Caterpillar C3.3 / C4.4 Generator Sets Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C3.3, C4.4 Generator Sets, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C3.3 / C4.4 Generator Sets 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.
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
SHEET 3....1128
SHEET 4....1129
SHEET 5....1130
SHEET 6....1131
SHEET 7....1132
SHEET 8....1133
SHEET 9....1134
SHEET 10....1135
SHEET 11....1136
SHEET 12....1137
SHEET 13....1138
SHEET 14....1139
SHEET 15....1140
SHEET 16....1141
SHEET 17....1142
SHEET 18....1143
SHEET 19....1144
SHEET 20....1145
SHEET 21....1146
SHEET 22....1147
SHEET 23....1148
SHEET 24....1149
SHEET 25....1150
SHEET 26....1151
SHEET 27....1152
SHEET 28....1153
SHEET 29....1154
SHEET 30....1155
SHEET 31....1156
SHEET 32....1157
RENR9561 - Schematic (C3.3 and C4.4 Generator Sets Electrical System)....1158
Collage....1159
Main....1170
RENR9703 - Disassembly & Assembly (C3.3 and C4.4 Generator Sets)....1172
Alternator - Remove and Install....1175
Bearing Clearance - Check....1178
Camshaft - Remove and Install....1181
Camshaft Gear - Remove and Install....1184
Connecting Rod Bearings - Install....1187
Connecting Rod Bearings - Remove....1190
Coolant Temperature Switch - Remove and Install....1192
Crankcase Breather - Remove and Install....1194
Crankshaft - Install....1197
Crankshaft - Remove....1203
Crankshaft Front Seal - Install....1206
Crankshaft Front Seal - Remove....1208
Crankshaft Main Bearings - Remove and Install - Crankshaft in position....1210
Crankshaft Pulley - Remove and Install....1220
Crankshaft Rear Seal - Install....1222
Crankshaft Rear Seal - Remove....1226
Crankshaft Wear Sleeve (Front) - Remove and Install....1228
Cylinder Head - Install - Four Cylinder Engines....1232
Cylinder Head - Install - Three Cylinder Engines....1237
Cylinder Head - Remove - Four Cylinder Engines....1244
Cylinder Head - Remove - Three Cylinder Engines....1248
Electric Starting Motor - Remove and Install....1254
Engine - Install....1256
Engine - Remove....1260
Engine Enclosure Group - Remove and Install....1265
Engine Lifting Group - Remove and Install....1271
Engine Oil Cooler - Install - Four Cylinder Engine....1274
Engine Oil Cooler - Install - Three Cylinder Engines....1277
Engine Oil Cooler - Remove - Four Cylinder Engines....1282
Engine Oil Cooler - Remove - Three Cylinder Engines....1285
Engine Oil Filter Base - Remove and Install....1289
Engine Oil Pan - Remove and Install....1292
Engine Oil Pressure Switch - Remove and Install....1296
Engine Oil Pump - Install....1298
Engine Oil Pump - Remove....1301
Engine Oil Relief Valve - Remove and Install....1304
Exhaust Manifold - Remove and Install - Four Cylinder Engines....1307
Exhaust Manifold - Remove and Install - Three Cylinder Engines....1310
Fan - Remove and Install....1314
Fan Drive - Remove and Install....1316
Fan Guard - Remove and Install....1318
Flywheel - Install....1320
Flywheel - Remove....1323
Flywheel Housing - Remove and Install....1326
Front Cover - Remove and Install....1330
Fuel Injection Lines - Remove and Install....1332
Fuel Injection Nozzles - Install....1336
Fuel Injection Nozzles - Remove....1338
Fuel Injection Pump - Install....1340
Fuel Injection Pump - Remove....1344
Fuel Priming Pump and Fuel Filter Base - Remove and Install....1348
Generator - Install....1352
Generator - Remove....1356
Generator Enclosure Group - Remove and Install....1360
Glow Plugs - Remove and Install....1364
Housing (Front) - Install....1368
Housing (Front) - Remove....1372
Idler Gear - Remove and Install....1376
Inlet and Exhaust Valve Guides - Remove and Install....1383
Inlet and Exhaust Valve Springs - Remove and Install....1387
Inlet and Exhaust Valves - Remove and Install....1392
Jacket Water Heater - Remove and Install....1399
Lifter Group - Remove and Install....1402
Muffler - Remove and Install....1404
Piston Cooling Jets - Remove and Install....1407
Pistons and Connecting Rods - Assemble....1409
Pistons and Connecting Rods - Disassemble....1413
Pistons and Connecting Rods - Install....1416
Pistons and Connecting Rods - Remove....1419
Radiator - Remove and Install....1421
Rocker Shaft - Assemble....1424
Rocker Shaft - Disassemble....1426
Rocker Shaft and Pushrod - Install - Four Cylinder Engines....1428
Rocker Shaft and Pushrod - Install - Three Cylinder Engines....1432
Rocker Shaft and Pushrod - Remove - Four Cylinder Engines....1436
Rocker Shaft and Pushrod - Remove - Three Cylinder Engines....1439
Speed_Timing Sensor - Remove and Install....1442
Turbocharger - Install - If Equipped....1444
Turbocharger - Remove - If Equipped....1447
V-Belts - Remove and Install....1450
Valve Mechanism Cover - Remove and Install - Four Cylinder Engines....1452
Valve Mechanism Cover - Remove and Install - Three Cylinder Engines....1456
Water Pump - Remove and Install....1460
Water Temperature Regulator - Remove and Install....1464
UENR0662 - Troubleshooting (C4.4 Engines)....1467
General Information....1472
Welding Precaution....1475
Electronic Service Tools....1477
Service Information Report....1483
System Overview....1485
Component Location....1488
Diesel Particulate Filter Regeneration....1498
Engine Monitoring System....1499
Diagnostic Capabilities....1501
Electrical Connectors....1503
Configuration Parameters....1510
Diagnostic Trouble Codes....1513
Event Codes....1545
Acceleration Is Poor or Throttle Response Is Poor....1566
Alternator Problem - Charging Problem and_or Noisy Operation....1577
Battery Problem....1580
Clean Emissions Module Has High Oxygen Level....1582
Coolant Contains Oil....1584
Coolant Level Is Low....1587
Coolant Temperature Is High....1589
Coolant Temperature Is Low....1595
Crankcase Breather Ejects Oil....1598
Crankcase Fumes Disposal Tube Has Oil Draining....1601
Cylinder Is Noisy....1605
DEF Pressure Does Not Respond....1609
DEF Pressure Is High....1611
DEF Pressure Is Low....1618
DEF Tank Level Is Low....1626
DEF Tank Temperature Is High....1630
DEF Tank Temperature Is Low....1633
Diesel Oxidation Catalyst Has Incorrect Inlet Temperature....1638
Diesel Oxidation Catalyst Has Low Conversion Efficiency....1641
Diesel Particulate Filter Collects Excessive Soot - If Equipped....1644
Diesel Particulate Filter Temperature Is Low - If Equipped....1649
Engine Cranks but Does Not Start....1652
Engine Does Not Crank....1664
Engine Has Early Wear....1668
Engine Has Mechanical Noise (Knock)....1671
Engine Misfires; Runs Rough or Is Unstable....1676
Engine Overcrank Occurrence....1686
Engine Overspeeds....1690
Engine Shutdown Occurrence....1693
Engine Shutdown Occurs Intermittently....1695
Engine Stalls at Low RPM....1698
Engine Top Speed Is Not Obtained....1702
Engine Vibration Is Excessive....1713
Exhaust Has Excessive Black Smoke....1716
Exhaust Has Excessive White Smoke....1722
Exhaust System Contains Coolant....1729
Exhaust System Contains Oil....1732
Exhaust Temperature Is High....1735
Fuel Consumption Is Excessive....1739
Fuel Contains Water....1745
Fuel Filter Is Restricted....1748
Fuel Pressure Is Low....1752
Fuel Rail Pressure Problem....1756
Fuel Temperature Is High....1771
Inlet Air Is Restricted....1775
Intake Manifold Air Pressure Is High....1777
Intake Manifold Air Pressure Is Low....1781
Intake Manifold Air Temperature Is High....1784
NOx Conversion Is Low....1788
NRS Exhaust Gas Temperature Is High....1800
NRS Mass Flow Rate Problem....1804
Oil Consumption Is Excessive....1811
Oil Contains Coolant....1816
Oil Contains Fuel....1819
Oil Level Is Low....1823
Oil Pressure Is Low....1825
Power Is Intermittently Low or Power Cutout Is Intermittent....1834
SCR Catalyst Has Incorrect Inlet Temperature....1842
SCR Warning System Problem....1846
Valve Lash Is Excessive....1856
Aftertreatment Identification Module - Test....1858
CAN Data Link - Test....1863
Coolant Level - Test....1869
Cooling Fan Control - Test - Hydraulic Driven Fan....1872
Data Link - Test....1877
Data Link Configuration Status - Test....1885
DEF Control Module Power - Test....1888
DEF Line Heater - Test....1893
DEF Pump - Test....1899
DEF Pump Pressure Sensor - Test....1903
DEF Pump Sensor Supply - Test....1906
DEF Tank Sensor - Test....1908
Electrical Power Supply - Test....1912
Ether Starting Aid - Test....1917
Fuel Transfer Pump - Test....1923
Glow Plug Starting Aid - Test....1929
Idle Validation - Test....1937
Indicator Lamp - Test....1945
Injector Data Incorrect - Test....1949
Injector Solenoid - Test....1953
Mode Selection - Test....1961
Motorized Valve - Test....1965
NOx Sensor - Test....1973
Power Take-Off - Test....1982
Relay - Test - Start Relay....1986
Relay - Test - Aftertreatment Power Relay....1990
Sensor Calibration Required - Test....1994
Sensor (Data Link Type) - Test....1999
Sensor Signal (Analog; Active) - Test....2005
Sensor Signal (Analog; Passive) - Test....2015
Sensor Supply - Test....2027
Solenoid Valve - Test - Solenoid Valves that Connect to the Engine ECM....2033
Solenoid Valve - Test - Solenoid Valves that Connect to the Dosing Control Unit (DCU)....2040
Soot Sensor - Test....2048
Speed Control - Test - Analog....2054
Speed Control - Test - PWM....2060
Speed_Timing - Test....2068
Switch Circuits - Test - Multiposition Throttle Switch....2078
Switch Circuits - Test - Air Filter Restriction Switch....2082
Valve Position - Test....2084
Water in Fuel - Test....2092
Service Tool Features....2097
Service Tool Error Identifiers....2129
Customer Passwords....2143
Factory Passwords....2144
ECM Will Not Accept Factory Passwords....2146
Electronic Service Tool Does Not Communicate....2147
Codes that Inhibit Operation of Aftertreatment System....2153
Test ECM Mode....2156
ECM Software - Install....2158
ECM - Replace....2160
Electrical Connectors - Inspect....2163
Cooling Fan - Calibrate - If Applicable....2170
Injector Code - Calibrate....2172
SCR Inducement Emergency Override....2175
UENR3999 - Schematic (C4.4 Marine Generator Set Electrical System)....2178
Feature....2178
Cover Page....2179
Schematics....0
Volume 1 of 3 - Engine Wiring....2181
Volume 2 of 3 - EMCP 4.2 Control Panel Wiring....2182
Volume 3 of 3 - MCS Control Panel Wiring....2183
Machine Views....0
Volume 1 of 3 - Engine Wiring....0
Left Side View....2184
Right Side View....2185
Top View....2186
Volume 2 of 3 - EMCP 4.2 Control Panel Wiring....0
Left Front Corner View....2187
Left Side View....2188
Volume 3 of 3 - MCS Control Panel Wiring....0
Left Front Corner View....2189
Left Side View....2190
UENR4439 - Specifications (C3.3 Generator Sets)....2191
Engine Design....2193
Fuel Injection Lines....2195
Fuel Injection Pump....2197
Fuel Injectors....2200
Fuel Transfer Pump....2202
Lifter Group....2205
Rocker Shaft....2207
Valve Mechanism Cover....2210
Cylinder Head Valves....2212
Cylinder Head....2217
Turbocharger....2221
Exhaust Manifold....2223
Camshaft....2225
Camshaft Bearings....2229
Engine Oil Filter....2231
Engine Oil Pump....2233
Engine Oil Pressure....2236
Engine Oil Bypass Valve....2237
Engine Oil Pan....2239
Crankcase Breather....2243
Water Temperature Regulator and Housing....2246
Water Pump....2248
Cylinder Block....2250
Crankshaft - Steel Crankshaft....2254
Crankshaft Seals....2257
Connecting Rod Bearing Journal - Steel Crankshaft....2259
Main Bearing Journal - Steel Crankshaft....2260
Connecting Rod - For Use With Steel Crankshaft....2262
Piston and Rings....2267
Piston Cooling Jet....2270
Front Housing and Covers....2272
Gear Group (Front)....2274
Flywheel....2278
Flywheel Housing....2280
Crankshaft Pulley....2282
Fan Drive....2284
Engine Lifting Bracket....2286
Alternator....2287
Starter Motor....2289
Glow Plugs....2291
UENR4440 - Systems Operation (C3.3 Generator Sets)....2293
General Information....2294
Fuel System....2298
Air Inlet and Exhaust System....2300
Lubrication System....2306
Cooling System....2308
Basic Engine....2310
Electrical System....2312
UENR4440 - Testing and Adjusting (C3.3 Generator Sets)....2315
Fuel System - Inspect....2317
Air in Fuel - Test....2318
Finding Top Center Position for No. 1 Piston....2321
Fuel Injection Nozzle - Test....2323
Fuel Injection Pump Timing - Check....2329
Fuel Injection Pump Timing - Adjust....2330
Fuel Quality - Test....2331
Fuel System - Prime....2333
Fuel System Pressure - Test....2336
Air Inlet and Exhaust System - Inspect....2339
Wastegate - Test....2340
Exhaust Temperature - Test....2342
Engine Crankcase Pressure (Blowby) - Test....2343
Compression - Test....2345
Engine Valve Lash - Inspect_Adjust....2346
Valve Depth - Inspect....2350
Valve Guide - Inspect....2353
Engine Oil Pressure - Test....2355
Engine Oil Pump - Inspect....2357
Excessive Bearing Wear - Inspect....2361
Excessive Engine Oil Consumption - Inspect....2362
Increased Engine Oil Temperature - Inspect....2363
Cooling System - Check - Overheating....2364
Cooling System - Inspect....2366
Cooling System - Test....2368
Engine Oil Cooler - Inspect....2375
Water Temperature Regulator - Test....2377
Piston Ring Groove - Inspect....2378
Connecting Rod - Inspect....2381
Connecting Rod Bearings - Inspect....2383
Main Bearings - Inspect....2384
Cylinder Block - Inspect....2385
Cylinder Head - Inspect....2386
Piston Height - Inspect....2388
Flywheel - Inspect....2390
Flywheel Housing - Inspect....2393
Gear Group - Inspect....2396
Alternator - Test....2398
Battery - Test....2400
Electric Starting System - Test....2401
Glow Plugs - Test....2405
V-Belt - Test....2407
UENR4470 - Specifications (C4.4 Marine Generator Set)....2409
Engine Design....2412
Fuel Injection Lines....2414
Fuel Injection Pump....2416
Fuel Injection Nozzles....2418
Fuel Filter Base....2420
Fuel Filter Base - Duplex Filter....2422
Fuel Manifold (Rail)....2425
Lifter Group....2427
Rocker Shaft....2429
Valve Mechanism Cover....2432
Cylinder Head Valves....2433
Cylinder Head....2436
Turbocharger....2441
Aftercooler....2444
Exhaust Manifold....2446
Exhaust Elbow....2448
Camshaft....2450
Camshaft Bearings....2453
Engine Oil Filter Base....2454
Engine Oil Filter Base - Duplex Filters....2456
Engine Oil Cooler....2458
Engine Oil Pump....2460
Engine Oil Pressure....2463
Engine Oil Pan....2464
Engine Oil Pan Drain Valve....2467
Breather Mounting Bracket....2468
Crankcase Breather....2470
Water Lines - Engines with a Keel Cooler....2472
Water Lines - Engines with a Heat Exchanger....2474
Water Temperature Regulator and Housing....2476
Water Connection Group....2478
Water Pump....2480
Auxiliary Water Pump....2481
Heat Exchanger....2484
Cylinder Block....2486
Crankshaft....2488
Crankshaft Seals....2491
Connecting Rod Bearing Journal....2493
Main Bearing Journal....2494
Connecting Rod....2495
Piston and Rings....2499
Piston Cooling Jet....2501
Front Housing and Covers....2503
Gear Group (Front)....2505
Flywheel....2508
Flywheel Housing....2510
Generator Coupling....2512
Engine and Generator Mounting Group....2514
Crankshaft Pulley....2516
Belt Tensioner....2518
Belt Guard....2520
Fan Drive....2522
Engine Lifting Bracket....2524
Engine Barring Group....2528
Alternator and Regulator....2530
Electric Starting Motor - 12 V....2532
Electric Starting Motor - 24 V....2534
Air Starting Motor....2536
Glow Plugs....2538
Control Panel Mounting....2540
Magnetic Pickup....2542
Coolant Temperature Sensor....2543
Coolant Temperature Sensor - Coolant Temperature Shutdown....2545
Engine Coolant Pressure Sensor....2547
Fuel Pressure Sensor - M.C.S. Fuel Pressure Sensors....2549
Engine Oil Pressure Sensor....2551
Engine Oil Pressure Sensor - Engine Oil Filter Inlet Pressure Sensor....2552
Engine Oil Pressure Switch - M.C.S. Engine Oil Pressure Switch....2554
Engine Oil Temperature Sensor - M.C.S. Engine Oil Temperature Sensor....2555
Boost Pressure Sensor....2557
Inlet Manifold Temperature Sensor....2559
Temperature Sensor (Exhaust)....2560
Speed_Timing Sensor....2561
Electronic Control Module....2563
Heater Mounting Group - If Equipped....2565
UENR4471 - Systems Operation (C4.4 Marine Generator Set)....2566
Introduction....2567
Basic Engine....2574
Air Inlet and Exhaust System....2582
Cooling System....2589
Lubrication System....2596
Electrical System....2598
Cleanliness of Fuel System Components....2602
Fuel Injection....2604
Electronic Control System....2617
Power Sources....2632
Glossary of Electronic Control Terms....2636
UENR4471 - Testing and Adjusting (C4.4 Marine Generator Set)....2644
Fuel System - Inspect....2646
Finding Top Center Position for No. 1 Piston....2647
Fuel Injection Timing - Check....2650
Fuel Quality - Test....2653
Fuel System - Prime....2655
Gear Group (Front) - Time....2657
Air Inlet and Exhaust System - Inspect....2659
Turbocharger - Inspect....2662
Compression - Test....2666
Engine Valve Lash - Inspect....2668
Valve Depth - Inspect....2673
Valve Guide - Inspect....2676
Engine Oil Pressure - Test....2678
Engine Oil Pump - Inspect....2679
Excessive Bearing Wear - Inspect....2681
Excessive Engine Oil Consumption - Inspect....2682
Increased Engine Oil Temperature - Inspect....2683
Cooling System - Check - Overheating....2684
Cooling System - Inspect....2686
Cooling System - Test....2688
Engine Oil Cooler - Inspect....2695
Water Temperature Regulator - Test....2697
Water Pump - Inspect....2698
Position the Valve Mechanism Before Maintenance Procedures....2699
Piston Ring Groove - Inspect....2702
Connecting Rod - Inspect....2705
Cylinder Block - Inspect....2707
Cylinder Head - Inspect....2708
Piston Height - Inspect....2711
Flywheel - Inspect....2714
Flywheel Housing - Inspect....2717
Gear Group - Inspect....2720
Crankshaft Pulley - Check....2722
Alternator - Test....2724
Battery - Test....2726
Charging System - Test....2727
V-Belt - Test....2728
Electric Starting System - Test....2730
UENR4472 - Disassembly and Assembly (C4.4 Marine Generator Set)....2734
Engine - Remove and Install....2739
Generator - Remove and Install....2756
Control System - Remove and Install - M.C.S. Control System Panel....2769
Control System - Remove and Install - Non M.C.S. Control System Panel....2777
Fuel Priming Pump - Remove and Install - Non M.C.S. Fuel Priming Pump....2785
Fuel Priming Pump - Remove and Install - M.C.S. Fuel Priming Pump....2792
Flow Control Valve - Remove and Install....2798
Fuel Filter Base - Remove and Install - M.C.S. Duplex Secondary Fuel Filter Base....2805
Fuel Filter Base - Remove and Install - Non M.C.S. Secondary Fuel Filter Base....2812
Fuel Filter Base - Remove and Install - M.C.S. Duplex Primary Fuel Filter Base....2818
Fuel Filter Base - Remove and Install - Non M.C.S. Primary Fuel Filter Base....2824
Fuel Manifold (Rail) - Remove and Install - M.C.S. Regulated Engines....2830
Fuel Manifold (Rail) - Remove and Install - Non M.C.S Arrangement....2841
Relief Valve (Fuel) - Remove and Install - Fuel Rail Pressure Relief Valve....2850
Relief Valve (Fuel) - Remove and Install - Low Pressure System Relief Valve....2857
Fuel Injection Lines - Remove and Install - Double Wall Fuel Injection Lines....2867
Fuel Injection Lines - Remove and Install - Non M.C.S. Fuel Injection Lines....2875
Fuel Cooler - Remove and Install....2884
Fuel Injection Pump - Remove and Install....2890
Fuel Injection Pump Gear - Remove and Install....2901
Electronic Unit Injector - Remove....2905
Electronic Unit Injector - Install....2911
Air Cleaner Housing - Remove and Install....2918
Turbocharger - Remove and Install....2923
Exhaust Manifold - Remove and Install....2935
Exhaust Elbow - Remove and Install....2943
Inlet Manifold - Remove and Install - Inlet Elbow from the Cylinder Head to the Aftercooler....2946
Inlet and Exhaust Valve Springs - Remove and Install....2951
Inlet and Exhaust Valves - Remove and Install....2960
Engine Oil Filter Base - Remove and Install - M.C.S. Duplex Engine Oil Filter Base....2967
Engine Oil Filter Base - Remove and Install - None M.C.S. Arrangement....2976
Engine Oil Cooler - Remove and Install....2979
Engine Oil Relief Valve - Remove and Install....2984
Engine Oil Pump - Remove and Install....2988
Water Pump - Remove and Install....2993
Water Temperature Regulator - Remove and Install....3003
Auxiliary Water Pump - Remove and Install....3007
Auxiliary Water Pump - Disassemble....3013
Auxiliary Water Pump - Assemble....3016
Aftercooler - Remove and Install - Keel-Cooled....3020
Aftercooler - Disassemble - Air - to - Air Charge Cooler....3032
Aftercooler - Disassemble - Keel-cooled....3036
Aftercooler - Assemble - Air - to - Air Charge Cooler....3038
Aftercooler - Assemble - Keel-cooled....3042
Heat Exchanger - Disassemble - Sea Water Cooled Engine....3044
Heat Exchanger - Assemble - Sea Water Cooled Engines....3046
Heat Exchanger - Remove and Install - Sea Water Cooled Engine....3049
Expansion Tank - Remove and Install - Sea Water Cooled Engines....3061
Radiator - Disassemble....3067
Radiator - Assemble....3071
Radiator - Remove and Install....3076
Flywheel - Remove and Install....3085
Crankshaft Rear Seal - Remove and Install....3091
Flywheel Housing - Remove and Install....3096
Crankshaft Pulley - Remove and Install....3104
Crankshaft Front Seal - Remove and Install....3107
Front Cover - Remove and Install....3111
Gear Group (Front) - Remove and Install....3116
Idler Gear - Remove and Install....3130
Housing (Front) - Remove and Install....3143
Crankcase Breather - Remove and Install....3153
Valve Mechanism Cover - Remove and Install....3162
Rocker Shaft and Push Rod - Remove and Install....3170
Rocker Shaft - Disassemble....3182
Rocker Shaft - Assemble....3185
Cylinder Head - Remove....3188
Cylinder Head - Install....3196
Lifter Group - Remove and Install....3204
Camshaft - Remove and Install....3208
Camshaft Gear - Remove and Install....3213
Camshaft Bearings - Remove and Install....3227
Engine Oil Pan - Remove and Install....3230
Piston Cooling Jets - Remove and Install....3241
Pistons and Connecting Rods - Remove and Install....3245
Pistons and Connecting Rods - Disassemble....3252
Pistons and Connecting Rods - Assemble....3256
Connecting Rod Bearings - Remove and Install - Connecting rods in position....3261
Crankshaft Main Bearings - Remove and Install - Crankshaft in position....3268
Crankshaft - Remove and Install....3278
Crankshaft Timing Ring - Remove and Install....3291
Crankshaft Gear - Remove and Install....3294
Bearing Clearance - Check....3299
Check Valve - Remove and Install....3302
Camshaft Position Sensor - Remove and Install....3305
Crankshaft Position Sensor - Remove and Install....3308
Switch (Coolant Level) - Remove and Install - Coolant Level Switch for Keel-Cooled Engines....3311
Switch (Coolant Level) - Remove and Install - Coolant Level Switch for Sea water Cooled Engines....3316
Fuel Level Sensor - Remove and Install....3321
Pressure Sensor (Engine Coolant) - Remove and Install - Engine Cooling System Pressure Sensor....3325
Pressure Sensor (Sea Water) - Remove and Install - Auxiliary Water Pump Pressure Sensor....3330
Coolant Temperature Sensor - Remove and Install - Engine Cooling System Temperature Sensor....3335
Coolant Temperature Sensor - Remove and Install - Engine Cooling System Temperature Shutdown Sensor....3340
Engine Oil Pressure Sensor - Remove and Install - M.C.S Oil Filter Base Inlet Pressure Sensor....3345
Engine Oil Pressure Sensor - Remove and Install - Low Oil Pressure Shutdown Switch....3350
Engine Oil Pressure Sensor - Remove and Install - Engine Oil Pressure Sensor and M.C.S Engine Oil Pressure Sensor....3355
Engine Oil Temperature Sensor - Remove and Install....3360
Thermowell - Remove and Install....3364
Fuel Pressure Sensor - Remove and Install - M.C.S. Duplex Primary Fuel Filter Base Inlet Fuel Pressure Sensor....3367
Fuel Pressure Sensor - Remove and Install - M.C.S Duplex Primary Fuel Filter Base Outlet Pressure Sensor....3372
Fuel Pressure Sensor - Remove and Install - M.C.S. Duplex Secondary Fuel Filter Base Inlet Pressure Sensor....3377
Fuel Pressure Sensor - Remove and Install - M.C.S. Duplex Secondary Fuel Filter Base Outlet Pressure Sensor....3381
Fuel Pressure Sensor - Remove and Install - Non M.C.S. Duplex Secondary Fuel Filter Base Fuel Pressure Sensor....3386
Fuel Temperature Sensor - Remove and Install....3390
Temperature Sensor (Exhaust) - Remove and Install....3394
Boost Pressure Sensor - Remove and Install....3396
Inlet Air Temperature Sensor - Remove and Install....3398
Glow Plug - Remove and Install....3401
Jacket Water Heater - Remove and Install....3406
Alternator Belt - Remove and Install....3410
Belt Tensioner - Remove and Install - Non-Radiator Equipped Engines....3415
Belt Tensioner - Remove and Install - Radiator Equipped Engines....3419
Fan - Remove and Install....3425
Fan Drive - Remove and Install....3435
Electronic Control Module - Remove and Install....3437
Alternator - Remove and Install....3445
Electric Starting Motor - Remove and Install....3457
Air Starting Motor - Remove and Install....3461
UENR4473 - Troubleshooting (C4.4 Marine Generator Set)....3464
Welding Precaution....3467
System Overview....3469
Glossary....3477
Electronic Service Tools....3483
Indicator Lamps....3490
Replacing the ECM....3495
Self-Diagnostics....3498
Sensors and Electrical Connectors....3500
Engine Wiring Information....3505
ECM Harness Connector Terminals....3508
Programming Parameters....3510
Test ECM Mode....3511
Factory Passwords....3513
Flash Programming....3514
Injector Code - Calibrate....3516
Customer Specified Parameters....3519
Customer Specified Parameters Table....3526
Customer Specified Parameters Worksheet....3529
System Configuration Parameters....3531
Acceleration Is Poor or Throttle Response Is Poor....3533
Alternator Is Noisy....3544
Alternator Problem....3547
Battery Problem....3549
Coolant Contains Oil....3551
Coolant Level Is Low....3553
Coolant Pressure Is High....3554
Coolant Temperature Is High....3555
Crankcase Breather Ejects Oil....3562
Crankcase Fumes Disposal Tube Has Oil Draining....3565
Cylinder Is Noisy....3570
ECM Does Not Communicate with Other Modules....3574
ECM Will Not Accept Factory Passwords....3575
Electronic Service Tool Does Not Communicate....3576
Engine Cranks but Does Not Start....3580
Engine Does Not Crank....3592
Engine Has Early Wear....3595
Engine Has Mechanical Noise (Knock)....3598
Engine Misfires; Runs Rough or Is Unstable....3602
Engine Overspeeds....3611
Engine Shutdown Occurs Intermittently....3613
Engine Top Speed Is Not Obtained....3616
Engine Vibration Is Excessive....3626
Exhaust Has Excessive Black Smoke....3629
Exhaust Has Excessive White Smoke....3633
Exhaust Temperature Is High....3638
Fuel Consumption Is Excessive....3641
Fuel Filter Is Restricted - Primary Fuel Filter....3645
Fuel Filter Is Restricted - Secondary Fuel Filter....3647
Fuel Rail Pressure Problem....3649
Fuel Temperature Is High....3663
Inlet Air Is Restricted....3666
Inlet Air Temperature Is High....3667
Intake Manifold Air Pressure Is Low....3670
Intake Manifold Air Temperature Is High....3672
Oil Consumption Is Excessive....3676
Oil Contains Coolant....3680
Oil Contains Fuel....3683
Oil Filter Differential Pressure Problem....3686
Oil Pressure Is Low....3688
Oil Temperature Is High....3697
Power Is Intermittently Low or Power Cutout Is Intermittent....3701
Sea Water Pump Pressure Is Low....3709
Valve Lash Is Excessive....3711
Diagnostic Trouble Codes - Engine Diagnostic Trouble Codes....3713
Diagnostic Trouble Codes - MCS Control Panel Diagnostic Trouble Codes....3718
Event Codes....3720
CAN Data Link - Test....3724
Data Link - Test....3729
ECM Memory - Test....3738
Electrical Connector - Inspect....3739
Electrical Power Supply - Test....3748
Glow Plug Starting Aid - Test....3755
Injector Data Incorrect - Test....3767
Injector Solenoid - Test....3771
Relay - Test - Electric Fuel Lift Pump Relay....3780
Relay - Test - Starting Motor Relay....3786
Sensor Calibration Required - Test....3792
Sensor Supply - Test....3795
Sensor Signal (Analog; Active) - Test....3811
Sensor Signal (Analog; Passive) - Test....3825
Solenoid Valve - Test....3833
Speed_Timing - Test....3839
UENR8296 - Schematic (C4.4 XQ125 Rental Generator Set Electrical System)....3848
Features....3848
Cover Page....3850
Schematic....3851
Machine Views....0
Left Side View....3852
Rear View....3853
Right Side View....3854
