Caterpillar C3.4B Generator Set Engine Repair Service Manual PDF with Wiring Diagrams - MCATC3.4BGEN.zip
A full factory-style service and repair guide for Caterpillar C3.4B Generator Set Engines, complete with Electrical Wiring Diagrams, delivering every technical detail you need to service, troubleshoot, fix, and overhaul these units just like a trained technician.
The workshop service and repair manual for Caterpillar C3.4B Generator Set Engines covers:
* 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.
KENR9132 - Schematic (C3.4B Industrial Engine Electrical System).pdf
M0100127 - Systems Operation (C3.4B Generator Set Engines).pdf
M0100127 - Testing and Adjusting (C3.4B Generator Set Engines).pdf
M0121714 - Disassembly and Assembly (C3.4B Generator Set Engines).pdf
UENR0611 - Troubleshooting (C3.4B Engines).pdf
UENR7492 - Schematic (C3.4B XQ60 Rental Generator Set Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 1,064 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR9132 - Schematic (C3.4B Industrial Engine Electrical System)....2
M0100127 - Systems Operation (C3.4B Generator Set Engines)....4
Introduction....5
Basic Engine....10
Air Inlet and Exhaust System....18
Clean Emissions Module....27
DEF Dosing Control System....29
Cooling System....40
Lubrication System....43
Electrical System....44
Cleanliness of Fuel System Components....46
Fuel Injection....48
Electronic Control System....59
Power Sources....72
Glossary of Electronic Control Terms....76
M0100127 - Testing and Adjusting (C3.4B Generator Set Engines)....84
Fuel System - Inspect....85
Air in Fuel - Test....86
Finding Top Center Position for No. 1 Piston....89
Fuel Quality - Test....90
Fuel System - Prime....92
Fuel System Pressure - Test....95
Gear Group (Front) - Time....99
Air Inlet and Exhaust System - Inspect....101
Turbocharger - Inspect....103
Exhaust Cooler (NRS) - Test....108
Compression - Test....110
Engine Valve Lash - Inspect....112
Valve Depth - Inspect....115
Valve Guide - Inspect....117
Diesel Exhaust Fluid Quality - Test....119
Aftertreatment SCR System Dosing - Test....124
Diesel Exhaust Fluid Tank - Flush....126
Engine Oil Pressure - Test....130
Engine Oil Pump - Inspect....131
Excessive Bearing Wear - Inspect....132
Excessive Engine Oil Consumption - Inspect....133
Increased Engine Oil Temperature - Inspect....134
M0121714 - Disassembly and Assembly (C3.4B Generator Set Engines)....135
Fuel Priming Pump - Remove and Install....140
Flow Control Valve - Remove and Install....145
Fuel Filter Base - Remove and Install....149
Water Separator and Fuel Filter (Primary) - Remove and Install....157
Fuel Manifold (Rail) - Remove and Install....163
Fuel Injection Lines - Remove....169
Fuel Injection Lines - Install....175
Exhaust Cooler (NRS) - Remove and Install....182
Throttle Valve (Intake Air) - Remove and Install - Rear Facing Inlet Elbow....186
Throttle Valve (Intake Air) - Remove and Install - Side Facing Inlet Elbow....193
Fuel Injection Pump - Remove....199
Fuel Injection Pump - Install....202
Fuel Injection Pump Gear - Remove....206
Fuel Injection Pump Gear - Install....211
Electronic Unit Injector - Remove....214
Electronic Unit Injector - Install....219
Turbocharger - Remove - Top Mounted Turbocharger....224
Turbocharger - Remove - Side Mounted Turbochargers....230
Turbocharger - Install - Side Mounted Turbocharger....236
Turbocharger - Install - Top Mounted Turbocharger....243
Wastegate Solenoid - Remove and Install....249
Exhaust Gas Recirculation Valve - Remove and Install....253
Selective Catalytic Reduction (SCR) Canister - Remove and Install....262
Clean Emissions Module - Remove and Install - Flywheel Mounted Diesel Oxidation Catalyst (DOC)....267
Clean Emissions Module - Remove and Install - Top Mounted Diesel Oxidation Catalyst (DOC)....271
Diesel Exhaust Fluid Lines - Remove and Install....275
Diesel Exhaust Fluid Pump - Remove and Install....282
DEF Injector and Mounting - Remove and Install....287
Diesel Exhaust Fluid Tank - Remove and Install....293
Manifold (DEF Heater) - Remove and Install....298
Solenoid Valve (DEF Heater Coolant) - Remove and Install....307
Flexible Exhaust Pipe - Remove and Install - Flexible Exhaust Pipe from the Turbocharger and the Diesel Oxidation Catalyst (DOC)....310
Flexible Exhaust Pipe - Remove and Install - Flexible Exhaust Pipe Between DOC and the SCR....313
Exhaust Manifold - Remove and Install - Side Mounted Turbocharger Exhaust Manifold....322
Exhaust Manifold - Remove and Install - Top Mounted Turbocharger Exhaust Manifold....327
Support and Mounting (CEM) - Remove and Install - Flywheel Housing Mounted CEM....332
Support and Mounting (CEM) - Remove and Install - Top Mounted DOC....335
Inlet Manifold - Remove and Install....342
Inlet and Exhaust Valve Springs - Remove and Install....351
Inlet and Exhaust Valves - Remove and Install....357
Inlet and Exhaust Valve Guides - Remove and Install....364
Engine Oil Filter Base - Remove and Install....368
Engine Oil Cooler - Remove....372
Engine Oil Cooler - Install....376
Engine Oil Relief Valve - Remove and Install....380
Engine Oil Pump - Remove....382
Engine Oil Pump - Install....384
Water Pump - Remove....386
Water Pump - Install....389
Water Temperature Regulator - Remove and Install....392
Engine Lifting Bracket - Remove....396
Engine Lifting Bracket - Install....398
Flywheel - Remove....400
Flywheel - Install....403
Crankshaft Rear Seal - Remove and Install....406
Flywheel Housing - Remove and Install - Stressed Cylinder Block....411
Flywheel Housing - Remove and Install - Non-Stressed Cylinder Block....419
Power Take-Off Drive - Remove and Install....427
Crankshaft Pulley - Remove and Install....434
Crankshaft Front Seal - Remove and Install....437
Front Cover - Remove and Install....441
Idler Gear - Remove....448
Idler Gear - Install....454
Housing (Front) - Remove....458
Housing (Front) - Install....462
Accessory Drive - Remove and Install....470
Crankcase Breather - Remove....477
Crankcase Breather - Install....480
Valve Mechanism Cover - Remove and Install....483
Rocker Shaft and Pushrod - Remove....493
Rocker Shaft - Disassemble....498
Rocker Shaft - Assemble....500
Rocker Shaft and Pushrod - Install....503
Cylinder Head - Remove....509
Cylinder Head - Install....513
Lifter Group - Remove and Install....521
Camshaft - Remove and Install....525
Camshaft Gear - Remove and Install....529
Camshaft Bearings - Remove and Install....535
Engine Oil Pan - Remove and Install - Pressed Steel Oil Pan....538
Engine Oil Pan - Remove and Install - Cast Iron Engine Oil Pan....544
Balancer - Remove....550
Balancer - Install....555
Piston Cooling Jets - Remove and Install....560
Pistons and Connecting Rods - Remove....563
Pistons and Connecting Rods - Disassemble....566
Pistons and Connecting Rods - Assemble....569
Pistons and Connecting Rods - Install....574
Connecting Rod Bearings - Remove - Connecting rods in position....578
Connecting Rod Bearings - Install - Connecting rods in position....581
Crankshaft Main Bearings - Remove and Install....585
Crankshaft - Remove....593
Crankshaft - Install....596
Crankshaft Timing Ring - Remove and Install....599
Bearing Clearance - Check....602
Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor on Engine....605
Camshaft Position Sensor - Remove and Install....612
Crankshaft Position Sensor - Remove and Install....615
Coolant Temperature Sensor - Remove and Install....618
Engine Oil Pressure Switch - Remove and Install....621
Fuel Temperature Sensor - Remove and Install....624
Temperature Sensor (Exhaust) - Remove and Install - Exhaust Manifold Temperature Sensor for NRS....628
Temperature Sensor (Exhaust) - Remove and Install....630
Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor Exhaust before SCR....633
Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor Exhaust After SCR....636
Pressure Sensor (Exhaust Back Pressure) - Remove and Install....639
Inlet Manifold Temperature Sensor - Remove and Install....644
Inlet Manifold Pressure Sensor - Remove and Install....646
Glow Plugs - Remove and Install....648
Alternator Belt - Remove and Install....651
Idler Pulley - Remove and Install....654
Fan - Remove and Install....657
Fan Drive - Remove and Install....660
Alternator - Remove....663
Alternator - Install....666
Electric Starting Motor - Remove and Install....670
UENR0611 - Troubleshooting (C3.4B Engines)....673
General Information....676
Welding Precaution....679
Electronic Service Tools....681
Service Information Report....685
System Overview....687
Component Location....689
Diesel Particulate Filter Regeneration....698
Engine Monitoring System....699
Diagnostic Capabilities....700
Electrical Connectors....701
Configuration Parameters....703
Diagnostic Trouble Codes....704
Acceleration Is Poor or Throttle Response Is Poor....718
Alternator Problem - Charging Problem and_or Noisy Operation....724
Battery Problem....727
Coolant Contains Oil....729
Coolant Level Is Low....732
Coolant Temperature Is High....733
Crankcase Breather Ejects Oil....738
Cylinder Is Noisy....742
Diesel Particulate Filter Active Regeneration Occurrence Is Excessive....745
Diesel Particulate Filter Active Regeneration Was Interrupted....748
Diesel Particulate Filter Collects Excessive Soot....750
Diesel Particulate Filter Has Differential Pressure Problem....754
Diesel Particulate Filter Temperature Is Low....758
Engine Cranks but Does Not Start....761
Engine Does Not Crank....767
Engine Has Early Wear....771
Engine Has Mechanical Noise (Knock)....774
Engine Misfires; Runs Rough or Is Unstable....778
Engine Overspeeds....782
Engine Shutdown Occurs Intermittently....783
Engine Stalls at Low RPM....786
Engine Top Speed Is Not Obtained....789
Engine Vibration Is Excessive....794
Exhaust Has Excessive Black Smoke....797
Exhaust Has Excessive White Smoke....801
Exhaust System Contains Coolant....805
Exhaust System Contains Oil....807
Fuel Consumption Is Excessive....809
Fuel Contains Water....815
Fuel Rail Pressure Problem....817
Fuel Temperature Is High....824
Inlet Air Is Restricted....825
Intake Manifold Air Pressure Is High....827
Intake Manifold Air Pressure Is Low....829
Intake Manifold Air Temperature Is High....832
NRS Mass Flow Rate Problem....835
Oil Consumption Is Excessive....838
Oil Contains Coolant....842
Oil Contains Fuel....845
Oil Pressure Is Low....849
Power Is Intermittently Low or Power Cutout Is Intermittent....854
Valve Lash Is Excessive....858
Data Link - Test....860
ECM Memory - Test....865
Electrical Power Supply - Test....869
Glow Plug Starting Aid - Test....874
Idle Validation - Test....883
Indicator Lamp - Test....892
Injector Data Incorrect - Test....896
Injector Solenoid - Test....901
Mode Selection - Test....909
Motorized Valve - Test....914
Oxygen Level - Test....921
Power Take-Off - Test....929
Relay - Test - Start Relay....935
Relay - Test - ECM Main Relay....943
Sensor Signal (Analog; Active) - Test - Exhaust Gas Pressure Sensor....947
Sensor Signal (Analog; Active) - Test....953
Sensor Signal (Analog; Passive) - Test....962
Sensor Supply - Test....970
Solenoid Valve - Test....975
Speed Control - Test....983
Speed_Timing - Test....990
Switch Circuits - Test - Throttle Switch....999
Switch Circuits - Test - Air Filter Restriction Switch....1004
Switch Circuits - Test - Engine Oil Pressure Switch....1011
Valve Position - Test....1016
Water in Fuel - Test....1023
Service Tool Features....1028
Electronic Service Tool Does Not Communicate....1031
ECM Software - Install....1034
ECM - Replace....1037
Electrical Connectors - Inspect....1039
Injector Code - Calibrate....1044
UENR7492 - Schematic (C3.4B XQ60 Rental Generator Set Electrical System)....1047
Features....1047
Cover Page....1048
Schematic....1050
Machine Views....0
Engine Left Side View....1051
Engine Right Side View....1052
Panel Front View....1053
Panel Inside View....1054
Panel Rear View....1055
Caterpillar C3.4B Generator Set Engines Repair Service Manual