Caterpillar C7 Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C7 Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Caterpillar C7 Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
ENGINE - INDUSTRIAL
Model Prefix
C7 INDUSTRIAL ENGINE JKL
C7 INDUSTRIAL ENGINE JRA
C7 INDUSTRIAL ENGINE JTF
C7 INDUSTRIAL ENGINE PRY
C7 INDUSTRIAL ENGINE TEF
ENGINE - MACHINE
Model Prefix
C7 ENGINE - MACHINE C7C
C7 ENGINE - MACHINE KHX
ENGINE - TRUCK
Model Prefix
C7 TRUCK ENGINE C7S
C7 TRUCK ENGINE FML
C7 TRUCK ENGINE FMM
C7 TRUCK ENGINE JRT
C7 TRUCK ENGINE KAL
C7 TRUCK ENGINE LBM
C7 TRUCK ENGINE NPH
C7 TRUCK ENGINE RMF
C7 TRUCK ENGINE SAP
C7 TRUCK ENGINE TSK
C7 TRUCK ENGINE WAX
C7 TRUCK ENGINE YPG
MARINE PRODUCTS
Model Prefix
C7 MARINE ENGINE C7B
C7 MARINE ENGINE C7D
C7 MARINE ENGINE C7X
C7 MARINE ENGINE C7Z
C7 MARINE ENGINE M7A
C7 MARINE ENGINE M7G
PETROLEUM PRODUCTS
Model Prefix
C7 PETROLEUM ENGINE C7P
C7 PETROLEUM ENGINE K2A
C7 PETROLEUM ENGINE P7L
C7 POWER PACKAGE PGZ
PRODUCT DETAILS:
Total Pages: 4,603 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
RENR9342 - Troubleshooting (C7 and C9 On-Highway Engines).pdf
RENR9818 - Testing & Adjusting (C7 On-highway Engine).pdf
RENR9818 - Systems Operation (C7 On-highway Engine).pdf
RENR1282 - Testing & Adjusting (On-Highway Engines Electronic PTO Installation and Application Guide).pdf
RENR1282 - Troubleshooting (On-Highway Engines Electronic PTO Installation and Application Guide).pdf
RENR9817 - Specifications (C7 On-highway Engines).pdf
RENR9707 - Disassembly and Assembly (C7 On-Highway Engine).pdf
RENR1282 - Systems Operation (On-Highway Engines Electronic PTO Installation and Application Guide).pdf
RENR1282 - Specifications (On-Highway Engines Electronic PTO Installation and Application Guide).pdf
RENR7944-05 - Schematic C7 (On-Highway Engine Electrical System 270-9415-09).pdf
KENR6278-02 - Schematic (C7 On-Highway Engine Electrical System (Interactive) 270-9415-03).pdf
SENR9939 - Testing & Adjusting (C7 Engines for Caterpillar Built Machines).pdf
SENR9939 - Systems Operation (C7 Engines for Caterpillar Built Machines).pdf
SENR9938 - Specifications (C7 Engines for Caterpillar Built Machines).pdf
RENR9218 - Disassembly & Assembly (C7 Engines for Caterpillar Built Machines).pdf
SEBU8089 - Operation & Maintenance Manual (C7 Industrial Engine).pdf
SEBP4436 - Parts Manual (C7 Industrial Engine).pdf
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display).pdf
RENR7458 - Disassembly & Assembly (C7 On-Highway Engine).pdf
RENR7571 - Specifications (C7 On-highway Engine).pdf
RENR7572 - Systems Operation, Testing & Adjusting (C7 On-highway Engine).pdf
SEBU7766 - Operation & Maintenance Manual (C7 On-highway Engine).pdf
SEBU7926 - Operation & Maintenance Manual (C7 Urban Transit Bus Engines).pdf
SENR9517 - Troubleshooting (C7, C9 On-highway Engines).pdf
RENR7913 - Schematic (C7 On-Highway Engine Electrical System).pdf
RENR7872 - Schematic (C7 On-Highway Engine Electrical System).pdf
RENR7691 - Schematic (C7 On-Highway Engine Electrical System).pdf
RENR7933 - Schematic (C7 Industrial Engine Electrical System).pdf
MAIN SECTIONS
KENR6278-02 - Schematic (C7 On-Highway Engine Electrical System (Interactive) 270-9415-03)....3
Features....3
Cover Page....5
Information....0
Related Electrical Service Manuals....6
Additional Information....0
Harness 266-2251 Connector and Splice Locations....7
Harness 278-1739 Connector and Splice Locations (Standard and Remote ECM)....8
Harness 280-1089 Connector and Splice Locations....9
Harness 280-1149 and 278-1738 Connector and Splice Locations (Standard and Remote ECM)....10
Harness 280-9205 Connector and Splice Locations (350HP RV)....11
Harness 283-9351 Connector and Splice Locations (350HP RV)....12
Schematic....13
Machine Views....0
Left Side View of Engine....14
Right Side View of Engine....15
Top View of Engine....16
RENR1282 - Specifications (On-Highway Engines Electronic PTO Installation and Application Guide)....17
Component Installation....18
General Information....38
Switches....39
RENR1282 - Systems Operation (On-Highway Engines Electronic PTO Installation and Application Guide)....45
General Information....46
Programmable Parameters....61
RENR1282 - Testing & Adjusting (On-Highway Engines Electronic PTO Installation and Application Guide)....79
PTO Configurations - Test....80
PTO Parameters - Program....112
RENR1282 - Troubleshooting (On-Highway Engines Electronic PTO Installation and Application Guide)....116
0030-08 PTO Throttle signal invalid (29)....117
0030-13 PTO Throttle out of calibration (29)....118
0071-14 PTO Shutdown (47)....119
0231-02 J1939 Data Incorrect (58)....120
0231-12 J1939 Device Not Responding....121
030-08 PTO Throttle signal invalid (29)....122
PTO Shutdown Timer - Test....123
PTO Switch Circuit - Test....127
PTO Switch ON Lamp Circuit - Test....143
Remote PTO Accelerator Position Sensor Circuit - Test....151
RENR7458 - Disassembly & Assembly (C7 On-Highway Engine)....162
RENR7571 - Specifications (C7 On-highway Engine)....238
RENR7572 - Systems Operation, Testing & Adjusting (C7 On-highway Engine)....302
RENR7691 - Schematic (C7 On-Highway Engine Electrical System)....390
RENR7872 - Schematic (C7 On-Highway Engine Electrical System)....392
RENR7913 - Schematic (C7 On-Highway Engine Electrical System)....394
RENR7913-02_OUT....394
RENR7913-02_IN....395
RENR7933 - Schematic (C7 Industrial Engine Electrical System)....396
Features....396
Cover Page....397
Information....0
CID/MID/FMI....398
Connectors....399
Connectors Table....400
Specification and Related Manuals....401
Standard Electrical....402
Schematic....403
Machine Views....0
Connector and Splice Locations for Harness 198-2713....404
Engine....405
Fuel Filter Left Side View....406
Intake Air Heater Wiring....407
RENR7944-05 - Schematic C7 (On-Highway Engine Electrical System 270-9415-09)....408
RENR9218 - Disassembly & Assembly (C7 Engines for Caterpillar Built Machines)....410
Air Inlet Heater Solenoid - Remove and Install....413
Alternator - Remove and Install....416
Atmospheric Pressure Sensor - Remove and Install....419
Bearing Clearance - Check....422
Camshaft - Install....425
Camshaft - Remove....428
Camshaft Bearings - Remove and Install....430
Camshaft Gear - Remove and Install....434
Camshaft Idler Gear - Remove and Install....437
Connecting Rod Bearings - Install....440
Connecting Rod Bearings - Remove....442
Coolant Temperature Sensor - Remove and Install....444
Crankshaft - Install....447
Crankshaft - Remove....450
Crankshaft Front Seal - Install....452
Crankshaft Front Seal - Remove....454
Crankshaft Gear - Remove and Install....456
Crankshaft Main Bearings - Install....459
Crankshaft Main Bearings - Remove....463
Crankshaft Rear Seal - Install....467
Crankshaft Rear Seal - Remove....469
Cylinder Head - Install....471
Cylinder Head - Remove....476
Electric Starting Motor - Remove and Install....480
Electronic Control Module - Remove and Install....483
Engine Oil Filter Base - Assemble....486
Engine Oil Filter Base - Disassemble....489
Engine Oil Filter Base and Oil Cooler - Install....492
Engine Oil Filter Base and Oil Cooler - Remove....495
Engine Oil Pan - Remove and Install....498
Engine Oil Pressure Sensor - Remove and Install....502
Engine Oil Pump - Assemble....505
Engine Oil Pump - Disassemble....507
Engine Oil Pump - Install....509
Engine Oil Pump - Remove....511
Exhaust Manifold - Remove and Install....513
Fan Drive Mounting Group - Remove and Install....517
Flywheel - Install....520
Flywheel - Remove....522
Flywheel Housing - Remove and Install....524
Front Cover - Remove and Install....527
Fuel Filter Base - Remove and Install....530
Fuel Pressure Sensor - Remove and Install....533
Fuel Transfer Pump - Install....536
Fuel Transfer Pump - Remove....539
Housing (Front) - Install....542
Housing (Front) - Remove....545
Injection Actuation Pressure Sensor - Remove and Install....547
Inlet Air Temperature Sensor - Remove and Install....550
Inlet Manifold - Install....553
Inlet Manifold - Remove....555
Inlet and Exhaust Valve Guides - Remove and Install....557
Inlet and Exhaust Valve Seat Inserts - Remove and Install....560
Inlet and Exhaust Valves - Remove and Install....563
Lifter Group - Remove and Install....567
Piston Cooling Jets - Remove and Install....571
Pistons and Connecting Rods - Assemble....574
Pistons and Connecting Rods - Disassemble....579
Pistons and Connecting Rods - Install....581
Pistons and Connecting Rods - Remove....585
Rocker Shaft - Assemble....588
Rocker Shaft - Disassemble....590
Rocker Shaft and Pushrod - Install....592
Rocker Shaft and Pushrod - Remove....594
SpeedTiming Sensor - Remove and Install....596
Turbocharger - Install....599
Turbocharger - Remove....601
Turbocharger Outlet Pressure Sensor - Remove and Install....603
Unit Injector - Install....606
Unit Injector - Remove....611
Unit Injector Hydraulic Pump - Install....615
Unit Injector Hydraulic Pump - Remove....621
Unit Injector Sleeve - Install....629
Unit Injector Sleeve - Remove....632
Valve Mechanism Cover - Remove and Install....635
Valve Mechanism Cover Base - Remove and Install....638
Vibration Damper and Pulley - Remove and Install....642
Water Pump - Assemble....644
Water Pump - Disassemble....646
Water Pump - Install....648
Water Pump - Remove....650
Water Temperature Regulator - Remove and Install....652
RENR9342 - Troubleshooting (C7 and C9 On-Highway Engines)....655
ARD Combustion Air - Test....660
ARD Fuel Pressure - Test....673
ARD Ignition - Test....687
ARD Nozzle - Test....711
ARD Purge Air - Test....723
ARD Stationary Regeneration Does Not Activate....730
Acceleration Is Poor or Throttle Response Is Poor....732
Air Inlet Heater - Test....735
Air Shutoff - Test....766
Air System Verification Test....777
Auxiliary Brake - Test....785
Auxiliary Speed Control Can Not Be Set....793
Auxiliary Speed Control Kickout Occurrence....797
Axle Speed Select - Test....801
Clean Gas Induction - Test....809
Component Location....821
Configuration Parameters....830
Coolant Contains Oil....832
Coolant Level - Test....833
Coolant Level Is Low....847
Coolant Temperature Is High....849
Coolant Temperature Is Low....852
Cooling Fan Control - Test....857
Cooling Fan Is Always ON....871
Crankcase Pressure Is High....872
Crankcase Pressure Is Low....875
Cruise Control Parameters....877
Customer Device - Test....882
Customer Passwords....888
Data Link - Test....889
Data Link Parameters....897
Dedicated PTO Parameters....898
Diagnostic Capabilities....905
Diagnostic Trouble Codes....907
Diesel Particulate Filter Collects Excessive Soot....927
Diesel Particulate Filter Has Differential Pressure Problem....941
Diesel Particulate Filter Has High Ash Load....945
Diesel Particulate Filter Identification Signal - Test....947
Diesel Particulate Filter Temperature Is High....950
Diesel Particulate Filter Temperature Is Low....953
Driver Questionnaire Response....956
Driver Questionnaire....958
Driver Reward Parameter....960
Dyno Mode....961
ECM - Replace....962
ECM Identification Parameters....964
ECM Memory - Test....965
ECM Software - Install....968
ECM Will Not Accept Factory Passwords....970
Electrical Connectors - Inspect....971
Electrical Connectors....979
Electrical Power Supply - Test....980
Electronic Service Tool Does Not Communicate....990
Electronic Service Tools....997
Emissions Parameters....1007
Engine Cranks but Does Not Start....1011
Engine Does Not Crank....1013
Engine Has Early Wear....1015
Engine Misfires, Runs Rough or Is Unstable....1017
Engine Monitoring Lamp Parameters....1020
Engine Monitoring Parameters....1022
Engine Monitoring System....1023
Engine Overspeeds....1025
Engine Rating Parameters....1026
Engine Running - Test....1027
Engine Shutdown Occurs Intermittently....1032
Engine Shutdown Override Occurrence....1034
Engine Speed - Test....1037
Engine Vibration Is Excessive....1048
Engine_Gear Parameters....1050
Exhaust Has Black Smoke....1053
Exhaust Has Excessive White Smoke....1054
Exhaust Temperature Is High....1056
Factory Passwords....1057
Fan Control Parameters....1058
Fuel Consumption Is Excessive....1060
Fuel Injection Pump - Test....1062
Fuel Level - Test....1068
Fuel Rail Pressure Problem....1076
Fuel System Pressure - Test....1079
Fuel Tank Parameters....1106
General Information....1107
Idle Parameters....1108
Idle Speed Is High....1112
Indicator Lamp - Test....1114
Indicator Lamp Problem....1119
Injector Solenoid - Test....1120
Injector Trim File - Install....1135
Input Selection Parameters....1137
Intake Manifold Air Pressure Is Low....1146
Intake Manifold Air Temperature Is High....1148
Kickout Bypass - Test....1150
Maintenance Parameters....1156
Multi-Torque - Test....1158
Oil Contains Coolant....1161
Oil Contains Fuel....1163
Oil Pressure Is Low....1165
Output Selection Parameters....1167
Password Parameters....1175
Power Is Intermittently Low or Power Cutout Is Intermittent....1176
Power Take-Off - Test....1179
Programmable Parameters....1195
Quick Stop Occurrence....1196
Retarder - Test....1197
Retarder Does Not Activate....1198
Security Access Parameters....1199
Sensor Signal (Analog, Active) - Test....1200
Sensor Signal (Analog, Passive) - Test....1221
Sensor Signal (PWM) - Test....1234
Sensor Supply - Test....1252
Service Information Report....1268
Shutdown (PTO) - Test....1270
Shutdown Timer (Idle) - Test....1276
Shutdown Timer (PTO) - Test....1281
Smart Idle Parameters....1285
Solenoid Valve - Test....1286
Speed Control (Auxiliary) - Test....1298
Speed Control (PTO) - Test....1304
Starting Aid - Test....1311
Symptom Troubleshooting....1316
System Overview....1317
Tachometer - Test....1330
Test ECM Mode....1338
Theft Deterrent Is Active....1340
Timer Parameters....1341
Timing - Calibrate....1345
Torque Limit - Test....1351
Trip Parameters....1357
Turbocharger - Test....1360
Turbocharger Air Line Has Oil Present....1376
Valve Lash Is Excessive....1380
Vehicle Activity Report Parameters....1382
Vehicle Overspeeds....1383
Vehicle Speed - Calibrate....1384
Vehicle Speed - Test....1388
Vehicle Speed Limit Is Not Obtained....1402
Vehicle Speed Parameters....1405
Welding Precaution....1409
RENR9707 - Disassembly and Assembly (C7 On-Highway Engine)....1410
Air Compressor - Remove and Install....1414
Air Inlet Cover - Remove and Install....1420
Air Inlet Heater Solenoid - Remove and Install....1425
Alternator - Remove and Install....1428
Atmospheric Pressure Sensor - Remove and Install....1430
Bearing Clearance - Check....1432
Camshaft - Install....1435
Camshaft - Remove....1438
Camshaft Bearings - Remove and Install....1441
Camshaft Gear - Remove and Install....1444
Camshaft Idler Gear - Remove and Install....1446
Clean Gas Induction Cooler - Remove and Install....1449
Clean Gas Induction Pressure Sensor - Remove and Install....1453
Clean Gas Induction Temperature Sensor - Remove and Install....1455
Clean Gas Induction Valve - Assemble....1458
Clean Gas Induction Valve - Disassemble....1461
Clean Gas Induction Valve - Install....1464
Clean Gas Induction Valve - Remove....1466
Combustion Body - Remove and Install....1469
Combustion Head - Remove and Install....1479
Connecting Rod Bearings - Install....1484
Connecting Rod Bearings - Remove....1486
Coolant Temperature Sensor - Remove and Install....1488
Crankshaft - Install....1490
Crankshaft - Remove....1493
Crankshaft Front Seal - Install....1495
Crankshaft Front Seal - Remove....1497
Crankshaft Gear - Remove and Install....1499
Crankshaft Main Bearings - Install....1502
Crankshaft Main Bearings - Remove....1506
Crankshaft Rear Seal - Install....1509
Crankshaft Rear Seal - Remove....1511
Cylinder Head - Install....1513
Cylinder Head - Remove....1519
Diesel Particulate Filter - Assemble....1525
Diesel Particulate Filter - Disassemble....1535
Disconnecting Snap To Connect Fittings....1543
Electric Starting Motor - Remove and Install....1547
Electronic Control Module - Remove and Install....1549
Engine Oil Filter Base and Oil Cooler - Assemble....1551
Engine Oil Filter Base and Oil Cooler - Disassemble....1553
Engine Oil Filter Base and Oil Cooler - Install....1555
Engine Oil Filter Base and Oil Cooler - Remove....1558
Engine Oil Pan - Remove and Install....1560
Engine Oil Pressure Sensor - Remove and Install....1564
Engine Oil Pump - Assemble....1567
Engine Oil Pump - Disassemble....1569
Engine Oil Pump - Install....1571
Engine Oil Pump - Remove....1573
Exhaust Manifold - Remove and Install....1575
Fan Drive Mounting Group - Remove and Install....1580
Flame Detection Temperature Sensor - Remove and Install....1583
Flywheel - Install....1587
Flywheel - Remove....1589
Flywheel Housing - Remove and Install....1591
Front Cover - Install....1595
Front Cover - Remove....1597
Fuel Filter Base - Remove and Install....1599
Fuel Injection Pump - Install....1601
Fuel Injection Pump - Remove....1605
Fuel Lines - Remove and Install....1609
Fuel Manifold (ARD) - Assemble....1614
Fuel Manifold (ARD) - Disassemble....1617
Fuel Manifold (ARD) - Install....1620
Fuel Manifold (ARD) - Remove....1624
Fuel Manifold (Rail) - Remove and Install....1628
Fuel Pressure Regulator - Remove and Install....1632
Fuel Pressure Sensor - Remove and Install - Main....1635
Fuel Pressure Sensor - Remove and Install - Pilot....1638
Fuel Pressure Sensor - Remove and Install - Rail....1641
Fuel Priming Pump - Remove and Install....1644
Fuel Transfer Pump - Install....1646
Fuel Transfer Pump - Remove....1649
Housing (Front) - Install....1652
Housing (Front) - Remove....1655
Inlet Air Temperature Sensor - Remove and Install....1657
Inlet Manifold Pressure Sensor - Remove and Install....1659
Inlet Manifold Temperature Sensor - Remove and Install....1661
Inlet and Exhaust Valve Guides - Remove and Install....1663
Inlet and Exhaust Valve Seat Inserts - Remove and Install....1666
Inlet and Exhaust Valves - Remove and Install....1669
Lifter Group - Remove and Install....1672
Oil Manifold - Remove and Install....1677
Piston Cooling Jets - Remove and Install....1680
Pistons and Connecting Rods - Assemble....1682
Pistons and Connecting Rods - Disassemble....1686
Pistons and Connecting Rods - Install....1688
Pistons and Connecting Rods - Remove....1691
Relief Valve (Fuel) - Remove and Install....1693
Rocker Shaft - Assemble....1697
Rocker Shaft - Disassemble....1699
Rocker Shaft and Pushrod - Install....1701
Rocker Shaft and Pushrod - Remove....1703
Solenoid Valve (ARD Main Fuel) - Remove and Install....1705
Speed_Timing Sensor - Remove and Install....1708
Turbocharger - Install....1710
Turbocharger - Remove....1713
Turbocharger Outlet Temperature Sensor - Remove and Install....1716
Unit Injector - Install....1718
Unit Injector - Remove....1722
Unit Injector Sleeve - Install....1725
Unit Injector Sleeve - Remove....1727
Valve Mechanism Cover - Remove and Install....1729
Valve Mechanism Cover Base - Remove and Install....1731
Vibration Damper and Pulley - Remove and Install....1736
Water Pump - Assemble....1738
Water Pump - Disassemble....1740
Water Pump - Install....1742
Water Pump - Remove....1744
Water Temperature Regulator - Remove and Install....1747
RENR9817 - Specifications (C7 On-highway Engines)....1750
Air Compressor....1753
Air Differential Pressure Sensor....1758
Air Inlet Cover....1759
Air Inlet Elbow....1760
Air Lines - Aftertreatment Regeneration Device....1777
Atmospheric Pressure Sensor....1780
Belt Tensioner....1781
Camshaft....1785
Clean Gas Induction Cooler....1787
Connecting Rod Bearing Journal....1788
Connecting Rod....1789
Coolant Temperature Sensor....1792
Crankshaft Pulley....1793
Crankshaft Seals....1794
Crankshaft....1798
Cylinder Block Cover Group....1799
Cylinder Block....1801
Cylinder Head Valves....1805
Cylinder Head....1809
Diesel Particulate Filter Temperature and Pressure Sensor....1813
Diesel Particulate Filter....1814
Electric Starting Motor....1815
Electronic Control Wiring Group - Aftertreatment Regeneration Device....1826
Engine Control Module....1828
Engine Design 01_03_2009....1829
Engine Design....1834
Engine Oil Filter Base....1836
Engine Oil Level Switch....1840
Engine Oil Pan ....1841
Engine Oil Pan....1860
Engine Oil Pressure Sensor....1862
Engine to Transmission Adapter ....1863
Engine to Transmission Adapter....1864
Exhaust Combustion Group - Aftertreatment Regeneration Device Horizontal Configuration....1868
Exhaust Combustion Group - Aftertreatment Regeneration Device Vertical Configuration....1871
Exhaust Elbow....1874
Exhaust Extension....1875
Exhaust Manifold....1876
Fan Drive Mounting Group....1878
Flywheel Housing....1882
Flywheel....1884
Front Housing and Covers....1892
Fuel Control Manifold - Aftertreatment Regeneration Device....1894
Fuel Filter Base....1897
Fuel Injection Lines....1902
Fuel Injection Pump....1912
Fuel Injector....1922
Fuel Pressure Sensor....1927
Gear Group (Front)....1928
Idler Pulley....1930
Inlet Air Temperature Sensor....1932
Inlet Manifold Air Pressure Sensor....1933
Jacket Water Heater....1934
Magnetic Switch - Air Inlet Heater Relay....1935
Main Bearing Journal....1937
Piston Cooling Jet....1938
Piston and Rings....1943
Solenoid Valve....1952
Speed_Timing Sensor....1953
Turbocharger Oil Lines....1955
Turbocharger....1956
Valve Actuator - Clean Gas Induction (CGI)....1958
Valve Mechanism Cover....1961
Valve Rocker Arms, Lifters, and Bridges....1965
Vibration Damper....1969
Water Lines....1970
Water Pump....1974
Water Temperature Regulator....1976
RENR9818 - Systems Operation (C7 On-highway Engine)....1979
Air Inlet and Exhaust System....1980
Basic Engine....1988
Cooling System....1993
Electrical System....1998
Electronic Control System Components....2006
Fuel System....2011
General Information....2018
Lubrication System....2022
RENR9818 - Testing & Adjusting (C7 On-highway Engine)....2026
Aftercooler - Test....2028
Air Inlet and Exhaust System - Inspect....2035
Air in Fuel - Test....2044
Alternator - Test....2047
Battery - Test....2049
Charging System - Test....2052
Connecting Rod Bearings - Inspect....2055
Cooling System - Check - Overheating....2056
Cooling System - Inspect....2061
Cooling System - Test....2063
Cylinder Block - Inspect....2071
Electric Starting System - Test....2073
Engine Crankcase Pressure (Blowby) - Test....2076
Engine Oil Pressure - Test....2078
Engine Oil Pressure Sensor - Test....2082
Engine Speed - Check....2083
Engine Valve Lash - Inspect_Adjust....2085
Excessive Bearing Wear - Inspect....2089
Excessive Engine Oil Consumption - Inspect....2090
Exhaust Temperature - Test....2091
Finding Top Center Position for No. 1 Piston....2092
Flywheel - Inspect....2094
Flywheel Housing - Inspect....2098
Fuel Injector - Test....2103
Fuel Quality - Test....2105
Fuel System - Inspect....2107
Fuel System - Prime....2109
Fuel System Pressure - Test....2112
Gear Group (Front) - Time....2113
Increased Engine Oil Temperature - Inspect....2115
Inlet Manifold Pressure - Test....2116
Main Bearings - Inspect....2119
Pinion Clearance - Adjust....2121
Piston Ring Groove - Inspect....2123
Turbocharger - Inspect....2124
Vibration Damper - Check - Viscous Vibration Damper....2128
Water Pump - Test....2130
Water Temperature Regulator - Test....2132
SEBP4436 - Parts Manual (C7 Industrial Engine)....2134
Parts Manual....2134
C7 Industrial Engine....2134
Product and Dealer Information....2135
Informations produit et concessionnaire....2136
Información del Producto/Distribuidor....2137
Informações Sobre Produto e Revendedor....2138
Produkt- und Händlerinformation....2139
TABLE OF CONTENTS....2141
GENERAL INFORMATION....2156
REPAIR ALTERNATIVES....2166
SUPPLEMENTAL COOLANT ADDITIVES....2171
MAINTENANCE PARTS....2176
INDEX....2190
INDEX....2198
INDICE....2208
ÍNDICE....2217
STICHWORTVERZEICHNIS....2226
ENGINE ARRANGEMENT....2235
ENGINE AR....2235
ENGINE AR- CORE....2239
BASIC ENGINE....2247
ADAPTER GP- ENGINE TO TMSN....2247
AIR COMPRESSOR GP....2251
BELT TENSIONER GP....2263
BELT- SERPENTINE....2270
BRACKET GP- ENGINE....2272
CAMSHAFT GP....2273
CARRIER GP- SEAL....2275
CLUTCH GP....2276
COMPRESSOR GP- REFRIGERANT....2282
COVER GP- CYLINDER BLOCK....2286
COVER GP- FLYWHEEL HOUSING....2287
COVER GP- FRONT HOUSING....2289
COVER GP- VALVE MECHANISM....2292
CRANKSHAFT GP....2301
CYLINDER BLOCK GP....2307
CYLINDER HEAD AS....2312
CYLINDER HEAD GP....2316
DAMPER & PULLEY GP....2322
DRAIN GP- ENGINE OIL....2325
DRIVE GP- ACCESSORY....2330
DRIVE GP- FAN....2341
DRIVE GP- WATER PUMP....2345
FASTENER GP- CYLINDER HEAD....2347
FASTENER GP- DAMPER....2348
FASTENER GP- DAMPER & PULLEY....2349
FASTENER GP- ENGINE....2352
FASTENER GP- ENGINE MOUNTING....2353
FASTENER GP- FAN DRIVE....2354
FASTENER GP- FLYWHEEL....2363
FASTENER GP- FRONT COVER....2365
FASTENER GP- FRONT HOUSING....2367
FASTENER GP- LIFTING....2368
FASTENER GP- VALVE COVER....2370
FLANGE GP- OUTPUT SHAFT....2371
FLYWHEEL GP....2372
GEAR GP- FRONT....2384
GEAR GP- REAR....2386
GOVERNOR GP- AIR COMPRESSOR....2388
HOUSING GP- FLYWHEEL....2391
HOUSING GP- FRONT....2398
IDLER GP- BELT....2400
IDLER GP-BELT....2402
LIFTER GP- VALVE....2403
LIFTING GP- ENGINE....2404
LINES GP- AIR COMPRESSOR....2408
MANIFOLD GP- CYLINDER BLOCK....2412
MOUNTING GP- ALTERNATOR....2413
MOUNTING GP- ENGINE....2419
MOUNTING GP- FAN DRIVE....2423
MOUNTING GP- REFRIGERANT COMPR....2428
MOUNTING GP- TORQUE CONVERTER....2431
MOUNTING GP- TRANSMISSION....2433
PAN GP- OIL....2434
PISTON & ROD GP....2440
PLUG GP- CYLINDER BLOCK....2442
PLUG GP- ENGINE....2444
PLUG GP- FLYWHEEL HOUSING....2447
POWER TAKE- OFF GP....2448
PULLEY GP....2451
PULLEY GP- AUXILIARY DRIVE....2458
PULLEY GP- CRANKSHAFT....2460
PULLEY GP- ENGINE....2463
PULLEY GP- FAN....2464
PULLEY GP- FAN & ALT DRIVE....2470
PULLEY GP- FAN DRIVE....2471
PULLEY GP- IDLER....2473
PULLEY- ALTERNATOR....2477
ROCKER ARM GP....2481
SEAL GP- CRANKSHAFT....2483
SUPPORT GP- ENGINE....2486
V-BELT SET....2493
VALVE MECHANISM GP....2499
LUBRICATION SYSTEM....2504
ADAPTER GP- OIL LINE....2504
BREATHER GP....2505
DRAIN GP- OIL....2506
FILLER GP- ENGINE OIL....2510
FILTER GP- ENGINE OIL....2516
FUMES DISPOSAL GP....2518
GAUGE GP- OIL LEVEL ( DIPSTICK)....2523
LINES GP- ENGINE OIL....2530
LINES GP- OIL....2536
LINES GP- TURBOCHARGER OIL....2537
MANIFOLD GP- ENGINE OIL....2543
PLUG GP- ENGINE OIL MANIFOLD....2545
PUMP GP- ENGINE OIL....2546
VALVE GP- FLUID SAMPLING....2548
COOLING SYSTEM....2549
ADAPTER GP- FAN....2549
ADAPTER- FAN....2555
COOLANT CONDITIONER GP....2557
COOLER GP- ENGINE OIL....2559
ELBOW GP- WATER....2560
FAN GP- BLOWER....2563
FAN GP- SUCTION....2568
GUARD GP- RADIATOR....2574
LINES GP- WATER....2575
PLUG GP- WATER LINES....2584
PUMP GP- WATER....2586
RADIATOR GP....2593
AIR INLET AND EXHAUST SYSTEM....2599
ADAPTER GP- AIR INLET MANIFOLD....2599
AIR CLEANER GP....2600
CAP AS- AIR CLEANER....2605
CAP AS- RAIN....2606
CLAMP- BAND....2607
COVER GP- AIR INLET....2608
DUST EJECTOR GP....2609
ELBOW GP- AIR INLET....2611
ELBOW GP- EXHAUST....2619
EXTENSION GP- EXHAUST....2621
FASTENER GP- INLET MAN COVER....2622
LINES GP- AIR....2625
MANIFOLD GP- EXHAUST....2627
MUFFLER AS....2636
MUFFLER GP....2637
MUFFLER GP- SPARK ARRESTOR....2639
PLUG GP- AIR INLET MANIFOLD....2640
PRECLEANER GP....2641
SHUTOFF GP- AIR....2644
SPACER GP- INLET MANIFOLD....2646
TURBOCHARGER GP....2648
FUEL SYSTEM....2663
COOLER GP- FUEL....2663
COVER GP- FUEL FILTER BASE....2664
COVER GP- PRIMING PUMP....2665
FILTER GP- FUEL....2666
FILTER GP- PRIMARY FUEL....2669
FILTER GP- WATER SEP & FUEL....2670
INJECTOR GP- FUEL....2675
LINES GP- FLEXIBLE FUEL....2679
LINES GP- FUEL....2681
LINES GP- FUEL FILTER....2682
LINES GP- INJECTOR HYD PUMP....2693
PUMP & MTG GP- UNIT INJ HYD....2694
PUMP GP- FUEL INJECTION....2704
PUMP GP- FUEL PRIMING....2708
PUMP GP- FUEL PRM & PRIM FILTER....2711
PUMP GP- UNIT INJECTOR HYD....2713
REGULATOR GP- FUEL PRESSURE....2718
WATER SEP & FUEL PRM PUMP GP....2720
ELECTRICAL AND STARTING SYSTEM....2722
ALTERNATOR GP- CHARGING....2722
BATTERY GP....2749
CABLE GP- BATTERY....2752
CONNECTION GP- ELECTRICAL....2753
CONTROL & MTG GP- ENGINE ELEK....2754
CONTROL GP- AUTO START/ STOP....2759
CONTROL GP- ENGINE SPEED....2763
CONTROL GP- REMOTE SPEED....2765
CONVERTER GP- ELECTRICAL....2766
FASTENER GP- GROUND STUD....2768
FASTENER GP- WIRING HARNESS....2770
HARNESS AS- PANEL....2771
HARNESS AS- WIRING....2771
HEATER GP- JACKET WATER....2772
MODULE GP- INTERFACE....2774
SENSOR GP- COOLANT LEVEL....2775
SENSOR GP- ENGINE....2776
SENSOR GP- LIQUID LEVEL....2779
SENSOR GP- POSITION....2781
SENSOR GP- PRESSURE....2783
SENSOR GP- SPEED....2792
SENSOR GP- TEMPERATURE....2797
STARTING AID GP....2805
STARTING AID GP- ETHER....2810
STARTING MOTOR GP- ELECTRIC....2812
SUPPORT GP- BATTERY....2837
SWITCH GP- MAGNETIC....2838
SWITCH GP- TOGGLE....2842
VALVE GP- ETHER STARTING....2843
WIRING GP- ELECTRONIC CONTROL....2845
WIRING GP- ENGINE....2847
WIRING GP- HEATER....2856
OPERATOR STATION....2860
AMMETER GP....2860
CONTROL GP- UNPRGMED MONITOR....2861
GAUGE GP- COOLANT TEMPERATURE....2862
GAUGE GP- ENGINE OIL PRESSURE....2863
GAUGE GP- FUEL PRESSURE....2864
MODULE GP- DISPLAY....2865
MOUNTING GP- INSTRUMENT....2866
MOUNTING GP- INSTRUMENT PANEL....2867
PANEL GP- INSTRUMENT....2871
TACHOMETER GP- ELECTRIC....2876
VOLTMETER GP....2880
ENCLOSURES, GUARDS AND BASES....2883
BASE GP- ENGINE....2883
PANEL AS....2885
SERVICE EQUIPMENT AND SUPPLIES....2886
CHART- PLATE & FILM....2886
KIT-FUEL PRIMING PUMP....2887
KIT- GASKET....2887
PRIME PACKAGE....2888
PLUG AS....2888
PUMP & MOUNTING GP....2889
PUMP GP- GEAR....2893
PART NUMBER INDEX....2895
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display)....2918
SEBU7766 - Operation & Maintenance Manual (C7 On-highway Engine)....3002
SEBU7926 - Operation & Maintenance Manual (C7 Urban Transit Bus Engines)....3234
SEBU8089 - Operation & Maintenance Manual (C7 Industrial Engine)....3462
SENR9517 - Troubleshooting (C7, C9 On-highway Engines)....3556
SENR9938 - Specifications (C7 Engines for Caterpillar Built Machines)....3964
Air Inlet Elbow 1....3971
Air Inlet Elbow 2....3973
Air Inlet Elbow 3....3974
Air Inlet Elbow 4....3976
Air Inlet Elbow 5....3977
Air Inlet Elbow 6....3979
Air Inlet Elbow 7....3981
Air Inlet Heater....3982
Alternator and Regulator 1....3984
Alternator and Regulator 2....3986
Alternator and Regulator 3....3988
Alternator and Regulator 4....3990
Alternator and Regulator 5....3992
Atmospheric Pressure Sensor 1....3994
Atmospheric Pressure Sensor 2....3995
Atmospheric Pressure Sensor 3....3997
Belt Tensioner 1....3998
Belt Tensioner 2....4000
Belt Tensioner 3....4002
Belt Tensioner 4....4004
Belt Tensioner 5....4005
Belt Tensioner 6....4007
Boost Pressure Sensor 1....4009
Boost Pressure Sensor 2....4011
Boost Pressure Sensor 3....4012
Camshaft 1....4013
Camshaft 2....4015
Camshaft 3....4017
Camshaft 4....4020
Connecting Rod 1....4022
Connecting Rod 2....4025
Connecting Rod 3....4028
Connecting Rod 4....4031
Connecting Rod Bearing Journal 2....4034
Connecting Rod Bearing Journal....4035
Coolant Temperature Sensor 1....4036
Coolant Temperature Sensor 2....4037
Coolant Temperature Sensor 3....4038
Crankcase Breather 1....4040
Crankcase Breather 2....4042
Crankshaft 1....4043
Crankshaft 2....4045
Crankshaft Pulley 1....4047
Crankshaft Pulley 2....4049
Crankshaft Pulley 3....4050
Crankshaft Seals 1....4052
Crankshaft Seals 2....4055
Crankshaft Seals 3....4058
Crankshaft Seals 4....4063
Cylinder Block 1....4066
Cylinder Block 2....4070
Cylinder Block 3....4075
Cylinder Block Cover Group 1....4079
Cylinder Block Cover Group 2....4081
Cylinder Block Cover Group 3....4083
Cylinder Head 1....4085
Cylinder Head 2....4088
Cylinder Head Valves 1....4091
Cylinder Head Valves 2....4094
Cylinder Head Valves 3....4098
Cylinder Head Valves 4....4103
Cylinder Head Valves 5....4109
Cylinder Head Valves 6....4113
Electric Starting Motor 1....4116
Electric Starting Motor 2....4119
Electric Starting Motor 3....4122
Electric Starting Motor 4....4124
Electric Starting Motor 5....4126
Electric Starting Motor 6....4129
Electric Starting Motor 7....4132
Electronic Control Unit....4135
Electronic Unit Injector 1....4137
Electronic Unit Injector 2....4139
Engine Design....4142
Engine Oil Filter Base - Remote Oil Filter 5....4144
Engine Oil Filter Base - Remote Oil Filter 6....4148
Engine Oil Filter Base - Remote Oil Filter....4151
Engine Oil Filter Base 1....4154
Engine Oil Filter Base 2....4157
Engine Oil Filter Base 3....4162
Engine Oil Filter Base 4....4164
Engine Oil Lines....4167
Engine Oil Pan 1....4169
Engine Oil Pan 2....4171
Engine Oil Pan 3....4173
Engine Oil Pan 4....4175
Engine Oil Pan 5....4177
Engine Oil Pan 6....4179
Engine Oil Pan 7....4181
Engine Oil Pan 8....4183
Engine Oil Pan 9....4185
Engine Oil Pressure Sensor 1....4187
Engine Oil Pressure Sensor 2....4188
Engine Oil Pressure Sensor....4189
Engine Oil Pump - Gerotor Pump....4191
Engine Oil Pump 1....4193
Engine Oil Pump 2....4196
Exhaust Manifold 1....4198
Exhaust Manifold 2....4200
Exhaust Manifold 3....4202
Exhaust Manifold 4....4204
Fan Drive Mounting Group 1....4206
Fan Drive Mounting Group 2....4208
Fan Drive Mounting Group 3....4210
Fan Drive Mounting Group 4....4213
Fan Drive Mounting Group 5....4215
Fan Drive Mounting Group 6....4217
Flywheel 1....4219
Flywheel 2....4221
Flywheel 3....4223
Flywheel 4....4225
Flywheel 5....4227
Flywheel 6....4229
Flywheel Housing 1....4231
Flywheel Housing 2....4233
Flywheel Housing 3....4235
Flywheel Housing 4....4238
Flywheel Housing 5....4240
Flywheel Housing 6....4242
Flywheel Housing 7....4244
Front Housing and Covers 1....4246
Front Housing and Covers 2....4248
Front Housing and Covers 3....4250
Fuel Filter Base 1....4252
Fuel Filter Base 2....4254
Fuel Filter Base 3....4256
Fuel Filter Base 4....4258
Fuel Filter Base 5....4260
Fuel Filter and Water Separator 1....4262
Fuel Filter and Water Separator 2....4264
Fuel Pressure Sensor 1....4266
Fuel Pressure Sensor 2....4267
Fuel Pressure Sensor 3....4268
Fuel Pressure Sensor 4....4270
Fuel Priming Pump....4272
Gear Group (Front) 1....4274
Gear Group (Front) 2....4276
Injection Actuation Pressure Sensor 1....4278
Injection Actuation Pressure Sensor 2....4280
Injection Actuation Pressure Sensor 3....4282
Inlet Air Temperature Sensor 1....4284
Inlet Air Temperature Sensor 2....4286
Inlet Air Temperature Sensor 3....4287
Inlet Manifold 1....4288
Inlet Manifold 2....4289
Lifter Group....4290
Magnetic Switch 1....4292
Magnetic Switch 2....4294
Magnetic Switch 3....4296
Main Bearing Journal 1....4298
Main Bearing Journal 2....4299
Muffler 1....4300
Muffler 2....4302
Muffler 3....4304
Piston Cooling Jet 1....4307
Piston Cooling Jet 2....4309
Piston Cooling Jet 3....4311
Piston and Rings 1....4313
Piston and Rings 2....4315
Piston and Rings 3....4318
Piston and Rings 4....4320
Piston and Rings 5....4323
Rear Seal Carrier....4326
SpeedTiming Sensor....4328
Turbocharger 1....4330
Turbocharger 2....4332
Turbocharger 3....4335
Turbocharger 4....4337
Turbocharger 5....4339
Turbocharger 6....4341
Turbocharger Adapter....4343
Unit Injector Hydraulic Pump 1....4345
Unit Injector Hydraulic Pump 2....4349
Unit Injector Hydraulic Pump 3....4352
Unit Injector Hydraulic Pump 4....4355
Unit Injector Hydraulic Pump 5....4358
Valve Mechanism 1....4361
Valve Mechanism 2....4364
Valve Mechanism 3....4367
Valve Mechanism Cover 10....4371
Valve Mechanism Cover 11....4372
Valve Mechanism Cover 12....4374
Valve Mechanism Cover 4....4376
Valve Mechanism Cover 5....4378
Valve Mechanism Cover 6....4380
Valve Mechanism Cover 7....4382
Valve Mechanism Cover 8....4384
Valve Mechanism Cover 9....4386
Vibration Damper 1....4387
Vibration Damper 2....4389
Vibration Damper 3....4391
Vibration Damper 4....4393
Vibration Damper 5....4395
Water Line 1....4397
Water Line 2....4399
Water Line 3....4401
Water Pump 1....4403
Water Pump 2....4405
Water Pump 3....4407
Water Pump 4....4409
Water Pump 5....4411
Water Pump 6....4413
Water Pump 7....4415
Water Temperature Regulator 1....4418
Water Temperature Regulator 2....4420
Water Temperature Regulator 3....4422
Water Temperature Regulator 4....4424
SENR9939 - Systems Operation (C7 Engines for Caterpillar Built Machines)....4426
Air Inlet and Exhaust System....4427
Basic Engine....4436
Cooling System....4441
Electrical System....4444
Electronic Control System Components....4451
Fuel System....4455
General Information....4483
Lubrication System....4487
SENR9939 - Testing & Adjusting (C7 Engines for Caterpillar Built Machines)....4494
Aftercooler - Test....4496
Air Inlet and Exhaust System - Inspect....4503
Air in Fuel - Test....4507
Battery - Test....4510
Charging System - Test....4513
Compression - Test....4518
Connecting Rod Bearings - Inspect....4519
Cooling System - Check - Overheating....4520
Cooling System - Inspect....4525
Cooling System - Test....4527
Cylinder Block - Inspect....4538
Electric Starting System - Test....4540
Electronic Unit Injector - Test....4541
Engine Crankcase Pressure (Blowby) - Test....4543
Engine Oil Pressure - Test....4545
Engine Oil Pump - Inspect....4552
Engine Valve Lash - InspectAdjust....4553
Excessive Bearing Wear - Inspect....4558
Excessive Engine Oil Consumption - Inspect....4559
Exhaust Temperature - Test....4561
Finding Top Center Position for No. 1 Piston....4562
Flywheel - Inspect....4565
Flywheel Housing - Inspect....4569
Fuel Quality - Test....4574
Fuel System - Inspect....4576
Fuel System - Prime....4578
Fuel System Pressure - Test....4580
Gear Group (Front) - Time....4584
Increased Engine Oil Temperature - Inspect....4587
Inlet Manifold Pressure - Test....4588
Main Bearings - Inspect....4591
Pinion Clearance - Adjust....4592
Piston Ring Groove - Inspect....4594
Turbocharger - Inspect....4595
Vibration Damper - Check....4601
Water Pump - Test....4603
Water Temperature Regulator - Test....4606
Caterpillar C7 Engines Repair Service Manual
