engine manual c7 t3

SEBU8089-02August 2008

Operation andMaintenanceManualC7 Industrial EngineJRA1-Up (Engine)JTF1-Up (Engine)

SAFETY.CAT.COM

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by NOTICE labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

SEBU8089-02 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 7

Burn Prevention ...................................................... 9

Fire Prevention and Explosion Prevention ............ 10

Crushing Prevention and Cutting Prevention ........ 12

Mounting and Dismounting ................................... 12

Before Starting Engine .......................................... 12

Engine Starting ..................................................... 12

Engine Stopping ................................................... 13

Electrical System .................................................. 13

Engine Electronics ................................................ 14

Product Information Section

Model Views ......................................................... 15

Product Identification Information ........................ 18

Operation Section

Lifting and Storage ................................................ 19

Gauges and Indicators .......................................... 20

Features and Controls .......................................... 24

Engine Diagnostics ............................................... 27

Engine Starting ..................................................... 32

Engine Operation .................................................. 37

Engine Stopping ................................................... 38

Cold Weather Operation ....................................... 40

Maintenance Section

Refill Capacities .................................................... 42

Maintenance Recommendations .......................... 47

Maintenance Interval Schedule ............................ 49

Warranty Section

Warranty Information ............................................ 89

Reference Information Section

Engine Ratings ..................................................... 90

Customer Service ................................................. 92

Reference Materials .............................................. 94

Index Section

Index ..................................................................... 98

4 SEBU8089-02Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engines permanent record.

See the section in the Operation and MaintenanceManual, Maintenance Records for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU8089-02 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU8089-02Safety SectionSafety Messages

Safety Sectioni03203384

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messages onyour engine. The exact location and a description ofthe safety messages are reviewed in this section.Please become familiar with all safety messages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if theillustrations are not visible. Use a cloth, water,and soap to clean the safety messages. Do notuse solvents, gasoline, or other harsh chemicals.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety messages. Thesafety messages that are loosened could drop offof the engine.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partof the engine that is replaced, install a new safetymessage on the replacement part. Your Caterpillardealer can provide new safety messages.

g00986753Illustration 1(1) Universal warning label

SEBU8089-02 7Safety Section

General Hazard Information

(1) Universal Warning

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManual. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

g00934493Illustration 2

The Universal warning label is typically located oneach side of the valve cover base.

i02566298

General Hazard InformationSMCS Code: 1000; 7405


Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

Filler caps

Grease fittings

Pressure taps

Breathers

Drain plugs

Use caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

8 SEBU8089-02Safety SectionGeneral Hazard Information

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

Ensure that all protective guards and all covers aresecured in place on the engine.

Never put maintenance fluids into glass containers.Glass containers can break.

Use all cleaning solutions with care.

Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

The engine is stopped. Ensure that the enginecannot be started.

Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

Do not attempt any repairs that are not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi) when the air nozzleis deadheaded. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tools Catalog for the following items:

Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.


Burn Prevention

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01480768

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

10 SEBU8089-02Safety SectionFire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i02469590

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Fire Prevention and Explosion Prevention


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can cause anexplosion that can result in injury. Refer to thisOperation and Maintenance Manual, Starting withJump Start Cables for specific instructions.

Do not charge a frozen battery. This may cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 C(120 F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

12 SEBU8089-02Safety SectionCrushing Prevention and Cutting Prevention

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

i01372247

Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

Mount the engine and dismount the engine only atlocations that have steps and/or handholds. Do notclimb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you mount theengine or when you dismount the engine. Use a handline to raise and lower tools or supplies.

i00911989

Before Starting EngineSMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. All protectiveguards and all protective covers must be installedif the engine must be started in order to performservice procedures. To help prevent an accident thatis caused by parts in rotation, work around the partscarefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

On the initial start-up of a new engine or an enginethat has been serviced, prepare to stop the engineif an overspeed condition occurs. This may beaccomplished by shutting off the fuel supply to theengine and/or shutting off the air supply to the engine.

See the Service Manual for repairs and foradjustments.

i02136012

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.


Engine Stopping

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

If there is a possibility that unburned gas remains inthe exhaust system, refer to the purge procedure inthis Operation and Maintenance Manual, EngineStarting topic in the Operation Section.

Start the engine from the operators compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, Engine Starting topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature and the oiltemperature during heater operation.

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

i01462046

Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, EngineStopping (Operation Section) in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

To stop an electronically controlled engine, cut thepower to the engine.

i01489749

Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative jump start cable should be connectedlast from the external power source to the negative terminal of the starting motor. If the starting motoris not equipped with a negative terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

Grounding Practices


Typical exampleGrounding Stud To Battery Ground

14 SEBU8089-02Safety SectionEngine Electronics


Typical example

Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frame groundstrap with a direct path to the battery must be used.This path may be provided by way of a starting motorground, a starting motor ground to the frame, or adirect engine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative- battery terminal with a wire that is adequate tohandle the full charging current of the alternator.

i02784356

Engine ElectronicsSMCS Code: 1000; 1400; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control: WARNING, DERATE, andSHUTDOWN. These engine monitoring modes havethe ability to limit engine speed and/or the enginepower.

Many of the parameters that are monitored by theECM can be programmed for the engine monitoringfunctions. The following parameters can be monitoredas a part of the Engine Monitoring System:

Operating Altitude

Engine Coolant Level

Engine Coolant Temperature

Engine Oil Pressure

Engine Speed

Fuel Temperature

Intake Manifold Air Temperature

System Voltage

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

SEBU8089-02 15Product Information Section

Model Views

Product InformationSection

Model Viewsi02112288

Model View IllustrationsSMCS Code: 1000

g01075652Illustration 13Left side view(1) Belt tensioner(2) Lifting eyes(3) Engine oil level gauge(4) Air inlet heater relay(5) Engine control module (ECM)(6) Engine oil filler(7) Fuel priming pump(8) Fuel filter(9) Unit injector hydraulic pump(10) Air compressor(11) Crankcase breather

g01075656Illustration 14Right side view

(12) Exhaust manifold(13) Turbocharger(14) Engine oil filter(15) Alternator

i02920111

Engine DescriptionSMCS Code: 1000

The Caterpillar C7 Engine has the followingcharacteristics:

In-Line 6 cylinder

Four stroke cycle

Hydraulically Actuated Electronic Unit Injection(HEUI)

Turbocharged

Air-to-air aftercooled

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.

16 SEBU8089-02Product Information SectionModel Views

g00407141Illustration 15Cylinder and valve location(A) Exhaust valve(B) Inlet valve

Table 1

C7 Industrial Engine Specifications

Arrangement andCylinders In-Line 6 cylinder

Bore 110 mm (4.3 inch)

Stroke 127 mm (5.0 inch)

Aspiration TurbochargedATAAC(1)

Displacement 7.2 L (440 in3)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

Valve Lash (inlet) 0.38 mm (0.015 inch)

Valve Lash (exhaust) 0.64 mm (0.025 inch)(1) Air-to-air aftercooled

Electronic Engine FeaturesThe Caterpillar C7 Industrial Engines are designed forelectronic controls. The integral on board computercontrols the operation of the engine. Currentoperating conditions are monitored. The ElectronicControl Module (ECM) controls the response of theengine to these conditions and to the demands of theoperator. These conditions and operator demandsdetermine the precise control of fuel injection by theECM. The electronic engine control system providesthe following features:

Engine speed governor

Automatic air/fuel ratio control

Torque rise shaping

Injection timing control

System diagnostics

For more information on electronic engine features,refer to the Operation and Maintenance Manual,Engine Features and Controls topic (OperationSection).

Additional Features

The following additional features provide increasedengine fuel economy and serviceability:

Cold starting capability

Tampering detection

Diagnostics

Hydraulic Electronic Unit Injectors

Hydraulically Actuated Electronic Unit Injectors(HEUI) perform the following functions: pumping offuel, fuel metering, and fuel timing.

The unit injectors are controlled by the ECM whichuses the camshaft position and the engine speedsignals from the engine speed/timing sensors andthe inlet air pressure sensors. The engines rated rpmis identified on the Information Plate.

Engine Diagnostics

The engine has built-in diagnostics in order to ensurethat all of the components are functioning properly.In the event of a deviation from the programmedlimits, the operator will be alerted to the conditionby a DIAGNOSTIC lamp that is mounted on thecontrol panel. Under certain conditions, the enginehorsepower may be limited. A Caterpillar electronicservice tool may be used to display the diagnosticcode.

There are three types of diagnostic codes: active,logged, and event.

Most of the diagnostic codes are logged and storedin the ECM. For additional information, refer tothe Operation and Maintenance Manual, EngineDiagnostics topic (Operation Section).

The ECM provides an electronic governor thatcontrols the injector output in order to maintain thedesired engine rpm. The functionality of electronicgovernor is similar to the Caterpillar mechanicalgovernor.

Engine Cooling and LubricationThe cooling system consists of the followingcomponents:

SEBU8089-02 17Product Information Section

Model Views

Centrifugal pump that is driven by belts

Water temperature regulator which regulates theengine coolant temperature

Oil cooler and radiator which incorporates a shuntsystem

The engine lubricating oil that is supplied is cooled.The engine lubricating oil is also filtered. Bypassvalves provide unrestricted flow of lubrication oilto the engine components during the followingconditions:

High oil viscosity

Plugged oil cooler or plugged oil filter elements(paper cartridge)

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predicted by theaverage power that is demanded. The average powerthat is demanded is based on fuel consumption ofthe engine over a period of time. Reduced hours ofoperation at full throttle and/or operating at reducedthrottle settings result in a lower average powerdemand. Reduced hours of operation will increasethe length of operating time before an engineoverhaul is required. For more information, refer tothe Operation and Maintenance Manual, OverhaulConsiderations topic (Maintenance Section).

Aftermarket Products andCaterpillar Engines

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel, afour micron[c] absolute high efficiency fuel filter is re-quired for all Caterpillar Hydraulic Electronic Unit In-jectors. Caterpillar High Efficiency Fuel Filters meetthese requirements. Consult your Caterpillar dealerfor the proper part numbers.

When auxiliary devices, accessories, or consumables(filters, additives, catalysts, etc) which are madeby other manufacturers are used on Caterpillarproducts, the Caterpillar warranty is not affectedsimply because of such use.

However, failures that result from the installationor use of other manufacturers devices,accessories, or consumables are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.

Welding and Caterpillar ElectronicEngines

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

To help avoid damage to the electronic controls,proper welding procedures are necessary. Beforewelding on an engine that is equipped with electroniccontrols, observe the following precautions:

1. Turn off the engine. Place the key start switch inthe OFF position.

2. If the machine has a battery disconnect switch,open the switch. Otherwise, disconnect thenegative - battery cable from the battery of thevehicle.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, electrical components, and other com-ponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as closeas possible to the weld. This will help reduce the pos-sibility of damage.

3. Clamp the ground cable from the welder to thecomponent that will be welded. Place the clampas close as possible to the weld.

4. Protect wiring harnesses from welding debris andspatter. Use proper welding procedures.

18 SEBU8089-02Product Information SectionProduct Identification Information

Product IdentificationInformation

i02414123

Plate Locations and FilmLocationsSMCS Code: 1000

Engine IdentificationCaterpillar engines are identified with serial numbers,with performance specification numbers, and witharrangement numbers. In some of the cases,modification numbers are used. These numbersare shown on the Serial Number Plate and theInformation Plate that are mounted on the engine.

Caterpillar dealers need these numbers in order todetermine the components that were included withthe engine. This permits accurate identification ofreplacement part numbers.

Serial Number Plate


The Serial Number Plate is located on the right sideof the cylinder block.

The following information is stamped on the SerialNumber Plate: engine serial number, engine model,and arrangement number.

Information Plate


Typical example

The Information Plate is on the front valve cover.The following information is on the InformationPlate: engine serial number, engine model, enginearrangement number, maximum altitude of theengine that is possible to achieve the rated power,horsepower, high idle, full load rpm, fuel settings, andother information.

Emission Certification

g00284658Illustration 18Film for EPA Emission Certification

g00415538Illustration 19Film for European Emission Certification

The film for the EPA Emission Certification (ifequipped) and/or the film for the European EmissionCertification (if equipped) is located on the side ofthe engine.

SEBU8089-02 19Operation SectionLifting and Storage

Operation Section

Lifting and Storagei02055889

Product LiftingSMCS Code: 1000; 1404; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

Engine Lifting with a Fuel Tank

Lift eyes or tank can fail when lifting tank con-taining fluids resulting in possible personal injury.Drain tank of all fluids before lifting.

Lifting the engine with a fuel tank that is mountedto the engine requires special equipment andprocedures. Do not lift the unit with fuel in the fueltank. Consult your Caterpillar dealer for informationregarding fixtures for proper lifting of your completepackage.

i02068367

Product StorageSMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life.

To help prevent excessive engine wear, use thefollowing guidelines:

Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, Maintenance Interval Schedule(Maintenance Section).

If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, Refill Capacities and Recommendations(Maintenance Section).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

For more detailed information on engine storage, seeSpecial Instruction, SEHS9031, Storage ProcedureFor Caterpillar Products.

Your Caterpillar dealer can assist in preparing theengine for extended storage periods.

20 SEBU8089-02Operation SectionGauges and Indicators

Gauges and Indicatorsi01465281

Gauges and IndicatorsSMCS Code: 1900; 7450

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the literature that isprovided by the OEM.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine the cause of any significant change in thereadings. Then, correct any cause of any significantchange in the readings. Consult your Caterpillardealer for assistance.

Caterpillar requires one lamp in addition to the gaugepackage that is normally provided. The Diagnosticlamp is yellow or amber. The Diagnostic lamp willcommunicate the status of the engines electronicsystem. The optional red Warning lamp is alsoavailable. This red Warning lamp warns the operatorof engine problems.

The following conditions are some examples of theengine problems:

Low oil pressure

High coolant temperature

Low coolant level

High inlet air temperature

Engine Oil Pressure Typical oilpressure for an engine at rated speedwith SAE 10W30 or with SAE 15W40 is

240 to 480 kPa (35 to 70 psi).

A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check the oil level. Maintain the oil level at theproper amount.

If the gauge continues to fluctuate, consult yourCaterpillar dealer.

The diagnostic lamp will turn on if the oil pressuredrops below 35 kPa (5 psi) at low idle rpm. Thediagnostic code will be logged in the Engine ControlModule (ECM).

Engine Oil Temperature This gaugeindicates the engine oil temperature. Anoil temperature that is higher than normal

indicates a heat problem in the lubrication systemand/or the cooling system. This problem can damagethe cylinder heads, the cylinder liners, the pistons,and the crankshaft bearings.

Jacket Water Coolant Temperature Typical temperature range is 88 to 102 C(190 to 215 F). The maximum allowable

temperature with the pressurized cooling system is105 C (220 F). Higher temperatures may occurunder certain conditions. The water temperaturereading may vary according to load. The readingshould never exceed the boiling point for thepressurized system that is being used.

If the engine is operating above the normal rangeor steam becomes apparent, perform the followingprocedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

4. Check the coolant level.

Tachometer This gauge indicates enginespeed. When the throttle control lever ismoved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

SEBU8089-02 21Operation Section

Gauges and Indicators

Note: The default high idle rpm and the full load rpmare stamped on the Information Plate.

Ammeter This gauge indicates theamount of charge or of discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of 0(zero).

Service Hour Meter This gaugeindicates the total number of clock hoursof engine operation. Hours of operation

are logged in the ECM. A service tool is needed toretrieve the hours from the ECM. A Service HourMeter may be installed on the engine.

Fuel Pressure This gauge indicates fuelpressure to the electronic unit injectors fromthe fuel filter. The indicator should indicate

the NORMAL range. A decrease in fuel pressureusually indicates a plugged fuel filter.

Fuel Level This gauge indicates thelevel of fuel in the fuel tank. The fuel levelgauge registers the fuel level only when the

ignition switch is in the ON position.

i02238470

Engine Monitoring System(EMS)SMCS Code: 7490

g00788015Illustration 21(1) Main unit (2) Tachometer (unit) (3) Quad gauge

22 SEBU8089-02Operation SectionGauges and Indicators

The Caterpillar Engine Monitoring System (EMS) isan option. The engine parameters are displayed inboth digital display and analog. The EMS display isfor electronically controlled engines.

The EMS includes three individual gauge units. Theunits can be installed in various combinations. Themain unit must be used if any of the units are used.

For information on installation and troubleshooting,refer to Installation Guide, REHS0871.

EMS Main Unit

g00595165Illustration 22(4) Engine oil pressure(5) Engine coolant temperature(6) Fuel pressure(7) Inlet manifold temperature(8) Fuel temperature(9) Engine coolant level(10) Battery voltage(11) Active engine derate(12) Auxiliary temperature(13) Auxiliary pressure

The Engine Monitoring System provides warninglamps. Refer to Illustration 22. The EngineMonitoring System provides a LCD display for engineparameters. When the scroll switch is depressed,the parameters will scroll on the screen. The EMSdisplays the real time value for the parameter that isselected. The default is engine speed.

The parameters are abbreviated on the LCD display.Table 2 lists the parameters.

Table 2

Abbreviation Parameter

Spd Engine Speed

GA-1 Engine Oil Pressure

GA-2 Coolant Temperature

GA-3 Battery Voltage

GA-4 Fuel Pressure

Boost Boost Pressure

IAirT Inlet Air Temperature

FuelT Fuel Temperature

AccrP Auxiliary Pressure

AccrT Auxiliary Temperature

Fuel Fuel Rate

Hrs Engine Hours

Load Percent of Engine Load(speed and derate)

Note: For detailed information on the exactparameters for your engine, refer to the Operationand Maintenance Manual, Gauges and Indicators.

Quad Gauge Unit

g00595166Illustration 23(14) Engine oil pressure(15) Engine coolant temperature(16) Battery voltage(17) Fuel pressure

The quad gauge unit displays the followinginformation: engine oil pressure, engine coolanttemperature, battery voltage, and fuel pressure


Gauges and Indicators

Note: The gauge needles may not always return tozero position when the engine is not running.


Tachometer Unit


(18) Tachometer

The tachometer displays the engine speed (rpm) onan analog gauge.


Communication Data LinkThe EMS provides two pins that are connected tothe data link. The data link is available to share datawith other modules. The ECM processes engineparameters. The parameters will then be transmittedto the EMS through the data link. The EMS receivesthe information. The information is then displayedon various gauges.

For additional information, refer to theTroubleshooting Manual, Cat Data LinkCircuit-Test.

24 SEBU8089-02Operation SectionFeatures and Controls

Features and Controlsi02414027

Sensors and ElectricalComponentsSMCS Code: 1439; 1900; 7400

Sensor LocationsIllustration 25 shows the typical locations of thesensors for a C7 Industrial Engine. Specific enginesmay appear different from the illustration due todifferences in applications.


Typical exampleLeft side view

(1) Injection actuation pressure sensor(2) Inlet air temperature sensor(3) Atmospheric pressure sensor

(4) Boost pressure sensor(5) Engine oil temperature sensor(6) Engine speed/timing sensor

(7) Coolant temperature sensor(8) Engine oil pressure sensor

Failure of Sensors

All Sensors

A failure of any of the sensors may be caused by oneof the following malfunctions:

Sensor output is open.

Sensor output is shorted to - battery or + battery.

Measured reading of the sensor is out of thespecification.


Features and Controls

Atmospheric Pressure SensorAtmospheric pressure sensor (3) measures theatmospheric pressure in the crankcase. A signal issent to the Electronic Control Module (ECM).

Table 3

Atmospheric Pressure Sensor

Operating pressurerange 0 to 116 kPa (0 to 16.8 psi)

Boost Pressure SensorBoost pressure sensor (4) provides a signal whichcorresponds to turbocharger outlet pressure to theECM. The air/fuel ratio control utilizes the actualengine speed and the turbocharger outlet pressure inorder to control the transient smoke level. The ECMcan control injection timing and the amount of fuelthat is injected. When the throttle is increased andwhen the engine demands more fuel, the fuel limit iscontrolled in order to reduce overall smoke levels ofthe engine exhaust.

Failure of the Boost Pressure Sensor

The ECM will detect failure of the boost pressuresensor. The operator will be warned of the problemthrough the diagnostic lamp. The strategies that arerelated to the boost will be disabled. Engine powerwill be severely reduced in the event of a failure of theboost pressure sensor. A failure of the boost pressuresensor will not cause a shutdown of the engine.

Coolant Temperature SensorCoolant temperature sensor (7) monitors enginecoolant temperature. The output of the ECM canindicate a high coolant temperature through a relayor a lamp. The coolant temperature sensor is usedby the ECM to determine initiation of the Cold StartStrategy.

Table 4

Coolant Temperature Sensor

Activation temperature for the highcoolant temperature fault 103C (217F)

Activation temperature for the veryhigh coolant temperature fault 106C (229F)

Failure of the Coolant TemperatureSensor

The ECM will detect a failure of the coolanttemperature sensor. The diagnostic lamp willwarn the operator about the status of the coolanttemperature sensor. A failure of the coolanttemperature sensor will not cause a shutdown of theengine or any horsepower change.

Engine Oil Pressure SensorEngine oil pressure sensor (8) is an absolute pressuresensor that measures the engine oil pressure inthe main oil gallery. The engine oil pressure sensordetects engine oil pressure for diagnostic purposes.The engine oil pressure sensor sends a signal to theECM.

Table 5

Engine Oil Pressure Sensor

Operating pressurerange 0 to 690 kPa (0 to 100 psi)

Low Oil Pressure Warning

The setpoint is dependent upon the engine speed.The fault will be active and logged only if the enginehas been running for more than 15 seconds.

Very Low Oil Pressure Warning

The very low oil pressure setpoint is dependent uponthe engine speed. If the DERATE mode of the enginemonitoring system is selected, the ECM will deratethe engine power. The engine horsepower will belimited.

Failure of the Engine Oil Pressure Sensor

The ECM will detect failure of the engine oil pressuresensor. The diagnostic lamp warns the user about thestatus of the engine oil pressure sensor. The engineoil pressure related strategies will be disabled in theevent of a failure of the engine oil pressure sensor. Afailure of the engine oil pressure sensor will not causea shutdown of the engine or any horsepower change.

Engine Oil Temperature SensorEngine oil temperature sensor (5) monitors thetemperature of the engine oil. The ECM uses theinformation from the engine oil temperature sensorin order to adjust the timing of the fuel injection andthe pressure of the fuel injection.

26 SEBU8089-02Operation SectionFeatures and Controls

Table 6

Engine Oil Temperature Sensor

Operating temperaturerange 40 to 120C (40 to 258F)

Engine Speed/Timing SensorIf the ECM does not receive a signal from primaryspeed/timing sensor (6), the DIAGNOSTIC lampwill indicate a diagnostic fault code which will belogged in the ECM memory.

If the ECM does not receive a signal from the primaryspeed/timing sensor, the ECM will read the signalfrom the secondary speed/timing sensor. The ECMcontinually checks in order to determine if there is asignal from both sensors. If either sensor fails, thefaulty sensor should be replaced.

Intermittent failure of the sensors will cause erraticengine control.

Injection Actuation PressureSensorInjection actuation pressure sensor (1) providesa signal of the injection actuation pressure to theECM. The ECM modifies the current to the injectionactuation pressure control valve (not shown) inorder to control the injection actuation pressure. Thedesired actuation pressure is based on the followingengine parameters: quantity of fuel, injection timing,engine speed, and engine operating mode.

Inlet Air Temperature SensorInlet air temperature sensor (2) measures the inlet airtemperature. A signal is sent to the Electronic ControlModule (ECM). The inlet air temperature sensor isalso used by the ECM to determine initiation of theCold Start Strategy.

Table 7

Inlet Air Temperature Sensor

Operating temperaturerange 40 to 120C (40 to 258F)

Throttle Position SensorThe Throttle Position Sensor (TPS) sends a signal tothe ECM. The signal from the TPS is required in orderto govern engine speed. The throttle position sensorsignal is used by the ECM in order to calculate thedesired engine speed. The TPS is calibrated duringthe initial installation of the engine.

Note: The throttle position sensor is not shown inthe illustration.

Failure of the Throttle Position Sensor

An intermittent failure in the TPS causes the enginespeed to vary erratically. The ECM will perform thefollowing process:

The ECM will detect the failure of the TPS.

The ECM will warn the operator of the failurethrough the diagnostic lamp.

The ECM will set the desired engine speed to lowidle.

SEBU8089-02 27Operation SectionEngine Diagnostics

Engine Diagnosticsi01463253

Diagnostic LampSMCS Code: 1000; 1900; 1901; 1902; 7451

The DIAGNOSTIC lamp is used to indicate theexistence of an active fault by flashing codes.

When the ignition switch is first turned on, theDIAGNOSTIC lamp will go through the followingprocedure:

The DIAGNOSTIC lamp will come on andthe DIAGNOSTIC lamp will remain on for fiveseconds. This checks the operation of the lamp.

The DIAGNOSTIC lamp will turn off.

The DIAGNOSTIC lamp will come on again andthe DIAGNOSTIC lamp will flash codes for anyactive diagnostic codes. Not all diagnostic codeshave a unique flash code.

The DIAGNOSTIC lamp will turn off for fiveseconds.

The DIAGNOSTIC lamp repeats all activediagnostic codes.

A fault diagnostic code will remain active until theproblem is repaired. The electronic control modulewill continue flashing the flash code at five secondintervals until the problem is repaired.

i02414604

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

Diagnostic LampUse the DIAGNOSTIC Lamp or CaterpillarElectronic Technician (ET) in order to determine thediagnostic flash code.

Use the following procedure to retrieve the diagnosticcodes if the engine is equipped with a DIAGNOSTIClamp:

1. Turn the ignition key to the ON position. Theengine does not need to be started in order to viewcodes. The engine does not need to be runningwhile the ignition switch is in the ON position.

The DIAGNOSTIC lamp blinks on and off at fivesecond intervals.

When the ignition key is in the ON position, thelamp is checked for proper operation. If thereare any active codes except for Code 34, thecodes are displayed at this time.

Note: The DIAGNOSTIC lamp will illuminate for fiveseconds. The lamp will stay on if there is an activediagnostic code.

2. The Active Diagnostic codes will always beflashed. There is no toggle switch that will shutoff the lamp.

3. The DIAGNOSTIC lamp will flash in order toindicate a two-digit code. The sequence of flashesrepresents the system diagnostic message.Each digit of the two-digit code is determined bycounting the number of flashes. The lamp flashesat a rate of two times per second. The lamp willpause for one second between digits. The lampwill pause for two seconds between codes.

Table 8 indicates the potential effect on the engineperformance with active flash codes. Table 8 alsoforms a list of Electronic diagnostic codes anddescriptions.

28 SEBU8089-02Operation SectionEngine Diagnostics

Table 8

Diagnostic Flash Codes for C7 Industrial Engine

Effect On Engine Performance Suggested Action by theOperator

Diagnostic Flash CodeEngineMisfire

LowPower

ReducedEngineSpeed

EngineShutDown

Shutdown theEngine(1)

Service(2)ScheduleServicefor theEngine.(3)

15 Open or Short Circuit of InjectionActuation Pressure Sensor X X

17 High Injection ActuationPressure X X

18Open or Short for the InjectionActuation Pressure ControlValve

X X

21 Sensor Supply Voltage AboveNormal or Below Normal (4) X X

24 Oil Pressure Sensor Fault (4) X

25 Inlet Manifold Air PressureSensor Fault(5) X

26 Atmospheric Pressure SensorFault(4) X X

27 Coolant Temperature SensorFault(4) X X X

28 Check the Adjustments for theThrottle Position Sensor. X X X

34 Loss Of Engine RPM Signal X X X

35 Event for Engine Overspeed X X

37 Fuel Pressure Sensor Fault(4) X

38 Inlet Manifold Air TemperatureSensor Fault(4) X X X

39Mechanical Failure of theInjection Actuation PressureSensor

X X

42 Check the Calibration of theTiming Sensor. X X X X X

46 Low Oil Pressure Event X X X

51 Intermittent Battery Power to theECM X X X X X

52 Personality Module Fault X X X X X

56The following parameters mustbe checked: Customer andSystem

X X X

59 Incorrect Engine Software X X X X

61 Event for High CoolantTemperature X X X X

62 Event for Low Coolant Level X X X X

63 Low Fuel Pressure Event X X X X(continued)


(Table 8, contd)

Diagnostic Flash Codes for C7 Industrial Engine

Effect On Engine Performance Suggested Action by theOperator

Diagnostic Flash CodeEngineMisfire

LowPower

ReducedEngineSpeed

EngineShutDown

Shutdown theEngine(1)

Service(2)ScheduleServicefor theEngine.(3)

64 Even for High Inlet Manifold AirTemperature X X X

72 Fault of Cylinder 1 or Cylinder 2 X X X

73 Fault of Cylinder 3 or Cylinder 4 X X X

74 Fault of Cylinder 5 or Cylinder 6 X X X(1) Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.(2) The operator should go to the nearest location for service.(3) The operator should investigate the problem at a convenient time.(4) The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.(5) These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at coldtemperatures, etc.

i02512380

Fault LoggingSMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.When the Electronic Control Module (ECM)generates an active diagnostic code, the code will belogged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with Caterpillar electronic service tools.The codes that have been logged can be clearedwith Caterpillar electronic service tools. The codesthat have been logged in the memory of the ECMwill be automatically cleared from the memory after100 hours. The following faults can not be clearedfrom the memory of the ECM without using a factorypassword: overspeed, low engine oil pressure, andhigh engine coolant temperature.

i02784364

Engine Operation with ActiveDiagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes duringnormal engine operation, the system has identifieda situation that is not within the specification. UseCaterpillar electronic service tools to check the activediagnostic codes.

Note: If the customer has selected DERATE and ifthere is a low oil pressure condition, the ElectronicControl Module (ECM) will limit the engine power untilthe problem is corrected. If the oil pressure is withinthe normal range, the engine may be operated at therated speed and load. However, maintenance shouldbe performed as soon as possible. Refer to Operationand Maintenance Manual, Diagnostic Flash CodeRetrieval for more information on flash codes.

The active diagnostic code should be investigated.The cause of the problem should be corrected assoon as possible. Operation of the engine andperformance of the engine can be limited as a resultof the active diagnostic code that is generated. Ifthe cause of the active diagnostic code is repairedand there is only one active diagnostic code, thediagnostic lamp will turn off.

30 SEBU8089-02Operation SectionEngine Diagnostics

i01456915

Engine Operation withIntermittent Diagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes duringnormal engine operation and the diagnostic lampshuts off, an intermittent fault may have occurred. Ifa fault has occurred, the fault will be logged into thememory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the enginebecause of an intermittent code. However, theoperator should retrieve the logged fault codesand the operator should reference the appropriateinformation in order to identify the nature of the event.The operator should log any observation that couldhave caused the lamp to light.

Low power

Limits of the engine speed

Excessive smoke, etc

This information can be useful to help troubleshootthe situation. The information can also be used forfuture reference. For more information on diagnosticcodes, refer to the Troubleshooting Guide for thisengine.

i02918535

Configuration ParametersSMCS Code: 1000; 1900; 1901; 1902

Customer specified parameters that will enhancethe fuel efficiency and the operators conveniencecan be programmed into the Electronic ControlModule (ECM). Some parameters may affectengine operation. This may lead to complaints fromthe operator about power or about performance.The following engine related parameters may beprogrammed by the customer by using Caterpillarelectronic service tools in order to influence theoperation of the engine:

Customer passwordThis parameter allows the customer to lock outcertain parameters by entering a password. Customerpasswords must be used to unlock any parametersthat are protected by customer passwords before theparameter can be changed. Factory passwords arerequired if this password is lost.

Customer Passwords

First Password ___________________________________________

Second Password ______________________________________

Power Rating (hp at rpm) ______________________________

Rating Selection (A-E) __________________________________

PTO Governor Parameters

PTO Engine Speed Ramp Rate____________rpm/sec

Engine Parameters

Top Engine Limit (TEL) at 100 percent load (IfApplicable) _______________________________________________

Torque Limit ______________________________________________

High Idle (If Applicable) ________________________________

Low Idle ___________________________________________________

Intermediate Speed ____________________________________

Engine Monitoring Mode

OFF ______________________________________________________

Warning _________________________________________________

Warning/Derate ________________________________________

Warning/Derate/Shutdown __________________________

Coolant Level Sensor Enable/Disable ____________

Fuel Pressure Sensor Enable/Disable ___________

Inlet Manifold Air Temperature SensorEnable/Disable _________________________________________

Equipment ID

Maintenance Indicator

Manual-Hours

Auto-Hours

Manual-Fuel

Auto-Fuel

Auxiliary Pressure

High Warning Set Point ________________________________

Auxiliary Temperature

High Warning Set Point ________________________________


The customer specified parameters can be changedas often as needed. Password protection is providedso that the customer can change the parameters. Thecustomer can authorize someone else to change theparameters. Ensure that a record of the parametersis kept in the Operation and Maintenance Manual.For detailed instructions on programming the enginefor optimum performance and for optimum fueleconomy, consult your Caterpillar dealer.

32 SEBU8089-02Operation SectionEngine Starting

Engine Startingi01486758

Before Starting EngineSMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and otherperiodic maintenance before the engine is started.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, MaintenanceInterval Schedule for more information.

For the maximum service life of the engine, makea thorough inspection before the engine is started.Look for the following items: oil leaks, coolantleaks, loose bolts, and trash buildup. Remove trashbuildup and arrange for repairs, as needed.

Inspect the cooling system hoses for cracks andfor loose clamps.

Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

Inspect the wiring for loose connections and forworn wires or frayed wires.

Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supply valve.

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Airmay have entered the filter housing. Also, when fuelfilters have been changed, some air pockets will betrapped in the engine. In these instances, prime thefuel system. Refer to the Operation and MaintenanceManual, Fuel System - Prime for more informationon priming the fuel system.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Do not start the engine or move any of the controlsif there is a DO NOT OPERATE warning tag orsimilar warning tag attached to the start switch orto the controls.

Ensure that the areas around the rotating parts areclear.

All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

Reset all of the shutoffs or alarm components.

Check the engine lubrication oil level. Maintain theoil level between the ADD mark and the FULLmark on the oil level gauge.

Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the FULL mark on the coolantrecovery tank.

If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (0.5 inch) of the bottom of the filler pipe. Ifthe engine is equipped with a sight glass, maintainthe coolant level in the sight glass.

Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

Ensure that any driven equipment has beendisengaged. Minimize electrical loads or removeany electrical loads.

i03203474

Starting the EngineSMCS Code: 1000; 1450

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

SEBU8089-02 33Operation SectionEngine Starting

Initial InspectionPerform the required daily maintenance and otherperiodic maintenance before you start the engine.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, Walk-AroundInspection topic (Maintenance Section) for moreinformation.

For the maximum service life of the engine, makea thorough inspection before you start the engine.Look for the following items: oil leaks, coolantleaks, loose bolts, and trash buildup. Remove trashbuildup and arrange for repairs, as needed.

Inspect the cooling system hoses for cracks andfor loose clamps.

Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

Inspect the wiring for loose connections and forworn wires or frayed wires.

Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supply valve.

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

Do not start the engine or do not move any of thecontrols if there is a DO NOT OPERATE warningtag or similar warning tag attached to the startswitch or to the controls.

Ensure that the areas around the rotating parts areclear.

All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

Reset all of the shutoffs or alarm components.

Check the engine lubrication oil level. Maintain theoil level between the ADD mark and the FULLmark on the oil level gauge.

Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the FULL mark on the coolantrecovery tank.

If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (.5 inch) of the bottom of the filler pipe. Ifthe engine is equipped with a sight glass, maintainthe coolant level in the sight glass.

Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

Ensure that any driven equipment has beendisengaged. Remove any electrical loads.

Cold Weather StartingStarting the engine and operation in cold weatheris dependent on the type of fuel that is used, the oilviscosity, and other optional starting aids. For moreinformation, refer to the Operation and MaintenanceManual, Cold Weather Operation topic (OperationSection).

Air Inlet Heater

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Note: There will be an indicator lamp on the controlpanel that is marked AIR INLET HEATER.

For detailed information on the operation of the AirInlet Heater, refer to Troubleshooting Manual, AirInlet Heater Circuit - Test.

Refer to the Owners Manual of the OEM for yourtype of controls. Use the following procedure to startthe engine.

1. Place the transmission in NEUTRAL. Disengagethe flywheel clutch in order to allow the engine tostart faster. This also reduces the draining of thebattery.

2. Turn the ignition switch to the ON position.


The WARNING and DIAGNOSTIC lamp (ifequipped) will flash while the engine is cranking.The lamp should turn off after proper engineoil pressure is achieved. If the lamp fails toflash, notify your authorized Caterpillar dealer.If the lamp continues to flash, the ElectronicControl Module (ECM) has detected a problemin the system. For more information, refer to theOperation and Maintenance Manual, DiagnosticFlash Code Retrieval (Operation Section).

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

3. Push the start button or turn the ignition switch tothe START position in order to crank the engine.

Do not push down or hold the throttle downwhile the engine is cranked. The system willautomatically provide the correct amount of fuelthat is needed to start the engine.

4. If the engine fails to start within 30 seconds,release the start button, or the ignition switch. Waitfor two minutes in order to allow the starting motorto cool before attempting to start the engine again.

Note: The WARNING and DIAGNOSTIC lamps (ifequipped) may come on after the engine is started. Ifthis occurs, the ECM has detected a problem with thesystem. For more information, refer to the Operationand Maintenance Manual, Diagnostic Flash CodeRetrieval (Operation Section) .

NOTICEOil pressure should rise within 15 seconds after theengine starts. Do not increase engine rpm until the oilpressure gauge indicates normal. If oil pressure is notindicated on the gauge within 15 seconds, DO NOToperate the engine. STOP the engine, investigate andcorrect the cause.

5. Allow the engine to idle for approximatelythree minutes. Idle the engine until the watertemperature gauge has begun to rise. Check allgauges during the warm-up period.

Note: Oil pressures and fuel pressures should be inthe normal range on the instrument panel. Enginesthat are equipped with WARNING lamps do nothave an operating range. The WARNING andDIAGNOSTIC lamp (if equipped) will flash whilethe engine is cranking. The lamp should turn offafter proper engine oil pressure or fuel pressureis achieved. Do not apply a load to the engine orincrease engine rpm until the oil pressure gaugeindicates at least normal pressure. Inspect the enginefor leaks and/or unusual noises.

After the engine has started, the air inlet heater maycontinue to operate in a Continuous mode and/or inan Intermittent mode. The air inlet heater will turnOFF when the sum of the coolant temperature andthe air inlet temperature exceeds 35 C or 127 F.

If the engine is operated with a low load, the enginewill reach normal operating temperature sooner thanidling the engine with no load. When the engine isidled in cold weather, increase the engine rpm toapproximately 1000 to 1200 rpm. This will warmup the engine more quickly. Do not exceed therecommended rpm in order to increase the speedof the warm-up. Limit unnecessary idle time to tenminutes.

Ether Injection System

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or startingfluids are highly flammable andtoxic and if improperly stored could result in injuryor property damage.

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Starting ProblemsAn occasional starting problem may be caused byone of the following items:

Low battery charge

Lack of fuel

Problem with the wiring harness

SEBU8089-02 35Operation SectionEngine Starting

If the engine fuel system has been run dry, fill thefuel tank and prime the fuel system. Refer to theOperation and Maintenance Manual, Fuel System -Prime topic (Maintenance Section).

If the other problems are suspected, perform theappropriate procedure in order to start the engine.

Problems with the Wiring Harness


ECM Connector J2/P2

Locate the ECM. Check the connector in order toensure that the connector is secure. Lightly pull eachof the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg (10 lb) offorce. The wire should remain in the connector.

2. If a wire is loose, push the wire back into theconnector. Pull the wire again in order to ensurethat the wire is secure.

3. Start the engine. If the engine does not start,consult the nearest Caterpillar dealer forassistance.

i02308903

Starting with Jump StartCablesSMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

If the installation is not equipped with a backupbattery system, it may be necessary to start theengine from an external electrical source.

For information on troubleshooting the chargingsystem, refer to Special Instruction, REHS0354,Charging System Troubleshooting.

Many batteries which are considered unusable arestill rechargeable. After jump starting, the alternatormay not be able to fully recharge batteries thatare severely discharged. The batteries must becharged to the proper voltage with a battery charger.For information on testing and charging, refer tothe Special Instruction, SEHS7633, Battery TestProcedure.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the generator set control switch to theOFF position. Turn all electrical accessories OFF be-fore attaching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch on the stalled engine to theOFF position. Turn off all accessories.


2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of the jumpstart cable to the positive cable terminal of theelectrical source.

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting combustible gasesthat are produced by some batteries.

4. Charge the batteries. The engine will not continueto run after starting if the batteries have not beencharged.

5. Start the engine.

6. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

Refer to the Electrical Schematic for your engine.Consult your Caterpillar dealer for more information.

i01646248

After Starting EngineSMCS Code: 1000

Note: In temperatures from 0 to 60C (32 to 140F),the warm-up time is approximately three minutes. Intemperatures below 0C (32F), additional warm-uptime may be required.

Note: Ensure that the self test for the monitoringsystem (if equipped) is completed before operatingthe engine under load.

When the engine idles during warm-up, observe thefollowing conditions:

Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This is notpossible in some applications.

Operate the engine at low idle until all systemsachieve operating temperatures. Check all gaugesduring the warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while theengine is operating. Comparing the data over timewill help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.

SEBU8089-02 37Operation SectionEngine Operation

Engine Operationi00718869

Engine OperationSMCS Code: 1000

Proper operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenance Manual are followe

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