3126B and 3126E On-highway Engines Caterpillar

Use this procedure under the following situation:

Use this procedure to determine if the clutch pedal position switch is preventing normal operation of cruise control, fast idle, idle set speed, or PTO operation:

The following switch circuits can also prevent the correct operation of the cruise control, idle set speed or PTO operation:

• service brake pedal position (switch 1)

• service brake pedal position (switch 2)

• neutral switch

• cruise control set/resume switch

• cruise control on/off switch

• PTO on/off switch

• cruise control pause switch

The switches are described in the respective circuit tests in Troubleshooting.

All of the following Customer Programmable Parameters can affect cruise control, fast idle, idle set speed, and PTO operation:

• "Low Cruise Control Speed Set Limit"

• "High Cruise Control Speed Set Limit"

• "Idle Vehicle Speed Limit"

• "Fast Idle RPM #1"

• "Fast Idle RPM #2"

• "Cruise/Idle/PTO Switch Configuration"

• "Idle/PTO Bump rpm"

• "Idle/PTO rpm Ramp Rate"

• "PTO Vehicle Speed Limit"

• "Cruise Pause Switch"

The vehicle speed calibration can also affect the cruise control, the idle set speed, and the PTO if the vehicle speed calibration is incorrectly programmed. Refer to Troubleshooting, "Customer Specified Parameters".

Clutch Switch

The clutch pedal position switch is normally closed when the pedal is released. Depressing the clutch pedal should open the circuit. This switch is OEM supplied. The clutch pedal position switch is typically a limit switch that is mounted near the pedal. The clutch pedal position switch is usually adjustable.

This switch may not be connected to an input on the ECM. The parameter "Clutch Pedal Position Switch" determines the input to the ECM. If the parameter is programmed to J1/P1:22 a switch must be connected to terminal 22. If the parameter is programmed to one of the J1939 options, the switch position will be transmitted to the ECM over the J1939 data link. If a problem is suspected with the J1939 data link, refer to Troubleshooting, "Powertrain Data Link Circuit - Test".

The following background information is related to this procedure:

The kickout switch refers to the switch that is used to exit the cruise control, the fast idle, the PTO, or the idle set speed.

The operation of the Caterpillar electronic engine cruise control is similar to the operation of the cruise controls that are installed in automobiles. The operation of fast idle, idle and PTO are similar to the operation of cruise except that the idle and the PTO govern engine rpm instead of vehicle speed.

Note: Idle in this procedure is an engine idle rpm above the programmed low idle rpm. Idle is set by using the cruise control on/off switch and the set/resume switch. Refer to Troubleshooting, "PTO Switch Circuit - Test" for additional information regarding the programmable options for the Dedicated PTO.

Note: Fast idle in this procedure is an engine idle rpm above the programmed low idle rpm. Fast idle is set by using a dedicated fast idle switch.

Cruise Control On/Off Switch

This switch must be on before cruise control or controlled idle can be activated. This switch is on when the switch is closed. When the switch is closed the following terminals are connected:

• ECM connector J1/P1 terminal 59 (cruise control on/off switch)

• Terminal 5 (AP sensor/switch sensor common)

Note: If the vehicle is programmed to use the "Dedicated PTO", the PTO on/off switch overrides the cruise control on/off switch. The PTO on/off switch overrides the cruise control on/off switch when the vehicle speed is within the range of the "PTO Vehicle Speed Limit" that is programmed.

Set/Resume Switch

With the cruise control on/off switch in the ON position and the vehicle speed within the range of the programmed "Low Cruise Control Speed Set Limit" and the "High Cruise Control Speed Set Limit", momentarily pressing the set switch will activate cruise control, and the ECM will maintain the current speed.

After a speed has been set and the speed is then disengaged by using the brake, the clutch, the cruise control pause switch, or the on/off switch, the ECM will seek the previous set speed when the resume switch is toggled. This assumes that the vehicle speed is above the "Low Cruise Control Speed Set Limit" for cruise control or the vehicle speed is below the "Idle/PTO Vehicle Speed Limit" for the idle and the PTO.

After a speed has been set, pressing and holding the set/resume switch in position will cause the engine to establish a new set speed. The system's reaction depends on the programming of the "Cruise/Idle/PTO Switch Configuration".

When the set/resume switch is momentarily pressed, the cruise set point will change one mph. The rate of change is dependent on the programmed "Idle/PTO Bump rpm" when the engine is setting on idle speed.

Cruise Control Pause Switch

The cruise control pause switch is not a switch that is wired to an input. The switch position is broadcast over a J1939 data link. The parameter "Cruise Pause Switch" must be programmed to use a cruise control pause switch. After a speed has been set and the speed is then disengaged by using the cruise control pause switch, the ECM will seek the previous set speed when the resume switch is toggled. This assumes that the vehicle speed is above the "Low Cruise Control Speed Set Limit" for cruise control or the vehicle speed is below the "Idle/PTO Vehicle Speed Limit" for the idle and the PTO.

Kickout Switches

The brake pedal position switches, the neutral switch, the cruise control pause switch, and the clutch pedal position switch are used in the cruise control mode, the PTO mode, the fast idle mode, and the idle mode to discontinue cruise operation, PTO operation, fast idle operation, or idle operation. The capability to override the idle shutdown timer is determined by the "Allow Idle Shutdown Override" parameter setting. The "Allow Idle Shutdown Override" is a Customer Parameter.

Usage of Transmission Style Switches

The "Transmission Style" parameter determines the switches that will be used. The following switches can be used.

• clutch pedal position

• neutral

• service brake pedal position (switch 1)

• service brake pedal position (switch 2)

Refer to Table 1 for additional information.

If the "Transmission Style" parameter is programmed to one of the following options, the input for the clutch pedal position switch is not used:

• "Automatic Options 1"

• "Automatic Option 2"

• "Automatic Option 3"

• "Automatic Option 4"

• "AT/MT/HT Option 1"

• "AT/MT/HT Option 2"

• "AT/MT/HT Option 3"

• "AT/MT/HT Option 4"

A service brake pedal position (switch 1) is required for all configurations. The service brake pedal position (switch 1) connects to the ECM through connector P1 terminal 45. The service brake pedal position (switch 2) connects to the ECM through connector P1 terminal 64. The clutch pedal position switch connects to the ECM through connector P1 terminal 22. The neutral switch connects to the ECM through connector P1 terminal 62.

Some engines that were built before JULY 1999 may have a Basic ECM. The Basic ECM was used only on General Motors chassis. Other chassis used engines that were built with a Full Feature ECM. Basic ECM software does not have the parameter for "Transmission Style". For these systems, a jumper wire must be installed between the clutch switch input and the sensor common when an automatic transmission is installed. When the jumper wire is installed, the "Clutch Switch" status will always indicate "OFF". Engines that were built after JULY 1999 use only one type of ECM that can be configured for "Basic" or "Full Feature" operation. A new parameter was added in order to provide this flexibility. The "Truck Manufacturer" parameter was added in order to allow the configuration of the "GM Basic" operation or the "Other Full Feature" operation. This parameter is programmed at Caterpillar when the engine is built. The parameter for "Transmission Style" is not available for engines that have software that is dated prior to SEP00 and the parameter for "Truck Manufacturer" is programmed to "GM". SEP00 and newer engines that are programmed to "GM" use the "Transmission Style" parameter. The factory default for the "GM" setting is the "Universal" option. The "Universal" option provides identical features as the "Basic" system that is described above. If the "Transmission Style" parameter is programmed to the "Universal" option, a jumper wire must be installed between the clutch switch input and the sensor common when an automatic transmission is installed. Otherwise, the "Transmission Style" parameter can be programmed to match the specific arrangement of the vehicle.

If the problem is with undetermined Cruise/Idle/PTO kickouts use the following procedure:

Operate the vehicle in Cruise/Idle/PTO mode.

After the kickout, review the status screen on an electronic service tool. The status screen for the parameter indicates the cause of the kickout. This must be performed before the ignition key switch is turned off. It is important to remember that the parameter will only indicate the last kickout since the ECM has been powered by the ignition key switch.

The following kickout status parameters are available:

• "Cruise Kickout"

• "Idle Kickout"

• "PTO Kickout"

• "Fast Idle Kickout"

This parameter is blank when the ECM is first powered up. If this parameter is blank, "No Occurrence" is indicated. This parameter remains blank until the ECM detects the use of the cruise/idle/PTO mode. Also, this parameter remains blank until the ECM detects the disengagement of the cruise/idle/PTO mode. Refer to Tables 2 and 3 in order to interpret the status screen kickout status parameter.

Illustration 1	g00643881
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch

Test Step 1. Determine the Type of Problem.

1. Connect the electronic service tool.

2. Turn the ignition key switch to the ON position.

3. If the vehicle will not allow setting a cruise speed, an idle speed or a PTO speed, check the following Customer Parameters:

   Cruise Control Parameters

   • "Low Cruise Control Speed Set Limit"

   • "High Cruise Control Speed Set Limit"

   Idle Parameters

   • "Fast Idle RPM #1"

   • "Fast Idle RPM #2"

   • "Idle Vehicle Speed Limit"

   • "Idle RPM Limit"

   • "Top Engine Limit" (TEL)

   PTO Parameters

   • "PTO Configuration"

   • "PTO Kickout Vehicle Speed Limit"

4. Ensure that the vehicle is not experiencing a problem due to one of these parameters. Refer to Troubleshooting, "Customer Specified Parameters" for a description of the parameters, if necessary.

5. Check the status screen that indicates the last cause of a kickout for one of the following modes:
   • Cruise Kickout

   • Idle Kickout

   • Fast Idle Kickout

   • PTO Kickout

   Refer to Tables 2, 3, 4, and 5 for the meaning of the status screen.

Expected Result:

The problem is due to a parameter setting or the problem is due to a normal kickout.

Results:

• Yes - Explain the proper operation of system to the driver.STOP

• No -

  Repair: Refer to Tables 2, 3, 4, and 5 for recommended troubleshooting.If a problem is still suspected with the clutch switch circuit perform the following procedure:

  Proceed to Test Step 2.

Test Step 2. Inspect Electrical Connectors and Wiring.

Illustration 2	g00773080

1. Thoroughly inspect ECM vehicle harness connector J1/P1, the firewall bulkhead connector and the terminals for the following switches in the connectors:
   • clutch pedal position switch (terminal 22)

   • AP sensor/switch sensor common (terminal 5)

   Refer to Troubleshooting, " Electrical Connectors - Inspect" for details.

2. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the switches.

   Refer to Illustration 2.

3. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

4. Check the harness and wiring for abrasion and pinch points from the sensor to the ECM.

Expected Result:

All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

Results:

• OK - Proceed to Test Step 3.

• Not OK -

  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.Verify that the repair eliminates the problem.

  STOP

Test Step 3. Check Clutch Switch Status on the Electronic Service Tool.

1. Access the status screen on the electronic service tool.

2. Turn the ignition key switch to the ON position.

3. Depress the clutch pedal while the status of the clutch pedal position switch is being observed. Also, release the clutch pedal while the status of the clutch pedal position switch is being observed.

Expected Result:

The switch status changes per the information in Table 6.

Results:

• Yes - The switch is operating normally.STOP

• Intermittent Problem Suspected - Proceed to Test Step 4.

• No - The ECM is not reading the switch status change. Proceed to Test Step 5.

Test Step 4. Operate the Vehicle and Check the Kickout Status Parameter.

1. For an intermittent Cruise Control Kickout, talk to the driver in order to determine the conditions when the kickout occurs. Topics of examination could be the following examples:
   • specific speed

   • road conditions

   • weather conditions

   Take the vehicle for a road test in order to duplicate these conditions and set the cruise control. Operate the vehicle in cruise control until the problem reoccurs.

2. For an intermittent idle kickout, talk to the driver in order to determine the conditions when the kickout occurs. A topic of examination could be the following example:
   • specific engine rpm

   Start the engine. Duplicate these conditions and set the idle rpm. Operate the vehicle in idle until the problem reoccurs.

   Note: The status screen will only indicate the last kickout. The status screen will lose this information if the ignition key switch is turned off.

3. Connect the electronic service tool and check the status screen for the last cause of the kickout. Refer to Tables 2 and 3 for an explanation of the status parameter.

4. If the status screen is blank, then either there was no kickout of the cruise control, or the power to the ECM was turned off before the information could be read. Repeat this test step.

   Note: A status screen that is blank indicates "No Occurrence" or "Not Kicked Out".

Expected Result:

RESULT 1 The status screen displays the following result:

• "Clutch Pedal Depressed"

RESULT 2 The status screen displays the following result:

• "Switch Turned Off"

RESULT 3 The status screen displays the following result:

• "Cruise Control PAUSE Switch"

RESULT 4 The status screen displays the following result:

• "Brake Pedal Depressed"

RESULT 5 The status screen displays the following result:

• "Vehicle Speed < Limit"

• "Bad Vehicle Speed"

• "Vehicle Speed ≥ Limit"

RESULT 6 The status screen displays the following result:

• "PTO Switch ON"

RESULT 7 The status screen displays the following result:

• "Neutral"

RESULT 8 The status screen displays the following result:

• "No Engine Speed"

RESULT 9 The status screen displays the following result:

• "Set Switch Timeout"

• "Resume Switch Timeout"

Results:

• Result 1 - Proceed to Test Step 5.

• Result 2 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Cruise Control Switch Circuit - Test"

  STOP

• Result 3 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Powertrain Data Link Circuit - Test"

  STOP

• Result 4 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Service Brake Pedal Position (Switch 1) Circuit - Test"

  STOP

• Result 5 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Vehicle Speed and Speedometer Circuit - Test"

  STOP

• Result 6 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "PTO Switch Circuit - Test"

  STOP

• Result 7 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Neutral Switch Circuit - Test"

  STOP

• Result 8 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Engine Speed/Timing Sensor Circuit - Test"

  STOP

• Result 9 -

  Repair: Perform the following diagnostic procedure:Troubleshooting, "Cruise Control Switch Circuit - Test"

  STOP

Test Step 5. Check the Switch Circuit for the ECM.

1. Turn the ignition key switch to the OFF position.

2. Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of the wires.

3. Disconnect vehicle harness connector P1 from the ECM.

4. Connect a 70-Termial breakout T to ECM connector J1 and connect P1 to the breakout T.

5. Install the jumper into terminal 22 (clutch pedal position switch) of the breakout T. Connect the other end of the jumper to terminal 5 AP sensor/switch sensor common of the ECM connector P1 of the breakout T.

6. Turn the ignition key switch to the ON position.

7. Connect the electronic service tool to the cab data link connector.

8. Access the status screen.

9. While the clutch switch status is being monitored on the status screen slowly remove the jumper from terminal 5 AP sensor/switch sensor common. Now, slowly insert the jumper into terminal 5 AP sensor/switch sensor common.

   Refer to Table 7.

Expected Result:

The switch status changes per the information in Table 7.

Results:

• Yes - The ECM is functioning properly. Proceed to Test Step 6.

• No - The ECM is NOT functioning properly.

  Repair: Perform the following repair:

  1. Temporarily connect a test ECM.

  2. Remove all jumpers and replace all connectors.

  3. Recheck the system for active diagnostic codes.

  4. Repeat the test step.

  5. If the problem is resolved with the test ECM, reconnect the suspect ECM.

  6. If the problem returns with the suspect ECM, replace the ECM.

  7. Verify that the repair eliminates the problem.

  STOP

Test Step 6. Insert A Jumper At The Clutch Switch.

1. Turn the ignition key switch to the OFF position.

2. Ensure that ECM vehicle harness connector J1/P1 is connected.

3. Find the clutch switch in the vehicle.

4. Disconnect the wires from the clutch switch terminals.

5. Turn the ignition key switch to the ON position.

6. Connect the electronic service tool to the cab data link connector.

7. Access the status screen.

8. While the switch status is being monitored on the status screen slowly connect the switch wires and slowly disconnect the switch wires.

   Refer to Table 8.

Expected Result:

The switch status changes per the information in Table 8.

Results:

• Yes -

  Repair: Perform the following repair:Replace the faulty switch.Verify that the repair eliminates the problem.

  STOP

• No - There is a problem in the harness between the switch and the ECM. Proceed to Test Step 7.

Test Step 7. Insert a Jumper at the Bulkhead Connector.

1. Turn the ignition key switch to the OFF position.

2. Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to each end of the wires.

3. Find the terminal for the clutch switch. Also, find the terminal for the sensor common for the AP sensor/switch. Look for the terminals in the engine side of the bulkhead connector for the vehicle harness.

4. Insert the jumper wire between the two terminals in the engine side of the bulkhead connector.

5. Turn the ignition key switch to the ON position.

6. Connect the electronic service tool to the cab data link connector.

7. Access the status screen.

8. While the switch status is being monitored on the status screen alternately remove the jumper wire between the two terminals, and alternately insert the jumper wire between the two terminals.

   Refer to Table 9.

Expected Result:

The switch status changes per the information in Table 9.

Results:

• Yes - The problem is in the vehicle wiring between the bulkhead connector and the switch.

  Repair: Perform the following repair:Inspect the vehicle wiring and repair the vehicle wiring, as required. If the problem still exists with the wiring, send the vehicle to the OEM dealer.

  STOP

• No - The problem is in the vehicle wiring between the bulkhead connector and the ECM.

  Repair: Perform the following repair:Inspect the vehicle wiring and repair the vehicle wiring, as required. If the problem still exists with the wiring, send the vehicle to the OEM dealer.

  STOP