Caterpillar C7.1 Series Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C7.1 Series Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Caterpillar C7.1 Series 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.
KENR8881 - Disassembly & Assembly (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9128 - Troubleshooting (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9226 - Troubleshooting (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9240 - Specifications (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9241 - Systems Operation (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9241 - Testing & Adjusting (C7.1 Engines for Caterpillar Built Machines).pdf
KENR9511 - Schematic (Marine Multi-Station Control System II Electrical System - Typical Dual Engine Installation).pdf
LEBW4976 - Application & Installation Guide (Diesel Fuel & Diesel Fuel Systems).pdf
M86193-01 - Disassembly and Assembly (C7.1 Marine Propulsion Engine).pdf
M87218 - Troubleshooting (C7.1 Commercial Marine Engine).pdf
M87219 - Systems Operation (C7.1 Commercial Marine Engine).pdf
M87219 - Testing and Adjustingn (C7.1 Commercial Marine Engine).pdf
M101251 - Specifications (C7.1 Marine Propulsion Engines).pdf
REHS1413 - Special Instruction - Installation of Cat Messenger for On-highway Engines.pdf
RENR1282 - Electronic PTO Installation & Application Guide (On-Highway Engines).pdf
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines).pdf
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines).pdf
RENR7651 - Systems Operation (Marine Multi-Station Control System).pdf
RENR7651 - Testing & Adjusting (Marine Multi-Station Control System).pdf
RENR7651 - Troubleshooting (Marine Multi-Station Control System).pdf
RENR7893 - Schematic (Marine Multi-Station Control System Electrical System - Typical Single Engine Installation).pdf
RENR7929 - Schematic (Marine Multi-Station Control System Electrical System - Typical Dual Engine Installation).pdf
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes(1100, 1105).pdf
SENR2995 - Product Safety.pdf
SENR3130 - Specifications - Torque Specifications.pdf
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products).pdf
SENR3130 - Torque Specifications.pdf
SERT4052 - Service Training (Acert Technology for On-Highwayheavy Duty Engines).pdf
UENR3262 - Disassembly & Assembly - Seal Installation.pdf
UENR5159 - Schematic (C7.1 Marine Engine Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 4,008 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
ENGINE - GENERATOR SET
Model Prefix
C7.1 GENERATOR SET ETG
C7.1 GENERATOR SET L7C
C7.1 GENERATOR SET MRP
C7.1 GENERATOR SET RMT
C7.1 GENERATOR SET STZ
C7.1 GENERATOR SET TX9
C7.1 GENERATOR SET TXR
C7.1 GENERATOR SET WG2
C7.1 GENERATOR SET WG3
C7.1 GEN GENERATOR SET T4T
C7.1DE150E GENERATOR SET GTW
C7.1DE200E GENERATOR SET ECW
C7.1DE200E GENERATOR SET GTP
C7.1DE200E GENERATOR SET GTY
ENGINE - INDUSTRIAL
Model Prefix
C7.1 ENGINE 6J6
C7.1 INDUSTRIAL ENGINE 630
C7.1 INDUSTRIAL ENGINE 673
C7.1 INDUSTRIAL ENGINE 770
C7.1 INDUSTRIAL ENGINE 881
C7.1 INDUSTRIAL ENGINE G92
C7.1 INDUSTRIAL ENGINE G9R
C7.1 INDUSTRIAL ENGINE M75
ENGINE - MACHINE
Model Prefix
C7.1 ENGINE - MACHINE 450
C7.1 ENGINE - MACHINE BD4
C7.1 ENGINE - MACHINE C7R
C7.1 ENGINE - MACHINE D7A
C7.1 ENGINE - MACHINE D8T
C7.1 ENGINE - MACHINE E7A
C7.1 ENGINE - MACHINE W7N
MARINE PRODUCTS
Model Prefix
C7.1 GENERATOR SET JME
C7.1 MARINE ENGINE GJN
C7.1 MARINE ENGINE JEZ
ENGINE - MACHINE
Model Prefix
C7.2 ENGINE - MACHINE KHX
C7.2 ENGINE - MACHINE TX7
MAIN SECTIONS
KENR8881 - Disassembly & Assembly (C7.1 Engines for Caterpillar Built Machines)............3
ARD Spark Plug - Remove and Install............9
Accessory Drive - Remove and Install - Accessory Drive SAE A............12
Accessory Drive - Remove and Install - Accessory Drive SAE B............19
Air Compressor - Remove and Install - Single Cylinder............28
Air Compressor - Remove and Install - Twin Cylinder Compressor............44
Air Control Valve - Remove and Install - Clean Emissions Module............61
Alternator - Install............66
Alternator - Remove............77
Alternator Belt - Remove and Install............84
Atmospheric Pressure Sensor - Remove and Install............88
Bearing Clearance - Check............91
Belt Tensioner - Remove and Install............94
Boost Pressure Sensor - Remove and Install............98
Camshaft - Remove and Install............101
Camshaft Bearings - Remove and Install............107
Camshaft Gear - Remove and Install............111
Camshaft Position Sensor - Remove and Install............125
Catalyst - Remove and Install - Diesel Oxidation Catalyst (DOC)............128
Combustion Head - Remove and Install - Pilot Only System............139
Connecting Rod Bearings - Install - Connecting rods in position............151
Connecting Rod Bearings - Remove - Connecting rods in position............155
Coolant Temperature Sensor - Remove and Install............159
Crankcase Breather - Install............162
Crankcase Breather - Remove............168
Crankshaft - Install............174
Crankshaft - Remove............183
Crankshaft Front Seal - Remove and Install............189
Crankshaft Gear - Remove and Install............193
Crankshaft Main Bearings - Remove and Install - Crankshaft in position............198
Crankshaft Position Sensor - Remove and Install............209
Crankshaft Rear Seal - Install............212
Crankshaft Rear Seal - Remove............220
Crankshaft Timing Ring - Remove and Install............223
Cylinder Head - Install............227
Cylinder Head - Remove............237
Diesel Particulate Filter - Assemble............247
Diesel Particulate Filter - Disassemble............252
Diesel Particulate Filter - Install............257
Diesel Particulate Filter - Remove............264
ECM Mounting Bracket - Remove and Install............270
Electric Starting Motor - Remove and Install............276
Electronic Control Module - Remove and Install - Electronic Control Module With Banjo Bolt Connections............279
Electronic Control Module - Remove and Install - Electronic Control Module With Quick Coupler Connections............290
Electronic Unit Injector - Install............302
Electronic Unit Injector - Remove............311
Engine Oil Cooler - Install - Engine Oil Cooler with a High Mounted Filter Base............319
Engine Oil Cooler - Install - Engine Oil Cooler with a Low Mounted Filter Base............325
Engine Oil Cooler - Remove - Engine Oil Cooler with a High Mounted Filter Base............331
Engine Oil Cooler - Remove - Engine Oil Cooler with a Low Mounted Filter Base............336
Engine Oil Filter Base - Remove and Install - Engine Oil Filter Base with Adapter............341
Engine Oil Filter Base - Remove and Install............347
Engine Oil Pan - Install - Aluminum Oil Pan............351
Engine Oil Pan - Remove - Aluminum Oil Pan............357
Engine Oil Pan Plate - Remove and Install - Aluminum Oil Pan............361
Engine Oil Pressure Sensor - Remove and Install............366
Engine Oil Pump - Install............369
Engine Oil Pump - Remove............373
Exhaust Cooler (NRS) - Remove and Install............376
Exhaust Manifold - Remove and Install............387
Fan - Remove and Install............397
Fan Drive - Remove and Install............401
Flame Detection Temperature Sensor - Remove and Install - Flame Detection Temperature Sensor for the ARD............404
Flexible Exhaust Pipe - Remove and Install............408
Flow Control Valve - Remove and Install............418
Flywheel - Install - Equipped with Rear Power Take-Off............424
Flywheel - Install............428
Flywheel - Remove - Equipped with Rear Power Take-Off............432
Flywheel - Remove............435
Flywheel Housing - Remove and Install (1)............438
Flywheel Housing - Remove and Install (2)............448
Flywheel Housing - Remove and Install (3)............459
Flywheel Housing - Remove and Install (4)............469
Flywheel Housing - Remove and Install (5)............479
Flywheel Housing - Remove and Install - Flywheel Housing that is Equipped with Rear Power Take-Off............487
Flywheel Housing - Remove and Install - Standard Housing............497
Flywheel Housing - Remove and Install - Type A, B, C, and D Wet Back-End Housing............504
Front Cover - Remove and Install - Heavy Duty Front Cover............541
Front Cover - Remove and Install............545
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter............549
Fuel Filter Base - Remove and Install - Twin Secondary Fuel Filter............555
Fuel Injection Lines - Install............562
Fuel Injection Lines - Remove............571
Fuel Injection Pump - Install............577
Fuel Injection Pump - Remove............582
Fuel Injection Pump Gear - Install............587
Fuel Injection Pump Gear - Remove............590
Fuel Manifold (ARD) - Remove and Install - Pilot Solenoid Only............593
Fuel Manifold (Rail) - Remove and Install............602
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP)............606
Fuel Pump (ARD) - Remove and Install............613
Fuel Temperature Sensor - Remove and Install............619
Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)............623
Gear Group (Front) - Remove and Install............644
Glow Plugs - Remove and Install............661
Housing (Front) - Install - Heavy Duty Housing (Front)............666
Housing (Front) - Install............674
Housing (Front) - Remove - Heavy Duty Housing (Front)............681
Housing (Front) - Remove............685
Idler Gear - Install............689
Idler Gear - Remove............698
Idler Pulley - Remove and Install - Flat Idler Pulley............704
Idler Pulley - Remove and Install - Grooved Idler Pulley............707
Ignition Coil (ARD) - Remove and Install - Clean Emissions Module............711
Inlet Air Control - Install - NRS Inlet Air Mixer............717
Inlet Air Control - Remove - NRS Inlet Air Mixer............725
Inlet Manifold Temperature Sensor - Remove and Install............730
Inlet and Exhaust Valve Springs - Remove and Install............733
Inlet and Exhaust Valves - Remove and Install............745
Lifter Group - Remove and Install - Hydraulic Lifter Group............753
Nozzle Heater Harness - Remove and Install - Heated Nozzle Connection............757
Piston Cooling Jets - Remove and Install............764
Pistons and Connecting Rods - Assemble............768
Pistons and Connecting Rods - Disassemble............773
Pistons and Connecting Rods - Install............777
Pistons and Connecting Rods - Remove............782
Pressure Sensor (Cooled Exhaust Gas) - Remove and Install - Differential Pressure Sensor............785
Pressure Sensor (DPF) - Remove and Install - Clean Emissions Module............796
Rear Power Take-Off (RPTO) - Install............802
Rear Power Take-Off (RPTO) - Remove............811
Refrigerant Compressor - Remove and Install............817
Relay (ARD Nozzle Heater) - Remove and Install - Clean Emissions Module............826
Relief Valve (Fuel) - Remove and Install............831
Rocker Shaft - Assemble............836
Rocker Shaft - Disassemble............839
Rocker Shaft and Pushrod - Install............842
Rocker Shaft and Pushrod - Remove............853
Soot Antenna - Remove and Install............858
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install............861
Temperature Sensor (DPF) - Remove and Install - Temperature Sensor (DPF) and Flame Detection Sensor............865
Throttle Valve (Intake Air) - Install............872
Throttle Valve (Intake Air) - Remove............877
Turbocharger - Install - First Stage Turbocharger 1............880
Turbocharger - Install - First Stage Turbocharger 2............887
Turbocharger - Install - Second Stage Turbocharger 1............896
Turbocharger - Install - Second Stage Turbocharger 2............905
Turbocharger - Remove - First Stage Turbocharger............914
Turbocharger - Remove - Second Stage Turbocharger............918
Valve Mechanism Cover - Remove and Install............922
Vibration Damper and Pulley - Install ............929
Vibration Damper and Pulley - Remove............933
Wastegate Solenoid - Remove and Install............936
Water Pump - Install............940
Water Pump - Remove............944
Water Separator and Fuel Filter (Primary) - Remove and Install............947
Water Temperature Regulator - Remove and Install............953
KENR9128 - Troubleshooting (C7.1 Engines for Caterpillar Built Machines)............957
5 Volt Sensor Supply Circuit - Test............961
ARD Combustion Supply Air Pressure Is Low............981
ARD Failed to Ignite............985
ARD Fuel Supply - Test............996
ARD Ignition - Test............1009
ARD Is Disabled............1038
ARD Loss of Combustion............1041
ARD Nozzle - Test............1048
ARD Nozzle Heater - Test............1055
ARD Pilot Fuel Pressure Is High............1086
ARD Pilot Fuel Pressure Is Low............1095
ARD Temperature Is Low............1102
Acceleration Is Poor or Throttle Response Is Poor............1110
Alternator Is Noisy............1119
Alternator Problem............1121
Battery Problem............1123
CAN Data Link Circuit - Test............1125
Coolant Contains Oil............1132
Coolant Level Is Low............1134
Coolant Temperature Is High............1135
Cooling Fan Control - Test............1140
Customer Specified Parameters Table............1148
Customer Specified Parameters Worksheet............1151
Customer Specified Parameters............1153
Cylinder Is Noisy............1159
Data Link Circuit - Test............1162
Data Link Configuration Status - Test............1172
Diagnostic Trouble Codes............1176
Diesel Particulate Filter Collects Excessive Soot............1191
Diesel Particulate Filter Has High Ash Load............1197
Diesel Particulate Filter Has High Inlet Pressure............1199
Diesel Particulate Filter Has Low Inlet Pressure............1202
Diesel Particulate Filter Identification Signal - Test............1205
Diesel Particulate Filter Requires Initial Regeneration............1214
Diesel Particulate Filter Temperature Is High............1215
Diesel Particulate Filter Temperature Is Low............1218
ECM Does Not Communicate with Other Modules............1220
ECM Harness Connector Terminals............1222
ECM Memory - Test............1225
ECM Will Not Accept Factory Passwords............1227
Electrical Connectors - Inspect............1229
Electronic Service Tool Does Not Communicate............1239
Electronic Service Tools............1242
Engine Cranks but Does Not Start............1248
Engine Does Not Crank............1259
Engine Has Early Wear............1262
Engine Has Mechanical Noise (Knock)............1264
Engine Misfires, Runs Rough or Is Unstable............1266
Engine Overspeeds............1274
Engine Pressure Sensor Open or Short Circuit - Test............1276
Engine Shutdown Occurs Intermittently ............1297
Engine Speed Does Not Change............1300
Engine SpeedTiming Sensor Circuit - Test............1302
Engine Stalls at Low RPM............1314
Engine Temperature Sensor Open or Short Circuit - Test (1)............1318
Engine Temperature Sensor Open or Short Circuit - Test (2)............1332
Engine Top Speed Is Not Obtained............1344
Engine Vibration Is Excessive............1353
Engine Wiring Information............1356
Ether Starting Aid - Test............1362
Event Codes............1370
Exhaust Has Excessive Black Smoke............1374
Exhaust Has Excessive White Smoke............1379
Factory Passwords............1383
Flash Programming............1385
Fuel Consumption Is Excessive............1387
Fuel Contains Water............1392
Fuel Pump Relay Circuit - Test............1394
Fuel Rail Pressure Problem............1407
Fuel Temperature Is High............1416
Glossary............1419
Glow Plug Starting Aid - Test............1427
Ignition Keyswitch Circuit and Battery Supply Circuit - Test............1439
Injector Code - Calibrate............1448
Injector Data Incorrect - Test............1452
Injector Solenoid Circuit - Test............1457
Inlet Air Is Restricted............1468
Inlet Air Temperature Is High............1470
Intake Manifold Air Pressure Is High............1473
Intake Manifold Air Pressure Is Low............1475
Intake Manifold Air Temperature Is High............1478
Motorized Valve - Test............1480
NRS Exhaust Gas Temperature Is High............1496
NRS Mass Flow Rate Problem............1500
Oil Consumption Is Excessive............1506
Oil Contains Coolant............1509
Oil Contains Fuel............1511
Oil Pressure Is Low............1514
Power Is Intermittently Low or Power Cutout Is Intermittent............1522
Programming Parameters............1529
Replacing the ECM............1530
Self-Diagnostics............1534
Sensor Calibration Required - Test............1536
Sensors and Electrical Connectors............1542
Solenoid Valve - Test............1549
Soot Sensor - Test............1565
Start Relay Circuit - Test............1573
System Configuration Parameters............1583
System Overview............1586
Test ECM Mode............1595
Throttle Switch Circuit - Test............1597
Valve Lash Is Excessive............1601
Valve Position Sensor - Test............1603
Water In Fuel Sensor - Test............1620
Welding Precaution............1627
KENR9226 - Troubleshooting (C7.1 Engines for Caterpillar Built Machines)............1630
System Configuration Parameters............1631
KENR9240 - Specifications (C7.1 Engines for Caterpillar Built Machines)............1634
Accessory Drive - SAE B............1637
Accessory Drive............1641
Air Compressor - Single Cylinder............1644
Air Compressor - Twin Cylinder Compressor............1649
Alternator............1655
Atmospheric Pressure Sensor............1662
Belt Tensioner............1664
Boost Pressure Sensor............1667
Camshaft Bearings............1669
Camshaft............1672
Connecting Rod ............1677
Connecting Rod Bearing Journal............1682
Coolant Temperature Sensor............1685
Crankcase Breather............1687
Crankshaft Seals............1690
Crankshaft............1693
Cylinder Block............1698
Cylinder Head Valves............1702
Cylinder Head............1705
Diesel Particulate Filter Temperature and Pressure Sensor............1712
Diesel Particulate Filter............1715
Electronic Control Module............1720
Electronic Control Wiring Group - Aftertreatment Regeneration Device............1723
Engine Design............1726
Engine Lifting Bracket............1730
Engine Oil Cooler............1732
Engine Oil Filter Base............1736
Engine Oil Pan............1739
Engine Oil Pressure Sensor............1743
Engine Oil Pressure............1745
Engine Oil Pump............1747
Exhaust Combustion (ARD) - Aftertreatment Regeneration Device............1752
Exhaust Cooler (NRS)............1757
Exhaust Gas Valve (NRS)............1761
Exhaust Manifold............1766
Exhaust Sensor and Lines (NRS)............1768
Fan Drive............1771
Flexible Exhaust Pipe............1774
Flywheel Housing - Flywheel Housing that is Equipped with Rear Power Take-Off............1777
Flywheel Housing............1782
Flywheel............1786
Front Housing and Covers............1789
Fuel Filter Base - Primary Fuel Filter Base............1793
Fuel Filter Base - Single Secondary Fuel Filter Base............1796
Fuel Filter Base - Twin Secondary Fuel Filter Base............1800
Fuel Injection Lines............1804
Fuel Injection Nozzles............1807
Fuel Injection Pump............1811
Fuel Manifold (ARD) - Aftertreatment Regeneration Device............1813
Fuel Manifold (Rail)............1816
Fuel Transfer Pump - Electric Transfer Pump............1818
Gear Group (Front)............1822
Glow Plugs............1827
Inlet Manifold Temperature Sensor............1830
Lifter Group............1832
Main Bearing Journal............1835
Piston Cooling Jet............1838
Piston and Rings............1840
Pressure Sensor (NOx Reduction System)............1844
Refrigerant Compressor............1846
Rocker Shaft............1848
SpeedTiming Sensor............1851
Starter Motor............1853
Temperature Sensor (NOx Reduction System)............1858
Turbocharger - Series Turbochargers............1860
Valve Mechanism Cover............1866
Vibration Damper and Pulley............1869
Water Pump............1872
Water Temperature Regulator and Housing............1874
KENR9241 - Systems Operation (C7.1 Engines for Caterpillar Built Machines)............1878
Engine Operation............1879
General Information............1973
KENR9241 - Testing & Adjusting (C7.1 Engines for Caterpillar Built Machines)............1979
Air Inlet and Exhaust System............1980
Basic Engine............2011
Cooling System............2040
Electrical System............2055
Fuel System............2067
Lubrication System............2090
KENR9511 - Schematic (Marine Multi-Station Control System II Electrical System - Typical Dual Engine Installation)............2100
Collage............2101
Main............2111
LEBW4976 - Application & Installation Guide (Diesel Fuel & Diesel Fuel Systems)............2113
Diesel Fuels............2121
Common Diesel Fuel............2122
Diesel Fuel Grades............2122
Low Grade............2122
High Grade............2122
American Society for Testing and Materials (ASTM)............2122
Diesel Fuel Types............2123
Crude Oil............2123
Residual Oil or Blended Heavy Fuel Oil (HFO)............2123
Distillate Fuel............2123
Marine Diesel Oil............2123
Aircraft Jet Fuels and Kerosene Type Fuels............2124
Biodiesel............2124
Ultra Low Sulfur Diesel (ULSD)............2124
Diesel Fuel Characteristics............2124
Diesel Fuel Selection............2126
Diesel Fuel Systems............2127
Basic Fuel System............2128
MUI Fuel System............2128
MEUI Fuel System............2128
HEUI Fuel System............2129
Common Rail Fuel System............2129
ACERT Technology............2130
Diesel Fuel System Design Considerations............2132
Fuel Storage Systems............2132
Main Fuel Tank............2132
Auxiliary Fuel Tanks............2133
Fuel Head Limiting Tank............2136
Base Mounted Tanks............2136
Fuel Tank Design Considerations............2137
Fuel Tank Sizing............2137
Fuel Tank Material............2137
Fuel Tank Installation............2137
Fuel Tank Drains............2137
Fuel Tank Grounding............2138
Fuel Tank Maintenance............2138
Fuel Transfer Systems............2138
Fuel Transfer Pumps............2140
Fuel Piping Design Considerations............2141
Fuel Supply Piping............2141
Fuel Return Piping............2142
Purging............2142
Siphoning & Check Valves............2142
Material............2142
Sizing............2143
Routing............2143
Fuel Filtration Systems............2143
Filter Micron Ratings............2144
Primary Fuel Filter Element Specification............2145
Duplex Fuel Filters............2145
Water Separation............2146
Miscellaneous Fuel System Considerations............2150
Fuel Temperature............2150
Fuel Coolers............2150
Fuel Heaters............2151
Partial Load Operation............2153
Burning Used Crankcase Oil............2153
Continuous Blending............2154
Fuel Conservation Practices............2156
Appendix 1............2157
Day Tank Sizing (When Day Tank Serves as a Heat Sink)............2157
Day Tank Calculations............2157
Day Tank Thermal Capacity Calculation............2158
Useful Fuel Formulas and Data............2167
Appendix 2............2169
Crude Oil Fuel............2169
Pretreatment of Crude Oils............2169
Crude Oil Maintenance Intervals............2171
Crude Oil Settling Tanks............2171
M101251 - Specifications (C7.1 Marine Propulsion Engines)............2177
Aftercooler............2179
Alternator............2181
Auxiliary Drive Pulley............2182
Auxiliary Sea Water Pump............2183
Belt Guard............2185
Boost Pressure Sensor............2187
Camshaft............2188
Connecting Rod............2189
Coolant Level Sensor............2191
Coolant Temperature Sensor............2192
Crankshaft............2194
Cylinder Block............2195
Cylinder Head Valves............2197
Cylinder Head............2199
Drive Shaft............2202
Engine Coolant Pressure Sensor............2203
Engine Design............2204
Engine Mounting............2206
Engine Oil Cooler - Transmission............2207
Engine Oil Cooler............2209
Engine Oil Pressure Sensor............2210
Engine Oil Temperature Sensor............2211
Engine Support (Rear)............2212
Exhaust Manifold............2213
Flywheel - Mounting............2214
Flywheel Housing............2215
Fuel Cooler............2216
Fuel Lines............2217
Fuel Manifold (Rail)............2218
Fuel Pressure Sensor............2220
Fuel Transfer Pump 1............2222
Fuel Transfer Pump 2............2223
Heat Exchanger............2225
Liquid Level Sensor (Water Separator)............2227
Pressure Sensor (Auxiliary)............2228
Speed_Timing Sensor............2229
Transmission Oil Pressure Sensor............2231
Transmission Oil Temperature Sensor............2232
Turbocharger Exhaust Temperature Sensor............2233
Turbocharger............2234
Valve Mechanism............2237
Water Connection Group............2239
Water Lines............2241
M86193-01 - Disassembly and Assembly (C7.1 Marine Propulsion Engine)............2242
Aftercooler - Remove and Install............2245
Alternator - Remove and Install............2251
Alternator Belt - Remove and Install............2255
Auxiliary Water Pump - Assemble............2259
Auxiliary Water Pump - Disassemble............2267
Auxiliary Water Pump - Remove and Install............2274
Bearing Clearance - Check............2277
Belt Tensioner - Remove and Install............2280
Boost Pressure Sensor - Remove and Install............2282
Camshaft - Remove and Install............2284
Camshaft Bearings - Remove and Install............2290
Camshaft Gear - Remove and Install............2294
Camshaft Position Sensor - Remove and Install............2308
Connecting Rod Bearings - Install - Connecting rods in position............2312
Connecting Rod Bearings - Remove - Connecting rods in position............2316
Coolant Level Sensor - Remove and Install............2321
Coolant Temperature Sensor - Remove and Install............2323
Crankcase Breather - Install............2326
Crankcase Breather - Remove............2330
Crankshaft - Install............2334
Crankshaft - Remove............2340
Crankshaft Front Seal - Remove and Install............2345
Crankshaft Gear - Remove and Install............2348
Crankshaft Main Bearings - Remove and Install - Crankshaft in position............2352
Crankshaft Rear Seal - Remove and Install............2362
Crankshaft Timing Ring - Remove and Install............2370
Cylinder Head - Install............2373
Cylinder Head - Remove............2382
ECM Mounting Bracket - Remove and Install............2389
Electric Starting Motor - Remove and Install............2392
Electronic Control Module - Remove and Install............2395
Engine Oil Cooler - Remove and Install............2398
Engine Oil Filter Base - Remove and Install............2405
Engine Oil Pan - Remove and Install............2407
Engine Oil Pan Plate - Remove and Install............2418
Engine Oil Pressure Sensor - Remove and Install............2422
Engine Oil Pump - Remove and Install............2425
Exhaust Manifold - Remove and Install............2429
Flow Control Valve - Remove and Install............2433
Flywheel - Remove and Install............2439
Flywheel Housing - Remove and Install............2445
Front Cover - Remove and Install............2452
Fuel Cooler - Remove and Install............2458
Fuel Filter Base - Remove and Install............2464
Fuel Injection Lines - Remove and Install............2468
Fuel Injection Pump - Remove and Install............2480
Fuel Injection Pump Gear - Install............2489
Fuel Injection Pump Gear - Remove............2493
Fuel Injector - Install............2496
Fuel Injector - Remove............2504
Fuel Manifold (Rail) - Install............2509
Fuel Manifold (Rail) - Remove and Install............2519
Fuel Manifold (Rail) - Remove............2523
Fuel Pressure Sensor - Remove and Install............2534
Fuel Temperature Sensor - Remove and Install............2536
Fuel Transfer Pump - Install............2539
Fuel Transfer Pump - Remove............2545
Gear Group (Front) - Remove and Install............2552
Glow Plugs - Remove and Install............2568
Heat Exchanger - Remove and Install............2579
Housing (Front) - Remove and Install............2585
Idler Gear - Remove and Install............2595
Inlet Air Temperature Sensor - Remove and Install............2607
Inlet and Exhaust Valves - Remove and Install............2609
Lifter Group - Remove and Install............2620
Piston Cooling Jets - Remove and Install............2623
Pistons and Connecting Rods - Assemble............2628
Pistons and Connecting Rods - Disassemble............2634
Pistons and Connecting Rods - Install............2638
Pistons and Connecting Rods - Remove............2642
Relief Valve (Fuel) - Remove and Install............2647
Rocker Arm - Assemble............2651
Rocker Arm - Disassemble............2655
Rocker Arm and Shaft - Install............2659
Rocker Arm and Shaft - Remove............2666
Speed_Timing Sensor - Remove and Install............2671
Transmission Oil Cooler - Remove and Install............2673
Transmission Oil Pressure Sensor - Remove and Install............2675
Transmission Oil Temperature Sensor - Remove and Install............2677
Turbocharger - Remove and Install............2679
Valve Mechanism Cover - Remove and Install............2685
Vibration Damper and Pulley - Remove and Install............2688
Water Pump - Remove and Install............2691
Water Temperature Regulator - Remove and Install............2695
M87218 - Troubleshooting (C7.1 Commercial Marine Engine)............2699
Acceleration Is Poor or Throttle Response Is Poor............2702
Alternator Is Noisy............2706
Alternator Problem............2709
Battery Problem............2711
Coolant Contains Oil............2713
Coolant Level Is Low............2716
Coolant Pressure Is Low............2718
Coolant Temperature Is High............2722
Crankcase Breather Ejects Oil............2727
Crankcase Fumes Disposal Tube Has Oil Draining............2730
Customer Specified Parameters Table............2734
Customer Specified Parameters............2736
Cylinder Is Noisy............2739
Data Link - Test............2743
Diagnostic Trouble Codes - Engine Diagnostic Trouble Codes............2748
ECM Does Not Communicate with Other Modules............2756
ECM Harness Connector Terminals............2758
ECM Software - Install............2760
ECM Will Not Accept Factory Passwords............2762
Electrical Power Supply - Test............2764
Electronic Service Tool Does Not Communicate............2768
Engine Cranks but Does Not Start............2772
Engine Does Not Crank............2776
Engine Has Early Wear............2779
Engine Has Mechanical Noise (Knock)............2783
Engine Misfires, Runs Rough or Is Unstable............2787
Engine Overcrank Occurrence............2791
Engine Overspeeds............2795
Engine Shutdown Occurrence............2797
Engine Shutdown Occurs Intermittently............2799
Engine Top Speed Is Not Obtained............2802
Engine Vibration Is Excessive............2806
Event Codes............2808
Exhaust Has Excessive Black Smoke............2817
Exhaust Has Excessive White Smoke............2821
Exhaust Temperature Is High............2825
Factory Passwords............2828
Flash Programming............2829
Fuel Consumption Is Excessive............2831
Fuel Contains Water............2834
Fuel Filter Is Restricted............2840
Fuel Level - Test............2842
Fuel Rail Pressure Problem............2845
Fuel Temperature Is High............2849
Fuel Transfer Pump - Test............2852
Glow Plug Starting Aid - Test............2860
Indicator Lamps............2868
Injector Code - Calibrate............2873
Injector Data Incorrect - Test............2876
Injector Solenoid - Test............2880
Inlet Air Is Restricted............2886
Inlet Air Temperature Is High............2888
Intake Manifold Air Temperature Is High............2891
Oil Consumption Is Excessive............2895
Oil Contains Coolant............2898
Oil Contains Fuel............2902
Oil Pressure Is Low............2905
Oil Temperature Is High............2910
Power Is Intermittently Low or Power Cutout Is Intermittent............2912
Programming Parameters............2916
Relay - Test - Start Relay............2917
Replacing the ECM............2921
Sea Water Pump Pressure Is Low............2924
Sea Water Pump Pressure Problem............2927
Self-Diagnostics............2929
Sensor Calibration Required - Test............2930
Sensor Signal (Analog, Active) - Test............2933
Sensor Signal (Analog, Passive) - Test............2938
Sensor Supply - Test............2944
Solenoid Valve - Test............2951
Speed Control (Analog) - Test............2955
Speed Control (PWM) - Test............2962
Speed_Timing - Test............2969
System Configuration Parameters............2973
System Overview............2975
Test ECM Mode............2980
Transmission Oil Pressure Is High............2982
Transmission Oil Temperature Is High............2984
Valve Lash Is Excessive............2986
Water in Fuel - Test............2988
Welding Precaution............2992
M87219 - Systems Operation (C7.1 Commercial Marine Engine)............2994
Air Inlet and Exhaust System............2995
Basic Engine............3001
Cleanliness of Fuel System Components............3009
Cooling System............3011
Electrical System............3015
Fuel Injection............3017
Glossary of Electronic Control Terms............3025
Introduction............3033
Lubrication System............3038
M87219 - Testing and Adjustingn (C7.1 Commercial Marine Engine)............3040
Air Inlet and Exhaust System - Inspect............3042
Alternator - Test............3045
Battery - Test............3047
Charging System - Test............3048
Compression - Test............3049
Connecting Rod - Inspect............3051
Cooling System - Check............3053
Cooling System - Inspect............3054
Cooling System - Test............3055
Crankshaft Pulley - Check............3060
Cylinder Block - Inspect............3062
Cylinder Head - Inspect............3063
Electric Starting System - Test............3065
Engine Oil Cooler - Inspect............3069
Engine Oil Pressure - Test............3071
Engine Oil Pump - Inspect............3072
Engine Valve Lash - Inspect............3074
Excessive Bearing Wear - Inspect............3079
Excessive Engine Oil Consumption - Inspect............3080
Finding Top Center Position for No. 1 Piston............3081
Flywheel - Inspect............3083
Flywheel Housing - Inspect............3086
Fuel Quality - Test............3089
Fuel System - Inspect............3091
Fuel System - Prime............3093
Gear Group (Front) - Time............3095
Gear Group - Inspect............3097
Increased Engine Oil Temperature - Inspect............3099
Piston Height - Inspect............3100
Piston Ring Groove - Inspect............3103
Position the Valve Mechanism Before Maintenance Procedures............3106
Turbocharger - Inspect............3109
V-Belt - Test............3113
Valve Depth - Inspect............3115
Valve Guide - Inspect............3118
Water Pump - Inspect............3120
Water Temperature Regulator - Test............3121
REHS1413 - Special Instruction - Installation of Cat Messenger for On-highway Engines............3122
RENR1282 - Electronic PTO Installation & Application Guide (On-Highway Engines)............3198
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)............3310
Abbreviations and Symbols............3311
ETR Component Descriptions............3320
ETR Introduction............3333
ETR Junction Box-Switchgear Not Required (OP,WT)............3335
ETR Junction Box-Switchgear Not Required (OP,WT,OS)............3352
ETR Junction Box-Switchgear Required (OP,WT,OS)............3377
Junction Box and Enclosure Group............3401
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)............3406
Crank Terminate Speed Calibration............3407
Diode Test............3409
Electric Protection System Functional Test............3410
Engine Oil Pressure Switch Test............3413
General Testing and Adjusting Information............3415
General Troubleshooting Information............3418
Magnetic Pickup Test............3419
Oil Step Speed Calibration............3422
Overspeed Calibration............3424
Overspeed Verification Test............3426
Slave Relay Test............3428
Troubleshooting the ETR Full Protective System (OP, WT, OS)............3430
Troubleshooting the ETR Partial Protection System (OP, WT)............3444
Water Temperature Contactor Switch Test............3453
RENR7651 - Systems Operation (Marine Multi-Station Control System)............3455
Data Link............3456
General Information............3457
Junction Box............3461
Marine Power Display............3464
Operator Controls............3472
RENR7651 - Testing & Adjusting (Marine Multi-Station Control System)............3482
Electrical Connector - Inspect............3483
Glossary of Terms............3499
Parameter - Program............3506
RENR7651 - Troubleshooting (Marine Multi-Station Control System)............3507
Active Station - Test............3509
Button Panel - Test............3512
Connector Locations............3518
Control Head - Calibrate............3525
Control Panel - Test............3527
Data Link (Engine Monitoring System and Engine Vision) - Test............3530
Data Link (Marine Power Display) - Test............3538
Diagnostic Code List............3549
E881 Multiple Stations on Master Control Data Link............3551
ECM CID 0091 - FMI 08............3553
ECM CID 0091 - FMI 13............3558
ECM CID 0116 - FMI 00............3559
ECM CID 0168 - FMI 00............3567
ECM CID 0168 - FMI 01............3570
ECM CID 0168 - FMI 02............3573
ECM CID 1383 - FMI 11............3582
Electronic Service Tool Will Not Communicate with PCP............3590
Engine Cranks but Will Not Start............3597
Gear Lockout - Test............3603
General Information............3605
PCP CID 0369 - FMI 07............3606
PCP CID 0700 - FMI 02............3610
PCP CID 0718 - FMI 07............3614
PCP CID 1326 - FMI 09............3621
PCP CID 1440 - FMI 03............3633
PCP CID 1440 - FMI 04............3637
PCP CID 1440 - FMI 07............3641
PCP CID 1440 - FMI 08............3645
PCP CID 1815 - FMI 04............3649
PCP CID 1815 - FMI 12............3653
PCP CID 1815 - FMI 13............3654
PCP CID 1816 - FMI 09............3656
PCP CID 1817 - FMI 09............3668
PCP CID 1821 - FMI 09............3675
PCP CID 1822 - FMI 09............3682
Service Tools............3694
Slow Vessel Mode - Test............3703
Station Does Not Transfer............3705
Switch Inputs Not Working............3708
Throttle Response Is Erratic............3714
Troll Does Not Function............3716
Using Caterpillar Electronic Technician (ET) to Determine Diagnostic Codes............3726
RENR7893 - Schematic (Marine Multi-Station Control System Electrical System - Typical Single Engine Installation)............3728
Collage............3729
Main............3744
RENR7929 - Schematic (Marine Multi-Station Control System Electrical System - Typical Dual Engine Installation)............3746
Collage............3747
Main............3762
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes(1100, 1105)............3764
SENR2995 - Product Safety............3778
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products)............3786
SENR3130 - Specifications - Torque Specifications............3806
SENR3130 - Torque Specifications............3826
Air Brake Fittings............3827
Air Conditioning Fittings............3829
Bulkhead Nuts............3831
English (SAE) Fasteners............3834
Flare Fittings............3839
General Information............3843
Ground Engaging Tool (G.E.T.) Fasteners............3846
Hose Clamps............3848
Installation of Fittings............3851
Metric (ISO) Fasteners............3855
Miscellaneous Fittings............3861
O-Ring Face Seal Fittings............3863
Plugs............3865
Straight Thread O-Ring Fittings............3869
Tapered Pipe Thread Fittings............3874
SERT4052 - Service Training (Acert Technology for On-Highwayheavy Duty Engines)............3876
UENR3262 - Disassembly & Assembly - Seal Installation............3938
Duo-Cone Seals - Install............3939
Lip Type Seals - Install............3967
O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY O-RINGS & OTHER O-RING APPLICATIONS............3976
UENR5159 - Schematic (C7.1 Marine Engine Electrical System)............4002
Features............4002
Cover Page............4004
Schematic............4005
Machine Views............0
Front View............4006
Left Side View............4007
Right Side View............4008
Top View............4009
Caterpillar C7.1 Series Engines Repair Service Manual
