Caterpillar C4.4 Engines Repair Service Manuals
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C4.4 Engines (GENERATOR SET ENGINE/INDUSTRIAL ENGINE/MACHINE ENGINE/PETROLEUM ENGINE/MARINE ENGINE), with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C4.4 Series Diesel Engines workshop service repair manual includes:
* 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.
ENGINE - GENERATOR SET
Model Prefix
C4.4 GENERATOR SET CK5
C4.4 GENERATOR SET CN3
C4.4 GENERATOR SET CN4
C4.4 GENERATOR SET CN6
C4.4 GENERATOR SET D4B
C4.4 GENERATOR SET D4D
C4.4 GENERATOR SET GLD
C4.4 GENERATOR SET GLE
C4.4 GENERATOR SET GTH
C4.4 GENERATOR SET L4R
C4.4 GENERATOR SET L4T
C4.4 GENERATOR SET LC4
C4.4 GENERATOR SET LC5
C4.4 GENERATOR SET MZT
C4.4 GENERATOR SET N4D
C4.4 GENERATOR SET N4E
C4.4 GENERATOR SET N4R
C4.4 GENERATOR SET N4X
C4.4 GENERATOR SET NCD
C4.4 GENERATOR SET NCE
C4.4 GENERATOR SET TX2
C4.4 GENERATOR SET TX3
C4.4 GENERATOR SET TXB
C4.4 GENERATOR SET XYC
C4.4 GENERATOR SET XYD
C4.4DE110E GENERATOR SET ECL
C4.4DE55E2 GENERATOR SET EC7
C4.4DE55E2 GENERATOR SET GT6
C4.4DE65E3 GENERATOR SET EC8
C4.4DE65E3 GENERATOR SET GT8
C4.4DE88E0 GENERATOR SET EC9
C4.4DE88E0 GENERATOR SET GT9
C4.4DE88E3 GENERATOR SET ECK
C4.4DE88E3 GENERATOR SET GTD
C4.4XQ100 GENERATOR SET XRB
C4.4XQ80 GENERATOR SET XRA
ENGINE - INDUSTRIAL
Model Prefix
C4.4 INDUSTRIAL ENGINE 2L2
C4.4 INDUSTRIAL ENGINE 433
C4.4 INDUSTRIAL ENGINE 440
C4.4 INDUSTRIAL ENGINE 444
C4.4 INDUSTRIAL ENGINE 446
C4.4 INDUSTRIAL ENGINE 447
C4.4 INDUSTRIAL ENGINE 448
C4.4 INDUSTRIAL ENGINE 477
C4.4 INDUSTRIAL ENGINE 4J4
C4.4 INDUSTRIAL ENGINE CF7
C4.4 INDUSTRIAL ENGINE JKT
C4.4 INDUSTRIAL ENGINE W23
C4.4 REMAN ENGINE P4X
ENGINE - MACHINE
Model Prefix
C4.4 ENGINE - MACHINE 444
C4.4 ENGINE - MACHINE 446
C4.4 ENGINE - MACHINE 448
C4.4 ENGINE - MACHINE C4E
C4.4 ENGINE - MACHINE C4Z
C4.4 ENGINE - MACHINE CRS
C4.4 ENGINE - MACHINE E7A
C4.4 ENGINE - MACHINE JKT
C4.4 ENGINE - MACHINE W23
C4.4 ENGINE - MACHINE W7N
C4.4B ENGINE - MACHINE C7N
C4.4B ENGINE - MACHINE W7N
MARINE PRODUCTS
Model Prefix
C4.4 GENERATOR SET L1K
C4.4 GENERATOR SET MMC
C4.4 GENERATOR SET NRP
C4.4 GENERATOR SET S1M
PETROLEUM PRODUCTS
Model Prefix
C4.4 PETROLEUM ENGINE 4T3
PRODUCT DETAILS:
Total Pages: 6,121 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
KENR5391 - Troubleshooting (C4.4 and C6.6 Engines for Caterpillar Built Machines).pdf
KENR6082 - Disassembly and Assembly (C4.4 Engines for Caterpillar Built Machines).pdf
KENR6216 - Disassembly & Assembly (C4.4 Industrial Engine).pdf
KENR6248 - Specifications (C4.4 (Mech) Industrial Engine).pdf
KENR6249 - Disassembly & Assembly (C4.4 (Mech) Industrial Engine & Generator Sets).pdf
KENR6642 - Specifications (C4.4 Engines for Caterpillar Built Machines).pdf
KENR6643 - Systems Operation (C4.4 Engines for Caterpillar Built Machines).pdf
KENR6643 - Testing and Adjusting (C4.4 Engines for Caterpillar Built Machines).pdf
KENR6900 - Systems Operation (C4.4 (Mech) Industrial Engine).pdf
KENR6900 - Testing & Adjusting (C4.4 (Mech) Industrial Engine).pdf
KENR9118 - Specifications (C4.4 Industrial Engine).pdf
KENR9119 - Systems Operation (C4.4 Industrial Engine).pdf
KENR9119 - Testing & Adjusting (C4.4 Industrial Engine).pdf
KENR9120 - Disassembly & Assembly (C4.4 Industrial Engine).pdf
KENR9122 - Schematic (C4.4 Industrial Engine Electrical System).pdf
KENR9205 - Disassembly & Assembly (C4.4 Generator Sets).pdf
KENR9562 - Schematic (C4.4 XQ45 & XQ60 Generator Set Electrical System).pdf
RENR9561 - Schematic (C3.3 and C4.4 Generator Sets Electrical System).pdf
RENR9703 - Disassembly and Assembly (C3.3 and C4.4 Generator Sets).pdf
RENR9952 - Specifications (C4.4 Generator Sets).pdf
RENR9953 - Systems Operation (C4.4 Generator Sets).pdf
RENR9953 - Testing & Adjusting (C4.4 Generator Sets).pdf
RENR9961 - Specifications (C4.4 Industrial Engine).pdf
RENR9964 - Schematic (C4.4 Industrial Engine Electrical System).pdf
RENR9965 - Systems Operation (C4.4 Industrial Engine).pdf
RENR9965 - Testing and Adjusting (C4.4 Industrial Engine).pdf
SEBU8606 - Operation & Maintenance Manual (C4.4 Industrial Engine).pdf
SERV1837 - Technical Presentation (C4.2, C4.4, C6.4, C6.6 (Acert) Engines with Common Rail Fuel System).pdf
KENR6082 - Disassembly and Assembly (C4.4 Engines for Caterpillar Built Machines)...3
Accessory Drive - Assemble...7
Accessory Drive - Disassemble...9
Accessory Drive - Install...11
Accessory Drive - Remove...14
Air Compressor - Remove and Install...16
Alternator - Install - Engines With an Automatic Belt Tensioner...27
Alternator - Install - Engines Without an Automatic Belt Tensioner...29
Alternator - Remove - Engines With an Automatic Belt Tensioner...31
Alternator - Remove - Engines Without an Automatic Belt Tensioner...33
Alternator Belt - Remove and Install - Engines With an Automatic Belt Tensioner...35
Balancer - Install...39
Balancer - Remove...45
Bearing Clearance - Check...51
Boost Pressure Sensor - Remove and Install...54
Camshaft - Remove and Install...57
Camshaft Bearings - Remove and Install...61
Camshaft Gear - Remove and Install...64
Connecting Rod Bearings - Install - Connecting rods in position...71
Connecting Rod Bearings - Remove - Connecting rods in position...75
Coolant Temperature Sensor - Remove and Install...78
Crankcase Breather - Remove and Install - Filtered Breather...82
Crankcase Breather - Remove and Install - Unfiltered Breather...88
Crankshaft - Install...90
Crankshaft - Remove...100
Crankshaft Front Seal - Remove and Install...107
Crankshaft Gear - Remove and Install...110
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...114
Crankshaft Position Sensor - Remove and Install...129
Crankshaft Pulley - Remove and Install - Engines With an Automatic Belt Tensioner...132
Crankshaft Pulley - Remove and Install - Engines Without an Automatic Belt Tensioner...136
Crankshaft Rear Seal - Install...139
Crankshaft Rear Seal - Remove...143
Crankshaft Timing Ring - Remove and Install...145
Cylinder Head - Install...149
Cylinder Head - Remove...158
ECM Mounting Bracket - Remove and Install...166
Electric Starting Motor - Remove and Install...169
Electronic Control Module - Remove and Install...172
Electronic Unit Injector - Install...179
Electronic Unit Injector - Remove...192
Engine Oil Cooler - Install...202
Engine Oil Cooler - Remove...205
Engine Oil Filter Base - Remove and Install...208
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...211
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...218
Engine Oil Pressure Sensor - Remove and Install...226
Engine Oil Pump - Remove and Install - Engines Without a Balancer Unit...230
Engine Oil Relief Valve - Remove and Install - Engines Without a Balancer Unit...236
Engine Oil Relief Valve - Remove and Install - Engines with a Balancer Unit...240
Exhaust Elbow - Remove and Install...244
Exhaust Manifold - Remove and Install...246
Fan - Remove and Install...250
Fan Drive - Remove and Install...253
Flywheel - Install...255
Flywheel - Remove...258
Flywheel Housing - Remove and Install...261
Front Cover - Remove and Install...267
Fuel Filter Base - Remove and Install - Secondary Fuel Filter...271
Fuel Injection Lines - Install...275
Fuel Injection Lines - Remove...279
Fuel Injection Pump - Install...283
Fuel Injection Pump - Remove...290
Fuel Injection Pump Gear - Install...296
Fuel Injection Pump Gear - Remove...300
Fuel Manifold (Rail) - Remove and Install...304
Fuel Pressure Sensor - Remove and Install...311
Fuel Priming Pump - Remove and Install - Electric Fuel Priming Pump...315
Fuel Transfer Pump - Install...319
Fuel Transfer Pump - Remove...324
Gear Group (Front) - Remove and Install...328
Glow Plugs - Remove and Install...336
Housing (Front) - Install...340
Housing (Front) - Remove...346
Idler Gear - Install...351
Idler Gear - Remove...364
Inlet Air Temperature Sensor - Remove and Install...377
Inlet and Exhaust Valve Springs - Remove and Install...380
Inlet and Exhaust Valves - Remove and Install...390
Lifter Group - Remove and Install...397
Piston Cooling Jets - Remove and Install...401
Pistons and Connecting Rods - Assemble...404
Pistons and Connecting Rods - Disassemble...409
Pistons and Connecting Rods - Install...413
Pistons and Connecting Rods - Remove...417
Position Sensor (Fuel Injection Pump) - Remove and Install...420
Rocker Shaft - Assemble...424
Rocker Shaft - Disassemble...427
Rocker Shaft and Pushrod - Install...430
Rocker Shaft and Pushrod - Remove...435
Turbocharger - Install...438
Turbocharger - Remove...441
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner...444
Vacuum Pump - Remove and Install...447
Valve Mechanism Cover - Remove and Install...450
Valve Mechanism Cover Base - Remove and Install...455
Wastegate Solenoid - Remove and Install...462
Water Pump - Install...466
Water Pump - Remove...470
Water Temperature Regulator - Remove and Install...473
KENR6216 - Disassembly & Assembly (C4.4 Industrial Engine)...477
Accessory Drive - Assemble...481
Accessory Drive - Disassemble...483
Accessory Drive - Install...485
Accessory Drive - Remove...488
Air Compressor - Remove and Install...490
Alternator - Install - Engines With an Automatic Belt Tensioner...501
Alternator - Install - Engines Without an Automatic Belt Tensioner...503
Alternator - Remove - Engines With an Automatic Belt Tensioner...505
Alternator - Remove - Engines Without an Automatic Belt Tensioner...507
Alternator Belt - Remove and Install - Engines With an Automatic Belt Tensioner...509
Balancer - Install...513
Balancer - Remove...519
Bearing Clearance - Check...525
Boost Pressure Sensor - Remove and Install...528
Camshaft - Remove and Install...531
Camshaft Bearings - Remove and Install...535
Camshaft Gear - Remove and Install...538
Connecting Rod Bearings - Install - Connecting rods in position...545
Connecting Rod Bearings - Remove - Connecting rods in position...549
Coolant Temperature Sensor - Remove and Install...552
Crankcase Breather - Remove and Install - Filtered Breather...556
Crankcase Breather - Remove and Install - Unfiltered Breather...562
Crankshaft - Install...564
Crankshaft - Remove...574
Crankshaft Front Seal - Remove and Install...581
Crankshaft Gear - Remove and Install...584
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...588
Crankshaft Position Sensor - Remove and Install...601
Crankshaft Pulley - Remove and Install - Engines With an Automatic Belt Tensioner...604
Crankshaft Pulley - Remove and Install - Engines Without an Automatic Belt Tensioner...608
Crankshaft Rear Seal - Install...611
Crankshaft Rear Seal - Remove...615
Crankshaft Timing Ring - Remove and Install...617
Cylinder Head - Install...621
Cylinder Head - Remove...630
ECM Mounting Bracket - Remove and Install...638
Electric Starting Motor - Remove and Install...641
Electronic Control Module - Remove and Install...644
Electronic Unit Injector - Install...651
Electronic Unit Injector - Remove...664
Engine Oil Cooler - Install...674
Engine Oil Cooler - Remove...677
Engine Oil Filter Base - Remove and Install...680
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...683
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...690
Engine Oil Pressure Sensor - Remove and Install...698
Engine Oil Pump - Remove and Install - Engines Without a Balancer Unit...702
Engine Oil Relief Valve - Remove and Install - Engines Without a Balancer Unit...708
Engine Oil Relief Valve - Remove and Install - Engines with a Balancer Unit...712
Exhaust Elbow - Remove and Install...716
Exhaust Manifold - Remove and Install - Side Mounted Exhaust Manifold...718
Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold...721
Fan - Remove and Install...725
Fan Drive - Remove and Install...728
Flywheel - Install...730
Flywheel - Remove...733
Flywheel Housing - Remove and Install...736
Front Cover - Remove and Install...742
Fuel Filter Base - Remove and Install - Secondary Fuel Filter...746
Fuel Injection Lines - Install...750
Fuel Injection Lines - Remove...754
Fuel Injection Pump - Install...758
Fuel Injection Pump - Remove...765
Fuel Injection Pump Gear - Install...771
Fuel Injection Pump Gear - Remove...775
Fuel Manifold (Rail) - Remove and Install...779
Fuel Pressure Sensor - Remove and Install...786
Fuel Priming Pump - Remove and Install - Electric Fuel Priming Pump...790
Fuel Priming Pump - Remove and Install - Manual Priming Pump...794
Fuel Transfer Pump - Install...798
Fuel Transfer Pump - Remove...803
Gear Group (Front) - Remove and Install...807
Glow Plugs - Remove and Install...815
Housing (Front) - Install...819
Housing (Front) - Remove...825
Idler Gear - Install...830
Idler Gear - Remove...843
Inlet Air Temperature Sensor - Remove and Install...856
Inlet and Exhaust Valve Springs - Remove and Install...859
Inlet and Exhaust Valves - Remove and Install...869
Lifter Group - Remove and Install...876
Piston Cooling Jets - Remove and Install...880
Pistons and Connecting Rods - Assemble...883
Pistons and Connecting Rods - Disassemble...888
Pistons and Connecting Rods - Install...892
Pistons and Connecting Rods - Remove...896
Position Sensor (Fuel Injection Pump) - Remove and Install...899
Rocker Shaft - Assemble...903
Rocker Shaft - Disassemble...906
Rocker Shaft and Pushrod - Install...909
Rocker Shaft and Pushrod - Remove...914
Turbocharger - Install - Side Mounted Turbochargers...917
Turbocharger - Install - Top Mounted Turbocharger ...920
Turbocharger - Remove - Side Mounted Turbochargers...925
Turbocharger - Remove - Top Mounted Turbocharger ...928
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner ...932
Vacuum Pump - Remove and Install...935
Valve Mechanism Cover - Remove and Install...1166
Valve Mechanism Cover Base - Remove and Install...1171
Wastegate Solenoid - Remove and Install...1178
Water Pump - Install...1182
Water Pump - Remove...1186
Water Temperature Regulator - Remove and Install...1189
KENR6248 - Specifications (C4.4 (Mech) Industrial Engine)...1193
Alternator and Regulator...1195
Balancer - If Equipped...1197
Camshaft Bearings...1198
Camshaft...1200
Connecting Rod - For Use With Spheroidal Graphite Iron (SGI) Crankshaft...1204
Connecting Rod - Steel Crankshaft...1208
Connecting Rod Bearing Journal - Spheroidal Graphite Iron Crankshaft...1212
Connecting Rod Bearing Journal - Steel Crankshaft...1213
Crankcase Breather...1216
Crankshaft - Spheroidal Graphite Iron (SGI) Crankshaft...1220
Crankshaft - Steel Crankshaft...1222
Crankshaft Pulley...1225
Crankshaft Seals...1228
Cylinder Block...1230
Cylinder Head Valves...1233
Cylinder Head...1238
Electric Starting Motor...1241
Engine Design...1243
Engine Lifting Bracket...1245
Engine Oil Bypass Valve...1246
Engine Oil Cooler...1250
Engine Oil Filter...1252
Engine Oil Pan...1255
Engine Oil Pressure...1258
Engine Oil Pump...1259
Exhaust Manifold...1266
Fan Drive...1268
Flywheel Housing...1270
Flywheel...1272
Front Housing and Covers...1274
Fuel Injection Lines...1276
Fuel Injection Pump...1277
Fuel Injectors...1280
Fuel Transfer Pump...1282
Gear Group (Front)...1285
Glow Plugs...1289
Lifter Group...1291
Main Bearing Journal - Spheroidal Graphite Iron (SGI) Crankshaft...1292
Main Bearing Journal - Steel Crankshaft...1293
Piston Cooling Jet...1294
Piston and Rings...1296
Rocker Shaft...1299
Turbocharger...1301
Valve Mechanism Cover...1303
Water Pump...1304
Water Temperature Regulator...1306
KENR6249 - Disassembly & Assembly (C4.4 (Mech) Industrial Engine & Generator Sets)...1308
Accessory Drive - Remove and Install...1312
Air Compressor - Remove and Install...1316
Alternator - Install - Engines With an Automatic Belt Tensioner...1339
Alternator - Install - Engines Without an Automatic Belt Tensioner...1343
Alternator - Remove - Engines With an Automatic Belt Tensioner...1347
Alternator - Remove - Engines Without an Automatic Belt Tensioner...1351
Alternator Belt - Remove and Install - Engines With an Automatic Belt Tensioner...1355
Balancer - Install...1363
Balancer - Remove...1375
Bearing Clearance - Check...1387
Camshaft - Remove and Install...1390
Camshaft Bearings - Remove and Install...1399
Camshaft Gear - Remove and Install...1405
Connecting Rod Bearings - Install - Connecting rods in position...1419
Connecting Rod Bearings - Remove - Connecting rods in position...1426
Crankcase Breather - Remove and Install - Filtered Breather...1432
Crankcase Breather - Remove and Install - Naturally Aspirated Engines...1438
Crankcase Breather - Remove and Install - Turbocharged Engines with Filtered Breather...1443
Crankcase Breather - Remove and Install - Turbocharged Engines with Unfiltered Breather...1451
Crankcase Breather - Remove and Install - Unfiltered Breather...1456
Crankshaft - Install...1458
Crankshaft - Remove...1478
Crankshaft Front Seal - Remove and Install...1492
Crankshaft Gear - Remove and Install...1498
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...1506
Crankshaft Pulley - Remove and Install - Engines With an Automatic Belt Tensioner...1536
Crankshaft Pulley - Remove and Install - Engines Without an Automatic Belt Tensioner...1544
Crankshaft Rear Seal - Install...1550
Crankshaft Rear Seal - Remove...1558
Crankshaft Wear Sleeve (Front) - Remove and Install...1562
Cylinder Head - Install...1566
Cylinder Head - Remove...1583
Electric Starting Motor - Remove and Install...1597
Engine Oil Cooler - Install...1603
Engine Oil Cooler - Remove...1609
Engine Oil Filter Base - Remove and Install...1615
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...1621
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...1636
Engine Oil Pump - Remove and Install - Engines Without a Balancer Unit...1652
Engine Oil Relief Valve - Remove and Install - Engines Without a Balancer Unit...1664
Engine Oil Relief Valve - Remove and Install - Engines with a Balancer Unit...1672
Exhaust Elbow - Remove and Install...1680
Exhaust Manifold - Remove and Install...1684
Fan - Remove and Install...1692
Fan Drive - Remove and Install...1698
Flywheel - Install...1702
Flywheel - Remove...1708
Flywheel Housing - Remove and Install...1714
Front Cover - Remove and Install...1725
Fuel Injection Lines - Remove and Install...1733
Fuel Injection Pump - Install ...1739
Fuel Injection Pump - Install...1743
Fuel Injection Pump - Remove...1750
Fuel Injection Pump Gear - Install...1760
Fuel Injection Pump Gear - Remove...1768
Fuel Injector - Install...1776
Fuel Injector - Remove...1778
Fuel Injector Cover - Remove and Install...1780
Fuel Priming Pump and Fuel Filter Base - Remove and Install...1783
Gear Group (Front) - Remove and Install...1787
Glow Plugs - Remove and Install...1804
Housing (Front) - Install...1812
Housing (Front) - Remove...1825
Idler Gear - Install...1835
Idler Gear - Remove...1856
Inlet and Exhaust Valve Guides - Remove and Install...1876
Inlet and Exhaust Valve Springs - Remove and Install...1880
Inlet and Exhaust Valves - Remove and Install...1896
Lifter Group - Remove and Install...1910
Piston Cooling Jets - Remove and Install...1918
Pistons and Connecting Rods - Assemble...1924
Pistons and Connecting Rods - Disassemble...1934
Pistons and Connecting Rods - Install...1942
Pistons and Connecting Rods - Remove...1950
Rocker Shaft - Assemble...1956
Rocker Shaft - Disassemble...1962
Rocker Shaft and Pushrod - Install...1967
Rocker Shaft and Pushrod - Remove...1976
Turbocharger - Install...1982
Turbocharger - Remove...1988
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner ...1994
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner...2000
Vacuum Pump - Remove and Install...2003
Valve Mechanism Cover - Remove and Install...2006
Water Pump - Install...2015
Water Pump - Remove...2023
Water Temperature Regulator - Remove and Install...2029
KENR6642 - Specifications (C4.4 Engines for Caterpillar Built Machines)...2038
Alternator...2040
Belt Tension Chart...2044
Boost Pressure Sensor...2047
Camshaft Bearings...2050
Camshaft...2054
Connecting Rod - For Use With Spheroidal Graphite Iron (SGI) Crankshaft...2058
Connecting Rod - For Use With Steel Crankshaft...2065
Connecting Rod Bearing Journal - Spheroidal Graphite Iron Crankshaft...2070
Connecting Rod Bearing Journal - Steel Crankshaft...2074
Coolant Temperature Sensor...2078
Crankcase Breather...2082
Crankshaft - Spheroidal Graphite Iron (SGI) Crankshaft...2086
Crankshaft - Steel Crankshaft...2091
Crankshaft Position Sensor...2097
Crankshaft Pulley...2100
Crankshaft Seals...2104
Cylinder Block...2108
Cylinder Head Valves...2113
Cylinder Head...2118
Electronic Control Module...2123
Engine Design...2127
Engine Lifting Bracket...2131
Engine Oil Bypass Valve...2134
Engine Oil Cooler...2140
Engine Oil Filter Base...2144
Engine Oil Pan...2149
Engine Oil Pressure Sensor...2155
Engine Oil Pressure...2159
Engine Oil Pump...2162
Exhaust Manifold...2171
Flywheel Housing...2174
Flywheel...2178
Front Housing and Covers...2182
Fuel Filter Base...2186
Fuel Filter...2190
Fuel Injection Lines...2197
Fuel Injection Nozzles...2202
Fuel Injection Pump...2206
Fuel Pressure Sensor...2211
Fuel Priming Pump...2215
Fuel Transfer Pump...2219
Gear Group (Front)...2223
Glow Plugs...2228
Inlet Manifold Temperature Sensor...2232
Lifter Group...2236
Main Bearing Journal - Spheroidal Graphite Iron (SGI) Crankshaft...2240
Main Bearing Journal - Steel Crankshaft...2244
Piston Cooling Jet...2249
Piston and Rings...2253
Rocker Shaft...2257
Starter Motor...2262
Turbocharger...2266
Valve Mechanism Cover...2271
Water Pump...2274
Water Temperature Regulator and Housing...2278
KENR6643 - Systems Operation (C4.4 Engines for Caterpillar Built Machines)...2282
Air Inlet and Exhaust System...2283
Basic Engine...2289
Cleanliness of Fuel System Components...2298
Cooling System...2300
Electrical System...2302
Electronic Control System...2305
Fuel Injection...2317
Glossary of Electronic Control Terms...2330
Introduction...2338
Lubrication System...2342
Power Sources...2344
KENR6643 - Testing and Adjusting (C4.4 Engines for Caterpillar Built Machines)...2348
Air Inlet and Exhaust System - Inspect...2350
Air in Fuel - Test...2354
Alternator - Test...2358
Battery - Test...2360
Charging System - Test...2361
Compression - Test...2362
Connecting Rod - Inspect...2364
Cooling System - Check...2368
Cooling System - Inspect...2370
Cooling System - Test...2371
Crankshaft Pulley - Check...2375
Cylinder Block - Inspect...2378
Cylinder Head - Inspect...2379
Electric Starting System - Test...2381
Engine Oil Cooler - Inspect...2385
Engine Oil Pressure - Test...2388
Engine Oil Pump - Inspect...2389
Engine Valve Lash - Inspect_Adjust...2392
Excessive Bearing Wear - Inspect...2397
Excessive Engine Oil Consumption - Inspect...2398
Finding Top Center Position for No. 1 Piston...2399
Flywheel - Inspect...2401
Flywheel Housing - Inspect...2404
Fuel Injection Timing - Check...2407
Fuel Quality - Test...2411
Fuel System - Inspect...2412
Fuel System - Prime...2413
Gear Group (Front) - Time...2416
Gear Group - Inspect...2418
Glow Plugs - Test...2420
Increased Engine Oil Temperature - Inspect...2422
Piston Height - Inspect...2423
Piston Ring Groove - Inspect...2425
Turbocharger - Inspect...2428
V-Belt - Test...2434
Valve Depth - Inspect...2436
Valve Guide - Inspect...2439
Water Pump - Inspect...2441
Water Temperature Regulator - Test...2442
KENR6900 - Systems Operation (C4.4 (Mech) Industrial Engine)...2443
Air Inlet and Exhaust System...2444
Basic Engine...2449
Cooling System...2451
Electrical System...2453
Fuel System...2457
General Information...2459
Lubrication System...2463
KENR6900 - Testing & Adjusting (C4.4 (Mech) Industrial Engine)...2465
Adjust...2467
Air Inlet and Exhaust System - Inspect...2470
Air in Fuel - Test...2471
Alternator - Test...2474
Battery - Test...2478
Compression - Test...2479
Connecting Rod - Inspect...2481
Connecting Rod Bearings - Inspect...2483
Cooling System - Check - Overheating...2484
Cooling System - Inspect...2486
Cooling System - Test...2488
Cylinder Block - Inspect...2495
Cylinder Head - Inspect...2496
Electric Starting System - Test...2500
Engine Crankcase Pressure (Blowby) - Test...2504
Engine Oil Cooler - Inspect...2506
Engine Oil Pressure - Test...2508
Engine Oil Pump - Inspect...2510
Engine Valve Lash - Inspect_Adjust...2513
Excessive Bearing Wear - Inspect...2516
Excessive Engine Oil Consumption - Inspect...2517
Exhaust Temperature - Test...2518
Finding Top Center Position for No. 1 Piston...2519
Flywheel - Inspect...2521
Flywheel Housing - Inspect...2524
Fuel Injection Nozzle - Test...2528
Fuel Quality - Test...2533
Fuel System - Inspect...2535
Fuel System - Prime...2536
Fuel System Pressure - Test...2538
Gear Group - Inspect...2540
Glow Plugs - Test...2541
Increased Engine Oil Temperature - Inspect...2543
Main Bearings - Inspect...2544
Piston Height - Inspect...2545
Piston Ring Groove - Inspect...2548
Troubleshooting...2551
Turbocharger - Inspect...2668
V-Belt - Test...2673
Valve Depth - Inspect...2675
Valve Guide - Inspect...2678
Water Temperature Regulator - Test...2681
KENR9118 - Specifications (C4.4 Industrial Engine)...2683
Accessory Drive - SAE B...2686
Accessory Drive...2688
Air Compressor - Single Cylinder...2689
Air Compressor - Twin Cylinder Compressor...2692
Alternator...2696
Atmospheric Pressure Sensor...2699
Balancer...2700
Belt Tensioner...2702
Boost Pressure Sensor...2703
Camshaft Bearings...2705
Camshaft...2706
Connecting Rod Bearing Journal...2709
Connecting Rod...2710
Coolant Temperature Sensor...2714
Crankcase Breather...2715
Crankshaft Pulley...2717
Crankshaft Seals...2719
Crankshaft...2721
Cylinder Block...2724
Cylinder Head Valves...2726
Cylinder Head...2729
Diesel Particulate Filter...2734
Electronic Control Module...2735
Engine Design...2737
Engine Lifting Bracket...2739
Engine Oil Cooler...2740
Engine Oil Filter Base...2742
Engine Oil Pan...2744
Engine Oil Pressure Sensor...2747
Engine Oil Pressure...2748
Engine Oil Pump...2749
Exhaust Cooler (NRS)...2752
Exhaust Gas Valve (NRS)...2754
Exhaust Manifold...2759
Exhaust Sensor and Lines (NRS)...2760
Fan Drive...2762
Flexible Exhaust Pipe...2763
Flywheel Housing...2764
Flywheel...2766
Front Housing and Covers...2768
Fuel Filter Base - Primary Fuel Filter Base...2770
Fuel Filter Base - Single Secondary Fuel Filter Base...2772
Fuel Filter Base - Twin Secondary Fuel Filter Base...2774
Fuel Injection Lines...2776
Fuel Injection Nozzles...2778
Fuel Injection Pump...2780
Fuel Manifold (Rail)...2782
Fuel Transfer Pump...2784
Gear Group (Front)...2786
Glow Plugs...2789
Inlet Manifold Temperature Sensor...2791
Lifter Group...2792
Main Bearing Journal...2794
Piston Cooling Jet...2795
Piston and Rings...2797
Pressure Sensor (NOx Reduction System)...2799
Refrigerant Compressor...2800
Rocker Shaft...2801
Speed_Timing Sensor...2804
Starter Motor...2806
Temperature Sensor (DPF Inlet)...2809
Temperature Sensor (NOx Reduction System)...2811
Turbocharger - Series Turbochargers...2813
Turbocharger - Single Turbocharger...2819
Valve Mechanism Cover...2824
Water Pump...2825
Water Temperature Regulator and Housing...2826
KENR9119 - Systems Operation (C4.4 Industrial Engine)...2828
Air Inlet and Exhaust System - Series Turbochargers...2829
Air Inlet and Exhaust System - Single Turbocharger...2838
Basic Engine...2847
Clean Emissions Module...2854
Cleanliness of Fuel System Components...2856
Cooling System...2858
Electrical System...2861
Electronic Control System...2864
Fuel Injection...2882
Glossary of Electronic Control Terms...2894
Introduction...2902
Lubrication System...2909
Power Sources...2911
KENR9119 - Testing & Adjusting (C4.4 Industrial Engine)...2915
Air Inlet and Exhaust System - Inspect...2917
Air in Fuel - Test...2920
Alternator - Test...2923
Battery - Test...2925
Charging System - Test...2926
Compression - Test...2927
Connecting Rod - Inspect...2929
Cooling System - Check...2931
Cooling System - Inspect...2933
Cooling System - Test...2934
Crankshaft Pulley - Check...2938
Cylinder Block - Inspect...2940
Cylinder Head - Inspect...2941
Electric Starting System - Test...2944
Engine Oil Cooler - Inspect...2948
Engine Oil Pressure - Test...2950
Engine Oil Pump - Inspect...2951
Engine Valve Lash - Inspect...2953
Excessive Bearing Wear - Inspect...2958
Excessive Engine Oil Consumption - Inspect...2959
Exhaust Cooler (NRS) - Test...2960
Finding Top Center Position for No. 1 Piston...2963
Flywheel - Inspect...2966
Flywheel Housing - Inspect...2969
Fuel Injection Timing - Check...2972
Fuel Quality - Test...2975
Fuel System - Inspect...2977
Fuel System - Prime...2978
Gear Group (Front) - Time...2980
Gear Group - Inspect...2982
Increased Engine Oil Temperature - Inspect...2984
Piston Height - Inspect...2985
Piston Ring Groove - Inspect...2988
Position the Valve Mechanism Before Maintenance Procedures...2991
Turbocharger - Inspect - Series Turbochargers...2994
Turbocharger - Inspect - Single Turbocharger...3000
V-Belt - Test...3005
Valve Depth - Inspect...3007
Valve Guide - Inspect...3010
Water Pump - Inspect...3012
Water Temperature Regulator - Test...3013
KENR9120 - Disassembly & Assembly (C4.4 Industrial Engine)...3014
Accessory Drive - Remove and Install - Accessory Drive SAE A...3019
Accessory Drive - Remove and Install - Accessory Drive SAE B...3023
Air Compressor - Remove and Install - Single Cylinder...3032
Air Compressor - Remove and Install - Twin Cylinder Compressor...3048
Alternator - Install...3066
Alternator - Remove...3075
Alternator Belt - Remove and Install...3081
Atmospheric Pressure Sensor - Remove and Install...3085
Balancer - Install...3087
Balancer - Remove...3096
Bearing Clearance - Check...3101
Belt Tensioner - Remove and Install...3104
Boost Pressure Sensor - Remove and Install...3107
Camshaft - Remove and Install...3110
Camshaft Bearings - Remove and Install...3115
Camshaft Gear - Remove and Install...3119
Camshaft Position Sensor - Remove and Install...3131
Connecting Rod Bearings - Install - Connecting Rods in Position...3134
Connecting Rod Bearings - Remove - Connecting Rods in Position...3138
Coolant Temperature Sensor - Remove and Install...3141
Crankcase Breather - Install...3144
Crankcase Breather - Remove...3149
Crankshaft - Install...3154
Crankshaft - Remove...3162
Crankshaft Front Seal - Remove and Install - Crankshaft Front Seal for Heavy Duty Front Cover...3167
Crankshaft Front Seal - Remove and Install...3171
Crankshaft Gear (Balancer Drive) - Remove and Install...3175
Crankshaft Gear - Remove and Install...3178
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...3183
Crankshaft Position Sensor - Remove and Install...3193
Crankshaft Pulley - Remove and Install...3196
Crankshaft Rear Seal - Install...3199
Crankshaft Rear Seal - Remove...3203
Crankshaft Timing Ring - Remove and Install...3205
Cylinder Head - Install...3208
Cylinder Head - Remove...3218
Diesel Particulate Filter - Install...3225
Diesel Particulate Filter - Remove...3234
Electric Starting Motor - Remove and Install...3240
Electronic Control Module - Install...3243
Electronic Control Module - Remove...3253
Electronic Unit Injector - Install...3260
Electronic Unit Injector - Remove...3267
Engine Oil Cooler - Install...3274
Engine Oil Cooler - Remove...3278
Engine Oil Filter Base - Remove and Install...3281
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...3284
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...3294
Engine Oil Pressure Sensor - Remove and Install...3302
Engine Oil Pump - Install...3305
Engine Oil Pump - Remove...3308
Exhaust Back Pressure Valve - Remove and Install...3311
Exhaust Cooler (NRS) - Remove and Install - Side mounted Turbocharger...3315
Exhaust Cooler (NRS) - Remove and Install - Top mounted Turbocharger...3323
Exhaust Cooler (NRS) - Remove and Install - Twin Turbocharger...3332
Exhaust Elbow - Remove and Install - Top Mounted and Side Mounted Turbocharger Exhaust Elbow...3340
Exhaust Elbow - Remove and Install...3343
Exhaust Manifold - Remove and Install - Single Turbocharger Exhaust Manifold...3346
Exhaust Manifold - Remove and Install - Twin Turbocharger Exhaust manifold...3352
Fan - Remove and Install...3358
Fan Drive - Remove and Install...3361
Flexible Exhaust Pipe - Remove and Install...3363
Flow Control Valve - Remove and Install...3372
Flywheel - Install...3378
Flywheel - Remove...3381
Flywheel Housing - Remove and Install - Standard Housing...3384
Flywheel Housing - Remove and Install - Wet Back End Housing...3392
Front Cover - Remove and Install - Heavy Duty Front Cover...3399
Front Cover - Remove and Install...3403
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter...3407
Fuel Filter Base - Remove and Install - Twin Secondary Fuel Filter...3415
Fuel Injection Lines - Install ...3423
Fuel Injection Lines - Install...3430
Fuel Injection Lines - Remove...3437
Fuel Injection Pump - Install...3443
Fuel Injection Pump - Remove...3448
Fuel Injection Pump Gear - Install...3452
Fuel Injection Pump Gear - Remove...3454
Fuel Manifold (Rail) - Remove and Install...3456
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP)...3460
Fuel Temperature Sensor - Remove and Install...3465
Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)...3469
Gear Group (Front) - Remove and Install...3485
Glow Plugs - Remove and Install...3497
Housing (Front) - Install - Heavy Duty Housing (Front)...3502
Housing (Front) - Install...3509
Housing (Front) - Remove - Heavy Duty Housing (Front)...3516
Housing (Front) - Remove...3520
Idler Gear - Install...3524
Idler Gear - Remove...3532
Idler Pulley - Remove and Install - Flat Idler Pulley...3538
Idler Pulley - Remove and Install - Grooved Idler Pulley...3541
Inlet Air Control - Install - NRS Induction Mixer...3544
Inlet Air Control - Remove - NRS Induction Mixer...3552
Inlet Manifold Temperature Sensor - Remove and Install...3557
Inlet and Exhaust Valve Springs - Remove and Install...3560
Inlet and Exhaust Valves - Remove and Install...3569
Lifter Group - Remove and Install - Hydraulic Lifter Group...3576
Piston Cooling Jets - Remove and Install...3580
Pistons and Connecting Rods - Assemble...3584
Pistons and Connecting Rods - Disassemble...3589
Pistons and Connecting Rods - Install...3593
Pistons and Connecting Rods - Remove...3597
Pressure Sensor (Cooled Exhaust Gas) - Remove and Install - NRS Inlet and Outlet Pressure Sensors...3600
Refrigerant Compressor - Remove and Install...3607
Relief Valve (Fuel) - Remove and Install...3615
Rocker Shaft - Assemble...3619
Rocker Shaft - Disassemble...3622
Rocker Shaft and Pushrod - Install...3625
Rocker Shaft and Pushrod - Remove...3632
Soot Antenna - Remove and Install...3636
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install...3639
Temperature Sensor (DPF) - Remove and Install...3642
Turbocharger - Install - First Stage Turbocharger...3645
Turbocharger - Install - Second Stage Turbocharger...3653
Turbocharger - Install - Side Mounted Turbochargers...3659
Turbocharger - Install - Top Mounted Turbocharger ...3664
Turbocharger - Install - Top Mounted Turbocharger...3670
Turbocharger - Remove - First Stage Turbocharger...3677
Turbocharger - Remove - Second Stage Turbocharger...3681
Turbocharger - Remove - Side Mounted Turbochargers...3686
Turbocharger - Remove - Top Mounted Turbocharger ...3689
Turbocharger - Remove - Top Mounted Turbocharger...3693
Valve Mechanism Cover - Remove and Install...3698
Wastegate Solenoid - Remove and Install...3705
Water Pump - Install...3711
Water Pump - Remove...3717
Water Separator and Fuel Filter (Primary) - Remove and Install...3720
Water Temperature Regulator - Remove and Install...3726
KENR9122 - Schematic (C4.4 Industrial Engine Electrical System)...3729
Collage...3730
Main...3745
KENR9205 - Disassembly & Assembly (C4.4 Generator Sets)...3747
Accessory Drive - Assemble...3751
Accessory Drive - Disassemble...3753
Accessory Drive - Install...3755
Accessory Drive - Remove...3758
Air Compressor - Remove and Install...3760
Alternator - Install - Engines With an Automatic Belt Tensioner...3771
Alternator - Install - Engines Without an Automatic Belt Tensioner...3773
Alternator - Remove - Engines With an Automatic Belt Tensioner...3775
Alternator - Remove - Engines Without an Automatic Belt Tensioner...3777
Alternator Belt - Remove and Install - Engines With an Automatic Belt Tensioner...3779
Balancer - Install...3783
Balancer - Remove...3789
Bearing Clearance - Check...3795
Boost Pressure Sensor - Remove and Install...3798
Camshaft - Remove and Install...3801
Camshaft Bearings - Remove and Install...3805
Camshaft Gear - Remove and Install...3808
Connecting Rod Bearings - Install - Connecting rods in position...3815
Connecting Rod Bearings - Remove - Connecting rods in position...3819
Coolant Temperature Sensor - Remove and Install...3822
Crankcase Breather - Remove and Install - Filtered Breather...3826
Crankcase Breather - Remove and Install - Unfiltered Breather...3832
Crankshaft - Install...3834
Crankshaft - Remove...3844
Crankshaft Front Seal - Remove and Install...3851
Crankshaft Gear - Remove and Install...3854
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...3858
Crankshaft Position Sensor - Remove and Install...3873
Crankshaft Pulley - Remove and Install - Engines With an Automatic Belt Tensioner...3876
Crankshaft Pulley - Remove and Install - Engines Without an Automatic Belt Tensioner...3880
Crankshaft Rear Seal - Install...3883
Crankshaft Rear Seal - Remove...3887
Crankshaft Timing Ring - Remove and Install...3889
Cylinder Head - Install...3893
Cylinder Head - Remove...3902
ECM Mounting Bracket - Remove and Install...3910
Electric Starting Motor - Remove and Install...3913
Electronic Control Module - Remove and Install...3916
Electronic Unit Injector - Install...3923
Electronic Unit Injector - Remove...3936
Engine Oil Cooler - Install...3946
Engine Oil Cooler - Remove...3949
Engine Oil Filter Base - Remove and Install...3952
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...3955
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...3962
Engine Oil Pressure Sensor - Remove and Install...3970
Engine Oil Pump - Remove and Install - Engines Without a Balancer Unit...3974
Engine Oil Relief Valve - Remove and Install - Engines Without a Balancer Unit...3980
Engine Oil Relief Valve - Remove and Install - Engines with a Balancer Unit...3984
Exhaust Elbow - Remove and Install...3988
Exhaust Manifold - Remove and Install...3990
Fan - Remove and Install...3994
Fan Drive - Remove and Install...3997
Flywheel - Install...3999
Flywheel - Remove...4002
Flywheel Housing - Remove and Install...4005
Front Cover - Remove and Install...4011
Fuel Filter Base - Remove and Install - Secondary Fuel Filter...4015
Fuel Injection Lines - Install...4019
Fuel Injection Lines - Remove...4023
Fuel Injection Pump - Install...4027
Fuel Injection Pump - Remove...4034
Fuel Injection Pump Gear - Install...4040
Fuel Injection Pump Gear - Remove...4044
Fuel Manifold (Rail) - Remove and Install...4048
Fuel Pressure Sensor - Remove and Install...4055
Fuel Priming Pump - Remove and Install - Electric Fuel Priming Pump...4059
Fuel Transfer Pump - Install...4063
Fuel Transfer Pump - Remove...4068
Gear Group (Front) - Remove and Install...4072
Glow Plugs - Remove and Install...4080
Housing (Front) - Install...4084
Housing (Front) - Remove...4090
Idler Gear - Install...4095
Idler Gear - Remove...4108
Inlet Air Temperature Sensor - Remove and Install...4120
Inlet and Exhaust Valve Springs - Remove and Install...4123
Inlet and Exhaust Valves - Remove and Install...4133
Lifter Group - Remove and Install...4140
Piston Cooling Jets - Remove and Install...4144
Pistons and Connecting Rods - Assemble...4147
Pistons and Connecting Rods - Disassemble...4152
Pistons and Connecting Rods - Install...4156
Pistons and Connecting Rods - Remove...4160
Position Sensor (Fuel Injection Pump) - Remove and Install...4163
Rocker Shaft - Assemble...4167
Rocker Shaft - Disassemble...4170
Rocker Shaft and Pushrod - Install...4173
Rocker Shaft and Pushrod - Remove...4178
Turbocharger - Install...4181
Turbocharger - Remove...4184
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner ...4187
V-Belts - Remove and Install - Engines Without an Automatic Belt Tensioner...4190
Vacuum Pump - Remove and Install...4193
Valve Mechanism Cover - Remove and Install...4196
Valve Mechanism Cover Base - Remove and Install...4201
Wastegate Solenoid - Remove and Install...4208
Water Pump - Install...4212
Water Pump - Remove...4216
Water Temperature Regulator - Remove and Install...4219
KENR9562 - Schematic (C4.4 XQ45 & XQ60 Generator Set Electrical System)...4223
Collage...4224
Main...4236
M0074066 - Troubleshooting (C4.4 and C6.6 Engines)...4238
General Information...4242
Welding Precaution...4245
Electronic Service Tools...4247
Service Information Report...4253
System Overview...4255
Component Location...4258
Engine Monitoring System...4270
Diagnostic Capabilities...4272
Electrical Connectors...4274
Configuration Parameters...4281
Diagnostic Trouble Codes...4284
Event Codes...4309
Acceleration Is Poor or Throttle Response Is Poor...4323
Alternator Problem...4335
Battery Problem...4338
Coolant Contains Oil...4340
Coolant Level Is Low...4343
Coolant Temperature Is High...4345
Cooling Fan Is Always ON...4351
Crankcase Breather Ejects Oil...4352
Crankcase Fumes Disposal Tube Has Oil Draining...4355
Cylinder Is Noisy...4359
Diesel Particulate Filter Collects Excessive Soot...4363
Diesel Particulate Filter Temperature Is Low...4368
Engine Cranks but Does Not Start...4371
Engine Does Not Crank...4384
Engine Has Early Wear...4388
Engine Has Mechanical Noise (Knock)...4391
Engine Misfires; Runs Rough or Is Unstable...4396
Engine Overcrank Occurrence...4407
Engine Overspeeds...4411
Engine Shutdown Occurrence...4414
Engine Shutdown Occurs Intermittently...4416
Engine Stalls at Low RPM...4419
Engine Top Speed Is Not Obtained...4423
Engine Vibration Is Excessive...4435
Exhaust Has Excessive Black Smoke...4439
Exhaust Has Excessive White Smoke...4445
Exhaust System Contains Coolant...4451
Exhaust System Contains Oil...4453
Fuel Consumption Is Excessive...4456
Fuel Contains Water...4462
Fuel Rail Pressure Problem...4465
Fuel Temperature Is High...4483
Inlet Air Is Restricted...4492
Intake Manifold Air Pressure Is High...4494
Intake Manifold Air Pressure Is Low...4498
Intake Manifold Air Temperature Is High...4501
NRS Exhaust Gas Temperature Is High...4505
NRS Mass Flow Rate Problem...4510
Oil Consumption Is Excessive...4516
Oil Contains Coolant...4521
Oil Contains Fuel...4524
Oil Level Is Low...4528
Oil Pressure Is Low...4530
Power Is Intermittently Low or Power Cutout Is Intermittent...4539
Valve Lash Is Excessive...4548
Aftertreatment Identification Module - Test...4550
CAN Data Link - Test...4555
Coolant Level - Test...4560
Cooling Fan Control - Test...4563
Cooling Fan Reversing - Test...4569
Cooling Fan Speed - Test...4572
Data Link - Test...4575
Data Link Configuration Status - Test...4584
Electrical Power Supply - Test...4587
Ether Starting Aid - Test...4591
Fuel Transfer Pump - Test...4597
Glow Plug Starting Aid - Test...4603
Idle Validation - Test...4609
Indicator Lamp - Test...4617
Injector Data Incorrect - Test...4620
Injector Solenoid - Test...4624
Mode Selection - Test...4633
Motorized Valve - Test...4637
Power Take-Off - Test...4645
Relay - Test - Start Relay...4649
Sensor Calibration Required - Test...4653
Sensor Signal (Analog; Active) - Test...4658
Sensor Signal (Analog; Passive) - Test...4666
Sensor Supply - Test...4674
Shutdown (Ground Level) - Test...4683
Solenoid Valve - Test...4688
Soot Sensor - Test...4696
Speed Control (Analog) - Test...4702
Speed Control (PWM) - Test...4709
Speed_Timing - Test...4717
Switch Circuits - Test - Multiposition Throttle Switch...4726
Switch Circuits - Test - Air Filter Restriction Switch...4730
Valve Position - Test...4734
Water in Fuel - Test...4742
Customer Passwords...4747
Factory Passwords...4748
ECM Will Not Accept Factory Passwords...4750
Electronic Service Tool Does Not Communicate...4751
Test ECM Mode...4757
ECM Software - Install...4759
ECM - Replace...4761
Electrical Connectors - Inspect...4764
Cooling Fan - Calibrate - If Applicable...4771
Injector Code - Calibrate...4773
RENR9952 - Specifications (C4.4 Generator Sets)...4776
Alternator and Regulator...4778
Balancer - If Equipped...4781
Camshaft...4783
Connecting Rod - For Use With Steel Crankshaft...4787
Connecting Rod Bearing Journal - Steel Crankshaft...4792
Crankcase Breather...4795
Crankshaft - Steel Crankshaft...4798
Crankshaft Pulley...4801
Crankshaft Seals...4803
Cylinder Block...4806
Cylinder Head Valves...4810
Cylinder Head...4816
Electric Starting Motor...4820
Engine Design...4823
Engine Lifting Bracket...4825
Engine Oil Bypass Valve...4826
Engine Oil Filter...4830
Engine Oil Pan...4833
Engine Oil Pressure...4835
Engine Oil Pump...4836
Exhaust Manifold...4844
Fan Drive...4846
Flywheel Housing...4848
Flywheel...4850
Front Housing and Covers...4852
Fuel Injection Lines...4855
Fuel Injection Nozzles...4857
Fuel Injection Pump...4859
Fuel Transfer Pump...4865
Gear Group (Front)...4868
Glow Plugs...4872
Lifter Group...4874
Main Bearing Journal - Steel Crankshaft...4876
Piston Cooling Jet...4879
Piston and Rings...4882
Rocker Shaft...4886
Turbocharger...4888
Valve Mechanism Cover...4891
Water Pump...4893
Water Temperature Regulator...4895
RENR9953 - Systems Operation (C4.4 Generator Sets)...4897
Air Inlet and Exhaust System...4898
Basic Engine...4903
Cooling System...4905
Electrical System...4907
Fuel System...4910
General Information...4912
Lubrication System...4916
RENR9953 - Testing & Adjusting (C4.4 Generator Sets)...4918
Air Inlet and Exhaust System - Inspect...4920
Air in Fuel - Test...4921
Alternator - Test...4924
Battery - Test...4926
Compression - Test...4927
Connecting Rod - Inspect...4929
Connecting Rod Bearings - Inspect...4931
Cooling System - Check - Overheating...4932
Cooling System - Inspect...4934
Cooling System - Test...4936
Cylinder Block - Inspect...4943
Cylinder Head - Inspect...4944
Electric Starting System - Test...4948
Engine Crankcase Pressure (Blowby) - Test...4952
Engine Oil Cooler - Inspect...4954
Engine Oil Pressure - Test...4956
Engine Oil Pump - Inspect...4958
Engine Valve Lash - Inspect_Adjust...4962
Excessive Bearing Wear - Inspect...4967
Excessive Engine Oil Consumption - Inspect...4968
Exhaust Temperature - Test...4969
Finding Top Center Position for No. 1 Piston...4970
Flywheel - Inspect...4972
Flywheel Housing - Inspect...4975
Fuel Injection Nozzle - Test...4979
Fuel Quality - Test...4984
Fuel System - Inspect...4986
Fuel System - Prime...4987
Fuel System Pressure - Test...4990
Gear Group - Inspect...4993
Glow Plugs - Test...4994
Increased Engine Oil Temperature - Inspect...4996
Main Bearings - Inspect...4997
Piston Height - Inspect...4998
Piston Ring Groove - Inspect...5001
Troubleshooting...5004
Turbocharger - Inspect...5121
Valve Depth - Inspect...5127
Valve Guide - Inspect...5130
Water Temperature Regulator - Test...5133
RENR9961 - Specifications (C4.4 Industrial Engine)...5135
Alternator...5137
Belt Tension Chart...5140
Boost Pressure Sensor...5141
Camshaft Bearings...5142
Camshaft...5144
Connecting Rod - For Use With Spheroidal Graphite Iron (SGI) Crankshaft...5146
Connecting Rod - For Use With Steel Crankshaft...5150
Connecting Rod Bearing Journal - Spheroidal Graphite Iron Crankshaft...5153
Connecting Rod Bearing Journal - Steel Crankshaft...5154
Coolant Temperature Sensor...5156
Crankcase Breather...5157
Crankshaft - Spheroidal Graphite Iron (SGI) Crankshaft...5159
Crankshaft - Steel Crankshaft...5161
Crankshaft Position Sensor...5165
Crankshaft Pulley...5166
Crankshaft Seals...5168
Cylinder Block...5170
Cylinder Head Valves...5172
Cylinder Head...5174
Electronic Control Module...5177
Engine Design...5179
Engine Lifting Bracket...5181
Engine Oil Bypass Valve...5182
Engine Oil Cooler...5186
Engine Oil Filter Base...5188
Engine Oil Pan...5191
Engine Oil Pressure Sensor...5194
Engine Oil Pressure...5195
Engine Oil Pump...5196
Exhaust Manifold...5201
Flywheel Housing ...5202
Flywheel...5204
Front Housing and Covers...5206
Fuel Filter Base...5209
Fuel Filter...5210
Fuel Injection Lines...5214
Fuel Injection Nozzles...5217
Fuel Injection Pump...5219
Fuel Pressure Sensor...5221
Fuel Priming Pump...5223
Fuel Transfer Pump...5225
Gear Group (Front)...5227
Glow Plugs...5230
Inlet Manifold Temperature Sensor...5231
Lifter Group...5232
Main Bearing Journal - Spheroidal Graphite Iron (SGI) Crankshaft...5233
Main Bearing Journal - Steel Crankshaft...5234
Piston Cooling Jet...5237
Piston and Rings...5239
Rocker Shaft...5241
Starter Motor...5244
Turbocharger...5246
Valve Mechanism Cover...5248
Water Pump...5249
Water Temperature Regulator and Housing...5250
RENR9964 - Schematic (C4.4 Industrial Engine Electrical System)...5252
RENR9965 - Systems Operation (C4.4 Industrial Engine)...5254
Air Inlet and Exhaust System...5255
Basic Engine...5261
Cleanliness of Fuel System Components...5269
Cooling System...5271
Electrical System...5273
Electronic Control System...5276
Fuel Injection ...5288
Glossary of Electronic Control Terms...5299
Introduction ...5307
Lubrication System...5311
Power Sources...5313
RENR9965 - Testing and Adjusting (C4.4 Industrial Engine)...5317
Adjust...5319
Air Inlet and Exhaust System - Inspect...5324
Air in Fuel - Test...5328
Alternator - Test...5332
Battery - Test...5334
Charging System - Test...5335
Compression - Test...5336
Connecting Rod - Inspect...5338
Cooling System - Check...5342
Cooling System - Inspect...5344
Cooling System - Test...5345
Crankshaft Pulley - Check...5349
Cylinder Block - Inspect...5352
Cylinder Head - Inspect...5353
Electric Starting System - Test...5355
Engine Oil Cooler - Inspect...5359
Engine Oil Pressure - Test...5362
Engine Oil Pump - Inspect...5363
Excessive Bearing Wear - Inspect...5366
Excessive Engine Oil Consumption - Inspect...5367
Finding Top Center Position for No. 1 Piston...5368
Flywheel - Inspect...5370
Flywheel Housing - Inspect...5373
Fuel Injection Timing - Check...5376
Fuel Quality - Test...5380
Fuel System - Inspect...5381
Fuel System - Prime...5382
Gear Group (Front) - Time...5385
Gear Group - Inspect...5387
Glow Plugs - Test...5389
Increased Engine Oil Temperature - Inspect...5391
Piston Height - Inspect...5392
Piston Ring Groove - Inspect...5394
Turbocharger - Inspect...5397
V-Belt - Test...5403
Valve Depth - Inspect...5405
Valve Guide - Inspect...5408
Water Pump - Inspect...5410
Water Temperature Regulator - Test...5411
SEBU8606 - Operation & Maintenance Manual (C4.4 Industrial Engine)...5412
UENR0600 - Specifications (C4.4 Engines for Caterpillar Built Machines)...5536
Engine Design...5539
Fuel Injection Lines...5543
Fuel Injection Pump...5545
Fuel Injection Nozzles...5548
Fuel Transfer Pump...5551
Fuel Filter Base - Single Secondary Fuel Filter Base...5555
Fuel Filter Base - Primary Fuel Filter Base...5558
Fuel Manifold (Rail)...5561
Lifter Group...5563
Rocker Shaft...5564
Valve Mechanism Cover...5566
Cylinder Head Valves...5569
Cylinder Head...5572
Turbocharger - Single Turbocharger...5579
Exhaust Gas Valve (NRS)...5585
Exhaust Sensor and Lines (NRS)...5592
Exhaust Cooler (NRS)...5595
Exhaust Manifold...5599
Flexible Exhaust Pipe...5602
Diesel Particulate Filter...5605
Camshaft...5608
Camshaft Bearings...5611
Engine Oil Filter Base...5612
Engine Oil Cooler...5614
Engine Oil Pump...5618
Engine Oil Pressure...5621
Engine Oil Pan...5622
Crankcase Breather...5627
Water Temperature Regulator and Housing...5630
Water Pump...5634
Cylinder Block...5637
Crankshaft...5641
Crankshaft Seals...5645
Connecting Rod Bearing Journal...5647
Main Bearing Journal...5648
Connecting Rod...5651
Piston and Rings...5655
Piston Cooling Jet...5659
Accessory Drive...5661
Front Housing and Covers...5663
Gear Group (Front)...5667
Flywheel...5672
Flywheel Housing...5675
Crankshaft Pulley...5678
Belt Tensioner...5681
Refrigerant Compressor...5684
Fan Drive...5686
Engine Lifting Bracket...5689
Alternator...5690
Starter Motor...5694
Coolant Temperature Sensor...5698
Engine Oil Pressure Sensor...5699
Boost Pressure Sensor...5700
Atmospheric Pressure Sensor...5702
Inlet Manifold Temperature Sensor...5703
Temperature Sensor (DPF Inlet)...5704
Pressure Sensor (NOx Reduction System)...5707
Temperature Sensor (NOx Reduction System)...5708
Speed_Timing Sensor...5710
Electronic Control Module...5712
Glow Plugs...5715
UENR0601 - Systems Operation (C4.4 Engines for Caterpillar Built Machines)...5718
Introduction...5719
Basic Engine...5726
Air Inlet and Exhaust System - Single Turbocharger...5733
Air Inlet and Exhaust System - Series Turbochargers...5742
Clean Emissions Module...5751
Cooling System...5753
Lubrication System...5756
Electrical System...5758
Cleanliness of Fuel System Components...5761
Fuel Injection...5763
Electronic Control System...5775
Power Sources...5793
Glossary of Electronic Control Terms...5797
UENR0601 - Testing and Adjusting (C4.4 Engines for Caterpillar Built Machines)...5805
Fuel System - Inspect...5807
Air in Fuel - Test...5808
Finding Top Center Position for No. 1 Piston...5811
Fuel Injection Timing - Check...5814
Fuel Quality - Test...5817
Fuel System - Prime...5819
Gear Group (Front) - Time...5821
Air Inlet and Exhaust System - Inspect...5823
Turbocharger - Inspect - Single Turbocharger...5826
Turbocharger - Inspect - Series Turbochargers...5831
Exhaust Cooler (NRS) - Test...5837
Compression - Test...5839
Engine Valve Lash - Inspect...5841
Valve Depth - Inspect...5846
Valve Guide - Inspect...5849
Engine Oil Pressure - Test...5851
Engine Oil Pump - Inspect...5852
Excessive Bearing Wear - Inspect...5854
Excessive Engine Oil Consumption - Inspect...5855
Increased Engine Oil Temperature - Inspect...5856
Cooling System - Check...5857
Cooling System - Inspect...5859
Cooling System - Test...5860
Engine Oil Cooler - Inspect...5864
Water Temperature Regulator - Test...5866
Water Pump - Inspect...5867
Position the Valve Mechanism Before Maintenance Procedures...5868
Piston Ring Groove - Inspect...5871
Connecting Rod - Inspect...5874
Cylinder Block - Inspect...5876
Cylinder Head - Inspect...5877
Piston Height - Inspect...5880
Flywheel - Inspect...5883
Flywheel Housing - Inspect...5886
Gear Group - Inspect...5889
Crankshaft Pulley - Check...5891
Alternator - Test...5893
Battery - Test...5895
Charging System - Test...5896
V-Belt - Test...5897
Electric Starting System - Test...5899
UENR0602 - Disassembly and Assembly (C4.4 Engines for Caterpillar Built Machines)...5903
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP)...5908
Flow Control Valve - Remove and Install...5913
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter...5919
Water Separator and Fuel Filter (Primary) - Remove and Install...5927
Fuel Manifold (Rail) - Remove and Install...5933
Relief Valve (Fuel) - Remove and Install...5937
Fuel Injection Lines - Remove...5941
Fuel Injection Lines - Install...5947
Exhaust Cooler (NRS) - Remove and Install - Twin Turbocharger...5954
Exhaust Cooler (NRS) - Remove and Install - Side mounted Turbocharger...5962
Exhaust Cooler (NRS) - Remove and Install - Top mounted Turbocharger...5970
Inlet Air Control - Remove - NRS Induction Mixer...5979
Inlet Air Control - Install - NRS Induction Mixer...5986
Fuel Injection Pump - Remove...5995
Fuel Injection Pump - Install...5999
Fuel Injection Pump Gear - Remove...6004
Fuel Injection Pump Gear - Install...6006
Electronic Unit Injector - Remove...6008
Electronic Unit Injector - Install...6015
Turbocharger - Remove - First Stage Turbocharger...6022
Turbocharger - Remove - Second Stage Turbocharger...6026
Turbocharger - Remove - Top Mounted Turbocharger...6031
Turbocharger - Remove - Side Mounted Turbochargers...6035
Turbocharger - Install - First Stage Turbocharger...6038
Turbocharger - Install - Second Stage Turbocharger...6046
Turbocharger - Install - Top Mounted Turbocharger...6052
Turbocharger - Install - Side Mounted Turbochargers...6058
Wastegate Solenoid - Remove and Install...6063
Exhaust Back Pressure Valve - Remove and Install...6069
Flexible Exhaust Pipe - Remove and Install...6073
Exhaust Manifold - Remove and Install - Twin Turbocharger Exhaust manifold...6083
Exhaust Manifold - Remove and Install - Single Turbocharger Exhaust Manifold...6089
Exhaust Elbow - Remove and Install...6095
Exhaust Elbow - Remove and Install - Top Mounted and Side Mounted Turbocharger Exhaust Elbow...6098
Diesel Particulate Filter - Remove...6101
Diesel Particulate Filter - Install...6108
Inlet and Exhaust Valve Springs - Remove and Install...6118
Inlet and Exhaust Valves - Remove and Install...6127
Engine Oil Filter Base - Remove and Install...6134
Engine Oil Cooler - Remove...6137
Engine Oil Cooler - Install...6140
Engine Oil Pump - Remove...6144
Engine Oil Pump - Install...6147
Water Pump - Remove...6150
Water Pump - Install...6153
Water Temperature Regulator - Remove and Install...6159
Flywheel - Remove...6162
Flywheel - Install...6165
Crankshaft Rear Seal - Remove...6168
Crankshaft Rear Seal - Install...6170
Flywheel Housing - Remove and Install - Wet Back End Housing...6174
Flywheel Housing - Remove and Install - Standard Housing...6182
Crankshaft Pulley - Remove and Install...6190
Crankshaft Front Seal - Remove and Install - Crankshaft Front Seal for Heavy Duty Front Cover...6193
Crankshaft Front Seal - Remove and Install...6197
Front Cover - Remove and Install - Heavy Duty Front Cover...6201
Front Cover - Remove and Install...6205
Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)...6209
Gear Group (Front) - Remove and Install...6229
Idler Gear - Remove...6244
Idler Gear - Install...6250
Housing (Front) - Remove - Heavy Duty Housing (Front)...6259
Housing (Front) - Remove...6263
Housing (Front) - Install - Heavy Duty Housing (Front)...6267
Housing (Front) - Install...6275
Accessory Drive - Remove and Install - Accessory Drive SAE B...6282
Accessory Drive - Remove and Install - Accessory Drive SAE A...6291
Crankcase Breather - Remove...6295
Crankcase Breather - Install...6300
Valve Mechanism Cover - Remove and Install...6305
Rocker Shaft and Pushrod - Remove...6312
Rocker Shaft - Disassemble...6316
Rocker Shaft - Assemble...6319
Rocker Shaft and Pushrod - Install...6322
Cylinder Head - Remove...6330
Cylinder Head - Install...6339
Lifter Group - Remove and Install - Hydraulic Lifter Group...6349
Camshaft - Remove and Install...6353
Camshaft Gear - Remove and Install...6358
Camshaft Bearings - Remove and Install...6372
Engine Oil Pan - Remove and Install - Aluminum and Pressed Steel Oil Pans...6376
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan...6388
Balancer - Remove...6396
Balancer - Install...6401
Piston Cooling Jets - Remove and Install...6410
Pistons and Connecting Rods - Remove...6414
Pistons and Connecting Rods - Disassemble...6417
Pistons and Connecting Rods - Assemble...6421
Pistons and Connecting Rods - Install...6426
Connecting Rod Bearings - Remove - Connecting Rods in Position...6430
Connecting Rod Bearings - Install - Connecting Rods in Position...6433
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position...6437
Crankshaft - Remove...6447
Crankshaft - Install...6452
Crankshaft Timing Ring - Remove and Install...6460
Crankshaft Gear - Remove and Install...6463
Crankshaft Gear (Balancer Drive) - Remove and Install...6468
Bearing Clearance - Check...6471
Refrigerant Compressor - Remove and Install...6474
Atmospheric Pressure Sensor - Remove and Install...6482
Camshaft Position Sensor - Remove and Install...6484
Crankshaft Position Sensor - Remove and Install...6487
Coolant Temperature Sensor - Remove and Install...6490
Engine Oil Pressure Sensor - Remove and Install...6493
Fuel Temperature Sensor - Remove and Install...6496
Soot Antenna - Remove and Install...6500
Temperature Sensor (DPF) - Remove and Install...6503
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install...6506
Pressure Sensor (Cooled Exhaust Gas) - Remove and Install - NRS Inlet and Outlet Pressure Sensors...6509
Boost Pressure Sensor - Remove and Install...6516
Inlet Manifold Temperature Sensor - Remove and Install...6519
Glow Plugs - Remove and Install...6522
Alternator Belt - Remove and Install...6527
Idler Pulley - Remove and Install - Flat Idler Pulley...6531
Idler Pulley - Remove and Install - Grooved Idler Pulley...6534
Belt Tensioner - Remove and Install...6537
Fan - Remove and Install...6540
Fan Drive - Remove and Install...6543
Electronic Control Module - Remove...6545
Electronic Control Module - Install...6554
Alternator - Remove...6564
Alternator - Install...6571
Electric Starting Motor - Remove and Install...6580
Air Compressor - Remove and Install - Single Cylinder...6583
Air Compressor - Remove and Install - Twin Cylinder Compressor...6599
Caterpillar C4.4 Engines Repair Service Manuals
