Caterpillar C4.2 and C6.4 Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C4.2 and C6.4 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C4.2 and C6.4 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.
KENR5342 - Troubleshooting (C4.2 and C6.4 Engines for Caterpillar Built Machines).pdf
KENR6740 - Specifications (C4.2 and C6.4 Engines for Caterpillar Built Machines).pdf
KENR6741 - Systems Operation (C4.2 and C6.4 Engines for Caterpillar Built Machines).pdf
KENR6741 - Testing and Adjusting (C4.2 and C6.4 Engines for Caterpillar Built Machines).pdf
KENR8105 - Disassembly and Assembly (C4.2 Engine for Caterpillar Built Machines).pdf
KENR8106 - Disassembly and Assembly (C6.4 Engine for Caterpillar Built Machines).pdf
PRODUCT DETAILS:
Total Pages: 1,203 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR8106 - Disassembly and Assembly (C6.4 Engine for Caterpillar Built Machines)...2
Muffler - Remove and Install...6
Fuel Priming Pump - Remove and Install...8
Fuel Filter Base - Remove and Install...11
Fuel Transfer Pump - Remove...15
Fuel Transfer Pump - Install...18
Fuel Injection Lines - Remove...20
Fuel Injection Lines - Install...24
Fuel Manifold (Rail) - Remove...27
Fuel Manifold (Rail) - Install...29
Fuel Injection Pump - Remove...30
Fuel Injection Pump - Install...35
Fuel Injection Pump Gear - Remove...40
Fuel Injection Pump Gear - Install...42
Electronic Unit Injector - Remove...44
Electronic Unit Injector - Install...47
Turbocharger - Remove...49
Turbocharger - Disassemble...51
Turbocharger - Assemble...54
Turbocharger - Install...57
Exhaust Manifold - Remove and Install...59
Air Inlet Heater - Remove and Install...61
Inlet Manifold - Remove and Install...67
Inlet and Exhaust Valve Springs - Remove and Install...71
Inlet and Exhaust Valves - Remove and Install...76
Inlet and Exhaust Valve Guides - Remove and Install...81
Inlet and Exhaust Valve Seat Inserts - Remove and Install...85
Engine Oil Cooler - Remove...89
Engine Oil Cooler - Disassemble...91
Engine Oil Cooler - Assemble...93
Engine Oil Cooler - Install...95
Engine Oil Relief Valve - Remove and Install...96
Engine Oil Bypass Valve - Remove and Install...98
Engine Oil Pump Relief Valve - Remove and Install...100
Engine Oil Pump - Remove...103
Engine Oil Pump - Install...107
Water Pump - Remove...110
Water Pump - Disassemble...112
Water Pump - Assemble...116
Water Pump - Install...120
Water Temperature Regulator - Remove and Install...122
Flywheel - Remove...124
Flywheel - Install...127
Crankshaft Rear Seal - Remove...130
Crankshaft Rear Seal - Install...132
Flywheel Housing - Remove and Install...135
Crankshaft Pulley - Remove and Install...139
Crankshaft Front Seal - Remove...143
Crankshaft Front Seal - Install...145
Gear Group (Front) - Remove - Idler Gear Only...147
Gear Group (Front) - Install - Idler Gear Only...151
Housing (Front) - Remove...156
Housing (Front) - Install...160
Front Plate - Remove...164
Front Plate - Install...166
Crankcase Breather - Remove and Install...168
Valve Mechanism Cover - Remove and Install...170
Valve Mechanism Cover Base - Remove and Install...172
Rocker Shaft and Pushrod - Remove...175
Rocker Shaft - Disassemble...177
Rocker Shaft - Assemble...180
Rocker Shaft and Pushrod - Install...183
Cylinder Head - Remove...185
Cylinder Head - Install...188
Lifter Group - Remove and Install...191
Camshaft - Remove and Install...194
Camshaft Gear - Remove and Install...198
Camshaft Bearings - Remove and Install...201
Engine Oil Pan - Remove...205
Engine Oil Pan - Install...208
Cylinder Liner - Remove...211
Cylinder Liner - Install...214
Piston Cooling Jets - Remove and Install...216
Pistons and Connecting Rods - Remove...219
Pistons and Connecting Rods - Disassemble...221
Pistons and Connecting Rods - Assemble...225
Pistons and Connecting Rods - Install...229
Connecting Rod Bearings - Remove...232
Connecting Rod Bearings - Install...234
Crankshaft Main Bearings - Remove...237
Crankshaft Main Bearings - Install...239
Crankshaft - Remove...241
Crankshaft - Install...246
Crankshaft Gear - Remove and Install...252
Bearing Clearance - Check...254
Crankshaft Position Sensor - Remove and Install - Primary Speed Timing Sensor...257
Coolant Temperature Sensor - Remove and Install...259
Engine Oil Pressure Sensor - Remove and Install...261
Position Sensor (Fuel Injection Pump) - Remove and Install...263
Fuel Pressure Sensor - Remove and Install...266
Boost Pressure Sensor - Remove and Install...268
Inlet Air Temperature Sensor - Remove and Install...270
Idler Pulley - Remove...272
Idler Pulley - Disassemble...273
Idler Pulley - Assemble...275
Idler Pulley - Install...277
Fan Drive - Remove...278
Fan Drive - Disassemble...279
Fan Drive - Assemble...281
Fan Drive - Install...284
Electronic Control Module - Remove and Install...285
Alternator - Remove and Install...288
Electric Starting Motor - Remove and Install...293
KENR5342 - Troubleshooting (C4.2 and C6.4 Engines for Caterpillar Built Machines)...298
General Information...301
Welding Precaution...302
Electronic Service Tools...304
System Overview...314
Component Location...316
Engine Monitoring System...330
Diagnostic Capabilities...332
Programmable Parameters...334
Electrical Connectors...335
Configuration Parameters...338
Diagnostic Trouble Codes...341
Event Codes...350
Symptom Troubleshooting...359
Acceleration Is Poor or Throttle Response Is Poor...361
Alternator Problem - Charging Problem and_or Noisy Operation...366
Battery Problem...368
Coolant Contains Fuel...369
Coolant Contains Oil...370
Coolant Temperature Is High...372
Cylinder Is Noisy...375
ECM Does Not Communicate with Other Modules...378
Engine Cranks but Does Not Start...379
Engine Does Not Crank...385
Engine Has Early Wear...387
Engine Has Mechanical Noise (Knock)...389
Engine Misfires; Runs Rough or Is Unstable...391
Engine Overspeeds...395
Engine Speed Does Not Change...396
Engine Stalls at Low RPM...397
Engine Top Speed Is Not Obtained...401
Engine Vibration Is Excessive...405
Exhaust Has Excessive Black Smoke...406
Exhaust Has Excessive White Smoke...409
Exhaust Temperature Is High...412
Fuel Consumption Is Excessive...413
Fuel Filter Is Restricted...416
Fuel Pressure Is High...418
Fuel Pressure Is Low...420
Fuel Rail Pressure Is High...423
Fuel Rail Pressure Is Low...425
Fuel Temperature Is High...427
Indicator Lamp Problem...429
Intake Manifold Air Pressure Is High...431
Intake Manifold Air Pressure Is Low...433
Intake Manifold Air Temperature Is High...435
Oil Consumption Is Excessive...438
Oil Contains Coolant...440
Oil Contains Fuel...442
Oil Pressure Is Low...444
Oil Temperature Is High...447
Power Is Intermittently Low or Power Cutout Is Intermittent...449
Valve Lash Is Excessive...452
CAN Data Link - Test...454
Cat Data Link - Test...461
Electrical Power Supply - Test...467
Fuel Rail Pump - Test...474
Indicator Lamp - Test...481
Injector Response - Test...486
Injector Solenoid - Test...499
Sensor Signal (Analog; Active) - Test...513
Sensor Signal (Analog; Passive) - Test...523
Sensor Supply - Test...531
Speed Control (PWM) - Test...542
Speed Control - Test...548
Speed_Timing - Test...555
Starting Aid - Test...564
Factory Passwords...575
ECM Will Not Accept Factory Passwords...576
Electronic Service Tool Does Not Communicate...577
Test ECM Mode...581
Injector Trim File - Install...583
ECM Software - Install...585
ECM - Configure...587
ECM - Replace...589
Electrical Connectors - Inspect...592
KENR6741 - Testing and Adjusting (C4.2 and C6.4 Engines for Caterpillar Built Machines)...600
Fuel System - Inspect...602
Air in Fuel - Test...604
Engine Speed - Check...608
Finding Top Center Position for No. 1 Piston...610
Fuel Injection Timing - Check...613
Fuel Quality - Test...615
Fuel System - Prime...616
Air Inlet and Exhaust System - Inspect...619
Turbocharger - Inspect...620
Exhaust Temperature - Test...621
Engine Crankcase Pressure (Blowby) - Test...622
Compression - Test...624
Engine Valve Lash - Inspect_Adjust...627
Valve Guide - Inspect...632
Engine Oil Pressure - Test...633
Engine Oil Pump - Inspect...635
Excessive Bearing Wear - Inspect...640
Excessive Engine Oil Consumption - Inspect...641
Cooling System - Check - Overheating...642
Cooling System - Inspect...645
Cooling System - Test...646
Engine Oil Cooler - Inspect...656
Water Temperature Regulator - Test...657
Piston Ring Groove - Inspect...659
Connecting Rod - Inspect...662
Connecting Rod Bearings - Inspect...665
Main Bearings - Inspect...666
Cylinder Block - Inspect...667
Cylinder Head - Inspect...668
Piston Height - Inspect...670
Flywheel - Inspect...673
Flywheel Housing - Inspect...676
Alternator - Test...679
Battery - Test...681
Electric Starting System - Test...682
KENR6741 - Systems Operation (C4.2 and C6.4 Engines for Caterpillar Built Machines)...683
Introduction...684
Basic Engine...687
Air Inlet and Exhaust System...689
Cooling System...695
Lubrication System...697
Electrical System...700
Fuel System...711
KENR6740 - Specifications (C4.2 and C6.4 Engines for Caterpillar Built Machines)...723
Fuel Injection Lines...725
Fuel Injection Pump...729
Fuel Injection Nozzles...739
Fuel Filter Base...744
Fuel Filter...754
Rocker Shaft...758
Valve Mechanism Cover...763
Cylinder Head...766
Exhaust Manifold...776
Camshaft...779
Engine Oil Pump...787
Engine Oil Bypass Valve...795
Engine Oil Pan...800
Water Temperature Regulator...803
Water Pump...808
Cylinder Block...814
Crankshaft...820
Connecting Rod Bearing Journal...824
Main Bearing Journal...829
Connecting Rod...836
Piston and Rings...845
Gear Group (Front)...853
Flywheel...860
Crankshaft Pulley...866
Fan Drive...873
Alternator and Regulator...875
Electric Starting Motor...880
Coolant Temperature Sensor...886
Fuel Temperature Sensor...891
Fuel Pressure Sensor...896
Engine Oil Pressure Sensor...911
Boost Pressure Sensor...926
Boost Pressure Sensor ...936
Speed_Timing Sensor...941
KENR8105 - Disassembly and Assembly (C4.2 Engine for Caterpillar Built Machines)...946
Fuel Priming Pump - Remove and Install...949
Fuel Filter Base - Remove and Install...952
Fuel Transfer Pump - Remove...955
Fuel Transfer Pump - Install...958
Fuel Injection Lines - Remove...960
Fuel Injection Lines - Install...964
Fuel Manifold (Rail) - Remove...967
Fuel Manifold (Rail) - Install...969
Fuel Injection Pump - Remove...970
Fuel Injection Pump - Install...975
Fuel Injection Pump Gear - Remove...980
Fuel Injection Pump Gear - Install...982
Electronic Unit Injector - Remove...984
Electronic Unit Injector - Install...987
Turbocharger - Remove...989
Turbocharger - Disassemble...991
Turbocharger - Assemble...994
Turbocharger - Install...997
Exhaust Manifold - Remove and Install...999
Inlet Manifold - Remove and Install...1001
Inlet and Exhaust Valve Springs - Remove and Install...1005
Inlet and Exhaust Valves - Remove and Install...1010
Inlet and Exhaust Valve Guides - Remove and Install...1016
Engine Oil Cooler - Remove...1020
Engine Oil Cooler - Disassemble...1022
Engine Oil Cooler - Assemble...1024
Engine Oil Cooler - Install...1026
Engine Oil Relief Valve - Remove and Install...1028
Engine Oil Bypass Valve - Remove and Install...1031
Engine Oil Pump - Remove...1033
Engine Oil Pump - Install...1037
Water Pump - Remove...1040
Water Pump - Disassemble...1042
Water Pump - Assemble...1046
Water Pump - Install...1050
Water Temperature Regulator - Remove and Install...1052
Flywheel - Remove...1054
Flywheel - Install...1057
Crankshaft Rear Seal - Remove...1060
Crankshaft Rear Seal - Install...1062
Flywheel Housing - Remove and Install...1065
Crankshaft Pulley - Remove and Install...1069
Crankshaft Front Seal - Remove...1073
Crankshaft Front Seal - Install...1075
Gear Group (Front) - Remove - Idler Gear Only...1077
Gear Group (Front) - Install - Idler Gear Only...1081
Housing (Front) - Remove...1086
Housing (Front) - Install...1090
Front Plate - Remove...1094
Front Plate - Install...1096
Crankcase Breather - Remove and Install...1098
Valve Mechanism Cover - Remove and Install...1100
Valve Mechanism Cover Base - Remove and Install...1103
Rocker Shaft and Pushrod - Remove...1106
Rocker Shaft - Disassemble...1108
Rocker Shaft - Assemble...1111
Rocker Shaft and Pushrod - Install...1114
Cylinder Head - Remove...1116
Cylinder Head - Install...1119
Lifter Group - Remove and Install...1122
Camshaft - Remove and Install...1125
Camshaft Gear - Remove and Install...1129
Camshaft Bearings - Remove and Install...1132
Engine Oil Pan - Remove...1136
Engine Oil Pan - Install...1139
Cylinder Liner - Remove...1142
Cylinder Liner - Install...1145
Piston Cooling Jets - Remove and Install...1147
Pistons and Connecting Rods - Remove...1150
Pistons and Connecting Rods - Disassemble...1152
Pistons and Connecting Rods - Assemble...1156
Pistons and Connecting Rods - Install...1160
Connecting Rod Bearings - Remove...1163
Connecting Rod Bearings - Install...1165
Crankshaft Main Bearings - Remove and Install...1168
Crankshaft - Remove...1171
Crankshaft - Install...1176
Crankshaft Gear - Remove and Install...1183
Bearing Clearance - Check...1185
Crankshaft Position Sensor - Remove and Install - Primary Speed Timing Sensor...1188
Coolant Temperature Sensor - Remove and Install...1190
Engine Oil Pressure Sensor - Remove and Install...1192
Position Sensor (Fuel Injection Pump) - Remove and Install...1195
Fuel Pressure Sensor - Remove and Install...1198
Boost Pressure Sensor - Remove and Install...1200
Inlet Air Temperature Sensor - Remove and Install...1202
Electronic Control Module - Remove and Install...1204
Alternator - Remove and Install...1207
Electric Starting Motor - Remove and Install...1212
Caterpillar C4.2 and C6.4 Engines Repair Service Manual
