C7 and C9 Industrial Engines Troubleshooting Manual

C7 and C9 Industrial Engines Troubleshooting Manual

 High resolution, searchable, printable PDF format  

Covers: 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