Caterpillar C7.1 Industrial Engine Troubleshooting Service Manual
C7.1 Industrial Engine
7701-Up (Engine)
Manual pdf 384 pages
Troubleshooting Section
Electronic Troubleshooting
i04029202
Welding Precaution
SMCS Code: 1000
Correct welding procedures are necessary in order to
avoid damage to the following components:
- Electronic Control Module (ECM) on the engine
- Clean Emissions Module (CEM)
- Sensors
- Associated components
Caterpillar C7.1 Industrial Engine Fix Manual
Table of Contents
Troubleshooting Section
Electronic Troubleshooting
Mode Switch Setup 38
Throttle Setup 39
Multiposition Switch Setup 42
Customer Specified Parameters
Customer Specified Parameters 43
Customer Specified Parameters Table 50
Customer Specified Parameters Worksheet 53
System Configuration Parameters
System Configuration Parameters 57
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is
Poor 59
Alternator Is Noisy 62
Alternator Problem 63
ARD Combustion Supply Air Pressure Is Low 63
ARD Failed to Ignite 65
ARD Is Disabled 69
ARD Loss of Combustion 70
ARD Pilot Fuel Pressure Is High 74
ARD Pilot Fuel Pressure Is Low 77
ARD Temperature Is Low 79
Battery Problem 83
Coolant Contains Oil 83
Coolant Level Is Low 84
Coolant Temperature Is High 85
Cylinder Is Noisy 88
Diesel Particulate Filter Collects Excessive Soot 89
Diesel Particulate Filter Has High Ash Load 92
Diesel Particulate Filter Has High Inlet Pressure 92
Diesel Particulate Filter Has Low Inlet Pressure 94
Diesel Particulate Filter Requires Initial
Regeneration 95
Diesel Particulate Filter Temperature Is High 96
Diesel Particulate Filter Temperature Is Low 97
ECM Does Not Communicate with Other
Modules 98
ECM Will Not Accept Factory Passwords 99
Electronic Service Tool Does Not Communicate 99
Engine Cranks but Does Not Start 100
Engine Does Not Crank 104
Engine Has Early Wear 105
Engine Has Mechanical Noise (Knock) 106
Engine Misfires, Runs Rough or Is Unstable 106
Engine Overspeeds 109
Engine Shutdown Occurs Intermittently 110
Engine Speed Does Not Change 111
Engine Stalls at Low RPM 112
Engine Top Speed Is Not Obtained 114
Engine Vibration Is Excessive 117
Exhaust Has Excessive Black Smoke 118
Exhaust Has Excessive White Smoke 121
Fuel Consumption Is Excessive 123
Fuel Contains Water 125
Fuel Rail Pressure Problem 126
Fuel Temperature Is High 131
Inlet Air Is Restricted 132
Inlet Air Temperature Is High 133
Intake Manifold Air Pressure Is High 134
Intake Manifold Air Pressure Is Low to 135
Intake Manifold Air Temperature Is High 137
NRS Exhaust Gas Temperature Is High, 138
NRS Mass Flow Rate Problem 140
Oil Consumption Is Excessive 143
Oil Contains Coolant 144
Oil Contains Fuel 145
Oil Pressure Is Low 146
Power Is Intermittently Low or Power Cutout Is
Intermittent 148
Valve Lash Is Excessive 151
Troubleshooting with a Diagnostic Code
Diagnostic Trouble Codes 152
Diagnostic Code Cross-Reference 159
No Diagnostic Codes Detected 164
Troubleshooting with an Event Code
Event Codes 165
Diagnostic Functional Tests
5 Volt Sensor Supply Circuit – Test 167
Analog Throttle Position Sensor Circuit – Test 177
ARD Fuel Supply – Test 182
ARD Ignition – Test 189
ARD Nozzle – Test 204
ARD Nozzle Heater – Test 207
CAN Data Link Circuit – Test 223
Data Link Circuit – Test 227
Diesel Particulate Filter Identification Signal –
Test 234
Digital Throttle Position Sensor Circuit – Test 240
ECM Memory – Test 249
Electrical Connectors – Inspect 250
Engine Pressure Sensor Open or Short Circuit –
Test 254
Engine Speed/Timing Sensor Circuit 267
Engine Temperature Sensor Open or Short Circuit 274
Engine Temperature Sensor Open or Short Circuit 281
4 KENR9106-01
Table of Contents
Ether Starting Aid 290
Fuel Pump Relay Circuit 294
Glow Plug Starting Aid 302
Idle Validation Switch Circuit 309
Ignition Key switch Circuit and Battery Supply Circuit, 314
Indicator Lamp Circuit 321
Injector Data Incorrect 324
Injector Solenoid Circuit 326
Mode Selection Circuit 332
Motorized Valve 336
PTO Switch Circuit, 344
Sensor Calibration Required 347
Solenoid Valve 350
Soot Sensor 359
Throttle Switch Circuit 363
Valve Position Sensor 366
Water In Fuel Sensor 377
Index Section
Index 381
Caterpillar C7.1 Industrial Engine Fix Manual
