Marine Engine and Genset Control Panel IIIB Caterpillar

Panel Does Not Power Up

The following are symptoms when the panel does not have power:

• Engine does not start

• SDU lights are not on

• DCU is not on

Use the following tasks to address this issue.

1. Check to see if the panel isolation breakers have been tripped.

2. Check power at the customer supplied power terminals. Ensure that the primary and secondary power lines at X1.1:1 and X1.1:3 have 24V (+). Ensure that X1.1:2 and X1.1:4 have 0V (-).

3. Check voltage from the ship power supply. Checking voltage includes checking wiring and circuit breakers.

4. Check the quint diode. Check for battery output voltage.

5. Check the connectors on the back of the Digital Control Unit (DCU). Ensure that the connectors are pushed securely and the screw terminals are tightened. Ensure that the panel wiring is correct.

6. Check the panel wiring at the Engine Control Switch (ECS).

7. Check that the 4Q24 circuit breaker is closed. Ensure that the wiring is not damaged or disconnected.

   Note: The 4Q24 circuit breaker provides power to the DCU.

Local Control Panel Does Not Start or Fully Shut Down Engine

Use the following checks if the engine will not start or fully shut down from the local control panel.

1. Check the status bar and alarm list for any alarms that have not been acknowledged. Refer to this Troubleshooting Guide, M0078007, General Information.

2. Ensure that the physical E-Stop button is not depressed. Ensure that the remote E-Stop is not engaged.

3. Check that the ECS is in "Local" mode.

   Note: Starting from the panel is disabled if the ECS is in "Remote" mode.

4. Ensure that the Crank Inhibit Switch is disabled. If enabled, the status bar will display "Start Disabled".

5. Check that all active shutdown alarms have been acknowledged and cleared.

   Note: Shutdown events must be acknowledged and cleared before the engine will be allowed to start.

6. Check for interlocks preventing the engine from starting. There are two types of interlocks that can prevent the engine from starting. The interlocks are either programmed or physical.

   1. Check that there are no programmed engine or transmission interlocks preventing start (such as neutral inhibit) on the "Start Conditions" screen of the DCU.

   2. For the physical interlock, check if the jumper wire between X4.C214 and terminal block "T229" is damaged or missing.

7. Check the "Hold Button to Start/Stop" setting if the engine attempts to start but then stops or does not fully shut down.

   1. A dialog box will appear on the DCU if this setting is configured. The dialog box displays "Are you sure you want to start/stop the engine?". Check the "Hold Button to Start/Stop" option under the DCU "Start/Stop/Prelube" setting in the web tool. Refer to the Programming Guide, LEBM0063, "Cat A&P Controls Programming Guide".

8. Check the panel and engine wiring. In the panel, check the Crank Inhibit Switch wiring. Check the crank output between the DCU and remote start.

   Note: The remote start is for the engine ECM start command.

   The issue is outside of the panel if +24V is present on C-1:29 while the DCU indicates cranking. Check the E-Stop for damaged or unplugged wiring to the engine.

9. Use the following steps if the engine does not start and the DCU displays "Engine Start Failed":

   1. Attempt an engine restart and monitor engine speed on the DCU.

   2. Check the speed sensor at the flywheel housing for correct installation depth if the "Engine Speed" parameter displays "- - - -".

   3. Perform the panel wiring troubleshooting from Step 8 if the DCU is reading engine speed.

10. Ensure that both the E-Stop and Crank Inhibit Switch are both disengaged if using Crank Override to start the engine.

11. Check the Cat^® Electronic Technician (Cat ET) Service Tool configurations (only for MGCP IIIB).

    1. Set the "Engine State Control Input" as "Not Installed" in the C32 Auxiliary and Genset engine software.

    2. Set the "Flexed Parameter - Fuel Enable Input" status as "Not Installed" or "Off" in the C18 Auxiliary and Genset engine software. This parameter must be set to either of these statuses to program the "Start/Stop" settings or to start the engine.

Local Control Panel Will Not Activate Second Starter

Use the following checks when the local control panel does not activate the second starter.

1. Check the status bar and alarm list. Refer to this Troubleshooting Guide, M0078007, General Information for more information.

2. Check the E-Stops. Ensure that the physical E-Stop button is not depressed. Ensure that the remote E-Stop is not engaged.

3. Ensure that the Engine Control Switch ("ECS") is in "Local" mode.

   Note: Starting from the panel is disabled if the "ECS" is in "Remote" mode.

4. Ensure that the Crank Inhibit Switch is disabled. If the switch is enabled, the status bar will display "Start Disabled".

5. Acknowledge and clear the active shutdown alarms.

   Note: Shutdown events must be acknowledged and cleared before the engine will be allowed to start.

6. Check that there are no engine or transmission interlocks, such as neutral inhibit, preventing start.

7. Check the panel and engine wiring. In the panel, check the Crank Inhibit Switch wiring. Check the Crank Output between DCU IO#6 and the remote start pin (C1:29).

   Note: The remote start is for the engine ECM start command.

   The issue is outside of the panel if +24V is present on the remote start pin while the DCU indicates cranking. Check the E-Stop for damaged or unplugged wiring to the engine.

8. Check that the Starter Select Switch and the associated relay have been installed. The relay is provided by the dealer. The switch and relay must be installed if a second starter is to be used.

9. Check the panel wiring at the Starter Select Switch and relay. If +24V is present on pin C1:66 while the DCU indicates cranking, the issue is outside the panel.

The Engine Will Not Shut Down from the DCU

Use the following checks if the engine will not shut down from the DCU.

1. Check the Engine Control Switch (ECS) configuration. Ensure that the ECS is in "Local" mode.

2. Check the panel and ECS wiring. Check the DCU Relay #1 wiring at terminal 88. Terminal 88 should have 24V while the DCU is indicating stopping. The Remote Stop pin (C1:36) should also indicate 24V. Check the remote stop wiring to the engine ECM.

The Local Throttle Control Does Not Work (MECP IIIB Only)

Use the following checks when troubleshooting the local control throttle:

1. Ensure that the Engine Control Switch (ECS) is in "Local" mode.

2. Ensure that the PWM rotary dial lock is disengaged.

3. Sweep the PWM rotary throttle until the desired engine speed is within 50 rpm of the actual speed.

4. Ensure that the ECS contact block is closed.

5. Check the Sync #2 wire to the engine ECM. Use a multimeter to check if 0V is on the connector pin (C1:35).

6. Check the PWM output from the Speed Brick with a multimeter. The duty cycle must be between 5% and 95% on connector C1:4.

7. Check the analog signal to the Speed Brick. Ensure that the analog potentiometer should have a 0 kOhm to 1 kOhm resistance on pins 1, 2, and 3.

8. Check power supply to the Speed Brick. The Speed Brick should have a 14V to 45V supply on pins B+ and B-.

9. Check the "Prop Throttle Configuration" in Cat ET.

   1. Enable the Secondary Throttle if necessary for C32 and C18.

   2. Change the "Desired Speed Input Configuration" if the required customer setting is not PWM for C9.3.

The Local Throttle Control Does Not Work (MGCP IIIB Only)

Use the following checks when troubleshooting the local control throttle:

1. Ensure that the Engine Control Switch (ECS) is in "Local" mode.

2. Ensure that the relay contacts 21 and 22 are open to the engine ECM Digital Throttle Enable input. Use a multimeter to ensure that 0V is on connector C1:37.

3. Ensure that the relay contacts 11 and 14 are closed to the Local Throttle Switch.

4. Ensure that the ECS contact block is closed.

5. Check the Local Control Switch for faulty wiring.

   • Use a multimeter to check if 0V is on connector C1:48 when the switch is pressed for "Raise Engine Speed".

   • Use a multimeter to check if 0V is on pin 38 when the switch is pressed for "Lower Engine Speed".

6. Check the auxiliary and genset throttle configurations in Cat ET.

   • Set the "Desired Speed Input Configuration" to "CAN" if the generator or auxiliary engine does not have a PWM speed sensor. Ensure that the "Secondary Desired Speed Input Configuration" is set to the required setting.

   Note: Do not set the "Desired Speed Input Configuration" and the "Secondary Desired Speed Input Configuration" to "CAN" on both inputs.

Engine Does Not Start When Commanded by Automatic Start (MGCP IIIB Only)

1. Check the "Starter 1" cranking time under the DCU "Start/Stop/Prelube" settings in the web tool. Refer to the Programming Guide, LEBM0063, "Cat A&P Controls Programming Guide".

2. Check the Crank Inhibit Switch wiring. Use a multimeter to ensure that the DCU terminals 88, 89, and 90 have +24V.

3. Check the Cat ET configurations.

   • Ensure that the "Engine State Control Input Configuration" is set to "Not Installed" in the C32 auxiliary and genset engine software.

   • Ensure that the "Flexed Parameter - Fuel Enable Input" is set to either "Not Installed" or "Off" in the C18 auxiliary and genset engine software

Engine Does Not Fully Shut Down After Pressing Stop Button

Check the "Hold Button to Start/Stop" setting under the DCU "Start/Stop/Prelube" menu on the web tool. Refer to the Programming Guide, LEBM0063, "Cat A&P Controls Programming Guide".

The Remote Start Does Not Work

Use the following checks if the remote start does not work.

1. Check the status bar. The status bar must show "Cranking Manual" or "Cranking Automatic".

   1. If the status bar displays "Start Disabled", ensure that the crank inhibit switch is not engaged. The crank inhibit switch must be off.

   2. If the status bar displays "Starting Denied", a shutdown event is active. The event must be acknowledged and cleared in the alarm list.

2. Ensure the Engine Control Switch (ECS) is in "Remote" mode.

   Note: Remote starting is disabled if the ECS is in "Local" mode.

3. Check the E-stops. Ensure that the physical E-stop button is not depressed and the remote E-Stop is not engaged.

4. Ensure that there are no engine or transmission interlocks such as neutral inhibit (MECP IIIB only) preventing start.

5. Check the Crank 2 wiring was installed or wired incorrectly if dual starters are installed. The switch could be pointing to the starter with no power (not energized).

6. Check the panel wiring for damaged or unplugged wiring going to the engine. Use a mutlimeter to check if +24V is on connector pin C1:29 while the DCU indicates cranking. If there is +24V, the issue is outside the panel.

The Remote Stop Does Not Work

If the remote stop does not work, use the following list of checks.

1. Check the status bar for engine states and alarms.

2. Ensure the Engine Control Switch (ECS) is in "Remote" mode.

   Note: Remote starting is disabled if the ECS is in "Local" mode.

3. Check for damaged or unplugged remote stop wiring on the DCU, UC3 terminals 6 and 7, and on X1.2 terminals 9 to 12. Use a multimeter to measure the voltage on connector pin C1:36 while the DCU indicates stopping. If 0V is on the connector pin, the issue is outside the panel.

The Remote Throttle Does Not Work (MECP IIIB Only)

1. Ensure that the Engine Control Switch (ECS) is in "Remote" mode.

   Note: Remote starting is disabled if the ECS is in "Local" mode.

2. Ensure that the ECS contact is open. The ECS contact must be open to enable the remote throttle.

3. Check PWM output from Vessel PowerTrain Control Throttle with a multimeter. The duty cycle must be between 10% and 90% on connector pin C1:10.

4. Check the engine for PWM 1 diagnostics. Check the DCU screen for any engine PWM 1 codes.

5. Check for damaged or unplugged wiring from the panel to the engine ECM.

The Remote Throttle Does Not Work (MGCP IIIB Only)

1. Ensure that the Engine Control Switch (ECS) is in "Remote" mode.

   Note: Remote starting is disabled if the ECS is in "Local" mode.

2. If the remote throttle is PWM or TCS1 (CAN), the remote throttle relay contacts 21 and 22 must be closed. When the relay contacts are closed, the engine ECM digital throttle enable input is disabled. Ensure that there is 0V on connector pin C1:37. For PWM, the duty cycle must be between 10% and 90% on connector pin C1:10.

3. If the remote throttle is digital, the remote throttle relay contacts 21 and 22 must be closed (short circuit), but remove the jumper at X1.1:61 or add the Remote Digital Enable in series to create an open circuit. The remote throttle relay contacts 11 and 12 must be closed to the Remote Digital Throttle Raise and Lower relays.

4. Check the auxiliary or genset throttle configurations in CAT ET. Refer to Step 6 in the "The Local Throttle Control Does Not Work (MGCP IIIB Only)" Section.

The Shutdown Override Does Not Work

1. An "Overspeed" shutdown event can never be overridden.

2. The E-Stop cannot be overridden.

3. If there is a SDU wire break detection code active, check the wiring from the "Shutdown Override" switch to terminals 18 and 19 on the SDU.

4. If there is no SDU wire break detection code active, check that the engine ECM configuration is correct in CAT ET. Refer to the Application & Installation Guide, LEBM0062, "Cat^® A&P Controls Application & Installation Guide" for further information. Check for damaged or unplugged wiring from C1:47 to X4:19 to terminal 10 on the SDU. The engine ECM sends out a status message only when the engine derates or shutdowns are being overridden.

5. Check the Marine Society regulations. Some Marine Societies never allow certain shutdowns to be overridden such as oil pressure. Check the SDU configuration using the web tool for what is enabled. Refer to the Programming Guide, LEBM0063, "Cat^® A&P Controls Programming Guide".

The Crank Inhibit Allows the Engine to Start

Check for crank inhibit switch failure. Replace the switch if failed.

The DCU Displays Shutdown Override Active Icon When Shutdown Override Switch Is Not Active

The DCU may have been started using the E-Start option. The E-Start option enables the shutdown override until the engine is stopped.

Alarm Is Active When Gauge Needle Is in the Green Section

Check the engine set points in Cat ET. If a set point in the engine ECM has been changed using Cat ET, the set point must also be changed in the DCU configuration.

Crank Override Does Not Work

Use the following checks if the crank override does not work.

1. Check the E-Stop button and crank inhibit switch. The engine will not crank if the E-Stop button is engaged. The engine will not crank if the crank inhibit switch is on.

2. Check the crank override switch and wiring. Ensure that the switch is functioning properly. Check for damaged or disconnected wiring from the switch to connector pin C1:57.