Caterpillar C7, C9 Truck Diesel Engine Troubleshooting Manual PDF

Covers: Caterpillar C7 and C9 Truck Diesel Engine Troubleshooting with serial prefixes-

• C7 – KAL
• C7 – LBM
• C7 – NPH
• C7 – SAP
• C7 – WAX
• C7 – YPG
• C9 – 9DG
• C9 – CKP
• C9 – ETK
• C9 – LFE
• C9 – LFR
• C9 – SRB

Troubleshooting Manual for Cat C7 and C9 Truck Diesel Engines.

Topics:

• 01 System Overview
• 02 Electronic Service Tools
• 03 Replacing the ECM
• 04 Sensors and Electrical Connectors
• 05 Programming Parameters
• 06 Test ECM Mode
• 07 Customer Passwords
• 08 ECM Date Time Stamped Information
• 09 ECM Snapshot
• 10 Factory Passwords
• 11 Flash Programming
• 12 Injector Trim File
• 13 Service Information Report
• 14 Customer Specified Parameters
• 15 Customer Specified Parameters Table
• 16 Customer Specified Parameters Worksheet
• 17 Cruise Control Parameters
• 18 Data Link Parameters
• 19 Dedicated PTO Parameters
• 20 Engine and Gear Parameters
• 21 Engine Monitoring Parameters
• 22 Exhaust Brake Parameters
• 23 Idle Parameters
• 24 Input Selections
• 25 Maintenance Parameters
• 26 Output Selections
• 27 Passwords
• 28 Selected Engine Rating
• 29 Smart Idle Parameters
• 30 Timer Parameters
• 31 Trip Parameters
• 32 Truck Manufacture Parameters
• 33 Vehicle Speed Parameters
• 34 System Configuration Parameters
• 35 Can Not Reach Top Engine RPM
• 36 Can Not Reach Vehicle Speed Limit
• 37 Check Engine Lamp or Warning Lamp Is Malfunctioning
• 38 Cruise Control, Idle, or PTO Can Not Be Set
• 39 Driver Questionnaire
• 40 Driver Questionnaire Response
• 41 ECM Will Not Accept Factory Passwords
• 42 Electronic Service Tool Will Not Communicate with ECM
• 43 Elevated Idle
• 44 Engine Cranks but Will Not Start
• 45 Engine Cranks but Will Not Start
• 46 Engine Has Early Wear
• 47 Engine Misfires, Runs Rough or Is Unstable
• 48 Engine Vibration
• 49 Engine Will Not Crank
• 50 Excessive Black Smoke
• 51 Excessive Fuel Consumption
• 52 Excessive White Smoke
• 53 Intermittent Cruise Control, Idle, or PTO Kickout
• 54 Intermittent Engine Shutdown
• 55 Intermittent Low Power or Power Cutout
• 56 Low Power, Poor or No Response to Throttle
• 57 Poor Acceleration or Response
• 58 Diagnostic Codes
• 59 No Diagnostic Code Detected (55)
• 60 0001-11 Cylinder #1 Injector current fault (72)
• 61 0002-11 Cylinder #2 Injector current fault (72)
• 62 0003-11 Cylinder #3 Injector current fault (73)
• 63 0004-11 Cylinder #4 Injector current fault (73)
• 64 0005-11 Cylinder #5 Injector current fault (74)
• 65 0006-11 Cylinder #6 Injector current fault (74)
• 66 0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
• 67 0022-13 Engine Speed Signal Calibration Not Performed (42)
• 68 0030-08 PTO Throttle signal invalid (29)
• 69 0030-13 PTO Throttle out of calibration (29)
• 70 0032-05 Turbo Wastegate Solenoid current low
• 71 0032-06 Turbo Wastegate Solenoid current high
• 72 0032-11 Turbo Wastegate Solenoid current mismatch
• 73 0041-03 8 Volt Supply voltage high (21)
• 74 0041-04 8 Volt Supply voltage low (21)
• 75 0042-11 Injection Actuation Pressure output fault
• 76 0043-02 Key Switch Fault (71)
• 77 0064-02 Secondary Engine Speed loss of signal (34)
• 78 0064-11 Secondary Engine Speed no pattern (34)
• 79 0070-05 Inlet Air Heater current low
• 80 0070-06 Inlet Air Heater current high
• 81 0071-00 Idle Shutdown Override (01)
• 82 0071-01 Idle Shutdown (47)
• 83 0071-14 PTO Shutdown (47)
• 84 0084-00 Vehicle Overspeed Warning (41)
• 85 0084-01 Vehicle Speed loss of signal (31)
• 86 0084-02 Vehicle Speed signal invalid (36)
• 87 0084-08 Vehicle Speed signal out of range (36)
• 88 0084-10 Vehicle Speed signal rate of change (36)
• 89 0084-14 Quick Stop Occurrence
• 90 0091-08 Throttle Position Invalid (32)
• 91 0091-13 Throttle Position out of calibration (28)
• 92 0094-01 Low Fuel Pressure Warning (63)
• 93 0094-03 Fuel Pressure voltage high (37)
• 94 0094-04 Fuel Pressure voltage low (37)
• 95 0094-11 Low Cranking Fuel Pressure (63)
• 96 0096-03 Fuel Level voltage high
• 97 0096-04 Fuel Level voltage low
• 98 0100-01 Low Oil Pressure Warning (46)
• 99 0100-03 Oil Pressure voltage high (24)
• 100 0100-04 Oil Pressure voltage low (24)
• 101 0100-11 Very Low Oil Pressure (46)
• 102 0102-01 Low Boost Pressure (25)
• 103 0102-02 Boost Pressure signal erratic
• 104 0102-03 Boost Pressure voltage high (25)
• 105 0102-04 Boost Pressure voltage low (25)
• 106 0102-07 Boost Pressure not responding
• 107 0105-00 High Intake Manifold Air Temperature Warning (64)
• 108 0105-03 Intake Manifold Air Temperature voltage high (38)
• 109 0105-04 Intake Manifold Air Temperature voltage low (38)
• 110 0105-11 Very High Intake Manifold Air Temperature (64)
• 111 0108-03 Barometric Pressure voltage high (26)
• 112 0108-04 Barometric Pressure voltage low (26)
• 113 0110-00 High Coolant Temperature Warning (61)
• 114 0110-03 Coolant Temperature voltage high (27)
• 115 0110-04 Coolant Temperature voltage low (27)
• 116 0110-11 Very High Coolant Temperature (61)
• 117 0111-01 Low Coolant Level Warning (62)
• 118 0111-02 Coolant Level signal invalid (12)
• 119 0111-03 Coolant Level voltage high (12)
• 121 0111-04 Coolant Level voltage low (12)
• 122 0111-11 Very Low Coolant Level (62)
• 123 0111-14 Low Coolant Level Warning
• 124 0128-03 Secondary Fuel Level voltage high
• 125 0128-04 Secondary Fuel Level voltage low
• 126 0164-00 Excessive Injection Actuation Pressure (17)
• 127 0164-02 Injection Actuation Pressure Signal Erratic (15)
• 128 0164-03 Injection Actuation Pressure voltage high (15)
• 129 0164-04 Injection Actuation Pressure voltage low (15)
• 130 0164-11 Injection Actuation Pressure system fault (39)
• 131 0168-00 Excessive ECM Battery Power (17)
• 132 0168-01 Low ECM Battery Power (17)
• 133 0168-02 ECM Battery Power Intermittent (51
• 134 0173-00 High Exhaust Gas Temperature Derate
• 135 0173-11 Very High Exhaust Gas Temperature Derate
• 136 0186-04 PTO Engine Shutdown Switch voltage low
• 137 0186-14 PTO Engine Shutdown Switch Occurrence (47)
• 138 0190-00 Engine Overspeed Warning (35)
• 139 0190-02 Primary Engine Speed Loss of Signal (34)
• 140 0190-11 Primary Engine Speed no pattern (34)
• 141 0224-11 Theft Deterrent Active (00)
• 142 24-14 Theft Deterrent Active with Engine Cranking (00)
• 143 0231-02 J1939 Data Incorrect (58)
• 144 0231-11 J1939 Data Link Fault (58)
• 145 0231-12 J1939 Device Not Responding
• 146 0231-14 Transmission Data Link Derate
• 147 0232-03 5 Volt Supply voltage high (21)
• 148 0232-04 5 Volt Supply voltage low (21)
• 149 0246-11 Brake Pedal Switch #1 Fault
• 150 0247-11 Brake Pedal Switch #2 Fault
• 151 0252-11 Engine Software Incorrect (59)
• 152 0253-02 Check Customer or System Parameters (56)
• 153 0253-14 Truck Manufacturer Parameter Not Programed
• 154 5 Volt Engine Pressure Sensor Supply Circuit – Test
• 155 Accelerator Pedal (Throttle) Position Sensor Circuit – Test
• 156 Air Inlet Heater Circuit – Test
• 157 ATA (SAE J1587 J1708) Data Link Circuit – Test
• 158 Change Oil Lamp Circuit – Test
• 159 Check Engine Lamp Circuit – Test
• 160 Clutch Pedal Position Switch Circuit – Test
• 161 Coolant Level Sensor Circuit – Test
• 162 Cooling Fan Circuit and AC Compressor Clutch Circuit – Test
• 163 Cooling Fan Circuit and AC High Pressure Switch Circuit – Test
• 164 Cruise Control Switch Circuit – Test
• 165 Diagnostic Enable Switch Circuit – Test
• 166 ECM Memory – Test
• 167 Electrical Connectors – Inspect
• 168 Engine Pressure Sensor Open or Short Circuit – Test
• 169 Engine Running Output Circuit – Test
• 170 Engine Speed, Timing Sensor Circuit – Test
• 171 Engine Temperature Sensor Open or Short Circuit – Test
• 172 Exhaust Brake Circuit – Test
• 173 Diesel Particulate Filter Circuit – Test
• 174 Fast Idle Enable Circuit – Test
• 175 Fast Idle Lamp Circuit – Test
• 176 Fuel Level Sensor Circuit – Test
• 177 Idle Shutdown Timer – Test
• 178 Ignore Brake, Clutch Switch Circuit – Test
• 179 Injection Actuation Pressure – Test
• 180 Injection Actuation Pressure Control Valve Circuit – Test
• 181 Injection Actuation Pressure Sensor – Test
• 182 Injector Solenoid Circuit – Test
• 183 Neutral Switch Circuit – Test
• 184 Powertrain Data Link Circuit – Test
• 185 PTO Engine RPM Set Speed (Input A and Input B) Circuit – Test
• 186 PTO Engine Shutdown Switch Circuit – Test
• 187 PTO Shutdown Timer – Test
• 188 PTO Switch Circuit – Test
• 189 PTO Switch ON Lamp Circuit – Test
• 190 Remote PTO Accelerator Position Sensor Circuit – Test
• 191 Service Brake Pedal Position (Switch 1) Circuit – Test
• 192 Service Brake Pedal Position (Switch 2) Circuit – Test
• 193 Starting Aid Output Circuit – Test
• 194 Tachometer Circuit – Test
• 195 Torque Limit Switch Circuit – Test
• 196 Transmission (AT,MT,HT) Relay Circuit – Test
• 197 Two Speed Axle Switch Circuit – Test
• 198 Vehicle Speed and Speedometer Circuit – Test
• 199 Wait To Start Lamp Circuit – Test
• 200 Warning Lamp Circuit – Test
• 201 Waste-gate Solenoid – Test

Pages: 852
Format: PDF
Compatibility: Windows/Mac/Tablet