Caterpillar C1.7 and C2.2 Industrial Engines Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C1.7 and C2.2 Industrial Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Caterpillar C1.7 and C2.2 Industrial 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.

PRODUCT DETAILS:
Total Pages: 1,922 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

M0064144 - Specifications (C1.7 and C2.2 Industrial Engines).pdf
M0064160 - Systems Operation (C1.7 and C2.2 Industrial Engines).pdf
M0064160 - Testing and Adjusting (C1.7 and C2.2 Industrial Engines).pdf
M0067036 - Troubleshooting (C1.7 and C2.2 Industrial Engine).pdf
M0067512 - Disassembly and Assembly (C1.7 and C2.2 Industrial Engines).pdf
M0112319 - Troubleshooting (C1.7 and C2.2 Industrial Engine).pdf
M0113757 - Systems Operation (C1.7 and C2.2 Industrial Engines).pdf
M0113757 - Testing and Adjusting (C1.7 and C2.2 Industrial Engines).pdf
M0113762 - Disassembly and Assembly (C1.7 and C2.2 Industrial Engines).pdf
M0113799 - Specifications (C1.7 and C2.2 Industrial Engines).pdf

TABLE OF CONTENTS
M0064144 - Specifications (C1.7 and C2.2 Industrial Engines)...1
  Engine Design...3
  Fuel Injection Lines...5
  Fuel Injection Pump...7
  Fuel Injection Nozzles...9
  Fuel Filter Base - Secondary Fuel Filter Base...11
  Fuel Manifold (Rail)...13
  Lifter Group...15
  Rocker Shaft...16
  Valve Mechanism Cover...19
  Cylinder Head Valves...21
  Cylinder Head...26
  Turbocharger...29
  Exhaust Gas Valve (NRS)...33
  Exhaust Cooler (NRS)...34
  Inlet Manifold...36
  Exhaust Manifold...38
  Camshaft...40
  Engine Oil Lines...43
  Engine Oil Filter...45
  Engine Oil Relief Valve...46
  Engine Oil Pump...48
  Engine Oil Pan...51
  Crankcase Breather...53
  Water Temperature Regulator...54
  Cylinder Block...57
  Crankshaft...59
  Connecting Rod Bearing Journal...62
  Main Bearing Journal...63
  Connecting Rod...64
  Piston and Rings...66
  Housing (Front)...70
  Gear Group (Front)...73
  Flywheel...75
  Flywheel Housing...76
  Crankshaft Pulley...78
  Belt Tension Chart...79
  Fan Drive...80
  Engine Lifting Bracket...81
  Alternator and Regulator...82
  Electric Starting Motor...85
  Coolant Temperature Sensor...87
  Engine Oil Pressure Switch...88
  Boost Pressure Sensor...89
  Inlet Manifold Temperature Sensor...90
  Speed_Timing Sensor...91
  Glow Plugs...93
M0064160 - Systems Operation (C1.7 and C2.2 Industrial Engines)...94
  General Information...95
  Glossary of Electronic Control Terms...101
  Electronic Control System Components...107
  Cleanliness of Fuel System Components...122
  Fuel System...124
  Air Inlet and Exhaust System...135
  Clean Emissions Module...141
  Lubrication System...143
  Cooling System...146
  Basic Engine...148
  Electrical System...151
M0064160 - Testing and Adjusting (C1.7 and C2.2 Industrial Engines)...157
  Fuel System - Inspect...158
  Air in Fuel - Test...159
  Finding Top Center Position for No. 1 Piston...162
  Fuel Injection Timing - Check...164
  Fuel Quality - Test...166
  Fuel System - Prime...168
  Gear Group (Front) - Time...171
M0067036 - Troubleshooting (C1.7 and C2.2 Industrial Engine)...173
  General Information...176
  Welding Precaution...179
  Electronic Service Tools...181
  System Overview...187
  Component Location...189
  Engine Monitoring System...199
  Diagnostic Capabilities...200
  Electrical Connectors...202
  Diagnostic Trouble Codes...208
  Acceleration Is Poor or Throttle Response Is Poor...217
  Alternator Problem...223
  Battery Problem...225
  Coolant Contains Oil...227
  Coolant Temperature Is High...230
  Cylinder Is Noisy...236
  Engine Cranks but Does Not Start...240
  Engine Does Not Crank...248
  Engine Has Early Wear...251
  Engine Has Mechanical Noise (Knock)...254
  Engine Misfires; Runs Rough or Is Unstable...259
  Engine Overspeeds...265
  Engine Shutdown Occurs Intermittently...269
  Engine Stalls at Low RPM...272
  Engine Top Speed Is Not Obtained...275
  Engine Vibration Is Excessive...282
  Exhaust Has Excessive Black Smoke...286
  Exhaust Has Excessive White Smoke...291
  Exhaust System Contains Coolant...296
  Exhaust System Contains Oil...299
  Fuel Consumption Is Excessive...303
  Fuel Rail Pressure Problem...309
  Fuel Temperature Is High...314
  Inlet Air Is Restricted...317
  Intake Manifold Air Temperature Is High...319
  Oil Consumption Is Excessive...323
  Oil Contains Coolant...327
  Oil Contains Fuel...330
  Oil Pressure Is Low...334
  Power Is Intermittently Low or Power Cutout Is Intermittent...339
  Valve Lash Is Excessive...343
  CAN Data Link - Test...345
  Data Link Configuration Status - Test...349
  Electrical Power Supply - Test...351
  Glow Plug Starting Aid - Test...355
  Idle Validation - Test...364
  Injector Solenoid - Test...371
  Motorized Valve - Test...377
  Relay - Test - Fan Drive Relay...387
  Relay - Test - Fuel Lift Pump Relay...392
  Relay - Test - Start Relay...397
  Sensor Signal (Analog; Active) - Test...403
  Sensor Signal (Analog; Passive) - Test...409
  Sensor Supply - Test...418
  Shutdown (Ground Level) - Test...426
  Solenoid Valve - Test...430
  Speed Control (Analog) - Test...436
  Speed_Timing - Test...443
  Valve Position - Test...454
  Service Tool Features...464
  Electronic Service Tool Does Not Communicate...469
  ECM Software - Install...475
  ECM - Replace...477
  Electrical Connectors - Inspect...479
  Injector Code - Calibrate...486
M0067512 - Disassembly and Assembly (C1.7 and C2.2 Industrial Engines)...490
  Fuel Filter Base - Remove and Install - Secondary Fuel Filter...493
  Fuel Manifold (Rail) - Remove and Install - 3 Cylinder Engines...502
  Fuel Injection Lines - Remove and Install - 3 Cylinder Engines...510
  Exhaust Cooler (NRS) - Remove and Install - 3 Cylinder Engines...519
  Fuel Injection Pump - Remove...529
  Fuel Injection Pump - Install...533
  Fuel Injection Pump Gear - Remove...538
  Fuel Injection Pump Gear - Install...541
  Fuel Injector - Remove and Install...544
  Turbocharger - Remove - 3 Cylinder Engines...551
  Turbocharger - Install - 3 Cylinder Engines...557
  Exhaust Gas Recirculation Valve - Remove and Install - 3 Cylinder Engines...564
  Clean Emissions Module - Remove and Install...571
  Exhaust Manifold - Remove and Install - 3 Cylinder Engines...575
  Exhaust Elbow - Remove and Install - Exhaust Elbow between the Turbocharger and the Clean Emissions Module (CEM)...581
  Support and Mounting (CEM) - Remove and Install...584
  Inlet Manifold - Remove and Install - 3 Cylinder Engines...589
  Inlet and Exhaust Valve Springs - Remove and Install...597
  Inlet and Exhaust Valves - Remove and Install...603
  Engine Oil Line - Remove and Install...611
  Engine Oil Cooler - Remove and Install...617
  Engine Oil Relief Valve - Remove and Install...622
  Engine Oil Pump - Remove...625
  Engine Oil Pump - Install...629
  Water Pump - Remove and Install...635
  Water Temperature Regulator Housing - Remove and Install...641
  Engine Lifting Bracket - Remove and Install...656
  Flywheel - Remove and Install...660
  Crankshaft Rear Seal - Remove and Install - Engines Without a Back Plate...666
  Crankshaft Wear Sleeve (Rear) - Remove and Install...669
  Flywheel Housing - Remove and Install...674
  Crankshaft Pulley - Remove and Install...678
  Crankshaft Front Seal - Remove and Install...684
  Housing (Front) - Remove...688
  Housing (Front) - Install...693
  Crankcase Breather - Remove and Install...699
  Valve Mechanism Cover - Remove and Install...708
  Rocker Shaft and Pushrod - Remove...721
  Rocker Shaft - Disassemble...725
  Rocker Shaft - Assemble...728
  Rocker Shaft and Pushrod - Install...731
  Cylinder Head - Remove - 3 Cylinder Engines...735
  Cylinder Head - Install - 3 Cylinder Engines...739
  Lifter Group - Remove and Install...746
  Camshaft - Remove...749
  Camshaft - Disassemble...752
  Camshaft - Assemble...754
  Camshaft - Install...756
  Engine Oil Pan - Remove and Install...760
  Pistons and Connecting Rods - Remove...764
  Pistons and Connecting Rods - Disassemble...767
  Pistons and Connecting Rods - Assemble...773
  Pistons and Connecting Rods - Install...779
  Connecting Rod Bearings - Remove - Connecting Rods in Position...783
  Connecting Rod Bearings - Install - Connecting Rods in Position...785
  Crankshaft Main Bearings - Remove...788
  Crankshaft Main Bearings - Install...794
  Crankshaft - Remove...801
  Crankshaft - Install...804
  Crankshaft Gear - Remove and Install...808
  Bearing Clearance - Check...812
  Primary Engine Speed_Timing Sensor - Remove and Install...815
  Secondary Engine Speed_Timing Sensor - Remove and Install...818
  Coolant Temperature Sensor - Remove and Install...821
  Engine Oil Pressure Switch - Remove and Install...824
  Boost Pressure Sensor - Remove and Install...827
  Inlet Manifold Temperature Sensor - Remove and Install...830
  Glow Plugs - Remove and Install...832
  V-Belts - Remove and Install...835
  Alternator - Remove and Install...839
  Electric Starting Motor - Remove and Install...844
M0112319 - Troubleshooting (C1.7 and C2.2 Industrial Engine)...847
  General Information...851
  Welding Precaution...854
  System Overview...856
  Component Location...859
  Diesel Particulate Filter Regeneration...864
  Engine Monitoring System...865
  Diagnostic Capabilities...867
  Configuration Parameters...869
  Diagnostic Trouble Codes...872
  Acceleration Is Poor or Throttle Response Is Poor...883
  Alternator Problem - Charging Problem and_or Noisy Operation...890
  Battery Problem...893
  Coolant Contains Oil...895
  Coolant Level Is Low...898
  Coolant Temperature Is High...900
  Coolant Temperature Is Low...906
  Cylinder Is Noisy...909
  Diesel Oxidation Catalyst Has Incorrect Inlet Temperature...913
  Diesel Oxidation Catalyst Has Low Conversion Efficiency...916
  Diesel Particulate Filter Collects Excessive Soot...919
  Diesel Particulate Filter Has Low Inlet Pressure...924
  Diesel Particulate Filter Temperature Is Low...926
  Engine Cranks but Does Not Start...928
  Engine Does Not Crank...937
  Engine Has Early Wear...940
  Engine Has Mechanical Noise (Knock)...943
  Engine Misfires; Runs Rough or Is Unstable...948
  Engine Overspeeds...954
  Engine Shutdown Occurs Intermittently...958
  Engine Stalls at Low RPM...961
  Engine Top Speed Is Not Obtained...965
  Engine Vibration Is Excessive...973
  Exhaust Has Excessive Black Smoke...976
  Exhaust Has Excessive White Smoke...982
  Exhaust System Contains Coolant...988
  Exhaust System Contains Oil...991
  Exhaust Temperature Is High...995
  Fuel Consumption Is Excessive...999
  Fuel Contains Water...1005
  Fuel Rail Pressure Problem...1008
  Fuel Temperature Is High...1014
  Inlet Air Is Restricted...1018
  Intake Manifold Air Pressure Is High...1020
  Intake Manifold Air Pressure Is Low...1023
  Intake Manifold Air Temperature Is High...1028
  Oil Consumption Is Excessive...1033
  Oil Contains Coolant...1037
  Oil Contains Fuel...1040
  Oil Level Is Low...1044
  Oil Pressure Is Low...1046
  Power Is Intermittently Low or Power Cutout Is Intermittent...1051
  SCR Warning System Problem...1055
  Valve Lash Is Excessive...1059
  CAN Data Link - Test...1061
  Data Link Configuration Status - Test...1066
  Electrical Power Supply - Test...1069
  Engine Speed - Test...1073
  Fuel Control - Test...1077
  Fuel Transfer Pump - Test...1083
  Glow Plug Starting Aid - Test...1088
  Idle Validation - Test...1095
  Indicator Lamp - Test...1103
  Injector Data Incorrect - Test...1107
  Injector Solenoid - Test...1111
  Mode Selection - Test...1119
  Motorized Valve - Test...1123
  Relay - Test - Start Relay...1131
  Sensor Calibration Required - Test...1135
  Sensor (Data Link Type) - Test...1139
  Sensor Signal (Analog; Active) - Test...1142
  Sensor Signal (Analog; Passive) - Test...1151
  Sensor Supply - Test...1159
  Speed Control (Analog) - Test...1162
  Speed Control (PWM) - Test...1170
  Speed_Timing - Test...1177
  Switch Circuits - Test - Air Filter Restriction Switch...1182
  Switch Circuits - Test - Multiposition Throttle Switch...1186
  Switch Circuits - Test - Engine Oil Pressure Switch...1190
  Valve Position - Test...1196
  Water in Fuel - Test...1203
  Service Tool Features...1209
  Service Tool Error Identifiers...1246
  Customer Passwords...1253
  Factory Passwords...1254
  ECM Will Not Accept Factory Passwords...1256
  Electronic Service Tool Does Not Communicate...1257
  Codes that Inhibit Operation of Aftertreatment System...1260
  Test ECM Mode...1263
  ECM Software - Install...1265
  ECM - Replace...1267
  Electrical Connectors - Inspect...1270
  Injector Code - Calibrate...1275
M0113757 - Systems Operation (C1.7 and C2.2 Industrial Engines)...1278
  General Information...1279
  Glossary of Electronic Control Terms...1285
  Electronic Control System Components...1291
  Cleanliness of Fuel System Components...1304
  Fuel System...1306
  Air Inlet and Exhaust System...1317
  Clean Emissions Module...1323
  Lubrication System...1325
  Cooling System...1328
  Basic Engine...1330
  Electrical System...1333
M0113757 - Testing and Adjusting (C1.7 and C2.2 Industrial Engines)...1339
  Fuel System - Inspect...1341
  Air in Fuel - Test...1342
  Finding Top Center Position for No. 1 Piston...1345
  Fuel Injection Timing - Check...1347
  Fuel Quality - Test...1349
  Fuel System - Prime...1351
  Gear Group (Front) - Time...1354
  Air Inlet and Exhaust System - Inspect...1356
  Turbocharger - Inspect...1358
  Exhaust Temperature - Test...1362
  Exhaust Cooler (NRS) - Test...1363
  Engine Crankcase Pressure (Blowby) - Test...1366
  Compression - Test...1368
  Engine Valve Lash - Inspect_Adjust...1372
  Valve Depth - Inspect...1378
  Valve Guide - Inspect...1381
  Engine Oil Pressure - Test...1383
  Engine Oil Pump - Inspect...1385
  Excessive Bearing Wear - Inspect...1389
  Excessive Engine Oil Consumption - Inspect...1390
  Cooling System - Check - Overheating...1391
  Cooling System - Inspect...1394
  Cooling System - Test...1395
  Water Temperature Regulator - Test...1403
  Water Pump - Inspect...1404
  Piston Ring Groove - Inspect...1406
  Connecting Rod - Inspect...1409
  Connecting Rod Bearings - Inspect...1411
  Main Bearings - Inspect...1412
  Cylinder Block - Inspect...1413
  Cylinder Head - Inspect...1415
  Piston Height - Inspect...1419
  Flywheel - Inspect...1422
  Flywheel Housing - Inspect...1425
  Gear Group - Inspect...1428
  Alternator - Test...1430
  Battery - Test...1432
  Charging System - Test...1433
  Coolant Temperature Switch - Test - Coolant Temperature Sensor...1434
  Electric Starting System - Test...1435
  Engine Oil Pressure Switch - Test...1436
  Glow Plugs - Test...1437
M0113762 - Disassembly and Assembly (C1.7 and C2.2 Industrial Engines)...1440
  Fuel Filter Base - Remove and Install - Secondary Fuel Filter...1443
  Fuel Manifold (Rail) - Remove and Install - 3 Cylinder Engines...1451
  Fuel Injection Lines - Remove and Install - 3 Cylinder Engines...1459
  Exhaust Cooler (NRS) - Remove and Install - 3 Cylinder Engines...1468
  Throttle Valve (Intake Air) - Remove...1480
  Throttle Valve (Intake Air) - Install...1483
  Fuel Injection Pump - Remove...1486
  Fuel Injection Pump - Install...1490
  Fuel Injection Pump Gear - Remove...1496
  Fuel Injection Pump Gear - Install...1499
  Fuel Injector - Remove and Install...1502
  Turbocharger - Remove - 3 Cylinder Engines...1509
  Turbocharger - Install - 3 Cylinder Engines...1514
  Exhaust Gas Recirculation Valve - Remove and Install...1521
  Clean Emissions Module - Remove and Install...1527
  Exhaust Manifold - Remove and Install - 3 Cylinder Engines...1537
  Exhaust Elbow - Remove and Install - Exhaust Elbow between the Turbocharger and the Clean Emissions Module (CEM)...1541
  Support and Mounting (CEM) - Remove and Install...1544
  Inlet Manifold - Remove and Install - 3 Cylinder Engines...1551
  Inlet and Exhaust Valve Springs - Remove and Install...1559
  Inlet and Exhaust Valves - Remove and Install...1565
  Engine Oil Line - Remove and Install...1573
  Engine Oil Cooler - Remove and Install...1579
  Engine Oil Relief Valve - Remove and Install...1584
  Engine Oil Pump - Remove - 3 Cylinder Engines...1587
  Engine Oil Pump - Install...1595
  Water Pump - Remove and Install...1605
  Water Temperature Regulator Housing - Remove and Install...1612
  Engine Lifting Bracket - Remove and Install...1620
  Flywheel - Remove and Install...1622
  Crankshaft Rear Seal - Remove and Install...1628
  Crankshaft Rear Seal - Remove and Install - Engines Without a Back Plate...1632
  Crankshaft Wear Sleeve (Rear) - Remove and Install...1635
  Flywheel Housing - Remove and Install...1640
  Crankshaft Pulley - Remove and Install...1644
  Crankshaft Pulley - Remove and Install - Multi V-Belt...1650
  Crankshaft Front Seal - Remove and Install...1655
  Housing (Front) - Remove...1659
  Housing (Front) - Install...1664
  Crankcase Breather - Remove and Install - C1.7...1670
  Valve Mechanism Cover - Remove and Install - C1.7...1679
  Rocker Shaft and Pushrod - Remove...1687
  Rocker Shaft - Disassemble...1691
  Rocker Shaft - Assemble...1694
  Rocker Shaft and Pushrod - Install...1697
  Cylinder Head - Remove - C1.7...1701
  Cylinder Head - Install - C1.7...1705
  Lifter Group - Remove and Install...1710
  Camshaft - Remove...1713
  Camshaft - Disassemble...1716
  Camshaft - Assemble...1718
  Camshaft - Install...1720
  Engine Oil Pan - Remove and Install - Cast Iron Engine Oil Pan only...1724
  Engine Oil Pan - Remove and Install - Steel Engine Oil Pan only...1728
  Pistons and Connecting Rods - Remove...1732
  Pistons and Connecting Rods - Disassemble...1735
  Pistons and Connecting Rods - Assemble...1741
  Pistons and Connecting Rods - Install...1747
  Connecting Rod Bearings - Remove - Connecting rods in position...1751
  Connecting Rod Bearings - Install - Connecting rods in position...1753
  Crankshaft Main Bearings - Remove...1756
  Crankshaft Main Bearings - Install...1762
  Crankshaft - Remove...1769
  Crankshaft - Install...1772
  Crankshaft Gear - Remove and Install...1777
  Bearing Clearance - Check...1781
  Primary Engine Speed_Timing Sensor - Remove and Install...1784
  Secondary Engine Speed_Timing Sensor - Remove and Install...1787
  Coolant Temperature Sensor - Remove and Install...1790
  Engine Oil Pressure Sensor - Remove and Install - 3 Cylinder Engines Only...1793
  Fuel Temperature Sensor - Remove and Install...1796
  Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor For Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF)...1800
  Pressure Sensor (DPF) - Remove and Install - Differential Pressure Sensor and Tube Assemblies...1804
  Boost Pressure Sensor - Remove and Install...1811
  Inlet Manifold Temperature Sensor - Remove and Install...1814
  Glow Plugs - Remove and Install...1816
  V-Belts - Remove and Install...1819
  Electronic Control Module - Remove and Install - Mounted Off Engine...1823
  Alternator - Remove and Install - Flat-Belt...1827
  Alternator - Remove and Install - V-Belt...1839
  Electric Starting Motor - Remove and Install...1846
M0113799 - Specifications (C1.7 and C2.2 Industrial Engines)...1850
  Engine Design...1852
  Fuel Injection Lines...1854
  Fuel Injection Pump...1856
  Fuel Filter Base - Secondary Fuel Filter Base...1858
  Fuel Manifold (Rail)...1860
  Lifter Group...1862
  Rocker Shaft...1863
  Valve Mechanism Cover...1866
  Cylinder Head Valves...1868
  Cylinder Head...1873
  Turbocharger...1877
  Exhaust Gas Valve (NRS) - Throttle Valve...1882
  Exhaust Gas Valve (NRS)...1883
  Exhaust Cooler (NRS)...1885
  Inlet Manifold...1886
  Exhaust Manifold...1888
  Camshaft...1889
  Engine Oil Lines...1892
  Engine Oil Filter...1894
  Engine Oil Relief Valve...1895
  Engine Oil Pump...1897
  Engine Oil Pan...1900
  Crankcase Breather...1902
  Water Temperature Regulator...1903
  Cylinder Block...1906
  Crankshaft...1908
  Connecting Rod Bearing Journal...1911
  Main Bearing Journal...1912
  Connecting Rod...1913
  Piston and Rings...1915
  Housing (Front)...1919
  Gear Group (Front)...1922
  Flywheel...1924
  Flywheel Housing...1925
  Crankshaft Pulley...1926
  Belt Tension Chart...1927
  Fan Drive...1928
  Engine Lifting Bracket...1929
  Alternator and Regulator...1930
  Electric Starting Motor...1933
  Coolant Temperature Sensor...1935
  Engine Oil Pressure Switch...1936
  Inlet Manifold Temperature Sensor...1937
  Inlet Manifold Temperature and Pressure Sensor...1938
  Temperature Sensor (DPF Inlet)...1939
  Temperature Sensor (DOC Inlet)...1940
  Speed_Timing Sensor...1941
  Glow Plugs...1943
 
Caterpillar C1.7 and C2.2 Industrial Engines Repair Service Manual