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Caterpillar C7 SAP Diesel Engine Complete Service Manual

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Covers: Caterpillar C7 Diesel Truck Engine (SAP serial number prefix)
Pages: 1,659
Format: PDF files (zipped)
Compatibility: Windows/Mac computers
Notes: 10-in-1 service manual set

This 10 volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for the Caterpillar C7 SAP diesel engine. Additionally, the Cat C7 SAP engine wiring diagrams are included in high resolution PDF format. This is a complete OEM reference for professional mechanics to service and repair the engine. View the manuals on your computer or print off pages as needed.

Sample topics in the Caterpillar C7 SAP Diesel Engine Complete Service Manual:

  • Engine Specifications
  • Sensor Specifications
  • Intake/Exhaust Specifications
  • Starter Specifications
  • Engine Mechanical Operation
  • Electronic Control System Operation
  • HEUI Fuel System Operation
  • Air Inlet and Exhaust System Operation
  • Lubrication System Operation
  • Cooling System Operation
  • Electrical System Operation
  • Fuel System Test
  • Air in Fuel Test
  • Engine Speed Check
  • Electronic Unit Injector Test
  • Finding Top Center Position
  • Fuel System Test/Prime
  • Gear Group (Front) Time
  • Air Inlet and Exhaust System Testing
  • Turbocharger Inspection
  • Inlet Manifold Pressure Test
  • Exhaust Temperature Test
  • Aftercooler Test
  • Engine Crankcase Pressure (Blowby) Test
  • Engine Valve Lash Inspect/Adjust
  • Engine Oil Pressure Test
  • Excessive Bearing Wear Inspect
  • Excessive Engine Oil Consumption Inspect
  • Increased Engine Oil Temperature Inspect
  • Cooling System Check Overheating
  • Water Temperature Regulator Test
  • Piston Ring Groove Inspect
  • Main Bearings Inspect
  • Cylinder Block Inspect
  • Flywheel Inspect
  • Vibration Damper Check
  • Alternator Test
  • Battery Test
  • Charging System Test
  • Electric Starting System Test
  • Engine Oil Pressure Sensor Test
  • Pinion Clearance Adjust
  • Using Electronic Service Tool
  • ECM Troubleshooting
  • Programming Parameters
  • Troubleshooting without a Diagnostic Code
  • Troubleshooting with a Diagnostic Code
  • Calibration Procedures
  • Complete Engine Disassembly/Assembly Procedures (With Illustrations)
  • Fuel System Disassembly/Assembly Procedures (With Illustrations)
  • Lubrication System Disassembly/Assembly Procedures (With Illustrations)
  • Cooling System Disassembly/Assembly Procedures (With Illustrations)
  • Torque Specifications
  • BA-921 Service Manual
  • Electronic PTO Service Manual
  • C7 SAP Electrical Schematic (SAP 1-3955)
  • C7 SAP Electrical Schematic (SAP 3956-Up)
  • And much more…

 

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Bore … 110.0 mm (4.33 inch)
Stroke … 127.0 mm (5.00 inch)
Displacement … 7.2 L (439 cu in)
Number of cylinders … 6
Cylinder arrangement … In-line
Valves per cylinder … 3
Type of combustion … Direct injection
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed from the flywheel end of the engine. The no. 1
cylinder is the front cylinder.
Crankshaft rotation (view from the flywheel end) … Counterclockwise
Valve lash with engine stopped (cold)
Inlet … 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust … 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Firing order … 1, 5, 3, 6, 2, 4

 00
71-11 Engine Shutdown Override Switch Occurrence
84-14 Quick Stop Occurrence
96-03 96-03 Fuel Level Voltage High
96-04 96-04 Fuel Level Voltage Low
186-04 PTO Engine Shutdown Switch Voltage Low
224-11 Theft Deterent Active
224-14 Theft Deterent Active with Engine Cranking
231-12 J1939 Device Not Responding
246-11 Brake Pedal Switch #1 Fault
247-11 Brake Pedal Switch #2 Fault
01 71-00 Idle Shutdown Override
12
111-02
Coolant Level signal invalid
111-03 Coolant Level voltage high
111-04 111-04 Coolant Level voltage low
15
164-02
164-02 Injection Actuation Pressure Signal Erratic
164-03 164-03 Injection Actuation Pressure Voltage High
164-04 164-04 InjectionActuation Pressure Voltage Low
16
173-00
High Exhaust Gas Temperature Derate
173-11 Very High Exhaust Gas Temperature Derate
17 164-00
164-00 Excessive Injection Actuation Pressure
18 42-11 Injection Actuation Pressure output fault
21
41-03 678-03 8 Volt Supply voltage high
41-04 678-04 8 Volt Supply voltage low
232-03 620-03 5 Volt Supply voltage high
232-04 620-04 5 Volt Supply voltage low
24
100-03
100-03 Oil Pressure voltage high
100-04 100-04 Oil Pressure voltage low
25
102-01
102-01 Low Boost Pressure
102-02 102-02 Boost Pressure signal erratic
102-03 102-03 Boost Pressure voltage high
102-04 102-04 Boost Pressure voltage low
102-07 102-07 Boost Pressure not responding
26
108-03
108-03 Barometric Pressure voltage high
108-04 108-04 Barometric Pressure voltage low
27
110-03
110-03 Coolant Temperature voltage high
110-04 110-04 Coolant Temperature voltage low
28 91-13 Throttle Position out of Calibration
29 30-08 PTO Throttle signal invalid
30-13 PTO Throttle out of calibration
31 84-01 Vehicle Speed loss of signal
32 91-08 Throttle Position Invalid
33
32-05 646-05 Turbo Wastegate Solenoid current low
32-06 646-06 Turbo Wastegate Solenoid current hig
32-11 646-11 Turbo Wastegate Solenoid current mismatch
34
64-02 Secondary Engine Speed loss of signal
64-11 Secondary Engine Speed no pattern
190-02 Primary Engine Speed loss of signal
190-11 Primary Engine Speed no pattern
35 190-00
190-15 Engine Overspeed Warning
36
84-02 Vehicle Speed signal invalid
84-08 Vehicle Speed signal out of range
84-10 Vehicle Speed signal rate of change
37
94-03 94-03 Fuel Pressure voltage high
94-04 94-04 Fuel Pressure voltage low
38
105-03
105-03 Intake Manifold Air Temperature voltage high
105-04 105-04 Intake Manifold Air Temperature voltage low
39 164-11
164-11 Injection Actuation Pressure system fault
41 84-00 Vehicle Overspeed Warning
42
22-11 637-11 Primary to Secondary Engine Speed Signal
Calibration
22-13 637-13 Engine Speed Signal Calibration Not Performed
44
128-03
Secondary Fuel Level voltage high
128-04 Secondary Fuel level voltage low
46 100-01
100-17 Low Oil Pressure Warning
100-11 100-18 Very Low Oil Pressure
47
71-01 Idle Shutdown
71-14 PTO Shutdown
186-14 PTO Engine Shutdown Switch Occurrence
49
70-05 729-05 Inlet Air Heater current low
70-06 729-06 Inlet Air Heater current high
51
168-00
168-00 Excessive ECM Battery Power
168-01 168-01 Low ECM Battery Power
168-02 168-02 ECM Battery Power Intermittent
55 N/A N/A No Diagnostic Code Detected
56
253-02
630-02 Check Customer or System Parameters
253-14 Truck Manufacturer Paremater Not Programmed
57 231-14
Transmission Data Link Derate
58
231-02
639-02 J1939 Data Incorrect
231-11 639-12 J1939 Data Link Fault
59 252-11
631-11 Engine Software Incorrect
61
110-00
110-15 High Coolant Temperature Warning
110-11 110-16 Very High Coolant Temperature
62
111-01
111-17 Low Coolant Level Warning
111-11 111-18 Very Low Coolant Level
111-14 Low Coolant Level Warning
63
94-01 Low Fuel Pressure Warning
94-11 Low Cranking Fuel Pressure
64 105-00
1636-15 High Intake Manifold Air Temperature Warning
105-11 1636-16 Very High Intake Manifold Air Temperature
71 43-02 Key Switch Fault
72
1-11 651-11 Cylinder #1 Injector current fault
2-11 652-11 Cylinder #2 Injector current fault
73
3-11 653-11 Cylinder #3 Injector current fault
4-11 654-11 Cylinder #4 Injector current fault
74
5-11 655-11 Cylinder #5 Injector current fault
6-11 656-11 Cylinder #6 Injector current fault

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