Caterpillar C3.8 Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar C3.8 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C3.8 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.
UENR0129 - Disassembly and Assembly (C3.8 Engines for Caterpillar Built Machines).pdf
UENR3423 - Troubleshooting (C3.3B and C3.8 Engines for Caterpillar Built Machines).pdf
KENR9884 - Testing and Adjusting (C3.8 Engines for Caterpillar Built Machines).pdf
KENR9884 - Systems Operation (C3.8 Engines for Caterpillar Built Machines).pdf
KENR9883 - Specifications (C3.8 Engines for Caterpillar Built Machines).pdf
PRODUCT DETAILS:
Total Pages: 1,033 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
UENR0129 - Disassembly and Assembly (C3.8 Engines for Caterpillar Built Machines)....2
Fuel Manifold (Rail) - Remove....5
Fuel Manifold (Rail) - Install....7
Fuel Injection Lines - Remove and Install....8
Exhaust Gas Recirculation Cooler - Remove and Install....10
Fuel Injection Pump - Remove....14
Fuel Injection Pump - Install....21
Fuel Injection Pump - Install ....24
Electronic Unit Injector - Remove and Install....27
Turbocharger - Remove and Install....30
Pressure Sensor (Mass Air Flow) - Remove and Install....33
Exhaust Gas Recirculation Valve - Remove and Install....35
Diesel Exhaust Fluid Lines - Remove and Install....36
Diesel Exhaust Fluid Filter - Remove and Install....41
Diesel Exhaust Fluid Pump - Remove and Install....43
DEF Injector and Mounting - Remove and Install....45
Solenoid Valve (DEF Heater Coolant) - Remove and Install....47
Exhaust Manifold - Remove and Install....48
Catalyst (SCR) - Remove and Install....50
Diesel Particulate Filter - Disassemble....55
Diesel Particulate Filter - Assemble....58
Diesel Particulate Filter - Remove and Install....61
Air Inlet Heater - Remove and Install....65
Inlet Manifold - Remove and Install....67
Inlet and Exhaust Valves - Remove and Install....69
Engine Oil Cooler - Remove and Install....76
Engine Oil Relief Valve - Remove and Install....78
Engine Oil Pump - Remove and Install....80
Water Pump - Remove and Install....82
Water Temperature Regulator - Remove and Install....86
Flywheel - Remove....89
Flywheel - Install....91
Crankshaft Rear Seal - Remove and Install....94
Crankshaft Rear Seal Carrier - Remove and Install....96
Flywheel Housing - Remove and Install....99
Crankshaft Pulley - Remove and Install....101
Crankshaft Front Seal - Remove and Install....103
Idler Gear - Remove and Install....106
Housing (Front) - Remove and Install....111
Fumes Disposal Filter - Remove and Install....116
Valve Mechanism Cover - Remove and Install....118
Rocker Shaft and Pushrod - Remove....125
Rocker Shaft - Disassemble....127
Rocker Shaft - Assemble....130
Rocker Shaft and Pushrod - Install....133
Cylinder Head - Remove....135
Cylinder Head - Install....138
Camshaft - Remove and Install....142
Camshaft Gear - Remove and Install....145
Engine Oil Pan - Remove and Install....147
Pistons and Connecting Rods - Remove....151
Pistons and Connecting Rods - Disassemble....154
Pistons and Connecting Rods - Assemble....157
Pistons and Connecting Rods - Install....162
Crankshaft - Remove....166
Crankshaft - Install....169
Crankshaft Gear - Remove and Install....172
Camshaft Position Sensor - Remove and Install....173
Crankshaft Position Sensor - Remove and Install....175
Coolant Temperature Sensor - Remove and Install....179
Engine Oil Pressure Sensor - Remove and Install....180
Boost Pressure Sensor - Remove and Install....181
Inlet Air Temperature Sensor - Remove and Install....182
Alternator - Remove and Install....183
Electric Starting Motor - Remove and Install....187
UENR3423 - Troubleshooting (C3.3B and C3.8 Engines for Caterpillar Built Machines)....189
General Information....192
Welding Precaution....217
UENR0129 - Disassembly and Assembly (C3.8 Engines for Caterpillar Built Machines)....219
Fuel Manifold (Rail) - Remove....222
Fuel Manifold (Rail) - Install....224
Fuel Injection Lines - Remove and Install....225
Exhaust Gas Recirculation Cooler - Remove and Install....227
Fuel Injection Pump - Remove....231
Fuel Injection Pump - Install....238
Fuel Injection Pump - Install ....241
Electronic Unit Injector - Remove and Install....244
Turbocharger - Remove and Install....247
Pressure Sensor (Mass Air Flow) - Remove and Install....250
Exhaust Gas Recirculation Valve - Remove and Install....252
Diesel Exhaust Fluid Lines - Remove and Install....253
Diesel Exhaust Fluid Filter - Remove and Install....258
Diesel Exhaust Fluid Pump - Remove and Install....260
DEF Injector and Mounting - Remove and Install....262
Solenoid Valve (DEF Heater Coolant) - Remove and Install....264
Exhaust Manifold - Remove and Install....265
Catalyst (SCR) - Remove and Install....267
Diesel Particulate Filter - Disassemble....272
Diesel Particulate Filter - Assemble....275
Diesel Particulate Filter - Remove and Install....278
Air Inlet Heater - Remove and Install....282
Inlet Manifold - Remove and Install....284
Inlet and Exhaust Valves - Remove and Install....286
Engine Oil Cooler - Remove and Install....293
Engine Oil Relief Valve - Remove and Install....295
Engine Oil Pump - Remove and Install....297
Water Pump - Remove and Install....299
Water Temperature Regulator - Remove and Install....303
Flywheel - Remove....306
Flywheel - Install....308
Crankshaft Rear Seal - Remove and Install....311
Crankshaft Rear Seal Carrier - Remove and Install....313
Flywheel Housing - Remove and Install....316
Crankshaft Pulley - Remove and Install....318
Crankshaft Front Seal - Remove and Install....320
Idler Gear - Remove and Install....323
Housing (Front) - Remove and Install....328
Fumes Disposal Filter - Remove and Install....333
Valve Mechanism Cover - Remove and Install....335
Rocker Shaft and Pushrod - Remove....342
Rocker Shaft - Disassemble....344
Rocker Shaft - Assemble....347
Rocker Shaft and Pushrod - Install....350
Cylinder Head - Remove....352
Cylinder Head - Install....355
Camshaft - Remove and Install....359
Camshaft Gear - Remove and Install....362
Engine Oil Pan - Remove and Install....364
Pistons and Connecting Rods - Remove....368
Pistons and Connecting Rods - Disassemble....371
Pistons and Connecting Rods - Assemble....374
Pistons and Connecting Rods - Install....379
Crankshaft - Remove....383
Crankshaft - Install....386
Crankshaft Gear - Remove and Install....389
Camshaft Position Sensor - Remove and Install....390
Crankshaft Position Sensor - Remove and Install....392
Coolant Temperature Sensor - Remove and Install....396
Engine Oil Pressure Sensor - Remove and Install....397
Boost Pressure Sensor - Remove and Install....398
Inlet Air Temperature Sensor - Remove and Install....399
Alternator - Remove and Install....400
Electric Starting Motor - Remove and Install....404
Electronic Service Tools....406
Service Information Report....413
Component Location....415
Engine Monitoring System....424
Diagnostic Capabilities....426
Electrical Connectors....428
Diagnostic Trouble Codes....442
Acceleration Is Poor or Throttle Response Is Poor....457
Alternator Problem - Charging Problem and_or Noisy Operation....460
Battery Problem....463
Coolant Contains Oil....464
Coolant Level Is Low....466
Coolant Temperature Is High....468
Cooling Fan Is Always ON....472
Cylinder Is Noisy....473
DEF Concentration Is Incorrect....477
DEF Module Does Not Respond....480
DEF Pressure Is High....486
DEF Pressure Is Low....490
DEF Tank Level Is Low....495
DEF Tank Temperature Is High....504
DEF Tank Temperature Is Low....506
Diesel Particulate Filter Active Regeneration Occurrence Is Excessive....508
Diesel Particulate Filter Error....512
Diesel Particulate Filter Regeneration Does Not Occur....515
Engine Cranks but Does Not Start....518
Engine Does Not Crank....521
Engine Has Early Wear....525
Engine Has Mechanical Noise (Knock)....528
Engine Misfires; Runs Rough or Is Unstable....533
Engine Overspeeds....538
Engine Shutdown Occurs Intermittently....541
Engine Stalls at Low RPM....544
Engine Top Speed Is Not Obtained....547
Engine Vibration Is Excessive....551
Exhaust Has Excessive White Smoke....552
Exhaust System Contains Oil....557
Exhaust Temperature Is High....560
Fuel Consumption Is Excessive....566
Fuel Rail Pressure Is High....570
Fuel Rail Pressure Is Low....576
Fuel Rail Temperature Is High....580
Intake Manifold Air Temperature Is High....581
NOx Conversion Is Low....584
Oil Consumption Is Excessive....587
Oil Contains Coolant....590
Oil Contains Fuel....593
Oil Pressure Is Low....597
SCR Catalyst Has Incorrect Inlet Temperature....601
Turbocharger Failure....604
Valve Lash Is Excessive....606
Data Link - Test....609
DEF Line Heater - Test....612
DEF Pump - Test....620
ECM Memory - Test....624
Electrical Power Supply - Test....627
Injector Data Incorrect - Test....631
Injector Solenoid - Test - Fuel Injector....635
Injector Solenoid - Test....640
Motorized Valve - Test....650
NOx Reduction System (NRS) - Test....652
NOx Sensor - Test....658
Relay - Test - ECM Main Relay....663
Sensor Signal (Analog; Active) - Test....665
Sensor Signal (Analog; Passive) - Test....675
Sensor Supply - Test....682
Solenoid Valve - Test - Pressure Relief Valve....685
Solenoid Valve - Test - Solenoid Valves that Connect to the Dosing Control Unit (DCU)....688
Solenoid Valve - Test - Suction Control Valve....692
Speed_Timing - Test....696
Starting Aid - Test....700
Cat ET Service Features - DEF Dosing System Test....702
Electronic Service Tool Does Not Communicate....714
Test ECM Mode....720
Engine Injector Trim File - Install....721
DEF Injector Trim File - Install - Injector Trim Code - Install....723
Injector Trim File - Install - Injector Trim Code - Install....725
ECM Software - Install....727
ECM - Replace....728
Electrical Connectors - Inspect....732
KENR9884 - Testing and Adjusting (C3.8 Engines for Caterpillar Built Machines)....735
Fuel System - Inspect....736
Air in Fuel - Test....738
Engine Speed - Check....741
Finding Top Center Position for No. 4 Piston....742
Fuel Injector - Test....744
Fuel Quality - Test....759
Air Inlet and Exhaust System - Inspect....761
Aftertreatment SCR System Dosing - Test....762
Diesel Exhaust Fluid Quality - Test....767
Diesel Exhaust Fluid Tank - Flush....772
Turbocharger - Inspect....776
Exhaust Temperature - Test....778
Engine Crankcase Pressure (Blowby) - Test....779
Compression - Test....780
Engine Valve Lash - Inspect_Adjust - C3.8 Engines....782
Engine Oil Pressure - Test....785
Engine Oil Pump - Inspect....787
Excessive Bearing Wear - Inspect....788
Excessive Engine Oil Consumption - Inspect....789
Cooling System - Check - Overheating....790
Cooling System - Inspect....792
Cooling System - Test....793
Water Temperature Regulator - Test....801
Piston Ring Groove - Inspect....803
Connecting Rod Bearings - Inspect....806
Main Bearings - Inspect....807
Cylinder Block - Inspect....808
Alternator - Test....810
Battery - Test....812
Electric Starting System - Test....815
KENR9884 - Systems Operation (C3.8 Engines for Caterpillar Built Machines)....818
General Information....819
Electronic Control System Components....825
Cleanliness of Fuel System Components....830
Fuel System - C3.8 Tier 4 Final EU Stage IV....832
Fuel System - C3.8 Tier 4 Interim; EU Stage IIIB....844
Air Inlet and Exhaust System....857
DEF Dosing Control System....871
Selective Catalytic Reduction (SCR) System....882
Lubrication System....884
Cooling System....890
Basic Engine....894
Electrical System....903
KENR9883 - Specifications (C3.8 Engines for Caterpillar Built Machines)....914
Engine Design....916
Fuel Injection Lines....918
Fuel Injection Pump - C3.8 Tier 4 Final; EU Stage IV) (BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....921
Fuel Injection Pump - C3.8 Tier 4 Interim; EU Stage IIIB) (AY41-Up; CD21-Up; GSL1-Up; B5W1-Up; SHY1-Up; ETL1-Up; BE71-Up; HP71-Up; GTC1-Up; NLC1-Up; JST1-Up; HCL1-Up....925
Fuel Injector....928
Valve Mechanism....930
Valve Mechanism Cover....934
Cylinder Head Valves....936
Cylinder Head....945
Injector (Diesel Exhaust Fluid) - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....951
Diesel Exhaust Fluid Tank - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....954
Diesel Exhaust Fluid Pump - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....956
Solenoid Valve (DEF Heater Coolant) - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....959
Clamp (Exhaust) - SCR) (BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....962
Exhaust Manifold....965
Exhaust Support - SCR) (BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....968
Diesel Particulate Filter....973
Camshaft....977
Engine Oil Cooler....982
Engine Oil Pump....984
Water Temperature Regulator....988
Cylinder Block....990
Crankshaft....995
Connecting Rod....1004
Piston and Rings....1007
Gear Group (Front) - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....1012
Flywheel....1021
Flywheel Housing....1023
Nitrogen Oxide Sensor - BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up....1025
Temperature Sensor (Exhaust) - SCR) (BL21-Up; MD21-Up; BL71-Up; HP21-Up; FD21-Up; DX21-Up)....1028
Coolant Temperature Sensor....1031
Boost Pressure Sensor....1033
Speed_Timing Sensor....1035
Air Inlet Heater....1038
Caterpillar C3.8 Engines Repair Service Manual
