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Caterpillar C7 and C9 Industrial Engines Troubleshooting Manual
Caterpillar C7 and C9 Industrial Engines Troubleshooting Manual
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Caterpillar C7 and C9 Industrial Engines Troubleshooting Manual

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Caterpillar C7 and C9 Industrial Engines Troubleshooting Manual

 High resolution, searchable, printable PDF format  

Covers: Cat C7 and C9 Industrial Engines With Serial Numbers:  

  • KCA1-Up (Engine)
  • KCB1-Up (Engine)
  • JAM1-Up (Engine)
  • BXS1-Up (Engine)

    Format: PDF
    Compatibility: Windows/Mac/Linux

    This Manual Include information, specifications, and illustrations For Troubleshooting Your C7 And C9 Industrial Engines , The Troubleshooting Manual Cover All Errors that With Diagnostic Code Or Without  Diagnostic Code.

    Table of Contents

    Troubleshooting Section
    Electronic Troubleshooting
    System Overview .................................................... 6
    Electronic Service Tools ........................................ 13
    Replacing the ECM ............................................... 15
    Sensors and Electrical Connectors ....................... 17
    Programming Parameters
    Programming Parameters ..................................... 23
    Dyno Mode ........................................................... 23
    Test ECM Mode .................................................... 23
    Customer Passwords ............................................ 24
    ECM Date/Time Stamped Information .................. 24
    ECM Snapshot ...................................................... 25
    Factory Passwords ............................................... 26
    Factory Passwords Worksheet ............................. 27
    Flash Programming .............................................. 27
    Service Information Report ................................... 28
    Customer Specified Parameters
    Customer Specified Parameters ........................... 30
    Customer Specified Parameters Table ................. 31
    Customer Specified Parameters Worksheet ......... 37
    Cruise Control Parameters ................................... 40
    Data Link Parameters ........................................... 44
    Dedicated PTO Parameters .................................. 44
    Driver Reward ....................................................... 47
    ECM Identification Parameters ............................. 47
    Engine/Gear Parameters ...................................... 48
    Engine Monitoring Parameters ............................. 51
    Idle Parameters .................................................... 51
    Input Selections .................................................... 52
    Maintenance Parameters ...................................... 56
    Output Selections ................................................. 57
    Security Access Parameters ................................. 58
    Selected Engine Rating ........................................ 58
    Smart Idle Parameters .......................................... 59
    Timer Parameters ................................................. 59
    Trip Parameters .................................................... 61
    Vehicle Activity Report Parameters ...................... 63
    Vehicle Speed Parameters ................................... 63
    System Configuration Parameters
    System Configuration Parameters ........................ 66
    Troubleshooting without a Diagnostic Code
    Can Not Reach Top Engine RPM ......................... 67
    Can Not Reach Vehicle Speed Limit ..................... 68
    Check Engine Lamp or Warning Lamp Is
    Malfunctioning ..................................................... 70
    Cooling Fan Is Always ON .................................... 70
    Cruise Control, Idle, or PTO Can Not Be Set ....... 72
    Driver Questionnaire ............................................. 74
    Driver Questionnaire Response ............................ 75
    ECM Will Not Accept Factory Passwords ............. 76
    Electronic Service Tool Will Not Communicate with
    ECM .................................................................... 76
    Engine Cranks but Will Not Start .......................... 77
    Engine Misfires, Runs Rough or Is Unstable ........ 79
    Engine Retarder (Compression Brake) Will Not Turn
    ON ....................................................................... 80
    Engine Vibration ................................................... 81
    Engine Will Not Crank ........................................... 82
    Excessive Black Smoke ........................................ 83
    Excessive Fuel Consumption ............................... 84
    Excessive White Smoke ....................................... 85
    Intermittent Cruise Control, Idle, or PTO Kickout .. 86
    Intermittent Low Power or Power Cutout .............. 87
    Low Power/Poor or No Response to Throttle ....... 89
    Poor Acceleration or Response ............................ 91
    Troubleshooting with a Diagnostic Code
    Diagnostic Codes .................................................. 93
    No Diagnostic Code Detected (55) ....................... 96
    0001-05 Cylinder #1 Injector current low (72) ....... 96
    0001-06 Cylinder #1 Injector current high (72) ..... 97
    0002-05 Cylinder #2 Injector current low (72) ....... 97
    0002-06 Cylinder #2 Injector current high (72) ..... 97
    0003-05 Cylinder #3 Injector current low (73) ....... 98
    0003-06 Cylinder #3 Injector current high (73) ..... 98
    0004-05 Cylinder #4 Injector current low (73) ....... 99
    0004-06 Cylinder #4 Injector current high (73) ..... 99
    0005-05 Cylinder #5 Injector current low (74) ....... 99
    0005-06 Cylinder #5 Injector current high (74) ... 100
    0006-05 Cylinder #6 Injector current low (74) ..... 100
    0006-06 Cylinder #6 Injector current high (74) ... 100
    0022-11 Primary to Secondary Engine Speed Signal
    Calibration (42) ................................................. 101
    0022-13 Engine Speed Signal Calibration Not
    Performed (42) .................................................. 102
    0030-08 PTO Throttle signal invalid (29) ............ 103
    0030-13 PTO Throttle out of calibration (29) ...... 103
    0041-03 8 Volt Supply voltage high (21) ............. 103
    0041-04 8 Volt Supply voltage low (21) .............. 104
    0043-02 Key Switch Fault (71) ........................... 104
    0052-11 Air Inlet Shutoff Shutdown (00) ............. 104
    0054-05 Auxiliary Output #06 current low (66) ... 105
    0054-06 Auxiliary Output #06 current high (66) .. 105
    0055-05 Auxiliary Output #07 current low (67) ... 106
    0055-06 Auxiliary Output #07 current high (67) .. 106
    0064-08 Secondary Engine Speed loss of signal
    (34) .................................................................... 106
    0071-00 Idle Shutdown Override (01) ................. 107
    0071-01 Idle Shutdown (47) ............................... 107
    0071-14 PTO Shutdown (47) .............................. 107
    0084-00 Vehicle Overspeed Warning (41) .......... 108
    0084-01 Vehicle Speed loss of signal (31) ......... 108
    0084-02 Vehicle Speed signal invalid (36) .......... 109
    0084-08 Vehicle Speed signal out of range (36) .. 109
    0084-10 Vehicle Speed signal rate of change
    (36) ..................................................................... 110
    0084-14 Quick Stop Occurrence ......................... 110
    0091-08 Throttle Position Invalid (32) .................. 110
    0091-13 Throttle Position out of calibration (28) .. 111
    0100-01 Low Oil Pressure Warning (46) .............. 111
    0100-03 Oil Pressure voltage high (24) ............... 114
    0100-04 Oil Pressure voltage low (24) ................ 115
    0100-11 Very Low Oil Pressure (46) .................... 115
    0102-03 Boost Pressure voltage high (25) .......... 119
    0102-04 Boost Pressure voltage low (25) ............ 119

    0105-00 High Intake Manifold Air Temperature
    Warning (64) ..................................................... 120
    0105-03 Intake Manifold Air Temperature voltage
    high (38) ............................................................ 121
    0105-04 Intake Manifold Air Temperature voltage low
    (38) .................................................................... 121
    0105-11 Very High Intake Manifold Air Temperature
    (64) .................................................................... 122
    0108-03 Barometric Pressure voltage high (26) .. 122
    0108-04 Barometric Pressure voltage low (26) .. 123
    0110-00 High Coolant Temperature Warning
    (61) .................................................................... 123
    0110-03 Coolant Temperature voltage high
    (27) .................................................................... 124
    0110-04 Coolant Temperature voltage low (27) .. 124
    0110-11 Very High Coolant Temperature (61) ..... 124
    0111-01 Low Coolant Level Warning (62) ........... 125
    0111-02 Coolant Level signal invalid (12) ........... 126
    0111-03 Coolant Level voltage high (12) ............ 126
    0111-04 Coolant Level voltage low (12) .............. 126
    0111-11 Very Low Coolant Level (62) ................. 127
    0111-14 Low Coolant Level Warning .................. 128
    0121-05 Low/High Retarder current low (14) ...... 129
    0121-06 Low/High Retarder current high (14) .... 129
    0122-05 Med/High Retarder current low (14) ..... 129
    0122-06 Med/High Retarder current high (14) .... 130
    0166-14 Rated Engine Power Special
    Instructions ........................................................ 130
    0168-01 Low ECM Battery Power (17) ............... 130
    0171-03 Ambient Air Temperature voltage high .. 131
    0171-04 Ambient Air Temperature voltage low ... 131
    0171-11 Ambient Air Temperature Data Lost ...... 131
    0174-00 High Fuel Temperature Warning (65) ... 132
    0174-03 Fuel Temperature voltage high (13) ...... 132
    0174-04 Fuel Temperature voltage low (13) ....... 132
    0190-00 Engine Overspeed Warning (35) .......... 133
    0190-08 Primary Engine Speed Loss of Signal
    (34) .................................................................... 133
    0191-07 Transmission Not Responding (68) ...... 133
    0212-03 5 Volt Sensor Supply #1 voltage high ... 134
    0212-04 5 Volt Sensor Supply #1 voltage low .... 134
    0224-11 Theft Deterrent Active (00) ................... 135
    0224-14 Theft Deterrent Active with Engine Cranking
    (00) .................................................................... 135
    0231-02 J1939 Data Incorrect (58) ..................... 135
    0231-12 J1939 Device Not Responding ............. 136
    0246-11 Brake Pedal Switch #1 Fault ................. 136
    0247-11 Brake Pedal Switch #2 Fault ................. 136
    0252-11 Engine Software Incorrect (59) ............. 137
    0253-02 Check Customer or System Parameters
    (56) .................................................................... 137
    0253-11 Check Transmission Customer Parameters
    (56) .................................................................... 138
    0283-05 Intake Valve Actuation System Oil Pressure
    Solenoid current low (97) .................................. 138
    0283-06 Intake Valve Actuation System Oil Pressure
    Solenoid current high (97) ................................. 138
    0283-07 Intake Valve Actuation Oil Pressure not
    responding (91) ................................................. 139
    0284-05 Engine Coolant Diverter current low
    (98) .................................................................... 139
    0284-06 Engine Coolant Diverter current high
    (98) .................................................................... 139
    0285-05 Intake Valve Actuator #1 current low
    (92) .................................................................... 140
    0285-06 Intake Valve Actuator #1 current high
    (92) .................................................................... 140
    0285-07 Intake Valve Actuator #1 not responding
    (92) .................................................................... 140
    0286-05 Intake Valve Actuator #2 current low
    (92) .................................................................... 141
    0286-06 Intake Valve Actuator #2 current high
    (92) .................................................................... 141
    0286-07 Intake Valve Actuator #2 not responding
    (92) .................................................................... 141
    0287-05 Intake Valve Actuator #3 current low
    (93) .................................................................... 142
    0287-06 Intake Valve Actuator #3 current high
    (93) .................................................................... 142
    0287-07 Intake Valve Actuator #3 not responding
    (93) .................................................................... 143
    0288-05 Intake Valve Actuator #4 current low
    (93) .................................................................... 143
    0288-06 Intake Valve Actuator #4 current high
    (93) .................................................................... 143
    0288-07 Intake Valve Actuator #4 not responding
    (93) .................................................................... 144
    0289-05 Intake Valve Actuator #5 current low
    (94) .................................................................... 144
    0289-06 Intake Valve Actuator #5 current high
    (94) .................................................................... 145
    0289-07 Intake Valve Actuator #5 not responding
    (94) .................................................................... 145
    0290-05 Intake Valve Actuator #6 current low
    (94) .................................................................... 145
    0290-06 Intake Valve Actuator #6 current high
    (94) .................................................................... 146
    0290-07 Intake Valve Actuator #6 not responding
    (94) .................................................................... 146
    0385-01 Low Intake Valve Actuation System Oil
    Pressure ............................................................ 146
    0385-03 Intake Valve Actuation System Oil Pressure
    voltage high (95) ............................................... 147
    0385-04 Intake Valve Actuation System Oil Pressure
    voltage low (95) ................................................. 147
    Diagnostic Functional Tests
    5 Volt Engine Pressure Sensor Supply Circuit -
    Test ................................................................... 148
    Accelerator Pedal (Throttle) Position Sensor Circuit -
    Test ................................................................... 152
    Air Inlet Shutoff Circuit - Test .............................. 161
    ATA (SAE J1587 / J1708) Data Link Circuit -
    Test ................................................................... 167
    Auxiliary Brake Circuit - Test ............................... 175
    Check Engine Lamp Circuit - Test ...................... 180
    Clutch Pedal Position Switch Circuit - Test ......... 183
    Coolant Level Sensor Circuit - Test .................... 188
    Cooling Fan Circuit and A/C High Pressure Switch
    Circuit - Test ...................................................... 197
    Cruise Control Switch Circuit - Test .................... 210
    Diagnostic Enable Switch Circuit - Test .............. 217

    Eaton Top 2 Transmission Circuit - Test ............. 221
    ECM Memory - Test ............................................ 228
    Electrical Connectors - Inspect ........................... 232
    Engine Coolant Diverter Circuit - Test ................. 237
    Engine Pressure Sensor Open or Short Circuit -
    Test ................................................................... 242
    Engine Running Output Circuit - Test ................. 247
    Engine Shutdown Output Circuit - Test ............... 251
    Engine Speed/Timing Sensor Circuit - Test ........ 255
    Engine Temperature Sensor Open or Short Circuit -
    Test ................................................................... 261
    Fan Override Switch Circuit - Test ...................... 265
    Idle Shutdown Timer - Test ................................. 269
    Ignition Keyswitch Circuit and Battery Supply Circuit -
    Test ................................................................... 272
    Ignore Brake/Clutch Switch Circuit - Test ........... 279
    Injector Solenoid Circuit - Test ............................ 282
    Intake Valve Actuation System Oil Pressure Circuit -
    Test ................................................................... 291
    Intake Valve Actuator Circuit - Test ..................... 296
    Intake Valve Actuator Response - Test ............... 304
    Multi-Torque - Test .............................................. 314
    Neutral Switch Circuit - Test ................................ 316
    Powertrain Data Link Circuit - Test ..................... 322
    PTO Engine RPM Set Speed (Input A and Input B)
    Circuit - Test ...................................................... 327
    PTO Shutdown Timer - Test ................................ 332
    PTO Switch Circuit - Test .................................... 334
    PTO Switch ON Lamp Circuit - Test ................... 343
    Remote PTO Accelerator Position Sensor Circuit -
    Test ................................................................... 347
    Retarder (Compression Brake) Solenoid Circuit -
    Test ................................................................... 354
    Service Brake Pedal Position (Switch 1) Circuit -
    Test ................................................................... 364
    Service Brake Pedal Position (Switch 2) Circuit -
    Test ................................................................... 369
    Starting Aid Output Circuit - Test ........................ 374
    Starting Aid Switch Circuit - Test ......................... 378
    Tachometer Circuit - Test .................................... 381
    Torque Limit Switch Circuit - Test ........................ 386
    Two Speed Axle Switch Circuit - Test ................. 389
    Vehicle Speed and Speedometer Circuit - Test .. 393
    Warning Lamp Circuit - Test ................................ 402
    Calibration Procedures
    Engine Speed/Timing Sensor - Calibrate ............ 406
    Injector Code - Calibrate ..................................... 408
    Vehicle Speed Circuit - Calibrate ........................ 410
    Index Section
    Index ................................................................... 413

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