2. Disconnect the control station ICH or the CSP.

3. Disconnect the data link cable for the control station from the PCP.

4. Connect the 8-pin connector on the PCP connector.

5. Connect the 12-pin connector on the 12-pin connector.

6. Measure the resistance between pin 7 and pin 10 on the 12-pin connector for the PCP. Wiggle the harness during the measurement in order to reveal an intermittent condition.

Expected Result:

The resistance is less than 20 Ohms.

Results:

• OK - The resistance is less than 20 Ohms.

  Repair: Temporarily replace the ICH or the CSP.

  STOP

• NOT OK - The resistance is greater than 20 Ohms.

  Repair: Replace the cable.

  After the repair, verify that the diagnostic code is NOT active.

  STOP

Test Step 9. INSPECT THE DATA LINK CONNECTIONS FOR THE ICH OR CSP.

Inspect the harnesses and wiring for the following conditions:

• Corrosion

• Abrasion

• Pinch points

• Incorrect attachment

Expected Result:

The harnesses and wiring are in good condition.

Results:

• OK - The harnesses and wiring are in good condition. Go to Test Step 10.

• NOT OK - Repair the harnesses and wiring or replace the harnesses and wiring.

  STOP

Test Step 10. VERIFY THE WIRING HARNESS FOR THE CONTROL STATION. THE VESSEL IS EQUIPPED WITH 2 OR MORE STATIONS ON THE CONTROL STATION DATA LINK.

Illustration 3	g03325937

Note: TEE connectors and terminating resistors are required.

Use a DVM in order to verify the correct cable pin outs. Refer to Table 3.

Expected Result:

The pin outs are correct.

Results:

• OK - Go to Test Step 11.

• NOT OK -

  Repair: Repair the cable or replace the cable.

  STOP

Test Step 11. VERIFY THE CORRECT NUMBER OF TERMINATING RESISTORS.

1. Verify that there are two terminating resistors connected to the control station data link. The terminating resistors for the data link for the control station should be located at the ends of the data link runs. Refer to Illustration 3

2. Disconnect the data link for the control station from the PCP.

3. Disconnect each control station from the data link.

4. Use a DVM in order to measure the resistance between pin 3 and pin 4 on the PCP connector.

Expected Result:

The resistance is between 57 and 63 Ohms.

Results:

• OK - The resistance is between 57 and 63 Ohms. Go to Test Step 12.

• NOT OK - The resistance is 120 Ohms.

  Repair: Add the missing terminating resistors to the data link run.

  Verify that the diagnostic code is NOT active.

  STOP

• NOT OK - The resistance is less than 63 Ohms. There is an extra terminating resistor in the circuit.

  Repair: Verify that the termination loops on the connector are not connected. Repair as required.

  Verify that the diagnostic code is NOT active.

  STOP

• NOT OK - The resistance is greater than 20000 Ohms. There is a broken wire in the circuit or there are no terminating resistors installed on the harness.

  Repair: Verify that the terminating resistors are installed. If they are, there could be an open circuit in the harness. Disconnect each section and retest.

  STOP

Test Step 12. MEASURE THE RESISTANCE THROUGH THE DATA LINK CABLE FOR THE CONTROL STATION. (SHORT CIRCUIT TEST)

1. Turn the keyswitch OFF.

2. Disconnect the control station ICH or CSP.

3. Disconnect the data link for the control station from the PCP.

4. Disconnect the termination resistors.

5. Measure the resistance between pin 3 (CAN+) and pin 4 (CAN -) on the 8-pin connector. Wiggle the harness during the measurement in order to reveal an intermittent condition.

6. Continue to test with the pin combinations that are listed in table 4.
   Show/hide table

   Table 4

   Measure from the 8-pin Connector Pin Number	Circuit Name	Measure to Pin Number	Circuit Name
   3	CAN data +	1	+PWR master
   3	CAN data +	2	-PWR master
   3	CAN data +	5	CAN shield
   3	CAN data +	6	CAN term loop -
   3	CAN data +	7	CAN term loop +
   4	CAN data -	1	+PWR master
   4	CAN data -	2	+PWR master
   4	CAN data -	5	-PWR master
   4	CAN data -	6	CAN term loop -
   4	CAN data -	7	CAN term loop +

Expected Result:

The resistance is greater than 20000 Ohms.

Results:

• OK - The resistance is greater than 20000 Ohms.

  Repair: Temporarily replace the suspected control head.

  Verify that the diagnostic code is NOT active.

  STOP

• NOT OK - The resistance IS NOT greater than 20000 Ohms.

  Repair: Repair the data link cable or replace the data link cable.

  Verify that the diagnostic code is NOT active.

  STOP