Caterpillar C7, C9 Truck Diesel Engine Troubleshooting Manual

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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

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

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 Wastegate Solenoid – Test

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