Caterpillar C3.3 C4.4 Generator Set Engines Workshop Repair Service Manual PDF - MCATC3.3C4.4GEN.zip
This is the full factory-level service and repair guide for Caterpillar C3.3 and C4.4 Generator Sets, complete with Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, overhaul, and rebuild these units the way trained technicians do.
Covered inside the Caterpillar C3.3 / C4.4 Generator Sets workshop service and repair manual:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
UENR8296 - Schematic (C4.4 XQ125 Rental Generator Set Electrical System).pdf
UENR4473 - Troubleshooting (C4.4 Marine Generator Set).pdf
UENR4472 - Disassembly and Assembly (C4.4 Marine Generator Set).pdf
UENR4471 - Testing and Adjusting (C4.4 Marine Generator Set).pdf
UENR4471 - Systems Operation (C4.4 Marine Generator Set).pdf
UENR4470 - Specifications (C4.4 Marine Generator Set).pdf
UENR4440 - Testing and Adjusting (C3.3 Generator Sets).pdf
UENR4440 - Systems Operation (C3.3 Generator Sets).pdf
UENR4439 - Specifications (C3.3 Generator Sets).pdf
UENR3999 - Schematic (C4.4 Marine Generator Set Electrical System).pdf
UENR0662 - Troubleshooting (C4.4 Engines).pdf
RENR9703 - Disassembly & Assembly (C3.3 and C4.4 Generator Sets).pdf
RENR9561 - Schematic (C3.3 and C4.4 Generator Sets Electrical System).pdf
M0120095 - Schematic (Marine Generator Set Control Panel (MGCP) II Electrical System).pdf
M0102043 - Disassembly and Assembly (C4.4 Generator Set Engines).pdf
M0072260 - Testing and Adjusting (C4.4 Generator Set Engines).pdf
M0072260 - Systems Operation (C4.4 Generator Set Engines).pdf
M0072258 - Specifications (C4.4 Generator Set Engines).pdf
PRODUCT DETAILS:
Total Pages: 3,822 pages
File Format: PDF
Language: English
M0072258 - Specifications (C4.4 Generator Set Engines)....2
Engine Design....5
Fuel Injection Lines....7
Fuel Injection Pump....9
Fuel Injection Nozzles....11
Fuel Transfer Pump....13
Fuel Filter Base....15
Fuel Filter Base - Single Secondary Fuel Filter Base....17
Fuel Filter Base - Twin Secondary Fuel Filter Base....19
Fuel Filter Base - Primary Fuel Filter Base....21
Fuel Manifold (Rail)....23
Lifter Group....25
Rocker Shaft....26
Valve Mechanism Cover....28
Cylinder Head Valves....29
Cylinder Head....32
Turbocharger - Series Turbochargers....37
Turbocharger - Single Turbocharger....44
Exhaust Gas Valve (NRS)....49
Exhaust Sensor and Lines (NRS)....54
Exhaust Cooler (NRS)....56
Exhaust Manifold....58
Flexible Exhaust Pipe....59
Diesel Particulate Filter....60
Camshaft....61
Camshaft Bearings....64
Engine Oil Filter Base....67
Engine Oil Cooler....72
Engine Oil Pump....76
Engine Oil Pressure....79
Engine Oil Pan....80
Crankcase Breather....83
Water Temperature Regulator and Housing....85
Water Pump....89
Cylinder Block....90
Crankshaft....92
Crankshaft Seals....95
Connecting Rod Bearing Journal....97
Main Bearing Journal....98
Connecting Rod....99
Piston and Rings....103
Piston Cooling Jet....105
Balancer....107
Accessory Drive....109
Accessory Drive - SAE B....110
Front Housing and Covers....112
Gear Group (Front)....114
Flywheel....117
Flywheel Housing....119
Crankshaft Pulley....121
Belt Tensioner....123
Refrigerant Compressor....124
Fan Drive....126
Engine Lifting Bracket....127
Alternator....128
Starter Motor....133
Coolant Temperature Sensor....138
Engine Oil Pressure Sensor....141
Boost Pressure Sensor....144
Atmospheric Pressure Sensor....147
Inlet Manifold Temperature Sensor....148
Temperature Sensor (DPF Inlet)....151
Pressure Sensor (NOx Reduction System)....153
Temperature Sensor (NOx Reduction System)....154
Speed_Timing Sensor....156
Electronic Control Module....158
Glow Plugs....161
Air Compressor - Twin Cylinder Compressor....163
Air Compressor - Single Cylinder....167
M0072260 - Systems Operation (C4.4 Generator Set Engines)....170
Introduction....171
Basic Engine....178
Air Inlet and Exhaust System - Series Turbochargers....185
Clean Emissions Module....194
Cooling System....196
Lubrication System....199
Electrical System....201
Cleanliness of Fuel System Components....204
Fuel Injection....206
Electronic Control System....218
Power Sources....236
Glossary of Electronic Control Terms....240
M0072260 - Testing and Adjusting (C4.4 Generator Set Engines)....248
Fuel System - Inspect....250
Air in Fuel - Test....251
Finding Top Center Position for No. 1 Piston....254
Fuel Injection Timing - Check....257
Fuel Quality - Test....260
Fuel System - Prime....262
Gear Group (Front) - Time....264
Air Inlet and Exhaust System - Inspect....266
Turbocharger - Inspect - Series Turbochargers....269
Exhaust Cooler (NRS) - Test....275
Compression - Test....277
Engine Valve Lash - Inspect....279
Valve Depth - Inspect....284
Valve Guide - Inspect....287
Diesel Exhaust Fluid Quality - Test....289
Aftertreatment SCR System Dosing - Test....298
Diesel Exhaust Fluid Tank - Flush....303
Engine Oil Pressure - Test....306
Engine Oil Pump - Inspect....307
Excessive Bearing Wear - Inspect....309
Excessive Engine Oil Consumption - Inspect....310
Increased Engine Oil Temperature - Inspect....311
Cooling System - Check....312
Cooling System - Inspect....314
Cooling System - Test....315
Engine Oil Cooler - Inspect....319
Water Temperature Regulator - Test....321
Water Pump - Inspect....322
Position the Valve Mechanism Before Maintenance Procedures....323
Piston Ring Groove - Inspect....326
Connecting Rod - Inspect....329
Cylinder Block - Inspect....331
Cylinder Head - Inspect....332
Piston Height - Inspect....335
Flywheel - Inspect....338
Flywheel Housing - Inspect....341
Gear Group - Inspect....344
Crankshaft Pulley - Check....346
Alternator - Test....348
Battery - Test....350
Charging System - Test....351
V-Belt - Test....352
Electric Starting System - Test....354
M0102043 - Disassembly and Assembly (C4.4 Generator Set Engines)....358
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP)....363
Flow Control Valve - Remove and Install....367
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter....373
Fuel Filter Base - Remove and Install - Twin Secondary Fuel Filter....381
Water Separator and Fuel Filter (Primary) - Remove and Install....389
Fuel Manifold (Rail) - Remove and Install....395
Relief Valve (Fuel) - Remove and Install....399
Fuel Injection Lines - Remove....403
Fuel Injection Lines - Install....409
Exhaust Cooler (NRS) - Remove and Install - Top Mounted Turbocharger....416
Exhaust Cooler (NRS) - Remove and Install - Side Mounted Turbocharger....425
Exhaust Cooler (NRS) - Remove and Install - Twin Turbochargers....433
Inlet Air Control - Remove - NRS Induction Mixer....441
Inlet Air Control - Install - NRS Induction Mixer....446
Fuel Injection Pump - Remove....454
Fuel Injection Pump - Install....458
Fuel Injection Pump Gear - Remove....463
Fuel Injection Pump Gear - Install....465
Electronic Unit Injector - Remove....468
Electronic Unit Injector - Install....475
Turbocharger - Remove - Side Mounted Turbochargers....482
Turbocharger - Remove - Top Mounted Turbocharger....485
Turbocharger - Remove - Second Stage Turbocharger....489
Turbocharger - Remove - First Stage Turbocharger....494
Turbocharger - Install - Top Mounted Turbocharger....498
Turbocharger - Install - Second Stage Turbocharger....504
Turbocharger - Install - First Stage Turbocharger....510
Turbocharger - Install - Side Mounted Turbochargers....518
Wastegate Solenoid - Remove and Install....523
Exhaust Back Pressure Valve - Remove and Install....529
Clean Emissions Module - Remove and Install....533
Diesel Exhaust Fluid Lines - Remove and Install....538
Diesel Exhaust Fluid Pump - Remove and Install....543
DEF Injector and Mounting - Remove and Install....548
Diesel Exhaust Fluid Tank - Remove and Install....554
Manifold (DEF Heater) - Remove and Install....559
Solenoid Valve (DEF Heater Coolant) - Remove and Install....568
Flexible Exhaust Pipe - Remove and Install....571
Exhaust Manifold - Remove and Install - Single Turbocharger Exhaust Manifold....581
Exhaust Manifold - Remove and Install - Twin Turbochargers Exhaust manifold....587
Exhaust Elbow - Remove and Install....593
Exhaust Elbow - Remove and Install - Top Mounted and Side Mounted Turbocharger Exhaust Elbow....596
Support and Mounting (CEM) - Remove and Install....599
Inlet and Exhaust Valve Springs - Remove and Install....603
Inlet and Exhaust Valves - Remove and Install....612
Engine Oil Filter Base - Remove and Install....619
Engine Oil Cooler - Remove....622
Engine Oil Cooler - Install....625
Engine Oil Pump - Remove....629
Engine Oil Pump - Install....632
Water Pump - Remove....635
Water Pump - Install....638
Water Temperature Regulator - Remove and Install....644
Flywheel - Remove....647
Flywheel - Install....650
Crankshaft Rear Seal - Remove....653
Crankshaft Rear Seal - Install....655
Flywheel Housing - Remove and Install - Wet Back End Housing....659
Flywheel Housing - Remove and Install - Standard Housing....667
Crankshaft Pulley - Remove and Install....675
Crankshaft Front Seal - Remove and Install....678
Crankshaft Front Seal - Remove and Install - Crankshaft Front Seal for Heavy Duty Front Cover....682
Front Cover - Remove and Install....686
Front Cover - Remove and Install - Heavy Duty Front Cover....690
Gear Group (Front) - Remove and Install....694
Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)....709
Idler Gear - Remove....729
Idler Gear - Install....735
Housing (Front) - Remove....744
Housing (Front) - Remove - Heavy Duty Housing (Front)....748
Housing (Front) - Install - Heavy Duty Housing (Front)....752
Housing (Front) - Install....760
Accessory Drive - Remove and Install - Accessory Drive SAE A....767
Accessory Drive - Remove and Install - Accessory Drive SAE B....771
Crankcase Breather - Remove....780
Crankcase Breather - Install....785
Valve Mechanism Cover - Remove and Install....790
Rocker Shaft and Pushrod - Remove....797
Rocker Shaft - Disassemble....801
Rocker Shaft - Assemble....804
Rocker Shaft and Pushrod - Install....807
Cylinder Head - Remove....815
Cylinder Head - Install....824
Lifter Group - Remove and Install - Hydraulic Lifter Group....834
Camshaft - Remove and Install....838
Camshaft Gear - Remove and Install....843
Camshaft Bearings - Remove and Install....857
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans....861
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan....873
Balancer - Remove....883
Balancer - Install....888
Piston Cooling Jets - Remove and Install....897
Pistons and Connecting Rods - Remove....901
Pistons and Connecting Rods - Disassemble....904
Pistons and Connecting Rods - Assemble....908
Pistons and Connecting Rods - Install....913
Connecting Rod Bearings - Remove - Connecting Rods in Position....917
Connecting Rod Bearings - Install - Connecting Rods in Position....920
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position....924
Crankshaft - Remove....934
Crankshaft - Install....939
Crankshaft Timing Ring - Remove and Install....947
Crankshaft Gear - Remove and Install....950
Crankshaft Gear (Balancer Drive) - Remove and Install....955
Bearing Clearance - Check....958
Refrigerant Compressor - Remove and Install....961
Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor on Engine....969
Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor Positioned in Original Equipment Manufacture (OEM) Exhaust Tube Assembly....974
Atmospheric Pressure Sensor - Remove and Install....979
Camshaft Position Sensor - Remove and Install....981
Crankshaft Position Sensor - Remove and Install....984
Coolant Temperature Sensor - Remove and Install....987
Engine Oil Pressure Sensor - Remove and Install....990
Fuel Temperature Sensor - Remove and Install....993
Ammonia Sensor - Remove and Install - Ammonia Sensor if Equipped....997
Soot Antenna - Remove and Install....1002
Temperature Sensor (Exhaust) - Remove and Install - Selective Catalytic Reduction (SCR) Temperature Sensor....1006
Temperature Sensor (DPF) - Remove and Install....1008
Temperature Sensor (Catalyst Inlet) - Remove and Install....1010
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install....1012
Pressure Sensor (Cooled Exhaust Gas) - Remove and Install - Differential Pressure Sensor and Inlet Pressure Sensor....1015
Boost Pressure Sensor - Remove and Install....1024
Inlet Manifold Temperature Sensor - Remove and Install....1027
Glow Plugs - Remove and Install....1030
Alternator Belt - Remove and Install....1035
Idler Pulley - Remove and Install - Grooved Idler Pulley....1039
Idler Pulley - Remove and Install - Flat Idler Pulley....1042
Belt Tensioner - Remove and Install....1045
Fan - Remove and Install....1048
Fan Drive - Remove and Install....1051
Electronic Control Module - Remove....1053
Electronic Control Module - Install....1062
Alternator - Remove....1072
Alternator - Install....1079
Electric Starting Motor - Remove and Install....1088
Air Compressor - Remove and Install - Single Cylinder Air Compressor....1091
Air Compressor - Remove and Install - Twin Cylinder Air Compressor....1107
M0120095 - Schematic (Marine Generator Set Control Panel (MGCP) II Electrical System)....1125
COVER....1125
SHEET 1....1126
SHEET 2....1127