Cat Caterpillar C7 C7.1 C7.2 C9 C9.3 Engine Service Repair Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your engine. Read and print pages, or copy the entire manual to your hard drive.

MODEL COVERS:

 ENGINE - GENERATOR SET:

C7 POWER PACKAGE PGZ
C7.1 GENERATOR SET ETG
C7.1 GENERATOR SET MRP

ENGINE - INDUSTRIAL:
C7 INDUSTRIAL ENGINE JKL
C7 INDUSTRIAL ENGINE JRA
C7 INDUSTRIAL ENGINE JTF
C7 INDUSTRIAL ENGINE PRY
C7 INDUSTRIAL ENGINE TEF
C7.1 INDUSTRIAL ENGINE 673
C7.1 INDUSTRIAL ENGINE 770
C7.1 INDUSTRIAL ENGINE 881
C7.1 INDUSTRIAL ENGINE G9R

ENGINE - MACHINE:
C7 ENGINE - MACHINE C7C
C7 ENGINE - MACHINE KHX
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
C7.2 ENGINE - MACHINE KHX

ENGINE - TRUCK:
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:
C7 MARINE ENGINE C7B
C7 MARINE ENGINE C7D
C7 MARINE ENGINE C7X
C7 MARINE ENGINE C7Z
C7 MARINE ENGINE M7A
C7 MARINE ENGINE M7G
C7.1 GENERATOR SET JME

PETROLEUM PRODUCTS:
C7 PETROLEUM ENGINE C7P
C7 PETROLEUM ENGINE K2A
C7 PETROLEUM ENGINE P7L

ENGINE - GENERATOR SET:
C9 GENERATOR SET C9E
C9 GENERATOR SET NBP
C9 GENERATOR SET NGP
C9 GENERATOR SET X3R

ENGINE - INDUSTRIAL:
C-9 INDUSTRIAL ENGINE CLJ
C9 INDUSTRIAL ENGINE JLW
C9 INDUSTRIAL ENGINE JSC
C9 INDUSTRIAL ENGINE MBD
C9 INDUSTRIAL ENGINE MNK
C9 INDUSTRIAL ENGINE REH
C9.3 INDUSTRIAL ENGINE C9N
C9.3 INDUSTRIAL ENGINE CS9
C9.3 INDUSTRIAL ENGINE D9N

ENGINE - MACHINE:
C-9 ENGINE - MACHINE 4ZF
C-9 ENGINE - MACHINE 7AZ
C-9 ENGINE - MACHINE CLJ
C-9 ENGINE - MACHINE SAN
C9 ENGINE - MACHINE THX
C9 ENGINE - MACHINE THY
C9 ENGINE - MACHINE TXD
C9.3 ENGINE - MACHINE MME
C9.3 ENGINE - MACHINE MYE
C9.3 ENGINE - MACHINE SSE
C9.3 ENGINE - MACHINE SYE
C9.3 ENGINE - MACHINE WDB
C9.3 ENGINE - MACHINE WYE

ENGINE - TRUCK:
C-9 TRUCK ENGINE MFF
C-9 TRUCK ENGINE MTB
C9 TRUCK ENGINE 9DG
C9 TRUCK ENGINE C9S
C9 TRUCK ENGINE CKP
C9 TRUCK ENGINE ETK
C9 TRUCK ENGINE LFE
C9 TRUCK ENGINE LFR
C9 TRUCK ENGINE SRB

MARINE PRODUCTS:
C9 GENERATOR SET SJB
C9 MARINE ENGINE C9A
C9 MARINE ENGINE C9B
C9 MARINE ENGINE C9Y
C9 MARINE ENGINE CSN
C9 MARINE ENGINE X9X
C9 MARINE ENGINE X9Y
C9 MARINE ENGINE Z9X

PETROLEUM PRODUCTS:
C9 PETROLEUM ENGINE KLW
C9 PETROLEUM ENGINE KLX
C9 PETROLEUM ENGINE P7Z
C9 PETROLEUM ENGINE P9L
C9 PETROLEUM ENGINE P9W

MANUAL COVERS:

• General Information
• Disassembly & Assembly (C7.1 Engines for Caterpillar Built Machines)\
• Troubleshooting (C7.1 Engines For Caterpillar Built Machines)\
• Specifications (C7.1 Engines for Caterpillar Built Machines)\
• Systems Operation (C7.1 Engines for Caterpillar Built Machines)\
• Testing & Adjusting (C7.1 Engines for Caterpillar Built Machines)\
• Schematic (Marine Multi-Station Control System II Electrical System - Typical Dual Engine Installation)\
• Schematic (AP1000E & BG1000E Wheel Type, AP1055E & BG1055E Track Type Asphalt Paver Electrical System)\
• Disassembly & Assembly (AP1000E & BG1000E Asphalt Pavers Engine Supplement)\
• Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)\
• Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)\
• Schematic (C9 Urban Transit Bus Engine Electrical System)\
• Systems Operation (Marine Multi-Station Control System)\
• Testing & Adjusting (Marine Multi-Station Control System)\
• Troubleshooting (Marine Multi-Station Control System)\
• Schematic (C9 Generator Set with EMCP 3 Electrical System)\
• Schematic (Marine Multi-Station Control System Electrical System - Typical Single Engine Installation)\
• Schematic (Marine Multi-Station Control System Electrical System - Typical Dual Engine Installation)\
• Disassembly & Assembly (C9 Generator Set Engine)\
• Troubleshooting (C7 & C9 Marine Engines)\
• Schematic (C9 Marine Engine Electrical System)\
• Troubleshooting (C9 Generator Set Engines)\
• Systems Operation (Fundamentals Electrical System for All Caterpillar Products)\
• Torque Specifications\
• Schematic - Fluid Power & Electrical Graphic Symbols\
• Specifications (C9 Marine Engines & C9 Marine Generator Sets)\
• Systems Operation (C9 Marine Engines & C9 Marine Generator Sets)\
• Testing & Adjusting (C9 Marine Engines & C9 Marine Generator Sets)\
• Disassembly & Assembly (C9 Marine Engines & C9 Marine Generator Sets)\
• Specifications (C9 Generator Set Engines)\
• Systems Operation (C9 Generator Set Engines)\
• Testing & Adjusting (C9 Generator Set Engines)\
• Disassembly & Assembly - Seal Installation\
• Schematic (C9 Generator Set with EMCP 4 Electrical System)\
• X Bonus_Material\
• Special Instruction - Installation of Cat Messenger for On-highway Engines
• Electronic PTO Installation & Application Guide (On-Highway Engines)
• Disassembly & Assembly (C7 On-Highway Engine)
• Specifications (C7 On-highway Engine)
• Systems Operation, Testing & Adjusting (C7 On-highway Engine)
• Schematic (C7 On-Highway Engine Electrical System)
• Schematic (C7 On-Highway Engine Electrical System)
• Schematic (C7 On-Highway Engine Electrical System)
• Applied Failure Analysis - Engine Valve Failure Modes(1100, 1105)
• Owner's Manual (Caterpillar Driver Information Display)
• Operation & Maintenance Manual (C7 On-highway Engine)
• Operation & Maintenance Manual (C7 Urban Transit Bus Engines)
• Product Safety
• Specifications - Torque Specifications
• Specifications (Torque Specifications for All Caterpillar Products)
• Troubleshooting (C7, C9 On-highway Engines)
• Air Compressor - Remove and Install - Twin Cylinder Compressor
• Air Compressor - Remove and Install - Single Cylinder
• Electric Starting Motor - Remove and Install
• Alternator - Install
• Alternator - Remove
• ECM Mounting Bracket - Remove and Install
• Electronic Control Module - Remove and Install - Electronic Control Module With Banjo Bolt Connections
• Electronic Control Module - Remove and Install - Electronic Control Module With Quick Coupler Connections
• Fan Drive - Remove and Install
• Fan - Remove and Install
• Belt Tensioner - Remove and Install
• Idler Pulley - Remove and Install - Grooved Idler Pulle Idler Pulley - Remove and Install - Flat Idler Pulley
• Alternator Belt - Remove and Install
• Glow Plugs - Remove and Install
• Inlet Manifold Temperature Sensor - Remove and Install
• Boost Pressure Sensor - Remove and Install
• Pressure Sensor (Cooled Exhaust Gas) - Remove and Install - Differential Pressure Sensor
• Temperature Sensor (Cooled Exhaust Gas) - Remove and Install
• Pressure Sensor (DPF) - Remove and Install - Clean Emissions Module
• Temperature Sensor (DPF) - Remove and Install - Temperature Sensor (DPF) and Flame Detection Sensor
• Soot Antenna - Remove and Install
• Flame Detection Temperature Sensor - Remove and Install - Flame Detection Temperature Sensor for the ARD
• Fuel Temperature Sensor - Remove and Install
• Engine Oil Pressure Sensor - Remove and Install
• Coolant Temperature Sensor - Remove and Install
• Crankshaft Position Sensor - Remove and Install
• Camshaft Position Sensor - Remove and Install
• Atmospheric Pressure Sensor - Remove and Install
• Refrigerant Compressor - Remove and Install
• Bearing Clearance - Check
• Crankshaft Gear - Remove and Install
• Crankshaft Timing Ring - Remove and Install
• Crankshaft - Install
• Crankshaft - Remove
• Crankshaft Main Bearings - Remove and Install - Crankshaft in position
• Connecting Rod Bearings - Install - Connecting rods in position
• Connecting Rod Bearings - Remove - Connecting rods in position
• Pistons and Connecting Rods - Install
• Pistons and Connecting Rods - Assemble
• Pistons and Connecting Rods - Disassemble
• Pistons and Connecting Rods - Remove
• Piston Cooling Jets - Remove and Install
• Engine Oil Pan Plate - Remove and Install - Aluminum Oil Pan
• Engine Oil Pan - Install - Aluminum Oil Pan
• Engine Oil Pan - Remove - Aluminum Oil Pan
• Camshaft Bearings - Remove and Install
• Camshaft Gear - Remove and Install
• Camshaft - Remove and Install
• Lifter Group - Remove and Install - Hydraulic Lifter Group
• Cylinder Head - Install
• Cylinder Head - Remove
• Rocker Shaft and Pushrod - Install
• Rocker Shaft - Assemble
• Rocker Shaft - Disassemble
• Rocker Shaft and Pushrod - Remove
• Valve Mechanism Cover - Remove and Install
• Crankcase Breather - Install
• Crankcase Breather - Remove
• Accessory Drive - Remove and Install - Accessory Drive SAE A
• Accessory Drive - Remove and Install - Accessory Drive SAE B
• Housing (Front) - Install - Heavy Duty Housing (Front)
• Housing (Front) - Install
• Housing (Front) - Remove
• Housing (Front) - Remove - Heavy Duty Housing (Front)
• Idler Gear - Install
• Idler Gear - Remove
• Gear Group (Front) - Remove and Install
• Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)
• Front Cover - Remove and Install
• Front Cover - Remove and Install - Heavy Duty Front Cover
• Crankshaft Front Seal - Remove and Install
• Vibration Damper and Pulley - Install
• Vibration Damper and Pulley - Remove
• Rear Power Take-Off (RPTO) - Install
• Rear Power Take-Off (RPTO) - Remove
• Flywheel Housing - Remove and Install
• Flywheel Housing - Remove and Install - Type A, B, C, and D Wet Back-End Housing
• Flywheel Housing - Remove and Install - Flywheel Housing that is Equipped with Rear Power Take-Off
• Flywheel Housing - Remove and Install - Standard Housing
• Crankshaft Rear Seal - Install
• Crankshaft Rear Seal - Remove
• Flywheel - Install
• Flywheel - Install - Equipped with Rear Power Take-Off.pdf
• Flywheel - Remove.pdf
• Flywheel - Remove - Equipped with Rear Power Take-Off
• Water Temperature Regulator - Remove and Install.
• Water Pump - Install
• Water Pump - Remove
• Engine Oil Pump - Install
• Engine Oil Pump - Remove
• Engine Oil Cooler - Install - Engine Oil Cooler with a Low Mounted Filter Base
• Engine Oil Cooler - Install - Engine Oil Cooler with a High Mounted Filter Base
• Engine Oil Cooler - Remove - Engine Oil Cooler with a Low Mounted Filter Base
• Engine Oil Cooler - Remove - Engine Oil Cooler with a High Mounted Filter Base
• Engine Oil Filter Base - Remove and Install - Engine Oil Filter Base with Adapter
• Engine Oil Filter Base - Remove and Install
• Inlet and Exhaust Valves - Remove and Install
• Inlet and Exhaust Valve Springs - Remove and Install
• Catalyst - Remove and Install - Diesel Oxidation Catalyst (DOC)
• Diesel Particulate Filter - Install
• Diesel Particulate Filter - Assemble
• Diesel Particulate Filter - Disassemble
• Diesel Particulate Filter - Remove
• Exhaust Manifold - Remove and Install
• Flexible Exhaust Pipe - Remove and Install
• Relay (ARD Nozzle Heater) - Remove and Install - Clean Emissions Module
• Combustion Head - Remove and Install - Pilot Only System
• Ignition Coil (ARD) - Remove and Install - Clean Emissions Module
• ARD Spark Plug - Remove and Install
• Nozzle Heater Harness - Remove and Install - Heated Nozzle Connection
• Air Control Valve - Remove and Install - Clean Emissions Module
• Wastegate Solenoid - Remove and Install
• Turbocharger - Install - First Stage Turbocharger 2
• Turbocharger - Install - Second Stage Turbocharger 2
• Turbocharger - Install - Second Stage Turbocharger 1
• Turbocharger - Install - First Stage Turbocharger 1
• Turbocharger - Remove - Second Stage Turbocharger
• Turbocharger - Remove - First Stage Turbocharger
• Electronic Unit Injector - Install
• Electronic Unit Injector - Remove
• Fuel Injection Pump Gear - Install
• Fuel Injection Pump Gear - Remove
• Fuel Injection Pump - Install
• Fuel Injection Pump - Remove
• Throttle Valve (Intake Air) - Install
• Throttle Valve (Intake Air) - Remove
• Inlet Air Control - Install - NRS Inlet Air Mixer
• Inlet Air Control - Remove - NRS Inlet Air Mixer
• Exhaust Cooler (NRS) - Remove and Install
• Fuel Injection Lines - Install
• Fuel Injection Lines - Remove
• Fuel Manifold (ARD) - Remove and Install - Pilot Solenoid Only
• Fuel Pump (ARD) - Remove and Install
• Relief Valve (Fuel) - Remove and Install
• Fuel Manifold (Rail) - Remove and Install
• Water Separator and Fuel Filter (Primary) - Remove and Install
• Fuel Filter Base - Remove and Install - Twin Secondary Fuel Filter
• Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter
• Flow Control Valve - Remove and Install
• Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP)
• Air Compressor - Single Cylinder
• Air Compressor - Twin Cylinder Compressor
• Glow Plugs
• Electronic Control Wiring Group - Aftertreatment Regeneration Device
• Electronic Control Module
• SpeedTiming Sensor
• Diesel Particulate Filter Temperature and Pressure Sensor
• Temperature Sensor (NOx Reduction System)
• Pressure Sensor (NOx Reduction System).pdf
• Inlet Manifold Temperature Sensor.pdf
• Atmospheric Pressure Sensor.pdf
• Boost Pressure Sensor
• Engine Oil Pressure Sensor
• Coolant Temperature Sensor
• Starter Motor
• Alternator
• Engine Lifting Bracket
• Fan Drive
• Refrigerant Compressor
• Belt Tensioner
• Flywheel Housing
• Flywheel Housing - Flywheel Housing that is Equipped with Rear Power Take-Off
• Flywheel
• Gear Group (Front)
• Front Housing and Covers
• Accessory Drive - SAE B
• Accessory Drive
• Piston Cooling Jet
• Piston and Rings
• Connecting Rod
• Main Bearing Journal
• Connecting Rod Bearing Journal
• Vibration Damper and Pulley
• Crankshaft Seals
• Crankshaft
• Cylinder Block
• Water Pump
• Water Temperature Regulator and Housing
• Crankcase Breather
• Engine Oil Pan
• Engine Oil Pressure
• Engine Oil Pump
• Engine Oil Cooler
• Engine Oil Filter Base
• Camshaft Bearings
• Camshaft
• Fuel Manifold (ARD) - Aftertreatment Regeneration Device
• Exhaust Combustion (ARD) - Aftertreatment Regeneration Device
• Diesel Particulate Filter
• Flexible Exhaust Pipe
• Exhaust Manifold
• Exhaust Cooler (NRS)
• Exhaust Sensor and Lines (NRS)
• Exhaust Gas Valve (NRS)
• Turbocharger - Series Turbochargers
• Cylinder Head
• Cylinder Head Valves
• Valve Mechanism Cover
• Rocker Shaft
• Lifter Group
• Fuel Manifold (Rail)
• Fuel Filter Base - Twin Secondary Fuel Filter Base
• Fuel Filter Base - Single Secondary Fuel Filter Base
• Fuel Filter Base - Primary Fuel Filter Base
• Fuel Transfer Pump - Electric Transfer Pump
• Fuel Injection Nozzles
• Fuel Injection Pump
• Fuel Injection Lines
• Engine Design
• Water In Fuel Sensor - Test
• Valve Position Sensor - Test
• Soot Sensor - Test
• Solenoid Valve - Test
• Sensor Calibration Required - Test
• Motorized Valve - Test
• Injector Solenoid Circuit - Test
• Injector Data Incorrect - Test
• Indicator Lamp Circuit - Test
• Ignition Key switch Circuit and Battery Supply Circuit - Test
• Glow Plug Starting Aid - Test
• Fuel Pump Relay Circuit - Test
• Engine Temperature Sensor Open or Short Circuit - Test
• Engine Speed Timing Sensor Circuit - Test
• Engine Pressure Sensor Open or Short Circuit - Test
• Electrical Connectors - Inspect
• ECM Memory - Test
• Diesel Particulate Filter Identification Signal - Test.pdf
• Data Link Configuration Status - Test.pdf
• Data Link Circuit - Test.pdf
• Cooling Fan Control - Test
• Cooling Fan - Calibrate
• CAN Data Link Circuit - Test
• ARD Nozzle Heater - Test
• ARD Nozzle - Test
• ARD Ignition - Test
• ARD Fuel Supply - Test
• 5 Volt Sensor Supply Circuit - Test
• ECM Harness Connector Terminals
• Engine Wiring Information
• Sensors and Electrical Connectorsf
• Self-Diagnostics
• Replacing the ECM
• Indicator Lamps
• Electronic Service Tools
• Glossary
• System Overview
• Welding Precaution
• Injector Code - Calibrate
• Flash Programming
• Factory Passwords
• Test ECM Mode
• Programming Parameters
• Engine - Install
• Engine - Remove
• Clean Emissions Module - Remove and Install
• Access Cover (Expansion Tank) - Remove and Install
• Air Aftercooler - Remove and Install
• Radiator, Hydraulic Oil Cooler, and Fuel Cooler - Install
• Radiator, Hydraulic Oil Cooler, and Fuel Cooler - Assemble
• Radiator, Hydraulic Oil Cooler, and Fuel Cooler - Disassemble
• Radiator, Hydraulic Oil Cooler, and Fuel Cooler - Remove
• Gear Motor (Fan Drive) - Install
• Gear Motor (Fan Drive) - Assemble
• Gear Motor (Fan Drive) - Disassemble
• Gear Motor (Fan Drive) - Remove
• Piston Pump (Fan Drive) - Install
• Piston Pump (Fan Drive) - Assemble
• Piston Pump (Fan Drive) - Disassemble
• Piston Pump (Fan Drive) - Remove
• Fan - Remove and Install
• Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install
• Water Separator, Primary Fuel Filter, and Fuel Priming Pump - Remove and Install
• Electric Starting Motor - Remove and Install
• Alternator - Remove and Install
• Battery - Remove and Install
• Air Cleaner - Remove and Install
• System Pressure - Release
• C-7 & C-9 (KAL1-UPYPG1-UP9DG1-UP) Troubleshooting
• C-7 (KAL1-UP) Disassembly & Assembly
• C-7 (KAL1-UP) Operation & Maintenance
• C-7 (KAL1-UP) Torque Specifications
• C-7 (YPG1-UPKAL1-UP) Specifications
• C-7 (YPG1-UPKAL1-UP) Systems Operation Testing & Adjusting
• Crankcase Ventilation Systems

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English 
Format: PDF

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