BoonDocker POLARIS: Non-turbo Control Box 600 IQ 2 INJ - Manual (Page 18)

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: [email protected] – fax: 208-524-7381
Revised 2-13-08 Copyright © 2004-2008 by Boondocker Page 18 of 19
VIII. Control Box Troubleshooting
Stuck Button
When the Control Box is first turned on, all buttons are checked to verify that a button is not stuck on. If a button is
detected to be on during power up, the button will be disabled and the following message will be displayed until
another button is pressed. To verify if a button really is stuck on, re-power the box without pressing any buttons.
Button is Stuck!
Note: A common problem is a bad ground connection on the sled causing the box to keep resetting itself. If a button
is being pressed when this occurs, the “button stuck” message will be displayed. Start the sled without pressing a
button and see if the message goes away. If it is not present, start looking for a disconnected ground on the sled (see
Other Issues below).
If a button really is stuck on, the Control Box can still function and adjust fuel properly. The Control Box can be sent
back to Boondocker to be serviced.
Injector Errors
The Control Box monitors the signals from the sled’s ECU. If it detects signals on one set of wires but not the other, it
will detect a fault on that injector and display one of the two error messages.
MAG Inj Error
Missing or bad signal detected on the MAG side injector.
PTO Inj Error
Missing or bad signal detected on the PTO side injector.
If either of these errors occur, the Control Box will still function and it will still try to make fuel adjustments, but the
intermittent injector connection will need to be fixed. Check for loose terminals in the connectors and frayed wires. If
the problem cannot be fixed, contact Boondocker to determine if the Control Box and harness need to be sent back to
be inspected or serviced.
Note: Injector errors that occur infrequently (more than several minutes apart) may be ignored since they are likely
caused by sporadic electrical noise. Try rerouting the Control Box harness so it is kept away from ignition, fuel pump,
and stator wires. Verify that the sled’s factory ground wire is securely attached.
Prev Inj Error
This means a previous injector fault has occurred which has not yet been
cleared. Press any button to clear this.
Other Issues
Engine runs erratically:
1. Verify that the ground on the sled’s harness has a good connection to the chassis.
2. Verify that the EFI Harness Ground Wire has a good connection.
3. Verify that all wiring is in good condition and that the wires have not pulled out of the terminals. To verify this,
look inside each connector and verify that the terminal pins are all at the same height. If a terminal is starting to
back out, it will appear to be lower in the connector, or the seal on the back-side will be protruding out farther
than the rest.
4. Unplug the EFI harness and plug original harness back into the injectors and verify that the sled runs OK.
5. If problem only occurs with Control Box plugged in, change all fuel adjustment settings to 0 and see if problem
persists.
6. Verify that the Control Box does not reset itself when the sled is running by doing the following:
a. When the sled is first powered up, change the menu screen on the Control Box to one of the fuel adjust
screens.
b. Run the sled.
c. Before shutting off the sled, verify that the screen is still on the same menu selection.
d. If the startup screen is displayed (showing version number etc.), the box has reset itself. This is likely caused
by bad voltage to the box due to an intermittent connection.