C7 and C9 Marine Engines Engine Synchronize Switch Circuit - Test Caterpillar


Engine Synchronize Switch Circuit - Test
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C7 and C9 Marine Engines [RENR9313]
ELECTRICAL AND STARTING SYSTEM
SWITCH GP
C7 and C9 Marine Engines Engine Synchronize Switch Circuit - Test
C7 and C9 Marine Engines Switch Circuits - Test

System Operation Description:

The Electronic Control Module (ECM) has two throttle inputs and two synchronization inputs. The synchronization inputs allow the ECM to respond to either of the throttle inputs. This capability allows all of the engines on a vessel to respond to a single throttle. This minimizes variations in speed and in load between engines during cruise operations.

Use this procedure in order to troubleshoot any suspect problems with engine synchronization. The following items can cause problems with engine synchronization:

  • Configuration parameters

  • Vessel wiring or components

  • ECM

The following configuration parameters affect engine synchronization:

  • Number of Synchronized Engines Configuration

  • Engine Location

  • Secondary Throttle Enable Status

These parameters must be programmed correctly in order for the engines to become synchronized. Refer to Troubleshooting, "System Configuration Parameters" for additional information on these parameters.

The synchronization inputs operate according to the following conditions:

When neither of the synchronization inputs are connected to the −Battery, the ECM will respond to the primary throttle input.

When Sync Input 1 is connected to the −Battery, the ECM will respond to the primary throttle input.

When Sync Input 2 is connected to the −Battery, the ECM will respond to the secondary throttle input.

If Sync Input 1 and Sync Input 2 are connected to the −Battery at the same time, the ECM will respond to the primary throttle input. The vessel's wiring should be designed to prevent this condition from occurring.

Note: The ECM will not transfer control between the throttle inputs unless the throttle inputs are within 50 rpm of each other.

There are four possible configurations for engine synchronization. The following information describes each configuration.

Single Engine Configuration




Illustration 1g01130005

Single engine configuration

In this configuration, a single engine can be controlled by two throttles. The secondary throttle is enabled by activation of the "Secondary Throttle Enable" switch.

Twin Engine Configuration




Illustration 2g01130061

Twin engine configuration

In this configuration, the position of the synchronization switch determines the throttle input that is recognized by each engine. Table 1 lists the engine's response to each position of the switch.

Table 1
Engine Response to the Synchronization Switch    
Position of the Synchronization Switch     Engine Response    
Starboard     Both engines respond to the starboard throttle.    
None     Each engine responds to a separate throttle.    
Port     Both engines respond to the port throttle.    

Multiple Engine Configuration Without a Dedicated Master Throttle




Illustration 3g01130062

Multiple engine configuration with one throttle that is designated as a master throttle

In these configurations, one of the throttles has been designated as the master throttle. When the synchronization switch is not activated, each engine will respond to the appropriate throttle. When the synchronize switch is activated, all of the engines will respond to the master throttle. Three engines and three throttles are shown. As many as five engines and five throttles can be connected in this manner.

Multiple Engine Configuration With a Dedicated Master Throttle




Illustration 4g01130063

Multiple engine configuration with a separate throttle that is used for the master throttle

In this configuration, the vessel is equipped with a master throttle in addition to a separate throttle for each engine. When the synchronization switch is not activated, each engine will respond to the appropriate throttle. When the synchronize switch is activated, all of the engines will respond to the master throttle.

Test Step 1. Verify that the Throttle Positions are Correct

  1. Determine the vessel's configuration for engine synchronization. Identify the two throttles that are connected to the throttle inputs for the ECM.

    Note: The ECM will not transfer control between the throttles unless the throttle positions are within 50 rpm of each other.

  1. Verify that the throttle positions are within 50 rpm of each other.

Expected Result:

The throttle positions are within 50 rpm of each other.

Results:

  • OK - The throttle positions are within 50 rpm of each other. Proceed to Test Step 2.

  • Not OK - The throttle positions are not within 50 rpm of each other.

    Repair: Adjust the throttles until the throttle positions are within 50 rpm of each other. Try to synchronize the engines.If the engines become synchronized, the problem is resolved. STOP.

    If the engines do not become synchronized, proceed to Test Step 2.

Test Step 2. Check the Configuration Parameters

  1. Connect the AVSpare Electronic Technician (ET) to the service tool connector.

  1. Verify that the following configuration parameters are programmed correctly:

    • Number of Synchronized Engines Configuration

    • Engine Location

    • Secondary Throttle Enable Status

    Refer to Troubleshooting, "System Configuration Parameters" for additional information on these parameters.

Expected Result:

The configuration parameters are programmed correctly.

Results:

  • OK - The configuration parameters are programmed correctly. Proceed to Test Step 3.

  • Not OK - The configuration parameters are not programmed correctly.

    Repair: Program the correct value for each parameter.Verify that the problem is resolved.

    STOP

Test Step 3. Check for Diagnostic Codes for the Throttle Inputs

  1. Check for the following diagnostic codes:

    • 91-13 Throttle Position calibration required

    • 1249-13 Secondary Throttle Position calibration required

Expected Result:

Neither diagnostic code is active or logged.

Results:

  • OK - Neither diagnostic code is active or logged. Proceed to Test Step 4.

  • Not OK - At least one of the diagnostic codes is logged.

    Repair: Perform the following procedure:

    1. Clear the logged codes.

    1. Slowly move the suspect throttle throughout the entire range. Move the throttle several times. Look for the diagnostic code to activate again.

      If the diagnostic code does not recur, attempt to synchronize the engines. If the engines become synchronized, the problem appears to be resolved.

      The original problem may have been caused by an intermittent problem in one of these components:

      • Throttle position sensor

      • Wiring for the throttle

      • An electrical connector

      If the diagnostic code recurs, there is a problem with the circuit for the throttle position sensor. Refer to Troubleshooting, "Throttle Position Sensor - Calibrate" for the troubleshooting procedure.

    STOP

  • Not OK - There is an active diagnostic code for a throttle.

    Repair: Troubleshoot the circuit for the throttle. Refer to Troubleshooting, "Throttle Position Sensor - Calibrate" for the troubleshooting procedure.Verify that the problem is resolved.

    STOP

Test Step 4. Check the Synchronization Inputs

  1. Turn the keyswitch to the OFF position.

  1. Disconnect the J1/P1 connectors for the suspect ECM.



    Illustration 5g01134499

    ECM side of the P1 connector

    (P1-35) Sync Input 1

    (P1-44) Sync Input 2

  1. Perform the resistance measurements that apply to your vessel's configuration:

    1. If the vessel has a single engine, measure the resistance between the points that are listed in Table 2. Be sure to wiggle the wires between the Secondary Throttle Enable Switch and the ECM as you make each measurement.

      Table 2
      Resistance Measurements for a Single Engine Configuration    
      Secondary Throttle Enable Switch Position     Terminals     Expected Result    
      Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63     Open circuit    
      Enabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    

    1. If the vessel has two engines, measure the resistance between the points that are listed in Table 3. Only perform the measurements on the engine that will not become synchronized. Be sure to wiggle the wires between the Synchronization Switch and the ECM as you make each measurement.

      Table 3
      Resistance Measurements for a Twin Engine Configuration    
      Engine     Synchronization Switch Position     Terminals     Expected Result    
      Port     None     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Port P1-35     P1-63     Less than ten Ohms    
      P1-44 P1-63     Open circuit    
      Starboard P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Starboard     None     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Port P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Starboard P1-35     P1-63     Less than ten Ohms    
      P1-44 P1-63     Open circuit    

    1. If the vessel has two engines and one throttle that is designated as the master throttle, measure the resistance between the points that are listed in Table 4. Only perform the measurements that apply to the appropriate engine and throttle configuration. Be sure to wiggle the wires between the synchronization switch and the ECM as you make each measurement.

      Table 4
      Resistance Measurements for a Multiple Engine Configuration With One Throttle that is Designated as a Master Throttle    
      Engine     Master Throttle     Synchronization Switch Position     Terminals     Expected Result    
      Port     Port     Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit
      Enabled P1-35 P1-63     Less than ten Ohms    
      P1-44 P1-63 Open circuit    
      Center Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Starboard Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Center     Port     Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit
      Enabled P1-35 P1-63     Open circuit    
      P1-44 P1-63 Less than ten Ohms    
      Center Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Less than ten Ohms    
      P1-44 P1-63     Open circuit    
      Starboard Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Starboard     Port     Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit
      Enabled P1-35 P1-63     Open circuit    
      P1-44 P1-63 Less than ten Ohms    
      Center Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    
      Starboard Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63 Open circuit    
      Enabled P1-35     P1-63     Less than ten Ohms    
      P1-44 P1-63     Open circuit    

    1. If the vessel has two engines and a dedicated master throttle, measure the resistance between the points that are listed in Table 5. Only perform the measurements that apply to the appropriate engine and throttle configuration. Be sure to wiggle the wires between the Synchronization Switch and the ECM as you make each measurement.

      Table 5
      Resistance Measurements for a Multiple Engine Configuration With a Dedicated Master Throttle    
      Synchronization Switch Position     Terminals     Expected Result    
      Disabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63     Open circuit    
      Enabled     P1-35     P1-63     Open circuit    
      P1-44 P1-63     Less than ten Ohms    

Expected Result:

The resistance measurements are correct.

Results:

  • OK - The resistance measurements are correct.

    Repair: Perform the following procedure:

    1. Connect the J1/P1 connectors.

    1. Attempt to synchronize the engines.

    1. If the engines will not synchronize, there may be a problem with the ECM.

      It is unlikely that the ECM has failed. Exit this procedure and perform this entire procedure again. If the engines will not synchronize, replace the ECM. Refer to Troubleshooting, "Replacing the ECM".

      Verify that the problem is resolved.

    STOP

  • Not OK - At least one resistance measurement is incorrect. There is a problem with the circuit for engine synchronization. There may be a problem with an electrical connector.

    Repair: Carefully inspect the wiring between the ECM and the Synchronization Switch. Refer to Troubleshooting, "Electrical Connectors - Inspect". Repair the wiring, when possible. Replace parts, if necessary. Verify that the problem is resolved.

    STOP

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