Complete service repair manual contains service, maintenance, and troubleshooting information for the Caterpillar C7 Engines. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Caterpillar C7 Diesel Engines is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

RENR7933 - Schematic (C7 Industrial Engine Electrical System).pdf
ERENR9218 - Disassembly & Assembly (C7 Engines for Caterpillar Built Machines).pdf
SENR9938 - Specifications (C7 Engines for Caterpillar Built Machines).pdf
SENR9939 - Systems Operation (C7 Engines for Caterpillar Built Machines).pdf
SENR9939 - Testing & Adjusting (C7 Engines for Caterpillar Built Machines).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
RENR7691 - Schematic (C7 On-Highway Engine Electrical System).pdf
RENR7872 - Schematic (C7 On-Highway Engine Electrical System).pdf
RENR7913 - Schematic (C7 On-Highway Engine Electrical System).pdf
SEBP4436 - Parts Manual (C7 Industrial Engine).pdf
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display).pdf
SEBU7766 - Operation & Maintenance Manual (C7 On-highway Engine).pdf
SEBU7926 - Operation & Maintenance Manual (C7 Urban Transit Bus Engines).pdf
SEBU8089 - Operation & Maintenance Manual (C7 Industrial Engine).pdf
...
 RENR7458 - Disassembly & Assembly (C7 On-Highway Engine)
 RENR7571 - Specifications (C7 On-highway Engine)
 RENR7572 - Systems Operation, Testing & Adjusting (C7 On-highway Engine)
 RENR7691 - Schematic (C7 On-Highway Engine Electrical System)
 RENR7872 - Schematic (C7 On-Highway Engine Electrical System)
 RENR7913 - Schematic (C7 On-Highway Engine Electrical System)
 RENR7933 - Schematic (C7 Industrial Engine Electrical System)
 RENR9218 - Disassembly & Assembly (C7 Engines for Caterpillar Built Machines)
    Air Inlet Heater Solenoid - Remove and Install
    Alternator - Remove and Install
    Atmospheric Pressure Sensor - Remove and Install
    Bearing Clearance - Check
    Camshaft Bearings - Remove and Install
    Camshaft Gear - Remove and Install
    Camshaft Idler Gear - Remove and Install
    Camshaft - Install
    Camshaft - Remove
    Connecting Rod Bearings - Install
    Connecting Rod Bearings - Remove
    Coolant Temperature Sensor - Remove and Install
    Crankshaft Front Seal - Install
    Crankshaft Front Seal - Remove
    Crankshaft Gear - Remove and Install
    Crankshaft - Install
    Crankshaft Main Bearings - Install
    Crankshaft Main Bearings - Remove
    Crankshaft Rear Seal - Install
    Crankshaft Rear Seal - Remove
    Crankshaft - Remove
    Cylinder Head - Install
    Cylinder Head - Remove
    Electric Starting Motor - Remove and Install
    Electronic Control Module - Remove and Install
    Engine Oil Filter Base and Oil Cooler - Install
    Engine Oil Filter Base and Oil Cooler - Remove
    Engine Oil Filter Base - Assemble
    Engine Oil Filter Base - Disassemble
    Engine Oil Pan - Remove and Install
    Engine Oil Pressure Sensor - Remove and Install
    Engine Oil Pump - Assemble
    Engine Oil Pump - Disassemble
    Engine Oil Pump - Install
    Engine Oil Pump - Remove
    Exhaust Manifold - Remove and Install
    Fan Drive Mounting Group - Remove and Install
    Flywheel Housing - Remove and Install
    Flywheel - Install
    Flywheel - Remove
    Front Cover - Remove and Install
    Fuel Filter Base - Remove and Install
    Fuel Pressure Sensor - Remove and Install
    Fuel Transfer Pump - Install
    Fuel Transfer Pump - Remove
    Housing (Front) - Install
    Housing (Front) - Remove
    Injection Actuation Pressure Sensor - Remove and Install
    Inlet Air Temperature Sensor - Remove and Install
    Inlet and Exhaust Valve Guides - Remove and Install
    Inlet and Exhaust Valve Seat Inserts - Remove and Install
    Inlet and Exhaust Valves - Remove and Install
    Inlet Manifold - Install
    Inlet Manifold - Remove
    Lifter Group - Remove and Install
    Piston Cooling Jets - Remove and Install
    Pistons and Connecting Rods - Assemble
    Pistons and Connecting Rods - Disassemble
    Pistons and Connecting Rods - Install
    Pistons and Connecting Rods - Remove
    Rocker Shaft and Pushrod - Install
    Rocker Shaft and Pushrod - Remove
    Rocker Shaft - Assemble
    Rocker Shaft - Disassemble
    SpeedTiming Sensor - Remove and Install
    Turbocharger - Install
    Turbocharger Outlet Pressure Sensor - Remove and Install
    Turbocharger - Remove
    Unit Injector Hydraulic Pump - Install
    Unit Injector Hydraulic Pump - Remove
    Unit Injector - Install
    Unit Injector - Remove
    Unit Injector Sleeve - Install
    Unit Injector Sleeve - Remove
    Valve Mechanism Cover Base - Remove and Install
    Valve Mechanism Cover - Remove and Install
    Vibration Damper and Pulley - Remove and Install
    Water Pump - Assemble
    Water Pump - Disassemble
    Water Pump - Install
    Water Pump - Remove
    Water Temperature Regulator - Remove and Install
 SEBP4436 - Parts Manual (C7 Industrial Engine)
 SEBU6875 - Owner's Manual (Caterpillar Driver Information Display)
 SEBU7766 - Operation & Maintenance Manual (C7 On-highway Engine)
 SEBU7926 - Operation & Maintenance Manual (C7 Urban Transit Bus Engines)
 SEBU8089 - Operation & Maintenance Manual (C7 Industrial Engine)
 SENR9938 - Specifications (C7 Engines for Caterpillar Built Machines)
    Air Inlet Elbow 1
    Air Inlet Elbow 2
    Air Inlet Elbow 3
    Air Inlet Elbow 4
    Air Inlet Elbow 5
    Air Inlet Elbow 6
    Air Inlet Elbow 7
    Air Inlet Heater
    Alternator and Regulator 1
    Alternator and Regulator 2
    Alternator and Regulator 3
    Alternator and Regulator 4
    Alternator and Regulator 5
    Atmospheric Pressure Sensor 1
    Atmospheric Pressure Sensor 2
    Atmospheric Pressure Sensor 3
    Belt Tensioner 1
    Belt Tensioner 2
    Belt Tensioner 3
    Belt Tensioner 4
    Belt Tensioner 5
    Belt Tensioner 6
    Boost Pressure Sensor 1
    Boost Pressure Sensor 2
    Boost Pressure Sensor 3
    Camshaft 1
    Camshaft 2
    Camshaft 3
    Camshaft 4
    Connecting Rod 1
    Connecting Rod 2
    Connecting Rod 3
    Connecting Rod 4
    Connecting Rod Bearing Journal 2
    Connecting Rod Bearing Journal
    Coolant Temperature Sensor 1
    Coolant Temperature Sensor 2
    Coolant Temperature Sensor 3
    Crankcase Breather 1
    Crankcase Breather 2
    Crankshaft 1
    Crankshaft 2
    Crankshaft Pulley 1
    Crankshaft Pulley 2
    Crankshaft Pulley 3
    Crankshaft Seals 1
    Crankshaft Seals 2
    Crankshaft Seals 3
    Crankshaft Seals 4
    Cylinder Block 1
    Cylinder Block 2
    Cylinder Block 3
    Cylinder Block Cover Group 1
    Cylinder Block Cover Group 2
    Cylinder Block Cover Group 3
    Cylinder Head 1
    Cylinder Head 2
    Cylinder Head Valves 1
    Cylinder Head Valves 2
    Cylinder Head Valves 3
    Cylinder Head Valves 4
    Cylinder Head Valves 5
    Cylinder Head Valves 6
    Electric Starting Motor 1
    Electric Starting Motor 2
    Electric Starting Motor 3
    Electric Starting Motor 4
    Electric Starting Motor 5
    Electric Starting Motor 6
    Electric Starting Motor 7
    Electronic Control Unit
    Electronic Unit Injector 1
    Electronic Unit Injector 2
    Engine Design
    Engine Oil Filter Base 1
    Engine Oil Filter Base 2
    Engine Oil Filter Base 3
    Engine Oil Filter Base 4
    Engine Oil Filter Base - Remote Oil Filter 5
    Engine Oil Filter Base - Remote Oil Filter 6
    Engine Oil Filter Base - Remote Oil Filter
    Engine Oil Lines
    Engine Oil Pan 1
    Engine Oil Pan 2
    Engine Oil Pan 3
    Engine Oil Pan 4
    Engine Oil Pan 5
    Engine Oil Pan 6
    Engine Oil Pan 7
    Engine Oil Pan 8
    Engine Oil Pan 9
    Engine Oil Pressure Sensor 1
    Engine Oil Pressure Sensor 2
    Engine Oil Pressure Sensor
    Engine Oil Pump 1
    Engine Oil Pump 2
    Engine Oil Pump - Gerotor Pump
    Exhaust Manifold 1
    Exhaust Manifold 2
    Exhaust Manifold 3
    Exhaust Manifold 4
    Fan Drive Mounting Group 1
    Fan Drive Mounting Group 2
    Fan Drive Mounting Group 3
    Fan Drive Mounting Group 4
    Fan Drive Mounting Group 5
    Fan Drive Mounting Group 6
    Flywheel 1
    Flywheel 2
    Flywheel 3
    Flywheel 4
    Flywheel 5
    Flywheel 6
    Flywheel Housing 1
    Flywheel Housing 2
    Flywheel Housing 3
    Flywheel Housing 4
    Flywheel Housing 5
    Flywheel Housing 6
    Flywheel Housing 7
    Front Housing and Covers 1
    Front Housing and Covers 2
    Front Housing and Covers 3
    Fuel Filter and Water Separator 1
    Fuel Filter and Water Separator 2
    Fuel Filter Base 1
    Fuel Filter Base 2
    Fuel Filter Base 3
    Fuel Filter Base 4
    Fuel Filter Base 5
    Fuel Pressure Sensor 1
    Fuel Pressure Sensor 2
    Fuel Pressure Sensor 3
    Fuel Pressure Sensor 4
    Fuel Priming Pump
    Gear Group (Front) 1
    Gear Group (Front) 2
    Injection Actuation Pressure Sensor 1
    Injection Actuation Pressure Sensor 2
    Injection Actuation Pressure Sensor 3
    Inlet Air Temperature Sensor 1
    Inlet Air Temperature Sensor 2
    Inlet Air Temperature Sensor 3
    Inlet Manifold 1
    Inlet Manifold 2
    Lifter Group
    Magnetic Switch 1
    Magnetic Switch 2
    Magnetic Switch 3
    Main Bearing Journal 1
    Main Bearing Journal 2
    Muffler 1
    Muffler 2
    Muffler 3
    Piston and Rings 1
    Piston and Rings 2
    Piston and Rings 3
    Piston and Rings 4
    Piston and Rings 5
    Piston Cooling Jet 1
    Piston Cooling Jet 2
    Piston Cooling Jet 3
    Rear Seal Carrier
    SpeedTiming Sensor
    Turbocharger 1
    Turbocharger 2
    Turbocharger 3
    Turbocharger 4
    Turbocharger 5
    Turbocharger 6
    Turbocharger Adapter
    Unit Injector Hydraulic Pump 1
    Unit Injector Hydraulic Pump 2
    Unit Injector Hydraulic Pump 3
    Unit Injector Hydraulic Pump 4
    Unit Injector Hydraulic Pump 5
    Valve Mechanism 1
    Valve Mechanism 2
    Valve Mechanism 3
    Valve Mechanism Cover 10
    Valve Mechanism Cover 11
    Valve Mechanism Cover 12
    Valve Mechanism Cover 4
    Valve Mechanism Cover 5
    Valve Mechanism Cover 6
    Valve Mechanism Cover 7
    Valve Mechanism Cover 8
    Valve Mechanism Cover 9
    Vibration Damper 1
    Vibration Damper 2
    Vibration Damper 3
    Vibration Damper 4
    Vibration Damper 5
    Water Line 1
    Water Line 2
    Water Line 3
    Water Pump 1
    Water Pump 2
    Water Pump 3
    Water Pump 4
    Water Pump 5
    Water Pump 6
    Water Pump 7
    Water Temperature Regulator 1
    Water Temperature Regulator 2
    Water Temperature Regulator 3
    Water Temperature Regulator 4
 SENR9939 - Systems Operation (C7 Engines for Caterpillar Built Machines)
    Air Inlet and Exhaust System
    Basic Engine
    Cooling System
    Electrical System
    Electronic Control System Components
    Fuel System
    General Information
    Lubrication System
 SENR9939 - Testing & Adjusting (C7 Engines for Caterpillar Built Machines)
     Aftercooler - Test
     Air in Fuel - Test
     Air Inlet and Exhaust System - Inspect
     Battery - Test
     Charging System - Test
     Compression - Test
     Connecting Rod Bearings - Inspect
     Cooling System - Check - Overheating
     Cooling System - Inspect
     Cooling System - Test
     Cylinder Block - Inspect
     Electric Starting System - Test
     Electronic Unit Injector - Test
     Engine Crankcase Pressure (Blowby) - Test
     Engine Oil Pressure - Test
     Engine Oil Pump - Inspect
     Engine Valve Lash - InspectAdjust
     Excessive Bearing Wear - Inspect
     Excessive Engine Oil Consumption - Inspect
     Exhaust Temperature - Test
     Finding Top Center Position for No. 1 Piston
     Flywheel Housing - Inspect
     Flywheel - Inspect
     Fuel Quality - Test
     Fuel System - Inspect
     Fuel System Pressure - Test
     Fuel System - Prime
     Gear Group (Front) - Time
     Increased Engine Oil Temperature - Inspect
     Inlet Manifold Pressure - Test
     Main Bearings - Inspect
     Pinion Clearance - Adjust
     Piston Ring Groove - Inspect
     Turbocharger - Inspect
     Vibration Damper - Check
     Water Pump - Test
     Water Temperature Regulator - Test

4 directories, 346 files

EXCERPT:
Component Description
Hydraulic Electronic Unit Injector
The HEUI fuel system utilizes a hydraulically actuated electronically controlled unit injector (5).
All fuel systems for diesel engines use a plunger and barrel in order to pump fuel under high pressure into the combustion chamber. This fuel is pumped into the combustion chamber in precise amounts in order to control engine performance. The HEUI uses engine oil under high pressure in order to power the plunger. All other fuel systems use a fuel injection pump camshaft lobe in order to power the plunger.
Because the HEUI is much different, a technician must use different troubleshooting methods.
The HEUI uses engine lubrication oil that is pressurized from 6 MPa (870 psi) to 28 MPa (4050 psi) in order to pump fuel from the injector.
The HEUI operates in the same way as a hydraulic cylinder in order to multiply the force of the high pressure oil. By multiplying the force of the high pressure oil, the HEUI can produce injection pressures that are very high. This multiplication of pressure is achieved by applying the force of the high pressure oil to a piston. The piston is larger than the plunger by approximately six times. The piston that is powered by engine lubrication oil under high pressure pushes on the plunger. This engine lubrication oil under high pressure is called the actuation pressure of the oil. The actuation pressure of the oil generates the injection pressure that is delivered by the unit injector. Injection pressure is greater than actuation pressure of the oil by approximately six times.
Low actuation pressure of the oil results in low injection pressure of the fuel. During conditions of low speed such as idle and start, low injection pressure is utilized.
High actuation pressure of the oil results in high injection pressure of the fuel. During conditions of high speed such as high idle and acceleration, high injection pressure is utilized.
...
Water Temperature Regulator - Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.
Illustration 54 g01152619
2. Remove bolts (1), pipe (2), and the gasket from water temperature regulator housing (3).
3. Remove the water temperature regulators.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
...

Caterpillar C7 Engines Workshop Repair & Service Manual