Download Caterpillar C16 7CZ Diesel Engine Complete Service Manual

It is Original 7-volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for the Caterpillar C16 7CZ diesel engine. Additionally, the Cat C16 7CZ 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.
Please contact us with your engine serial number if you have compatibility questions.

Topics in the Caterpillar C16 7CZ Diesel Engine Complete Service Manual:

Engine Specifications

Engine Systems Operation

General Information
Electronic Control System Components
Fuel System
Air Inlet and Exhaust System
Lubrication System
Cooling System
Basic Engine
BrakeSaver
Compression Brake
Electrical System
Disassembly and Assembly

Fuel Priming Pump – Remove and Install
Fuel Filter Base – Remove
Fuel Filter Base – Disassemble
Fuel Filter Base – Assemble
Fuel Filter Base – Install
Fuel Transfer Pump – Remove
Fuel Transfer Pump – Install
Electronic Unit Injector – Remove
Electronic Unit Injector – Install
Electronic Unit Injector Sleeve – Remove
Electronic Unit Injector Sleeve – Install
Turbocharger – Remove
Turbocharger – Disassemble
Turbocharger – Assemble
Turbocharger – Install
Exhaust Manifold – Remove and Install
Inlet and Exhaust Valve Springs – Remove and Install
Inlet and Exhaust Valves – Remove and Install
Inlet and Exhaust Valve Guides – Remove and Install
Inlet and Exhaust Valve Seat Inserts – Remove and Install
Inlet and Exhaust Valve Seals – Remove and Install
Engine Oil Filter Base – Remove
Engine Oil Filter Base – Disassemble
Engine Oil Filter Base – Assemble
Engine Oil Filter Base – Install
Engine Oil Cooler – Remove
Engine Oil Cooler – Disassemble
Engine Oil Cooler – Assemble
Engine Oil Cooler – Install
Engine Oil Pump – Remove
Engine Oil Pump – Disassemble
Engine Oil Pump – Assemble
Engine Oil Pump – Install
Water Pump – Remove
Water Pump – Disassemble
Water Pump – Assemble
Water Pump – Install
Water Temperature Regulator – Remove and Install
Engine Support (Front) – Remove and Install
Flywheel – Remove
Flywheel – Install
Crankshaft Rear Seal – Remove
Crankshaft Rear Seal – Install
Flywheel Housing – Remove and Install
Vibration Damper and Pulley – Remove and Install
Crankshaft Front Seal – Remove
Removal Procedure
Crankshaft Front Seal – Install
Front Cover – Remove
Front Cover – Install
Gear Group (Front) – Remove
Gear Group (Front) – Install
Housing (Front) – Remove
Housing (Front) – Install
Accessory Drive – Remove
Accessory Drive – Disassemble
Accessory Drive – Assemble
Accessory Drive – Install
Valve Mechanism Cover – Remove and Install
Valve Mechanism Cover Base – Remove and Install
Compression Brake – Remove – If Equipped
Compression Brake – Disassemble – If Equipped
Compression Brake – Assemble – If Equipped
◦ Assembly Procedure
Compression Brake – Install – If Equipped
Rocker Arm and Shaft – Remove
Rocker Arm – Disassemble
Rocker Arm – Assemble
Rocker Arm and Shaft – Install
Cylinder Head – Remove
Cylinder Head – Install
Camshaft – Remove
Camshaft – Install
Camshaft Gear – Remove and Install
Camshaft Bearings – Remove
Camshaft Bearings – Install
Engine Oil Pan – Remove and Install
Cylinder Liner – Remove
Cylinder Liner – Install
Piston Cooling Jets – Remove and Install
Pistons and Connecting Rods – Remove
Pistons and Connecting Rods – Disassemble
Pistons and Connecting Rods – Assemble
Pistons and Connecting Rods – Install
Connecting Rod Bearings – Remove
Connecting Rod Bearings – Install
Crankshaft Main Bearings – Remove
Crankshaft Main Bearings – Install
Crankshaft – Remove
Crankshaft – Install
Bearing Clearance – Check
BrakeSaver – Remove
BrakeSaver – Disassemble
BrakeSaver – Assemble
BrakeSaver – Install
BrakeSaver Engine Oil Pan – Remove and Install
BrakeSaver Engine Oil Pump – Remove
BrakeSaver Engine Oil Pump – Disassemble
BrakeSaver Engine Oil Pump – Assemble
BrakeSaver Engine Oil Pump – Install
BrakeSaver Control Valve – Remove
BrakeSaver Control Valve – Disassemble
BrakeSaver Control Valve – Assemble
BrakeSaver Control Valve – Install
Atmospheric Pressure Sensor – Remove and Install
Camshaft Position Sensor – Remove and Install
Crankshaft Position Sensor – Remove and Install
Coolant Temperature Sensor – Remove and Install
Engine Oil Pressure Sensor – Remove and Install
Fuel Temperature Sensor – Remove and Install
Boost Pressure Sensor – Remove and Install
Inlet Air Temperature Sensor – Remove and Install
Belt Tensioner – Remove and Install
Fan Drive – Remove
Fan Drive – Disassemble
Fan Drive – Assemble
Fan Drive – Install
Engine Control Module – Remove and Install
Electric Starting Motor – Remove and Install
Air Compressor – Remove and Install
Air Compressor Drive Gear – Remove
Air Compressor Drive Gear – Install – Two Cylinder
Air Compressor Drive Gear – Install
Testing and Adjusting

Fuel System – Inspect
Air in Fuel – Test
Electronic Unit Injector – Adjust
Electronic Unit Injector – Test
Finding Top Center Position for No. 1 Piston
Fuel Quality – Test
Fuel System – Prime
Fuel System Pressure – Test
Gear Group (Front) – Time
Air Inlet and Exhaust System – Inspect
Turbocharger – Inspect
Inlet Manifold Pressure – Test
Exhaust Temperature – Test
Aftercooler – Test
Inlet Manifold Pressure
Engine Crankcase Pressure (Blowby) – Test
Compression – 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
Cooling System – Inspect
Cooling System – Test
Water Temperature Regulator – Test
Water Pump – Test
Piston Ring Groove – Inspect
Connecting Rod Bearings – Inspect
Main Bearings – Inspect
Cylinder Block – Inspect
Cylinder Liner Projection – Inspect
Flywheel – Inspect
Flywheel Housing – Inspect
Vibration Damper – Check
Jake Brake Compression Brake Adjustment
Pacbrake Compression Brake Adjustment
Control Valve (Compression Brake) – Test
Solenoid Valve (Compression Brake) – Test
Battery – Test
Charging System – Test
Electric Starting System – Test
Pinion Clearance – Adjust
Troubleshooting

Electronic Service Tools
Replacing the ECM
Sensors and Electrical Connectors
Engine Wiring Harness Diagram
Vehicle Wiring Harness Diagram
Programming Parameters
Test ECM Mode
Customer Passwords
ECM Date-Time Stamped Information
ECM Snapshot
Factory Passwords
Factory Passwords Worksheet
Flash Programming
Service Information Report
Customer Specified Parameters
Customer Specified Parameters Table
Customer Specified Parameters Worksheet
System Configuration Parameters
Can Not Reach Top Engine RPM
Can Not Reach Vehicle Speed Limit
Check Engine Lamp or Warning Lamp Is Malfunctioning
Cooling Fan Is Always ON
Cruise Control, Idle, or PTO Can Not Be Set
Driver Questionnaire
Driver Questionnaire Response
ECM Will Not Accept Factory Passwords
Electronic Service Tool Will Not Communicate with ECM
Engine Cranks but Will Not Start
Engine Misfires, Runs Rough or Is Unstable
Engine Retarder (Compression Brake) Will Not Turn ON
Engine Vibration
Engine Will Not Crank
Excessive Black Smoke
Excessive Fuel Consumption
Excessive White Smoke
Intermittent Cruise Control, Idle, or PTO Kickout
Intermittent Engine Shutdown
Intermittent Low Power or Power Cutout
Low Power – Poor or No Response to Throttle
Poor Acceleration or Response
Diagnostic Codes
No Diagnostic Code Detected -55
5 Volt Engine Pressure Sensor Supply Circuit – Test
Accelerator Pedal (Throttle) Position Sensor Circuit – Test
Air Inlet Shutoff Circuit – Test
ATA (SAE J1587 J1708) Data Link Circuit – Test
Auxiliary Brake Circuit – Test
Check Engine Lamp Circuit – Test
Clutch Pedal Position Switch Circuit – Test
Coolant Level Sensor Circuit – Test
Cooling Fan Circuit and AC High Pressure Switch Circuit
Cruise Control Switch Circuit – Test
Diagnostic Enable Switch Circuit – Test
Eaton Top 2 Transmission Circuit – Test
ECM Memory – Test
Electrical Connectors – Inspect
Engine Pressure Sensor Open or Short Circuit – Test
Engine Running Output Circuit – Test
Engine Shutdown Output Circuit – Test
Engine Speed Timing Sensor Circuit – Test
Engine Temperature Sensor Open or Short Circuit – Test
Fan Override Switch Circuit – Test
Idle Shutdown Timer – Test
Ignition Keyswitch Circuit and Battery Supply Circuit – Test
Ignore Brake Clutch Switch Circuit – Test
Ignore Brake Clutch Switch Circuit – Test
Multi-Torque – Test
Neutral Switch Circuit – Test
Powertrain Data Link Circuit – Test
PTO Engine RPM Set Speed (Input A and Input
PTO Shutdown Timer – Test
PTO Switch Circuit – Test
PTO Switch ON Lamp Circuit – Test
Remote PTO Accelerator Position Sensor Circuit – Test
Retarder (Compression Brake) Solenoid Circuit – Test
Service Brake Pedal Position (Switch 1) Circuit – Test
Service Brake Pedal Position (Switch 2) Circuit – Test
Starting Aid Output Circuit – Test
Starting Aid Switch Circuit – Test
Tachometer Circuit – Test
Torque Limit Switch Circuit – Test
Two Speed Axle Switch Circuit – Test
Vehicle Speed and Speedometer Circuit – Test
Warning Lamp Circuit – Test
Engine Speed Timing Sensor – Calibrate
Injector Code – Calibrate
Vehicle Speed Circuit – Calibrate
Code-based Troubleshooting
0001-11 Cylinder #1 Injector current fault (72)
0002-11 Cylinder #2 Injector current fault (72)
0003-11 Cylinder #3 Injector current fault (73)
0004-11 Cylinder #4 Injector current fault (73)
0005-11 Cylinder #5 Injector current fault (74)
0006-11 Cylinder #6 Injector current fault (74)
0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
0022-13 Engine Speed Signal Calibration Not Performed (42)
0030-08 PTO Throttle signal invalid (29)
0030-13 PTO Throttle out of calibration (29)
0041-03 8 Volt Supply voltage high (21)
0041-04 8 Volt Supply voltage low (21)
0043-02 Key Switch Fault (71)
0052-11 Air Inlet Shutoff Shutdown (00)
0054-05 Auxiliary Output #06 current low (66)
0054-06 Auxiliary Output #06 current high (66)
0055-05 Auxiliary Output #07 current low (67)
0055-06 Auxiliary Output #07 current high (67)
0064-12 Secondary Engine Speed loss of signal (34)
0071-00 Idle Shutdown Override (01)
0071-01 Idle Shutdown (47)
0071-14 PTO Shutdown (47)
0084-00 Vehicle Overspeed Warning (41)
0084-01 Vehicle Speed loss of signal (31)
0084-02 Vehicle Speed signal invalid (36)
0084-08 Vehicle Speed signal out of range (36)
0084-10 Vehicle Speed signal rate of change (36)
0084-14 Quick Stop Occurrence
0091-08 Throttle Position Invalid (32)
0091-13 Throttle Position out of calibration (28)
0100-01 Low Oil Pressure Warning (46)
0100-03 Oil Pressure voltage high (24)
0100-04 Oil Pressure voltage low (24)
0100-11 Very Low Oil Pressure (46)
0102-00 Excessive Boost Pressure
0102-03 Boost Pressure voltage high (25)
0102-04 Boost Pressure voltage low (25)
0105-00 High Intake Manifold Air Temperature Warning (64)
0105-03 Intake Manifold Air Temperature voltage high (38)
0105-04 Intake Manifold Air Temperature voltage low (38)
0105-11 Very High Intake Manifold Air Temperature (64)
0108-03 Barometric Pressure voltage high (26)
0108-04 Barometric Pressure voltage low (26)
0110-00 High Coolant Temperature Warning (61) (1)
0110-00 High Coolant Temperature Warning (61)
0110-04 Coolant Temperature voltage low (27) (1)
0110-04 Coolant Temperature voltage low (27) (2)
0110-04 Coolant Temperature voltage low (27)
0111-02 Coolant Level signal invalid (12)
0111-03 Coolant Level voltage high (12) (1)
0111-03 Coolant Level voltage high (12)
0111-11 Very Low Coolant Level (62)
0121-05 Low High Retarder current low (14) (1)
0121-05 Low High Retarder current low (14)
0122-05 Med High Retarder current low (14)
0122-06 Med High Retarder current high (14)
0168-01 Low ECM Battery Power (17)
0168-02 ECM Battery Power Intermittent (51) (1)
0168-02 ECM Battery Power Intermittent (51) (2)
0168-02 ECM Battery Power Intermittent (51) (3)
0168-02 ECM Battery Power Intermittent (51)
0174-00 High Fuel Temperature Warning (65)
0174-03 Fuel Temperature voltage high (13)
0174-04 Fuel Temperature voltage low (13)
0190-00 Engine Overspeed Warning (35)
0190-12 Primary Engine Speed loss of signal (34)
0191-07 Transmission Not Responding (68)
0224-11 Theft Deterrent Active (00)
0224-14 Theft Deterrent Active with Engine Cranking (00)
0231-02 J1939 Data Incorrect (58)
0231-11 J1939 Data Link Fault (58)
0231-12 J1939 Device Not Responding
0232-03 5 Volt Supply voltage high (21)
0232-04 5 Volt Supply voltage low (21)
0246-11 Brake Pedal Switch #1 Fault
0247-11 Brake Pedal Switch #2 Fault
0249-11 J1922 Data Link Fault (58)
0252-11 Engine Software Incorrect (59)
0253-02 Check Customer or System Parameters (56)
0253-11 Check Transmission Customer Parameters (56)
Wiring Schematics (Foldout and Collage sizes)
On-Highway Engines Electronic PTO Installation and Application Guide
General Torque Specifications for All Caterpillar Products

Covers: Caterpillar C16 Diesel Engine with serial prefix-
7CZ 001 and up
Pages: 1,751
Format: PDF files (zipped)
File size: 59mb
Compatibility: Windows/Mac computers
Notes: Instant download only.

Caterpillar C16 7CZ Diesel Engine Full Complete Complete Service Manual