Download Caterpillar C7, C9 Truck Diesel Engine Troubleshooting Manual

It is Original Caterpillar C7 and C9 truck diesel engine troubleshooting manual covers troubleshooting procedures and fault codes. In this manual you will find detailed step-by-step instructions and accurate illustrations to correctly diagnose the Cat C7 and C9 truck diesel engine. View this manual on your computer/tablet or print off pages as needed.

Topics in the Cat C7 and C9 Truck Engine Troubleshooting Manual:

Electronic Troubleshooting
System Overview
Electronic Service Tools
Replacing the ECM
Sensors and Electrical Connectors
Programming Parameters
Programming Parameters
Test ECM Mode
Customer Passwords
ECM Date/Time Stamped Information
ECM Snapshot
Factory Passwords
Flash Programming
Injector Trim File
Service Information Report
Customer Specified Parameters
Customer Specified Parameters
Customer Specified Parameters Table
Customer Specified Parameters Worksheet
Cruise Control Parameters
Data Link Parameters
Dedicated PTO Parameters
Engine/Gear Parameters
Engine Monitoring Parameters
Exhaust Brake Parameters
Idle Parameters
Input Selections
Maintenance Parameters
Output Selections
Passwords
Selected Engine Rating
Smart Idle Parameters
Timer Parameters
Trip Parameters
Truck Manufacture Parameters
Vehicle Speed Parameters
System Configuration Parameters
System Configuration Parameters
Troubleshooting without a Diagnostic Code
Can Not Reach Top Engine RPM
Can Not Reach Vehicle Speed Limit
Check Engine Lamp or Warning Lamp Is
Malfunctioning
Cruise Control, Idle, or PTO Can Not Be Set
Driver Questionnaire
Driver Questionnaire Response
ECM Will Not Accept Factory Passwords
Electronic Service Tool Will Not Communicate with
ECM
Elevated Idle
Engine Cranks but Will Not Start
Engine Cranks but Will Not Start
Engine Has Early Wear
Engine Misfires, Runs Rough or Is Unstable
Engine Vibration
Engine Will Not Crank
Excessive Black Smoke
Excessive Fuel Consumption
Excessive White Smoke
Intermittent Cruise Control, Idle, or PTO Kickout
Intermittent Engine Shutdown
Intermittent Low Power or Power Cutout
Low Power/Poor or No Response to Throttle
Poor Acceleration or Response
Troubleshooting with a Diagnostic Code
Diagnostic Codes
No Diagnostic Code Detected (55)
0001-11 Cylinder #1 Injector current fault (72)
0002-11 Cylinder #2 Injector current fault (72)
0003-11 Cylinder #3 Injector current fault (73)
0004-11 Cylinder #4 Injector current fault (73)
0005-11 Cylinder #5 Injector current fault (74)
0006-11 Cylinder #6 Injector current fault (74)
0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
0022-13 Engine Speed Signal Calibration Not Performed (42)
0030-08 PTO Throttle signal invalid (29)
0030-13 PTO Throttle out of calibration (29)
0032-05 TurboWastegate Solenoid current low
0032-06 Turbo Wastegate Solenoid current high
0032-11 Turbo Wastegate Solenoid current mismatch
0041-03 8 Volt Supply voltage high (21)
0041-04 8 Volt Supply voltage low (21)
0042-11 Injection Actuation Pressure output fault
0043-02 Key Switch Fault (71)
0064-02 Secondary Engine Speed loss of signal
0064-11 Secondary Engine Speed no pattern
0070-05 Inlet Air Heater current low
0070-06 Inlet Air Heater current high
0071-00 Idle Shutdown Override (01)
0071-01 Idle Shutdown (47)
0071-14 PTO Shutdown (47)
0084-00 Vehicle Overspeed Warning (41)
0084-01 Vehicle Speed loss of signal (31)
0084-02 Vehicle Speed signal invalid (36)
0084-08 Vehicle Speed signal out of range (36)
0084-10 Vehicle Speed signal rate of change
0084-14 Quick Stop Occurrence
0091-08 Throttle Position Invalid (32)
0091-13 Throttle Position out of calibration (28)
0094-01 Low Fuel Pressure Warning (63)
0094-03 Fuel Pressure voltage high (37)
0094-04 Fuel Pressure voltage low (37)
0094-11 Low Cranking Fuel Pressure (63)
0096-03 Fuel Level voltage high
0096-04 Fuel Level voltage low
0100-01 Low Oil Pressure Warning (46)
0100-03 Oil Pressure voltage high (24
0100-04 Oil Pressure voltage low (24)
0100-11 Very Low Oil Pressure (46)
0102-01 Low Boost Pressure (25)
0102-02 Boost Pressure signal erratic
0102-03 Boost Pressure voltage high (25)
0102-04 Boost Pressure voltage low (25)
0102-07 Boost Pressure not responding
0105-00 High Intake Manifold Air Temperature Warning (64)
0105-03 Intake Manifold Air Temperature voltage high (38)
0105-04 Intake Manifold Air Temperature voltage low
0105-11 Very High Intake Manifold Air Temperature
0108-03 Barometric Pressure voltage high (26)
0108-04 Barometric Pressure voltage low (26)
0110-00 High Coolant Temperature Warning
0110-03 Coolant Temperature voltage high
0110-04 Coolant Temperature voltage low (27)
0110-11 Very High Coolant Temperature (61)
0111-01 Low Coolant Level Warning (62)
0111-02 Coolant Level signal invalid (12)
0111-03 Coolant Level voltage high (12)
0111-04 Coolant Level voltage low (12)
0111-11 Very Low Coolant Level (62)
0111-14 Low Coolant Level Warning
0128-03 Secondary Fuel Level voltage high
0128-04 Secondary Fuel Level voltage low
0164-00 Excessive Injection Actuation Pressure
0164-02 Injection Actuation Pressure Signal Erratic
0164-03 Injection Actuation Pressure voltage high
0164-04 Injection Actuation Pressure voltage low
0164-11 Injection Actuation Pressure system fault
0168-00 Excessive ECM Battery Power (17)
0168-01 Low ECM Battery Power (17)
0168-02 ECM Battery Power Intermittent (51)
0173-00 High Exhaust Gas Temperature Derate
0173-11 Very High Exhaust Gas Temperature Derate
0186-04 PTO Engine Shutdown Switch voltage low
0186-14 PTO Engine Shutdown Switch Occurrence
0190-00 Engine Overspeed Warning (35)
0190-02 Primary Engine Speed Loss of Signal
0190-11 Primary Engine Speed no pattern (34)
0224-11 Theft Deterrent Active (00)
0224-14 Theft Deterrent Active with Engine Cranking
0231-02 J1939 Data Incorrect (58)
0231-11 J1939 Data Link Fault (58)
0231-12 J1939 Device Not Responding
0231-14 Transmission Data Link Derate
0232-03 5 Volt Supply voltage high (21)
0232-04 5 Volt Supply voltage low (21)
0246-11 Brake Pedal Switch #1 Fault
0247-11 Brake Pedal Switch #2 Fault
0252-11 Engine Software Incorrect (59)
0253-02 Check Customer or System Parameters
0253-14 Truck Manufacturer Parameter Not Programmed
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit – Test
Accelerator Pedal (Throttle) Position Sensor Circuit – Test
Air Inlet Heater Circuit – Test
ATA (SAE J1587 / J1708) Data Link Circuit – Test
Change Oil Lamp Circuit – Test
Check Engine Lamp Circuit – Test
Clutch Pedal Position Switch Circuit – Test
Coolant Level Sensor Circuit – Test
Cooling Fan Circuit and A/C Compressor Clutch Circuit – Test
Cooling Fan Circuit and A/C High Pressure Switch Circuit – Test
Cruise Control Switch Circuit – Test
Diagnostic Enable Switch Circuit – Test
ECM Memory – Test
Electrical Connectors – Inspect
Engine Pressure Sensor Open or Short Circuit – Test
Engine Running Output Circuit – Test
Engine Speed/Timing Sensor Circuit – Test
Engine Temperature Sensor Open or Short Circuit – Test
Exhaust Brake Circuit – Test
Diesel Particulate Filter Circuit – Test
Fast Idle Enable Circuit – Test
Fast Idle Lamp Circuit – Test
Fuel Level Sensor Circuit – Test
Idle Shutdown Timer – Test
Ignore Brake/Clutch Switch Circuit – Test
Injection Actuation Pressure – Test
Injection Actuation Pressure Control Valve Circuit – Test
Injection Actuation Pressure Sensor – Test
Injector Solenoid Circuit – Test
Neutral Switch Circuit – Test
Powertrain Data Link Circuit – Test
PTO Engine RPM Set Speed (Input A and Input B) Circuit – Test
PTO Engine Shutdown Switch Circuit – Test
PTO Shutdown Timer – Test
PTO Switch Circuit – Test
PTO Switch ON Lamp Circuit – Test
Remote PTO Accelerator Position Sensor Circuit – Test
Service Brake Pedal Position (Switch 1) Circuit – Test
Service Brake Pedal Position (Switch 2) Circuit – Test
Starting Aid Output Circuit – Test
Tachometer Circuit – Test
Torque Limit Switch Circuit – Test
Transmission (AT/MT/HT) Relay Circuit – Test
Two Speed Axle Switch Circuit – Test
Vehicle Speed and Speedometer Circuit – Test
Wait To Start Lamp Circuit – Test
Warning Lamp Circuit – Test
Wastegate Solenoid – Test
Calibration Procedures
Engine Speed/Timing Sensor – Calibrate
Vehicle Speed Circuit – Calibrate

Covers: Caterpillar C7 and C9 Truck Engines with serial numbers-
SRB 1-Up
LFE 1-Up
9DG 1-Up
YPG 1-Up
NPH 1-Up
ETK 1-Up
KAL 1-Up
LBM 1-Up
CKP 1-Up
SAP 1-Up
LFR 1-Up
C7T 1-Up
WAX 1-Up
Pages: 408
Format: PDF
Compatibility: Windows/Mac/Tablet

Caterpillar C7 C9 Truck Diesel Engine Full Complete Troubleshooting Manual