C7 Engines for Combat and Tactical Vehicles Caterpillar

Use this procedure to determine if one of the following switches is preventing normal operation of cruise control, idle set speed, or extended idle:

• Cruise control on/off switch

• Cruise control set/resume switch

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

• Service brake pedal position (switch 1)

• Service brake pedal position (switch 2)

• Clutch pedal position switch

• Neutral switch

• PTO on/off switch

• Cruise control pause switch

The switches are described in the respective circuit tests.

All of the following customer programmable parameters can affect cruise control, idle set speed, and extended idle:

• "Low Cruise Control Speed Set Limit"

• "High Cruise Control Speed Set Limit"

• "Idle Vehicle Speed Limit"

• "Idle RPM 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"

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

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:

• J1/P1:59 (Cruise control on/off switch)

• J1/P1:5 (AP sensor/switch sensor common)

This switch may not be connected to an input on the Engine Control Module (ECM). The parameter "Cruise Control On/Off Switch" determines the input to the ECM. If the parameter is programmed to "J1/P1:59" a switch must be connected to terminal 59. 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".

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 the 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 set point for the cruise control will change one mph. The rate of change is dependent on the programmed "Idle/PTO Bump RPM" when an idle speed is set.

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.

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 PTO, the fast idle, 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 idle fast idle, and PTO are similar to the operation of cruise except that the idle, fast 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.

Kickout Switches

The service brake pedal position switches, the neutral switch and the clutch pedal position switch are used in the cruise control mode and the idle mode in order to discontinue cruise 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 with being dependent on the parameter setting:

• 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 Option 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 at P1:45. The service brake pedal position (switch 2) connects to the ECM at P1:64. The clutch pedal position switch connects to the ECM at P1:22. The neutral switch connects to the ECM P1:62.

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 parameter on the Caterpillar Electronic Technician (Cat ET). The status parameter on Cat ET indicates the cause. This must be performed before the 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 input for the key switch.

The following kickout status parameters are available:

• "Cruise Kickout"

• "Idle Kickout"

• "PTO Kickout"

• "Fast Idle Kickout"

This status area for each parameter is blank when the ECM is first powered up. If the status area is blank, a kickout has not occurred. The status area for each parameter remains blank until the ECM detects the use of the Cruise/Idle/PTO Mode. Also, the status area for each 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 for the kickout status parameter.

Illustration 1	g00862218
Circuit schematic for cruise control switches

Illustration 2	g00703076
P1 ECM connector

Test Step 1. Determine the Type of Problem

1. Connect Cat ET to the data link connector.

2. Turn the key switch to the ON position.

3. If the vehicle will not allow setting a cruise speed or an idle 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 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 items:
   • Cruise Control Kickout

   • Idle Kickout

   • Fast Idle Kickout

   • PTO Kickout

   Refer to Tables 2 and 3 for the meaning of the cause of the kickout.

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 and 3 for the meaning of the cause of the kickout.If a problem is still suspected with the cruise control on/off switch or the set/resume switch, perform the following procedure:

  Proceed to Test Step 2.

Test Step 2. Inspect Electrical Connectors and Wiring

1. Thoroughly inspect ECM vehicle harness connector J1/P1, the firewall bulkhead connector and the terminals for the following switches in the connectors:
   • J1/P1:5 (AP sensor/switch sensor common)

   • J1/P1:35 or J1/P1:44 (set/resume switch)

   • J1/P1:59 (cruise control on/off switch)

   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 for pinch points from the sensor to the ECM.

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 - 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 the Cruise Control Switch Status on Cat ET

1. Access the status screen on Cat ET.

2. Turn the key switch to the ON position.

3. Operate the cruise control on/off switch while the status of the cruise/idle on/off switch is being observed.

4. Leave the cruise control on.

5. Operate the set switch while the status of the set/resume switch is being observed.

   The status screen indicates "Set Switch ON" when the set switch is held in the SET position. The status screen indicates "Off" when the set switch is released.

6. Operate the resume switch while the status of the resume switch is being observed.

   The status screen indicates "Resume Switch ON" when the resume switch is held in the RESUME position. The status screen indicates "Off" when the resume switch is released.

Expected Result:

The switch status changes per the information in Table 4.

Results:

• Yes - The switches are 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 key switch is turned OFF.

3. Connect Cat ET 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.

Results:

• RESULT 1 - The status screen displays "Switch Turned Off". Proceed to Test Step 5.

• Result 2 - The status screen displays "Cruise Control PAUSE Switch".

  Repair: Proceed to Troubleshooting, "Powertrain Data Link Circuit - Test".

  STOP

• Result 3 - The status screen displays "Vehicle Speed < Limit", "Bad Vehicle Speed", or "Vehicle Speed ≥ Limit".

  Repair: Proceed to Troubleshooting, "Vehicle Speed Circuit - Test".

  STOP

• Result 4 - The status screen displays "PTO Switch ON".

  Repair: Proceed to Troubleshooting, "PTO Switch Circuit - Test".

  STOP

• Result 5 - The status screen displays "Neutral".

  Repair: Proceed to Troubleshooting, "Neutral Switch Circuit - Test".

  STOP

• Result 6 - The status screen displays "Brake".

  Repair: Proceed to Troubleshooting, "Service Brake Pedal Position (Switch 1) Circuit - Test".

  STOP

• Result 7 - The status screen displays "Clutch".

  Repair: Proceed to Troubleshooting, "Clutch Pedal Position Switch Circuit - Test".

  STOP

• Result 8 - The status screen displays "No Engine Speed".

  Repair: Proceed to Troubleshooting, "Engine Speed/Timing Switch Circuit - Test".

  STOP

Test Step 5. Check the Switch Circuit

1. Turn the 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 breakout T to ECM connector J1 and connect P1 to the breakout T.

5. Install the jumper into the suspect switch socket of the breakout T. Connect the other end of the jumper to ECM connector P1:5 (AP sensor/switch sensor common) of the breakout T.

6. Turn the key switch to the ON position.

7. Connect Cat ET to the data link connector.

8. Access the status screen.

9. While the switch status is being monitored on the status screen slowly remove the jumper from terminal 5 and slowly insert the jumper from P1:5 (AP sensor/switch sensor common).

   Refer to Table 5.

Expected Result:

The switch status changes per the information in Table 5.

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 Suspect Switch

1. Turn the key switch to the OFF position.

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

3. Find the suspect switch in the vehicle.

4. Disconnect the wires from the suspect switch terminals.

5. Turn the key switch to the ON position.

6. Connect Cat ET to the data link connector.

7. Access the status screen.

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

   Refer to Table 6.

Expected Result:

The switch status changes per the information in Table 6.

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 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 wire.

3. Find the suspect switch terminal and the sensor common terminal 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 key switch to the ON position.

6. Connect Cat ET to the 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 7.

Expected Result:

The switch status changes per the information in Table 7.

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