Caterpillar Cat C7 Marine Engine Parts Catalogue Manual.pdf

service repair manual download

1. SEBP4487-10
May 2007
Parts
Manual
See “General Information”
for New Parts Manual
Features.
C7 Marine Engine
C7D1-Up (Engine)
M7A1-Up (Engine)
This Parts Manual is also Available in .PDF Format on Compact Disc
(CD-ROM) - Caterpillar Form No. SERP4487

2. TABLE OF CONTENTS
Name Page Name Page
GENERAL INFORMATION ......... ......... A12
REPAIR ALTERNATIVES .......... .......... A22
SUPPLEMENTAL COOLANT ADDITIVES ... ... A27
MAINTENANCE PARTS ........... ........... A32
INDEX................... ................... A45
ENGINE ARRANGEMENT .......... .......... 1
ENGINEAR............... ............... 1
ENGINEAR-CORE............ ............ 9
BASIC ENGINE............... ............... 14
BRACKETGP-MOUNTING........ ........ 14
CAMSHAFTGP............. ............. 15
COVERGP-CYLINDERBLOCK...... ...... 16
COVERGP-ENGINE........... ........... 17
COVER GP-FLYWHEEL HOUSING . . . . . . . . 18
COVERGP-FRONTHOUSING...... ...... 19
COVER GP-VALVE MECHANISM . . . . . . . . . . 21
CRANKSHAFTGP............ ............ 31
CYLINDERBLOCKGP.......... .......... 37
CYLINDERBLOCKGP-LONG....... ....... 41
CYLINDERHEADAS........... ........... 42
CYLINDERHEADGP........... ........... 43
DAMPER&PULLEYGP......... ......... 46
DRAINGP-ENGINEOIL.......... .......... 48
FASTENERGP-DAMPER......... ......... 50
FASTENERGP-FRONTHOUSING.... .... 51
FASTENERGP-LIFTING......... ......... 52
FASTENER GP-VALVE MECHANISM . . . . . . 53
FLYWHEELGP.............. .............. 54
GEARGP-FRONT............ ............ 55
HOUSINGGP-FLYWHEEL........ ........ 57
HOUSINGGP-FRONT.......... .......... 58
LIFTERGP-VALVE............ ............ 59
LIFTINGGP-ENGINE........... ........... 60
MOUNTINGGP-ALTERNATOR...... ...... 62
MOUNTINGGP-ENGINE......... ......... 65
PANGP-OIL............... ............... 66
PISTON&RODGP............ ............ 68
PLUGGP-CYLINDERBLOCK....... ....... 70
PLUG GP-FLYWHEEL HOUSING . . . . . . . . . . 71
PULLEYGP-CRANKSHAFT........ ........ 72
ROCKERARMGP............ ............ 73
SEALGP-CRANKSHAFT......... ......... 75
SUPPORTGP-ENGINE.......... .......... 76
VALVEMECHANISMGP......... ......... 77
LUBRICATION SYSTEM .......... .......... 82
ADAPTERGP-OILLINE.......... .......... 82
BASEGP-OILFILTER.......... .......... 83
BREATHERGP.............. .............. 84
FILLERGP-ENGINEOIL......... ......... 87
FILTERGP-ENGINEOIL......... ......... 89
FILTER GP-RECIRCULATION . . . . . . . . . . . . . . 92
FITTINGGP-HYDRAULIC......... ......... 94
GAUGE GP-OIL LEVEL (DIPSTICK) . . . . . . . . 95
LINESGP-ENGINEOIL.......... .......... 97
LINESGP-SUMP............. ............. 98
LINES GP-TURBOCHARGER OIL . . . . . . . . . . 100
PUMPGP-ENGINEOIL.......... .......... 104
PUMPGP-SUMP............. ............. 106
SUPPORTGP-ENGINEOILLINES.... .... 108
VALVEGP-FLUIDSAMPLING....... ....... 109
COOLING SYSTEM ............. ............. 111
COOLERAS-OIL............. ............. 111
COOLERGP-ENGINEOIL........ ........ 114
COVER GP-MARINE TMSN COOLER . . . . . . 115
COVER GP-REGULATOR HOUSING . . . . . . 116
HEAT EXCHANGER GP-SEA WATER . . . . . . 117
LINES GP-AUXILIARY SEA WATER . . . . . . . . 127
LINESGP-WATER............ ............ 129
PLUGGP-EXPANSIONTANK....... ....... 132
PUMPGP-AUXILIARYSEAWATER.... .... 133
PUMPGP-WATER............ ............ 136
RECOVERYGP-COOLANT........ ........ 138
AIR INLET AND EXHAUST SYSTEM ..... ..... 139
AFTERCOOLERGP-RAWWATER..... ..... 139
AIRCLEANERGP............ ............ 146
DRAINGP-AFTERCOOLER........ ........ 151
ELBOWGP-EXHAUST.......... .......... 152
FASTENERGP-AIRCLEANER...... ...... 156
LINESGP-AIR.............. .............. 157
MANIFOLDGP-EXHAUST........ ........ 158
TURBOCHARGERGP.......... .......... 160
FUEL SYSTEM............... ............... 162
COOLERGP-FUEL............ ............ 162
FILTER&LINESGP-FUEL........ ........ 163
FILTERGP-FUEL............. ............. 165
INJECTORGP-FUEL........... ........... 167
LINESGP-FLEXIBLEFUEL........ ........ 168
PUMP&MTGGP-UNITINJHYD..... ..... 169
PUMPGP-FUELINJECTION....... ....... 175
PUMPGP-FUELPRIMING........ ........ 176
PUMPGP-UNITINJECTORHYD..... ..... 178
REGULATORGP-FUELPRESSURE.... .... 180
SEPARATORGP-WATER......... ......... 182
ELECTRICAL AND STARTING SYSTEM ... ... 183
ADAPTERGP-SENSOR......... ......... 183
ALTERNATORGP-CHARGING...... ...... 184
CAMERAGP............... ............... 193
CONTROL & MTG GP-ENGINE ELEK . . . . . . 195
CONTROL GP-ENGINE ELECTRONIC . . . . . . 196
SEBP4487-10 TABLE OF CONTENTS A1

3. TABLE OF CONTENTS
Name Page Name Page
GUARDGP-ALTERNATOR........ ........ 200
HARNESSAS-ENGINE.......... .......... 202
HARNESSAS-WIRING.......... .......... 205
HEATERGP-JACKETWATER....... ....... 206
MODULEGP-INTERFACE........ ........ 209
SENSORGP-COOLANTLEVEL...... ...... 211
SENSORGP-ENGINE.......... .......... 213
SENSORGP-POSITION......... ......... 217
SENSORGP-PRESSURE......... ......... 219
SENSORGP-SPEED........... ........... 226
SENSORGP-TEMPERATURE....... ....... 230
STARTINGMOTORGP-ELECTRIC.... .... 235
SWITCHAS............... ............... 241
SWITCHGP-MAGNETIC......... ......... 243
WIRINGGP-ENGINE........... ........... 250
WIRINGGP-INSTRUMENTPANEL.... .... 267
WIRINGGP-UNITINJECTOR....... ....... 268
OPERATOR STATION ............ ............ 269
CONTROLGP-MONITOR......... ......... 269
CONVERTERGP-ELECTRICAL...... ...... 271
DISPLAYGP-MONITOR.......... .......... 272
GAUGE GP-COOLANT
TEMPERATURE............. ............. 274
GAUGE GP-ENGINE OIL PRESSURE . . . . . . 276
GAUGE GP-ENGINE PERCENT LOAD . . . . . . 278
GAUGE GP-FUEL CONSUMPTION
RATE.................. .................. 279
GAUGEGP-FUELLEVEL......... ......... 282
GAUGEGP-FUELPRESSURE...... ...... 284
GAUGEGP-FUELTEMPERATURE.... .... 285
GAUGEGP-GEAROILPRESSURE.... .... 286
GAUGEGP-MANIFOLDAIRTEMP.... .... 288
GAUGE GP-MANIFOLD PRESSURE . . . . . . . . 290
GAUGE GP-OIL TEMPERATURE . . . . . . . . . . 291
METERGP-SERVICE........... ........... 294
MODULEAS............... ............... 296
MODULEGP-QUADGAUGE....... ....... 297
MODULE GP-SPEEDOMETER & TACH . . . . . . 299
PANELGP-CONTROL.......... .......... 301
SPEEDOMETERGP........... ........... 303
TACHOMETERGP-ELECTRIC...... ...... 304
VOLTMETERGP............. ............. 305
SERVICE EQUIPMENT AND SUPPLIES ... ... 309
CHART-PLATE&FILM.......... .......... 309
PART NUMBER INDEX ........... ........... B1
A2
TABLE OF CONTENTS SEBP4487-10

4. BASIC ENGINE
261-3721COVER GP-VALVE MECHANISM (contd. ) i02767061
GRAPHIC #1 <END> g01272220
SEBP4487-10
2of2 BASIC ENGINE 25

5. BASIC ENGINE
287-8149COVERGP-VALVE MECHANISM
AN ATTACHMENT
SMCS-1107 i02585901
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
11 271-2417 1 COVER GP-VALVE MECHANISM (BASE)
1A 1 244-4486 1 SEAL-COVER (VALVE MECHANISM BASE)
1B 1 245-6796 1 COVER AS-BASE
21 287-8148 1 COVER GP-VALVE MECHANISM
D2A 1 5P-5678 SEAL (2.1-M)(VALVE COVER MECHANISM)
M3 1 099-3649 13 BOLT (M8X1.25X4 0-MM)
41 8T-4224 13 WASHER-HARD (8.8X16X2-MM THK)
BF 4C-9612 SEALANT-SILICONE (3-ML)
B-USE AS REQUIRED
D-ORDER BY THE METER
F-NOT SHOWN
M-METRIC PART
26BASIC ENGINE 1of2 SEBP4487-10

6. BASIC ENGINE
287-8149COVER GP-VALVE MECHANISM (contd. ) i02585901
GRAPHIC #1 <END> g01286422
SEBP4487-10
2of2 BASIC ENGINE 27

7. BASIC ENGINE
307-7587COVERGP-VALVE MECHANISM
S/N: M7A1-UP
PART OF 307-0103, 307-0105 CYLINDER BLOCK GP-LONG
SMCS-1107 i02753021
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
11 229-8861 1 COVER AS (VALVE MECHANISM)
D1A 1 5P-5678 SEAL (2.1-M)
M2 1 099-3649 13 BOLT (M8X1.25X 40-MM)
31 8T-4224 13 WASHER-HARD (8.8X16X2-MM THK)
D-ORDER BY THE METER
M-METRIC PART
GRAPHIC #1 <END> g01380448
28BASIC ENGINE 1of1 SEBP4487-10

8. BASIC ENGINE
310-9247COVERGP-VALVE MECHANISM
S/N: M7A1-UP
PART OF 311-1467 COVER GP-VALVE MECHANISM
SMCS-1107 i02753122
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
11 304-4924 1SEALAS
GRAPHIC #1 <END> g01380648
SEBP4487-10
1of1 BASIC ENGINE 29

9. BASIC ENGINE
311-1467COVERGP-VALVE MECHANISM
S/N: M7A1-UP
SMCS-1107 i02753055
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
Y1 1 281-0332 1 FASTENER GP-VALVE MECHANISM 53
Y2 1 310-9247 1 COVER GP-VALVE MECHANISM 29
Y-SEPARATE ILLUSTRATION
GRAPHIC #1 <END> g01380558
30BASIC ENGINE 1of1 SEBP4487-10

10. BASIC ENGINE
210-5590CRANKSHAFT GP
S/N: C7D1-UP
SMCS-1202 i02557873
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
11 271-5658 1 CRANKSHAFT AS
1A 1 1B-8705 1 KEY-WOODRUFF
1B 1 2W-8147 1 GEAR (50-TEETH)
J2 1 212-4893 1 BEARING-THRUST (STANDARD)
AB 1 229-5153 BEARING-THRUST (0.25-MM US)
AB 1 229-5154 BEARING-THRUST(0.5-MM US)
AB 1 229-5155 BEARING-THRUST (0.5-MM OS)
AB 1 229-5156 BEARING-THRUST (0.5-MM US - 0.5-MM OS)
J3 1 107-7708 6 BEARING-MAIN (S TANDARD)
AB 1 145-0168 BEARING-MAIN (0.5-MM OS)
AB 1 145-0170 BEARING-MAIN (0.5-MM US - 0.5-MM OS)
AB 1 145-0162 BEARING-MAIN (0.25-MM US)
AB 1 145-0164 BEARING-MAIN (0.5-MM US)
ABF 1 7C-7980 1 SLEEVE-OIL SEAL
(THIS WEAR SLEEVE IS USED ONLY TO SALVAGE
(REPAIR) THE REAR SEAL SURFACE OF THE
CRANKSHAFT)
AVAILABLE REPAIR KIT(S):
AJ 196-9519 BEARING GP-MAIN (CRANKSHAFT)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
F-NOT SHOWN
J-KIT MARKED J SERVICES PARTS MARKED J
SEBP4487-10 1of2 BASIC ENGINE 31

11. BASIC ENGINE
210-5590CRANKSHAFT GP (contd. ) i02557873
GRAPHIC #1 <END> g00977492
32BASIC ENGINE 2of2 SEBP4487-10

12. BASIC ENGINE
210-5590CRANKSHAFT GP
SMCS-1202 i02682424
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
C1 1 227-5480 1 CRANKSHAFT AS
1A 1 1B-8705 1 KEY-WOODRUFF
1B 1 2W-8147 1 GEAR (50-TEETH )
J2 1 212-4893 1 BEARING-THRUST (STANDARD)
AB 1 229-5153 BEARING-THRUST (0.25-MM US)
AB 1 229-5154 BEARING-THRUST (0.5-MM US)
AB 1 229-5155 BEARING-THRUST (0.5-MM OS)
AB 1 229-5156 BEARING-THRUST (0.5-MM US - 0.5-MM OS)
J3 1 107-7708 6 BEARING-MAIN (S TANDARD)
AB 1 145-0168 BEARING-MAIN (0.5-MM OS)
AB 1 145-0170 BEARING-MAIN (0.5-MM US - 0.5-MM OS)
AB 1 145-0162 BEARING-MAIN (0.25-MM US)
AB 1 145-0164 BEARING-MAIN (0.5-MM US)
ABF 1 7C-7980 1 SLEEVE-OIL SEAL
(THIS WEAR SLEEVE IS USED ONLY TO SALVAGE
(REPAIR) THE REAR SEAL SURFACE OF THE
CRANKSHAFT)
AVAILABLE REPAIR KIT(S):
AJ 196-9519 BEARING GP-MAIN (CRANKSHAFT)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
J-KIT MARKED J SERVICES PARTS MARKED J
SEBP4487-10 1of2 BASIC ENGINE 33

13. BASIC ENGINE
210-5590CRANKSHAFT GP (contd. ) i02682424
GRAPHIC #1 <END> g00977492
34BASIC ENGINE 2of2 SEBP4487-10

14. BASIC ENGINE
210-5590CRANKSHAFT GP
S/N: C7D1-UP
SMCS-1202 i02682428
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
C1 1 271-5658 1 CRANKSHAFT AS
1A 1 1B-8705 1 KEY-WOODRUFF
1B 1 2W-8147 1 GEAR (50-TEETH)
J2 1 212-4893 1 BEARING-THRUST (STANDARD)
AB 1 229-5153 BEARING-THRUST (0.25-MM US)
AB 1 229-5154 BEARING-THRUST(0.5-MM US)
AB 1 229-5155 BEARING-THRUST (0.5-MM OS)
AB 1 229-5156 BEARING-THRUST (0.5-MM US - 0.5-MM OS)
J3 1 107-7708 6 BEARING-MAIN (S TANDARD)
AB 1 145-0168 BEARING-MAIN (0.5-MM OS)
AB 1 145-0170 BEARING-MAIN (0.5-MM US - 0.5-MM OS)
AB 1 145-0162 BEARING-MAIN (0.25-MM US)
AB 1 145-0164 BEARING-MAIN (0.5-MM US)
ABF 1 7C-7980 1 SLEEVE-OIL SEAL
(THIS WEAR SLEEVE IS USED ONLY TO SALVAGE
(REPAIR) THE REAR SEAL SURFACE OF THE
CRANKSHAFT)
AVAILABLE REPAIR KIT(S):
AJ 196-9519 BEARING GP-MAIN (CRANKSHAFT)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
J-KIT MARKED J SERVICES PARTS MARKED J
SEBP4487-10 1of2 BASIC ENGINE 35

15. BASIC ENGINE
210-5590CRANKSHAFT GP (contd. ) i02682428
GRAPHIC #1 <END> g00977492
36BASIC ENGINE 2of2 SEBP4487-10

16. BASIC ENGINE
221-4482CYLINDER BLOCK GP
SMCS-1201 i02690901
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
CY 1 1 305-8141 1 CYLINDER BLOCK GP 39
21 7N-5683 2 DOWEL
31 1W-8407 2 SLEEVE
41 6V-3538 2 DOWEL
C-CHANGE FROM PREVIOUS TYPE
Y-SEPARATE ILLUSTRATION
GRAPHIC #1 <END> g00800849
SEBP4487-10
1of1 BASIC ENGINE 37

17. BASIC ENGINE
263-3774CYLINDER BLOCK GP
PART OF 305-8141 CYLINDER BLOCK GP
SMCS-1201 i02347180
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
21 7E-2968 7 CAP-CRANKSHAFT BEARING
M3 1 9X-8916 14 BOLT (M16X2X140-MM)
41 5P-8247 14 WASHER-HARD (17 X32X3.5-MM THK)
M-METRIC PART
GRAPHIC #1 <END> g01175397
38BASIC ENGINE 1of1 SEBP4487-10

18. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING

NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

19. BASIC ENGINE
305-8141CYLINDER BLOCK GP
PART OF 221-4482 CYLINDER BLOCK GP
SMCS-1201 i02690923
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
Y1 1 263-3774 1 CYLINDER BLOCK GP 38
21 2M-6471 2 PLUG-CUP
31 3H-5552 1 PLUG-CUP
41 9S-8006 1 PLUG-O-RING
51 2M-9780 1 SEAL-O-RING
61 216-5586 1 BEARING-SLEEVE (CAMSHAFT)
71 2W-7213 6 BEARING-SLEEVE (CAMSHAFT)
Y-SEPARATE ILLUSTRATION
SEBP4487-10 1of2 BASIC ENGINE 39

20. BASIC ENGINE
305-8141CYLINDER BLOCK GP (contd. ) i02690923
GRAPHIC #1 <END> g01348114
40BASIC ENGINE 2of2 SEBP4487-10

21. BASIC ENGINE
307-0103CYLINDER BLOCK GP-LONG
S/N: M7A1-UP
425/460 MHP
PART OF 311-4990, 311-4993, 311-4995 ENGINE AR
SMCS-1020 i02752980
NOTE PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
Y 307-0207 1 BASE GP-OIL FILTER 83
Y 166-9132 1 COOLER GP-ENGINE OIL 114
Y 274-6781 1 COVER GP-CYLIN DER BLOCK 16
Y 121-0801 1 COVER GP-FLYWHEEL HOUSING 18
Y 280-7949 1 COVER GP-FRONT HOUSING 19
Y 307-7587 1 COVER GP-VALVE M ECHANISM 28
Y 307-0198 1 DAMPER & PULLEY GP 47
Y 311-3518 1 ENGINE AR-CORE 13
Y 116-4556 1 FASTENER GP-FRON T HOUSING 51
Y 215-4751 1 FLYWHEEL GP 54
Y 215-4750 1 HOUSING GP-FLYWHEEL 57
Y 270-7522 1 HOUSING GP-FRONT 58
Y 307-5832 1 LIFTING GP-ENGINE 61
Y 117-5125 1 LINES GP-ENGINE OIL 97
Y 192-2172 1 PAN GP-OIL 67
Y 156-0229 1 PLUG GP-CYLINDER BLOCK 70
Y-SEPARATE ILLUSTRATION
<END>
307-0105CYLINDER BLOCK GP-LONG
S/N: M7A1-UP
425/460 MHP
PART OF 311-4991, 311-4994, 311-4996 ENGINE AR
SMCS-1020 i02753374
NOTE PART NUMBER QTY
PART NAME 123456 (PRODUCT LEVEL)
SEE
PAGE
Y 307-0207 1 BASE GP-OIL FILTER 83
Y 166-9132 1 COOLER GP-ENGINE OIL 114
Y 274-6781 1 COVER GP-CYLINDER BLOCK 16
Y 121-0801 1 COVER GP-FLYWHEEL HOUSING 18
Y 280-7949 1 COVER GP-FRONT HOUSING 19
Y 307-7587 1 COVER GP-VALVE MECHANISM 28
Y 307-0198 1 DAMPER & PULLEY GP 47
Y 311-3518 1 ENGINE AR-CORE 13
Y 116-4556 1 FASTENER GP-FRONT HOUSING 51
Y 215-4751 1 FLYWHEEL GP 54
Y 215-4750 1 HOUSING GP-FLYWHEEL 57
Y 270-7522 1 HOUSING GP-FRONT 58
Y 307-5832 1 LIFTING GP-ENGINE 61
Y 117-5125 1 LINES GP-ENGINE OIL 97
Y 171-6746 1 PAN GP-OIL 66
Y 156-0229 1 PLUG GP-CYLINDER BLOCK 70
Y-SEPARATE ILLUSTRATION
<END>
SEBP4487-10 BASIC ENGINE 41