CAT C3.4B Service Manual by engineparts2

CAT C3.4B Cat C3.4B Diesel Engine with electronic high pressure common rail fuel system

FPT INDUSTRIAL

www.FPTIndustrialEngineParts.com

Printed in U.S.A

Cat C3.4B Service Manual Sections Engine Disassembly and Assembly__________________________ 3 Electrical System Schematic_____________________________ 604 Parts Specifications and Bolt Tightening Torque Values _______ 614 Systems Operation _____________________________________ 762 Testing and Adjusting___________________________________ 835 Troubleshooting_______________________________________ 942

Cat C3.4B Disassembly and Assembly

Crankshaft Timing Ring - Remove and Install _ _ _ _ _ _ _ _

102

Cylinder Head - Install

105

Cylinder Head - Remove

114

Diesel Particulate Filter - Install - Through Flow Diesel Particulate Filter _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

119

Diesel Particulate Filter - Install - Wall Flow Diesel Particulate Filter _ 124

Flexible Exhaust Pipe - Remove and Install _ _ _ _ _ _ _ _

219

Flow Control Valve - Remove and Install

229

Flywheel - Install

233

Flywheel - Remove

237

Flywheel Housing - Remove and Install - Non-Stressed Cylinder Block _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

240

Flywheel Housing - Remove and Install - Stressed Cylinder Block _ 248

Lifter Group - Remove and Install _ _ _ _ _ _ _ _ _ _ _ _

378

Oxygen Sensor - Remove and Install - Catalytic Converter

382

Piston Cooling Jets - Remove and Install

385

Pistons and Connecting Rods - Assemble

388

Pistons and Connecting Rods - Disassemble

393

Pistons and Connecting Rods - Install

396

Pistons and Connecting Rods - Remove

400

Water Pump - Remove _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

499

Water Separator and Fuel Filter (Primary) - Remove and Install _

502

Water Temperature Regulator - Remove and Install _ _ _ _ _ _

508

DEF Injector and Mounting - Remove and Install _________________

528

DEF Diesel Exhaust Fuel Lines - Remove and Install _____________

534

DEF Diesel Exhaust Fluid Pump - Remove and Install ____________

540

DEF Diesel Exhaust Fluid Tank - Remove and Install _____________ DEF Manifold Heater - Remove and Install _____________________ DEF Sensor, Temperature, Level, Quality, _____________________ Nitrogen Oxide Sensor ____________________________________

545 549 558 567

SCR Selective Catalytic Reduction Canister __________________ 575 Solenoid Valve DEF Heater Coolant ________________________ 580 CEM Clean Emission Module _____________________________ 583 Temperature Sensor Exhaust NRS Exhaust Manifold Temperature Sensor______________________594

Page 1 of 6

Product: ENGINE - MACHINE Model: C3.4B ENGINE -

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876230

Accessory Drive - Remove and Install SMCS - 1207-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

Page 2 of 6

Illustration 1

g02898881

C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 54) - Documentation

Illustration 2

Page 3 of 6

g02898938

1. If necessary, remove the Original Equipment Manufacturer's (OEM) driven equipment from accessory drive (4). Refer to the OEM for the correct procedure. 2. If the OEM driven equipment was not installed onto accessory drive (4). Remove cover plate (2) and remove gasket (3) (not shown). 3. Remove Allen head bolts (6) from accessory drive (4). Remove the accessory drive housing from the front housing. 4. Remove O-ring seals (7) from the accessory drive.

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1U-6396

O-Ring Assembly Compound

Loctite 506

NOTICE

C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 54) - Documentation

Page 4 of 6

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Inspect the bore in the front housing for damage. If necessary, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.

Illustration 3

g02898938

C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 54) - Documentation

Illustration 4

Page 5 of 6

g02898881

2. Install new O-ring seals (7) onto accessory drive (4). 3. Apply Tooling (A) onto O-ring seals (7). 4. Install accessory drive (4) to housing (5). 5. Apply Tooling (B) onto the threads of Allen head bolts (6). 6. Install Allen head bolts (6) to accessory drive (4). 7. Equally tighten the Allen head bolts (6) in order to pull accessory drive (4) into housing (5). 8. Tighten Allen head bolts to a torque of 25 N·m (221 lb in). 9. Ensure that there is tactile backlash between the idler gear and the accessory drive gear. 10. If necessary, install the OEM driven equipment to accessory drive (4). Refer to the OEM for the correct procedure. 11. If the OEM driven equipment was not installed onto accessory drive (4), position new gasket (3) (not shown) and cover plate (2) onto accessory drive (4). 12. Apply Tooling (B) onto the threads of bolts (1). 13. Install bolts (1) to cover plate (2). Tighten the bolts to a torque of 25 N·m (221 lb in).

C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 54) - Documentation

Page 6 of 6

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876249

Alternator - Install SMCS - 1405-012

Installation Procedure 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. If necessary, follow Step 2.e through Step 2.g in order to install alternator bracket (11) onto the cylinder block.

Illustration 1

g02815797

Illustration 2

g02673920

Illustration 3

g02815777

a. Position bracket (14) onto the cylinder block. b. Install bolts (13) to bracket (15) finger tight. c. If necessary, install bolt (14) to the coolant tube assembly. d. Tighten bolts (13) to a torque of 50 N·m (37 lb ft). e. Tighten bolts (14) to a torque of 25 N·m (221 lb in). f. Position tensioner (11) onto the fan drive assembly. g. Install bolt (12) to tensioner (11). Tighten the bolt to a torque of 50 N·m (37 lb ft) 3. If necessary, follow Step 3.a through Step 3.f in order to install pulley (8) to alternator (2). Note: Either of Tooling (A) may be required in order to carry out the installation of the alternator pulley. a. Place alternator (6) in a suitable support. b. Ensure that fan (10) is correctly oriented. c. Install fan (10) to shaft (9). d. Ensure that pulley (7) is correctly oriented.

e. Install pulley (7) and a new nut (8) to alternator shaft (9). f. Position a cranked ring spanner onto nut (9). Use a suitable tool in order to turn the shaft of the alternator in a counterclockwise direction. Tighten the nut to the correct torque. Refer to Specifications, "Alternator" for the correct torque. 4. Position the alternator onto bracket (4) and tensioner (11). 5. Install bolt (5) (not shown) and nut (3) finger tight. 6. Install bolt (2) and nut (1) (not shown) finger tight. 7. Install the alternator belt. Refer to Disassembly and Assembly , "Alternator Belt - Remove and Install" for the correct procedure. 8. Tighten the nut and bolt (2) to a torque of 50 N·m (37 lb ft). 9. Tighten nut and bolt (5) to a torque of 50 N·m (37 lb ft). 10. Connect the wiring harness assembly to the alternator. Refer to Specifications, "Alternator" for the correct torque. 11. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876269

Alternator - Remove SMCS - 1405-011

Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure. 1. Turn the battery disconnect switch to the OFF position.

Illustration 1

g02673920

Illustration 2

g02815777

2. Make temporary marks on the alternator harness in order to identify the locations for the connections during the assembly procedure. 3. Disconnect the harness assembly from alternator (6). 4. Support the weight of the alternator and remove nut (1) and bolt (2). 5. Remove nut (3) and bolt (5) (not shown) from alternator (6). 6. Remove alternator (6) from alternator bracket (4). 7. If necessary, follow Step 7.a through Step 7.e in order to remove pulley (7) from alternator (6). Note: Either of Tooling (A) may be required in order to carry out the removal of the alternator pulley. a. Place the alternator in a suitable support. b. Hold shaft (9) of alternator (6) with a suitable tool. Use a cranked ring spanner to loosen nut (8). c. Make a temporary mark on pulley (7) in order to show the correct orientation. d. Remove nut (8) and pulley (7) from shaft (9).

e. Remove fan (10) from shaft (9).

Illustration 3

g02815797

8. If necessary, follow Step 8.a through Step 8.c in order to remove tensioner (11) and alternator bracket (14) from the cylinder block. a. Remove bolt (12) and remove tensioner bracket (11). b. If necessary, remove bolt (14) (not shown) from the coolant tube assembly. c. Remove bolts (13) from alternator bracket (15). Remove the alternator bracket from the cylinder block. Note: Support the weight of the alternator bracket as the bolts are removed.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876209

Alternator Belt - Remove and Install SMCS - 1357-010

Removal Procedure 1. If the engine has guards, remove the guards. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. Note: Mark the direction of rotation of the alternator belt if the belt will be reused.

Illustration 1 Typical example

2. Loosen locking nut (2) and alternator tensioning bolt (1). 3. Loosen nut and bolt (4). 4. Loosen bolt (3) for adjusting bracket (5). 5. Remove alternator belt (6). Discard the alternator bolt. Note: Note the routing of the alternator belt before removal.

Installation Procedure

g02553437

Illustration 2 Typical example

g02553437

Illustration 3

g02553697

1. Ensure that all components of the pulleys and guide rollers are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. Ensure that the pulleys and guide rollers are free from dirt and build up from the old belt. 3. Install new alternator belt (6) onto pulleys. Ensure that the alternator belt is centered on all pulleys. Note: The ribs on the alternator belt must be located into the grooves of all pulleys. 4. Tighten bolt (1) until adjusting bracket (5) has reached the full extent of the available adjustment in Position (A). 5. Tighten bolt (3) to a torque of 50 N·m (37 lb ft). 6. Tighten nut and bolt (4) to a torque of 50 N·m (37 lb ft) 7. Rotate tensioning bolt (1) two complete revolutions in a counterclockwise direction. Tighten locking nut (2) to a torque of 30 N·m (266 lb in). 8. If the engine has guards, install the guards. Refer to the OEM for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876289

Balancer - Install SMCS - 1220-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Name

Qty

390-1131

Crankshaft Locking Pin

Balancer Timing Pin (Bolt M8 by 22mm)

Technologic 15

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged. 2. Check that the balancer drive gear is not worn or damaged. If necessary, replace the balancer drive gear.

Illustration 1

g02887016

Illustration 2

g02893017

Illustration 3

g02709625

3. Install Tooling (A) into Position (X) in the cylinder block. Tooling (A) must be located in Position (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 1. Note: Failure to locate the crankshaft in the correct position will cause severe engine damage. 4. Ensure that Tooling (B) is installed to balancer (4). Note: New balancers will be supplied with Tooling (B) in position. 5. If necessary, install dowels (9) to balancer (4). 6. Attach a suitable lifting device to the balancer. The weight is approximately 15 kg (33 lb). 7. Use the suitable lifting device in order to install the balancer to the cylinder block. 8. Install bolts (5) to the balancer. Tighten the bolts to a torque of 70 N·m (52 lb ft). 9. Remove the suitable lifting device from the balancer. 10. Install a new O-ring seal (8) onto suction pipe (3). Install the suction pipe assembly to the cylinder block.

11. Apply Tooling (C) onto the threads of bolt (7). Install bolt (7) finger tight. 12. Apply Tooling (C) onto the threads of bolts (6). Install bolts (6) finger tight. 13. Tighten bolt (7) to a torque of 10 N·m (89 lb in) 14. When M8 bolts are installed, tighten bolts (6) to a torque of 25 N·m (221 lb in). When M10 bolts are installed, tighten bolts (6) to a torque of 45 N·m (33 lb ft). 15. Remove Tooling (B) from Position (Z) in the balancer. 16. Remove Tooling (A) from Position (X) in the cylinder block. 17. Install a new O-ring seal (1) to plug (2). Install plug (2) into Position (X) in the cylinder block. Tighten the plug to a torque of 50 N·m (37 lb ft). End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876309

Balancer - Remove SMCS - 1220-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Name

Qty

390-1131

Crankshaft Locking Pin

Balancer Timing Pin (Bolt M8 by 22mm)

Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure. Note: In order to remove the balancer safely, the engine must be removed from the machine. The engine should be mounted in a suitable stand and placed in the inverted position.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

Illustration 1

g02887016

Illustration 2

g02709625

Illustration 3

g02893017

1. Remove plug (2) from Position (X) in the cylinder block. Remove O-ring seal (1) from the plug. 2. Install Tooling (A) into the cylinder block in Position (X). Note: Tooling (A) must be located in Position (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 1. 3. Remove bolts (6) from oil suction pipe (3). 4. Remove bolt (7) from oil suction pipe (3). 5. Remove oil suction pipe (3) from the cylinder block. Remove O-ring seal (8) from the oil suction pipe.

Movement of the counterweight can cause personal injury.

6. Install Tooling (B) in Position (Z) in order to prevent movement of the counterweights. Note: If Tooling (B) cannot be installed to the balancer, the crankshaft is not in the correct position. 7. Attach a suitable lifting device to balancer (4). Support the weight of balancer, the weight is approximately 15 kg (33 lb). 8. Use the suitable lifting device in order to remove the balancer from the cylinder block. 9. Do not remove dowels (9) unless the dowels are damaged.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05977048

Bearing Clearance - Check SMCS - 1203-535; 1219-535

Measurement Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

198-9142

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

198-9143

Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

198-9144

Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

198-9145

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Cat does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: • Ensure that the backs of the bearings and the bores are clean and dry. • Ensure that the bearing locking tabs are properly seated in the tab grooves. • The crankshaft must be free of oil at the contact points of Tooling (A). 1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1

g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04878890

Camshaft - Remove and Install SMCS - 1210-010

Removal Procedure Start By: a. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. The engine should be mounted on a suitable stand and placed in the inverted position.

Illustration 1

g02946416

2. Remove bolts (3) from thrust plate (1). 3. Make a temporary mark in order to identify the orientation of thrust plate (1). Slide the camshaft towards the front of the engine in order to allow removal of the thrust plate. Remove the thrust plate.

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed.

4. Carefully remove camshaft (3) from the cylinder block.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02946416

1. Clean camshaft (2) and clean thrust plate (1). Inspect the camshaft and the thrust plate for wear and damage. Refer to Specifications, "Camshaft" for more information. If necessary, replace any components that are worn or damaged. 2. Clean the camshaft bearing in the cylinder block. Inspect the camshaft bearing for wear and damage. Refer to Specifications, "Camshaft Bearings" for more information. If necessary, replace the camshaft bearing. Refer to Disassembly and Assembly, "Camshaft Bearing Remove and Install".

NOTICE Replace all lifters when a new camshaft is installed.

3. Inspect the lifters for wear and for damage. Refer to Specifications, "Lifter Group" for more information. If necessary, replace any lifters that are worn or damaged. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install" for the correct procedure.

4. Lubricate the lobes and the bearing surfaces of the camshaft with clean engine oil.

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed.

5. Carefully install camshaft (3) into the cylinder block. Leave the camshaft slightly protruding in order to allow installation of the thrust plate.

Illustration 3

g02948296

6. Lubricate thrust plate (1) with clean engine oil. Position the thrust plate onto the camshaft with the chamfer in Position (X) facing towards the cylinder block. Slide the camshaft into the cylinder block. 7. Install bolts (3) to thrust plate (1). Tighten the bolts to a torque of 25 N·m (221 lb in) End By: a. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05350999

Camshaft Bearings - Remove and Install SMCS - 1211-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1129

Camshaft Bushing Tool

390-1130

Handle

8H-0684

Ratchet Wrench

A B Start By:

a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02729141

1. Inspect camshaft bearing (1). Refer to Specifications, "Camshaft Bearings" for more information. 2. If camshaft bearing (1) is worn or damaged, use Tooling (A) and Tooling (B) in order to remove the camshaft bearing from the cylinder block. Note: Remove the camshaft bearing from the front of the cylinder block.

Installation Procedure Table 2 Required Tools Tool A B

Part Number

Part Description

Qty

390-1129

Camshaft Bushing Tool

390-1130

Handle

8H-0684

Ratchet Wrench

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean the bearing housing in the cylinder block. Ensure that the oil hole in the bearing housing is free from debris.

Illustration 2

g02948516

2. Lubricate the bearing housing in the cylinder block with clean engine oil. 3. Accurately align large oil Hole (X) in camshaft bearing (1) with the oil hole in the cylinder block. 4. Use Tooling (A) and Tooling (B) in order to install camshaft bearing (1) into the cylinder block. Note: Ensure that the oil holes are correctly aligned. If the oil is not correctly aligned, the camshaft bearing should be removed. End By: a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05350987

Camshaft Gear - Remove and Install SMCS - 1210-010-GE

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

Snap-on 650 Small Pry Bar

Start By: a. Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove" for the correct procedure.

NOTICE Keep all parts clean and free from contaminants. Contaminants may cause rapid wear and shorten component life.

NOTICE

1. Remove the idler gear. Refer to Disassembly and Assembly, "Idler Gear - Remove" for the correct procedure. 2. Ensure that Tooling (A) remains in position during the removal and installation procedures for the camshaft gear. 3. Remove Tooling (B).

Illustration 1

g02945576

4. Remove bolts (3) from camshaft (4). 5. Remove camshaft timing ring (2) from dowels (5). 6. Use Tooling (C) in order to remove camshaft gear (1) from camshaft (4).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. If Tooling (A) is not installed, install Tooling (A). Refer to Disassembly and Assembly, "Idler Gear - Remove" for the correct procedure.

Illustration 2

g02945576

Illustration 3

g02945776

Illustration 4

g02945716

Illustration 5

g02945837

3. Lubricate the teeth of gear (1) with clean engine oil. 4. Align the timing mark on camshaft (4) in Position (V) with the timing mark on the front housing in Position (W). 5. Position camshaft gear (1) onto camshaft (4). Ensure that dowel (6) is installed into Hole (X) in the camshaft. 6. Ensure that the chamfered tooth on the crankshaft gear in Position (Y) is between the timing marks in Positions (Z) on the camshaft gear. 7. Install Tooling (B). Refer to Disassembly and Assembly, "Idler Gear - Remove" for the correct procedure. 8. Install camshaft timing ring (2) onto dowels (5). 9. Install bolts (3) into camshaft (4). Tighten the bolts to a torque of 25 N·m (221 lb in). End By: a. Install the idler gear. Refer to Disassembly and Assembly, "Idler Gear - Install" for the correct procedure. b. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04878893

Camshaft Position Sensor - Remove and Install SMCS - 1912-010

Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02672140

1. Slide the locking tab into the unlocked position and disconnect harness assembly (4) from camshaft position sensor (3). 2. Remove bolt (1). Carefully remove camshaft position sensor (3) from front cover (2). Note: Do not use a lever to remove the camshaft position sensor. Make a note of the orientation of the camshaft position sensor for installation purposes. 3. Remove O-ring seal (5) from camshaft position sensor (3).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description Loctite 506

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02672140

1. Install a new O-ring seal (5) to camshaft position sensor (3). 2. Install camshaft position sensor (3) to front cover (2). Ensure that the camshaft position sensor is correctly orientated. 3. Apply Tooling (A) onto the threads of bolt (1). Install bolt (1) to the camshaft position sensor. Tighten the bolt to a torque of 10 N·m (89 lb in) 4. Connect harness assembly (4) to camshaft position sensor (3). Slide the locking tab into the locked position.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04881469

Connecting Rod Bearings - Install - Connecting rods in position SMCS - 1219-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

8T-3052

Degree Wheel

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Discard all used Connecting Rod fasteners.

1. Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove" and Disassembly and Assembly, "Crankshaft - Install" for the correct procedure. Ensure that the main bearing

shells are clean and free from wear and damage. If necessary, replace the main bearing shells. Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed. 2. Ensure that the crankshaft is in the bottom center position.

Illustration 1

g02015553

3. Install upper bearing shell (4) into connecting rod (5). Ensure that the locating tab for the upper bearing shell is correctly seated in the slot in the connecting rod. Note: The ends of the upper bearing shell must be centered in the connecting rod. The ends of the upper bearing shell must be equally positioned in relation to the mating faces of the connecting rod. 4. Lubricate upper bearing shell (4) with clean engine oil. 5. Carefully guide connecting rod (5) against the crankshaft pin. Note: Do not allow the connecting rod to contact the piston cooling jet. 6. Clean connecting rod cap (2). Install lower bearing shell (3) into connecting rod cap (2). Ensure that the locating tab for the lower bearing shell is correctly seated in the slot in the connecting rod cap. 7. Lubricate the pin of the crankshaft and lubricate lower bearing shell (3) with clean engine oil.

Illustration 2

g03005637

8. Install connecting rod cap (2) to connecting rod (5). Note: Ensure that etched number in Position (X) on connecting rod cap (2) matches etched number in Position (X) on connecting rod (5). Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Note: Do not reuse the old bolts in order to secure the connecting rod cap. 9. Install new bolts (1) and tighten to 50 N·m (36 lb ft). Turn the bolts an additional 70 degrees in a clockwise direction. Use Tooling (A) in order to achieve the required torque. 10. Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 and 4 then 2 and 3. Ensure that the installation procedure on one pair connecting rods is completed before starting the removal procedure on the next pair of connecting rods. 11. Repeat Step 1 through Step 10 in order to install the remaining connecting rod bearings. End By:

a. If necessary, install the balancer. Refer to Disassembly and Assembly, "Balancer Install" for the correct procedure. b. Install the engine oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04881389

Connecting Rod Bearings - Remove - Connecting rods in position SMCS - 1219-011

Removal Procedure Start By: a. Remove the engine oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. b. If necessary, remove the balancer. Refer to Disassembly and Assembly, "Balancer Remove " for the correct procedure

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Discard all used Connecting Rod fasteners.

Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1

and 4 then 2 and 3. Ensure that the installation procedure on one pair connecting rods is completed before starting the removal procedure on the next pair of connecting rods.

Illustration 1

g03005637

(X) Identification marks

Illustration 2

g01341322

1. The connecting rod and the connecting rod cap should have an etched number in Positions (X). The number on the connecting rod and the connecting rod cap must match. If necessary, make a temporary mark on connecting rod (5) and connecting rod cap (2) in order to identify the cylinder number. Note: Do not punch identification marks onto fracture split connecting rods. Do not stamp identification marks onto fracture split connecting rods. 2. Rotate the crankshaft so that required connecting rods are at bottom center position. Remove bolts (1) and discard the bolts. 3. Remove connecting rod cap (2) from connecting rod (5). 4. Remove lower bearing shell (3) from connecting rod cap (2). Keep the bearing shell and the connecting rod cap together. 5. Carefully push connecting rod (5) into the cylinder bore until connecting rod (5) is clear of the crankshaft. Remove upper bearing shell (4) from the connecting rod. Keep the bearing shells together. Note: Do not push the fracture split surfaces of the connecting rod as damage may result. Do not allow the connecting rod to contact the piston cooling jet. 6. Repeat Step 1 through Step 5 in order to remove the remaining bearing shells. Note: Fracture split connecting rods should not be left without the connecting rod caps installed. After the removal procedure for the bearing shells is complete, carry out the installation procedure as soon as possible. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876210

Coolant Temperature Sensor - Remove and Install SMCS - 1906-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system to a level below the coolant temperature sensor. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.

Illustration 1

g02671576

2. Slide the locking tab into the unlocked position. Disconnect harness assembly (1) from coolant temperature sensor (2). 3. Remove coolant temperature sensor (2) from the water temperature regulator housing. 4. Remove sealing washer (3) from coolant temperature sensor (2).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02671797

1. Install a new sealing washer (3) onto coolant temperature sensor (2). 2. Install coolant temperature sensor (2) to the water temperature regulator housing. Tighten the coolant temperature sensor to a torque of 25 N·m (221 lb in). 3. Connect harness assembly (1) to coolant temperature sensor (2). Slide the locking tab into the locked position. 4. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant Level - Check" and refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedures.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related websites: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876113

Crankcase Breather - Install SMCS - 1317-012

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Table 1 Required Tools Tool

Part Number

Part Description

Qty

1/2 Inch Drive x 19 mm Hex

1. Ensure that all components of the crankcase breather are clean and free from wear and damage. Replace any components that are worn or damaged.

Illustration 1

g02665516

2. If necessary, install studs (12) to front cover (1). Tighten the studs to a torque of 9 N·m (80 lb in). 3. If necessary, install spigot (3) and threaded insert (4). Press the spigot onto fuel injection pump shaft (2). Ensure that the spigot is correctly positioned onto fuel injection pump shaft (2). Install threaded insert (4). Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling (A) in order to tighten threaded insert (4) to a torque of 85 N·m (63 lb ft). 4. Install new breather element (4) to spigot (3). Install circlip (6) to spigot (3). Note: Ensure that the circlip is correctly seated into the retaining groove in the spigot. 5. Install new O-ring (7) to crankcase breather cover (11). 6. Position crankcase breather cover (11) onto front cover (1). 7. Install nuts (10) to studs (12). Tighten the nuts to a torque of 10 N·m (89 lb in). 8. Ensure that hose (8) is clean and free from restriction. 9. Connect hose (8) to crankcase breather cover (11) and tighten the hose clip securely. 10. Ensure that hose (9) is clean and free from restriction. 11. Connect hose (9) to crankcase breather cover (11) and tighten the hose clip securely.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04878895

Crankcase Breather - Remove SMCS - 1317-011

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Table 1 Required Tools Tool

Part Number

Part Description

Qty

1/2 Inch Drive x 19 mm Hex

Illustration 1

g02689857

1. Disconnect hose (8) from crankcase breather cover (11). 2. If necessary, disconnect hose (9) from crankcase breather cover (11). 3. Remove nuts (10) from studs (12). 4. Remove crankcase breather cover (11) from front cover (1). Remove O-ring (7) from the crankcase breather cover. 5. Remove circlip (6) from spigot (3). 6. Remove breather element (5) from spigot (3). 7. If necessary, use Tooling (A) in order to remove threaded insert (4) and spigot (3) from fuel injection pump shaft (2). 8. If necessary, remove studs (12) from front cover (1).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05354417

Crankshaft - Install SMCS - 1202-012

Installation Procedure Table 1 Required Tools Tool

Part Number

1U-8221

Lifting Sling

Dial Indicator

Magnetic Base and Stand

Part Description

Qty

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean the crankshaft and inspect the crankshaft for wear and damage. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 1

g03008302

2. If necessary, install a new crankshaft timing ring (1). Refer to Disassembly and Assembly, "Crankshaft Timing Ring - Remove and Install" for the correct procedure. 3. Ensure that parent bores for bearing shells in the cylinder block are clean. Ensure that the threads for the main bearing bolts in the cylinder block are clean and free from damage. 4. Clean the main bearing shells and the thrust washers. Inspect the main bearing shells and the thrust washers for wear and damage. If necessary, replace the main bearing shells and the thrust washers. Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed. 5. Install upper main bearing shells to the cylinder block. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove and Install" for the correct procedure. Note: The upper main bearing shells have a groove and an oil hole. 6. Lubricate upper main bearing shells with clean engine oil. 7. Attach Tooling (A) and a suitable lifting device to crankshaft (2). Lift the crankshaft into the cylinder block. The weight of the crankshaft is approximately 35 kg (77 lb). Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the main bearing shells.

8. Lubricate lower main bearing shells and lubricate the journals of the crankshaft with clean engine oil. Install lower main bearing caps. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove and Install" for the correct procedure. Note: The lower main bearing shells are plain bearings that do not have an oil hole. 9. Rotate the crankshaft in order to ensure that there is no binding. 10. Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Tooling (B) to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling (B) to measure the crankshaft end play. Refer to Specifications, "Crankshaft" for the correct information. 11. If necessary, install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install" for the correct procedure. 12. If the crankshaft has not been replaced or the crankshaft has not been reconditioned, install the connecting rod bearings. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure. End By: a. If necessary, install the power take-off drive. Refer to Disassembly and Assembly, "Power Take-Off Drive - Remove and Install" for the correct procedure. b. If necessary, install the balancer. Refer to Disassembly and Assembly, "Balancer - Install" for the correct procedure. c. Install the engine oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. d. If necessary, install the cylinder head. Refer to Disassembly and Assembly, "Cylinder head Install" for the correct procedure. e. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing Remove and Install" for the correct procedure. f. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876329

Crankshaft - Remove SMCS - 1202-011

Removal Procedure Table 1 Required Tools Tool

Part Number

1U-8221

Part Description Lifting Sling

Qty 2

Start By: a. Remove the engine oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. b. If necessary, remove the balancer. Refer to Disassembly and Assembly, "Balancer Remove" for the correct procedure. c. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel housing Remove and Install" for the correct procedure. d. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) Remove" for the correct procedure. e. If necessary, remove the power take-off drive. Refer to Disassembly and Assembly, "Power Take-Off Drive - Remove and Install" for the correct procedure. f. If necessary, remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure. g. If necessary, remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove" for the correct procedure.

h. Remove the main bearing caps. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. The engine should be mounted on a suitable stand and placed in the inverted position. 2. If the cylinder head, the pistons and the connecting rods have not been removed already, remove the connecting rod bearings. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove" for the correct procedure.

Illustration 1

g03008176

3. Attach Tooling (A) and a suitable lifting device to crankshaft (2). Lift the crankshaft out of the cylinder block. The weight of the crankshaft is approximately 35 kg (77 lb). Note: Do not damage any of the finished surfaces on the crankshaft. When the crankshaft is removed from the engine, the crankshaft must be supported on a suitable stand in order to prevent damage to the crankshaft timing ring.

4. Remove upper main bearing shells from the cylinder block. Refer to Disassembly and Assembly, "Crankshaft Main Bearings - Remove and Install" for the correct procedure. Note: The upper main bearing shells have a groove and an oil hole. 5. If necessary, remove the crankshaft timing ring (1). Refer to Disassembly and Assembly, "Crankshaft Timing Ring - Remove and Install" for the correct procedure.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i06821487

Crankshaft Front Seal - Remove and Install SMCS - 1160-010

Removal Procedure Table 1 Required Tools Tool

Part Number

B C

Part Description

Qty

Drill Bit (3 mm)

1U-7600

Slide Hammer Puller

1U-7262

Telescopic Magnet

Start By: a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02927001

1. Apply clean grease to Tooling (A) to prevent any swarf that is generated from entering the engine. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (1). 2. Use Tooling (B) with care to remove crankshaft front seal (1) from front cover (3) and crankshaft pulley adaptor (2). Alternate the position of Tooling (B) from one hole to another. Alternating the position of Tooling (B) will allow the crankshaft front seal to be easily removed from the crankshaft. 3. Use Tooling (C) to collect any swarf that has entered the engine.

Installation Procedure Table 2 Required Tools

Tool

Part Number

Part Description

Qty

D(1)

460-8232

Crankshaft Front Seal Installer

D(2)

390-1125

Crankshaft Front Seal Installer

(1)

Used for Procedure 1

(2)

Used for Procedure 2

Note: The tool used is determined by which crankshaft front seal is installed.

Procedure 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the crankshaft pulley adaptor and the front cover are clean and free from oil and damage.

Illustration 2

g02927218

Sectional view of the crankshaft front seal, the crankshaft pulley adaptor, and the installation tool

2. Use Tooling (D) and follow Step 2.a through Step 2.f to install crankshaft front seal (1). a. Position the adaptor of Tooling (D) onto the crankshaft pulley adaptor and secure with bolts. b. Position the new crankshaft front seal (1) over the adaptor onto the front of the crankshaft. c. Align the seal installer of Tooling (D) with the crankshaft. Note: Check that the installer of Tooling (D) is parallel to the adaptor. d. Install the nut and washer to the locator. e. Tighten the nut until the installer bottoms out on the adaptor to install crankshaft front seal (1) into front cover (3) and onto crankshaft pulley adaptor (2). f. Remove Tooling (D). End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install" for the correct procedure.

Procedure 2 1. Ensure that the crankshaft pulley adaptor and the front cover are clean and free from oil and damage. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g06128680

Sectional view of the crankshaft front seal, the crankshaft pulley adaptor, and the installation tool

2. Use Tooling (D) and follow Step 2.a through Step 2.d to install crankshaft front seal (1). a. Position the new crankshaft front seal (1) over the nose of the crankshaft into the recess in the front cover. b. Align Tooling (D) with the crankshaft and crankshaft front seal (1). c. Use a suitable tool to drive (D) and the new crankshaft front seal (1) into position. d. Remove Tooling (D). End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i07201514

Crankshaft Main Bearings - Remove and Install SMCS - 1203-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A(1) (1)

Part Description

Qty

445-2702

Housing

442-7300

Engine Turning Tool

This tool is used in the aperture for the electric starting motor.

Start By: a. Remove the engine oil pan and suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure. b. If necessary, remove the balancer. Refer to Disassembly and Assembly, "Balancer Remove" for the correct procedure.

NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position. The removal procedure and the installation procedure must be completed for each pair of main bearing shells before the next pair of main bearing shells are removed.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the main bearing cap is marked for the correct location and orientation.

Illustration 1

g03003177

Typical example

2. Remove bolts (1) and remove main bearing cap (2) from the cylinder block.

Illustration 2

g03003178

Typical example

3. Remove lower main bearing shell (3) from main bearing cap (2). Keep the main bearing shell and the main bearing cap together. Note: The lower main bearing shell is a plain bearing that has no oil holes.

Illustration 3

g03003457

Illustration 4

g03003257

4. Push out upper main bearing shell (5) with a suitable tool from the side opposite the locating tab. Use Tooling (A) to rotate the crankshaft while you push the bearing shell. Remove upper main bearing shell (5) from the cylinder block. Keep the bearing shells together. The thrust washers (4) are attached to number three upper main bearing shell, make a note of the orientation of the thrust washers for installation purposes. Note: The upper main bearing shell has a groove and oil hole.

Installation Procedure Table 2 Required Tools Tool

Part Number

8T-3052

Degree Wheel

Dial Indicator

Magnetic Base and Stand

Part Description

Qty

NOTICE This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.

The removal procedure and the installation procedure must be completed for each pair of main bearing shells before the next pair of main bearing shells are removed.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the main bearing shells are clean and free from wear and damage. If necessary, replace the main bearing shells. Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed. 2. Clean the journals of the crankshaft. Inspect the journals of the crankshaft for damage. If necessary, replace the crankshaft or recondition the crankshaft.

Illustration 5

g03003457

Illustration 6

g03003257

3. For number three main bearing, ensure that two thrust washers (4) are clean and free from wear and damage. If necessary, replace the thrust washers. Lubricate thrust washers (4) with clean engine oil. Note: The upper main bearing shell has a groove and oil hole. 4. Lubricate the crankshaft journal and upper main bearing shell (8) with clean engine oil. Slide upper main bearing shell (8) into position between the crankshaft journal and the cylinder block. Ensure that the locating tab for the upper main bearing shell is correctly seated in the slot in the cylinder block.

Illustration 7

g03003178

5. Install lower main bearing shell (3) into main bearing cap (2). Ensure that the locating tab for the lower main bearing shell is correctly seated into the slot in the bearing cap. Note: The lower main bearing shell is a plain bearing that has no oil holes.

Illustration 8

g03003700

6. Lubricate the crankshaft journal and the lower main bearing shell with clean engine oil. Install main bearing cap (5) to the cylinder block. Note: Ensure the correct orientation of the main bearing cap. The locating tab for the upper and the lower bearing should be on opposite sides of the engine. 7. Lubricate the threads of bolts (4) with clean engine oil. Lubricate the underside of the heads of bolts (4) with clean engine oil. 8. Install bolts (4) to main bearing cap (5). Evenly tighten the bolts to pull cap (5) into position. Ensure that the cap is correctly seated. Note: Do not tap the main bearing cap into position as the bearing shell may be dislodged. 9. Tighten bolts (4) to an initial torque of 50 N·m (37 lb ft). 10. Tighten bolts (4) to a torque of 80 N·m (59 lb ft).

Use Tooling (B) to turn the bolts through a further 90 degrees in a clockwise direction to achieve the correct final torque. 11. Check the crankshaft end play. Use Tooling (C) to measure the crankshaft end play. Refer to Specifications, "Crankshaft" for the correct information. 12. Remove Tooling (C). End By: a. If necessary, install the balancer. Refer to Disassembly and Assembly, "Balancer - Install" for the correct procedure. b. Install the suction pipe and engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884929

Crankshaft Position Sensor - Remove and Install SMCS - 1912-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 1

g02673817

1. Slide the locking tab into the unlocked position. Disconnect harness assembly (2) from crankshaft position sensor harness (1). 2. Cut cable strap (6). 3. Remove bolt (3) from the cylinder block. 4. Carefully remove crankshaft position sensor (5) from the cylinder block. Note: Do not use a lever to remove the crankshaft position sensor from the cylinder block. 5. Remove O-ring seal (4) (not shown) from crankshaft position sensor (5).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description Loctite 506

Qty 1

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02673817

1. Install a new O-ring seal (4) (not shown) to crankshaft position sensor (5). 2. Install crankshaft position sensor (5) to the cylinder block. 3. Apply Tooling (A) onto the threads of bolt (3). Install bolt (3) and tighten the bolt to a torque of 8 N·m (71 lb in). 4. Connect harness assembly (2) to crankshaft position sensor harness (1). Slide the locking tab into the locked position. 5. Install a new cable strap (6). Note: Ensure that the cable strap meets the Original Equipment Manufacturers (OEM) specification.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884930

Crankshaft Pulley - Remove and Install SMCS - 1205-010

Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02926996

1. Use a suitable method in order to prevent the crankshaft from rotating. 2. Remove bolts (1) from crankshaft pulley (2). 3. If equipped, remove crankshaft V-pulley (2). 4. Remove crankshaft multi V-pulley (3).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are free from wear and damage.

Illustration 2

g02926996

2. Install crankshaft multi V-pulley (3) onto the crankshaft. 3. If equipped, install crankshaft V-pulley (2). 4. Install bolts (1) to the crankshaft pulley. Tighten the bolts to a torque of 45 N·m (33 lb ft) Note: Use a suitable method in order to prevent the crankshaft from rotating when torquing the bolts. End By: a. Install the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884931

Crankshaft Rear Seal - Remove and Install SMCS - 1161-010

Removal Procedure Table 1 Required Tools Tool

Part Number

B C

Part Description

Qty

Drill Bit (3 mm)

1U-7600

Slide Hammer Puller

1U-7262

Telescopic Magnet

Start By: a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02873976

Typical example

1. Apply clean grease to Tooling (A) in order to prevent any swarf that is generated from entering the engine. Use Tooling (A) to drill three evenly spaced holes in crankshaft rear seal (4). 2. Use Tooling (B) with care in order to remove crankshaft rear seal (4) from flywheel housing (1). Alternate the position of Tooling (B) from one hole to another. Alternating the position of Tooling (B) will allow the crankshaft rear seal to be easily removed from the flywheel housing. 3. Apply clean grease to Tooling (A) in order to prevent any swarf that is generated from entering the engine. Use Tooling (A) to drill two evenly spaced holes in crankshaft wear sleeve (3).

4. Use Tooling (B) with care in order to remove crankshaft wear sleeve (3) from crankshaft (2). Alternate the position of Tooling (B) from one hole to the other. Alternating the position of Tooling (B) will allow the crankshaft wear sleeve to be easily removed from the crankshaft. 5. Use Tooling (C) to collect any swarf that is on the flywheel housing or crankshaft assembly.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

390-1124

Crankshaft Rear Seal Installer

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the flange of the crankshaft and the inside of the flywheel housing are clean and free from oil and damage.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 2 Typical example

g02876556

Illustration 3

g02876596

Sectional view of the crankshaft rear seal, the crankshaft, and the installation tool

2. Crankshaft rear seal (4) and crankshaft wear sleeve (3) are supplied as a crankshaft rear seal assembly (5) and should not be separated for installation. Note: Do not remove the crankshaft rear seal from the crankshaft wear sleeve. 3. Use Tooling (D) and follow Step 3.a through Step 3.f in order to install crankshaft rear seal assembly (5). a. Position the adaptor of Tooling (D) onto the palm of the crankshaft and secure with bolts. b. Position the new crankshaft rear seal assembly (5) over the adaptor onto the rear of the crankshaft. c. Align the seal installer of Tooling (D) with the crankshaft. Note: Check that the installer of Tooling (D) is parallel to the adaptor. d. Install the nut and washer to the locator. e. Tighten the nut until the installer bottoms out on the adaptor in order to install crankshaft rear seal assembly (5) into flywheel housing (1) and onto crankshaft (2). f. Remove Tooling (D).

End By: a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876331

Crankshaft Timing Ring - Remove and Install SMCS - 1202

Removal Procedure Start By: a. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove " for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 1

g03010798

1. Support crankshaft (4) on a suitable stand. 2. Remove Torx screws (1) from crankshaft timing ring (2). Do not reuse the Torx screws. 3. Carefully remove crankshaft timing ring (2) from crankshaft (4). Note: Ensure that the seal surface on adaptor (5) is not damaged when the crankshaft timing ring is removed. Note: Do not remove dowel (3) from the crankshaft unless the dowel is damaged.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the teeth of the crankshaft timing ring are clean and free from damage.

2. Support crankshaft (4) on a suitable stand.

Illustration 2

g03010798

3. If dowel (3) was removed, install a new dowel to crankshaft (4). 4. Position crankshaft timing ring (2) onto the crankshaft with the chamfer toward the crankshaft web. Align the hole in crankshaft timing ring with dowel (3) in the crankshaft. Carefully install the crankshaft timing ring to the crankshaft. Note: Ensure that the seal surface on adaptor (5) is not damaged when the crankshaft timing ring is installed. 5. Install new Torx screws (1). Tighten the Torx screws to a torque of 10 N·m (89 lb in). End By: a. Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install " for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05344332

Cylinder Head - Install SMCS - 1100-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

E14 Torx 1/2 Inch Drive Socket

227-4393

E18 Torx 1/2 Inch Drive Socket

8T-3052

Degree Wheel

Guide Bolt (M12 by 115mm)

Straight Edge

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

2. Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information.

Illustration 1

g03005897

Typical example

3. Inspect dowel (5) and dowel (6) for damage. If necessary, replace the dowels in the cylinder block. 4. Install Tooling (D) to the cylinder block. Refer to Illustration 1. 5. Align cylinder head gasket (4) with Tooling (D) and with dowel (5) and dowel (6). Install the cylinder head gasket onto the cylinder block. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 2

g03005660

6. Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb). Note: Use a spreader bar during the lifting operation in order to distribute the weight of the cylinder head. 7. Use Tooling (D) to align cylinder head (3) with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned onto dowels.

Illustration 3

g03005656

Illustration 4

g03005937

8. Clean Torx bolts (1) and Torx bolts (2). Follow Steps 8.a and 8.b for the procedure to inspect the Torx bolts. a. Check the length of the Torx bolts (1) and Torx bolts (2). b. Use Tooling (E) in order to check the threads of the Torx bolts. Refer to Illustration 4. Replace any Torx bolts that show visual reduction in the diameter of the thread over length (Y). 9. Lubricate the threads and the shoulder of Torx bolts (1) and Torx bolts (2) with clean engine oil. 10. Install Torx bolts (1) and Torx bolts (2) to cylinder head (3). 11. Remove Tooling (D). 12. Install remaining Torx bolts (1) to cylinder head (3). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 5

g03005658

Sequence for tightening the bolts for the cylinder head

13. Use Tooling (A) in order to tighten Torx bolts (2) to a torque of 130 N·m (96 lb ft) in the sequence that is shown in Illustration 5. 14. Use Tooling (B) in order to tighten Torx bolt (1) to a torque of 65 N·m (48 lb ft) in the sequence that is shown in Illustration 5.

Illustration 6

g03005916

15. Use Tooling (A), Tooling (B), and Tooling (C) in order to turn Torx bolts (1) and Torx bolts (2) through an additional angle in the sequence that is shown in Illustration 5. Turn Torx bolts (2) through 90 degrees. Turn Torx bolts (1) through 90 degrees.

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 7

g03017298

16. Use Tooling (A), Tooling (B), and Tooling (C) in order to turn Torx bolts (1) and Torx bolts (2) through an additional angle in the sequence that is shown in Illustration 5. Turn Torx bolts (2) through 70 degrees. Turn Torx bolts (1) through 60 degrees. 17. Install the injectors. Refer to Disassembly and Assembly, "Injector - Install" for the correct procedure. 18. Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure. 19. Install the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly Manual, "Rocker Shaft and Pushrod - Remove" for the correct procedure. 20. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold Remove and Install" for the correct procedure. 21. If necessary, install the water temperature regulator housing to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure. 22. Connect the upper radiator hose to the water temperature regulator housing .

23. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure. 24. If necessary, fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04887271

Cylinder Head - Remove SMCS - 1100-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

E14 Torx 1/2 Inch Drive Socket

227-4393

E18 Torx 1/2 Inch Drive Socket

Start By: a. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold Remove and Install". b. Remove the injectors. Refer to Disassembly and Assembly, "Injector - Remove". c. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly Manual, "Rocker Shaft and Pushrod - Remove". d. Remove the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies helps to prevent fluid loss and helps to keep contaminants from entering the system. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure. 2. Disconnect the upper radiator hose from the water temperature regulator housing.

Illustration 1 Typical example

g03005656

Illustration 2

g03005658

Sequence for tightening the bolts for the cylinder head

3. Use Tooling (A) and Tooling (B) in order to gradually loosen bolts (1) and bolts (2) in the reverse numerical order to the sequence that is shown in Illustration 2. Note: Follow the correct sequence in order to help prevent distortion of the cylinder head. 4. Remove bolts (1) and bolts (2) from cylinder head (3). Note: The bolts are two different lengths. Note the positions of the different bolts.

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Illustration 3

g03005660

Typical example

5. Attach a suitable lifting device to cylinder head (3). Support the weight of the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb). Note: Use a spreader bar during the lifting operation in order to distribute the weight of the cylinder head. 6. Use the lifting device to carefully lift cylinder head (3) off the cylinder block. Note: Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure.

NOTICE Place the cylinder head on a surface that will not scratch the face of the cylinder head.

Illustration 4

g03005663

7. Remove cylinder head gasket (4). 8. Note the position of dowel (5) and dowel (6) in the cylinder block. Do not remove the dowels unless the dowels are damaged. 9. If necessary, remove the water temperature regulator from the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install".

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343617

Diesel Particulate Filter - Install - Through Flow Diesel Particulate Filter SMCS - 108F-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bellows Protector

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 halfface respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.

NOTICE Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. If the flexible exhaust pipe was removed as an assembly, refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct installation procedure.

Illustration 1

g03017439

Illustration 2

g03017436

Illustration 3

g03022697

3. If necessary, install the temperature sensors (3) and temperature sensor (9) into the DPF. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure. 4. Position a new V-band clamp onto flexible exhaust pipe (8). 5. Attach a suitable lifting device to the assembly of the Diesel Particulate Filter (DPF) (6). The weight of the DPF is approximately 15 kg (33 lb). 6. Use the suitable lifting device in order to install the DPF to mounting bracket (12). Ensure that the flexible exhaust pipe is correctly seated onto the turbocharger and DPF with the alignment pin (13) (not shown) fully engaged. Note: Ensure that the exhaust gases flow in the direction of temporary mark. 7. Remove the suitable lifting device from the assembly of the DPF. 8. Position clamps (11) onto DPF (6). Loosely install bolts (10). 9. Loosely install the Original Equipment Manufacturer's (OEM) exhaust pipe assembly to outlet section (4) of the DPF. 10. Align the temporary alignment marks on DPF (6) and clamps (11) in Positions (A), (B), (C) and (D). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.

11. If a new DPF is being installed, the DPF must be aligned using flexible exhaust pipe (8) as the reference point. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 12. Position the V-band clamp onto the DPF. Tighten the flexible exhaust pipe clamp. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. 13. Tighten the OEM exhaust pipe assembly to the outlet section of the DPF. Refer to the OEM for the correct procedure. 14. Ensure that the DPF is installed in the original position and all of the temporary alignment marks are aligned. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 15. Tighten bolts (10) evenly in three stages. Tighten bolts (10) to an initial torque of 8 N·m (71 lb in) Tighten bolts (10) to a secondary torque of 16 N·m (141.6 lb in) Tighten bolts (10) to a final torque of 25 N·m (221 lb in). 16. If necessary, remove Tooling (A) from flexible exhaust pipe (8). 17. Connect the wiring harness assembly to connection (1) on temperature sensor (9). 18. Connect the wiring harness assembly to connection (2) on temperature sensor (3). 19. Connect the pressure sensor tube assembly (5) to the DPF. Tighten the connection to a torque of 25 N·m (221 lb in). 20. Connect the pressure sensor tube assembly (7) to the DPF. Tighten the connection to a torque of 30 N·m (265 lb in). End By: a. If the DPF has had an ash service, it will be necessary to use the electronic service tool in order to perform the "DPF Ash Cleaning" procedure. b. If the DPF required replacing and a new DPF has been installed, it will be necessary to use the electronic service tool in order to perform the "DPF Replacement Reset" procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343619

Diesel Particulate Filter - Install - Wall Flow Diesel Particulate Filter SMCS - 108F-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bellows Protector

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. Refer to Disassembly and Assembly, "Inspection of Parts" for the correct procedures. 2. If the flexible exhaust pipe was removed as an assembly, refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct installation procedure.

Illustration 1

g03372061

Illustration 2

g03372062

3. If necessary, install the temperature sensors (3) and temperature sensor (9) into the DPF. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure. 4. Position a new V-band clamp onto flexible exhaust pipe (12). 5. Attach a suitable lifting device to the assembly of the Diesel Particulate Filter (DPF) (4). The weight of the DPF is approximately 15 kg (33 lb). 6. Use the suitable lifting device in order to install the DPF to mounting bracket (10). Ensure that the flexible exhaust pipe is correctly seated onto the turbocharger and DPF with the alignment pin (not shown) fully engaged. Note: Ensure that the exhaust gases flow in the direction of temporary mark. 7. Remove the suitable lifting device from the assembly of the DPF. 8. Position clamps (5) onto DPF (4). Loosely install bolts (8). 9. Loosely install the Original Equipment Manufacturer's (OEM) exhaust pipe assembly to outlet section (6) of the DPF. 10. Align the temporary alignment marks on DPF (4) and clamps (5) in Positions (A), (B), (C) and (D). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.

11. If a new DPF is being installed, the DPF must be aligned using flexible exhaust pipe (12) as the reference point. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 12. Position the V-band clamp onto the DPF. Tighten the flexible exhaust pipe clamp. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. 13. Tighten the OEM exhaust pipe assembly to the outlet section of the DPF. Refer to the OEM for the correct procedure. 14. Ensure that the DPF is installed in the original position and all of the temporary alignment marks are aligned. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 15. Tighten bolts (8) evenly in three stages. Tighten bolts (8) to an initial torque of 8 N·m (71 lb in) Tighten bolts (8) to a secondary torque of 16 N·m (141.6 lb in) Tighten bolts (8) to a final torque of 25 N·m (221 lb in). 16. If necessary, remove Tooling (A) from flexible exhaust pipe (12). Note: Do not start the engine with the bellows protector in place. 17. Connect the wiring harness assembly to connection (1) on temperature sensor (2). 18. Connect the wiring harness assembly to connection (11) on temperature sensor (3). 19. Connect the pressure sensor tube assembly (9) to the DPF. Tighten the connection to a torque of 30 N·m (265 lb in). 20. Connect the pressure sensor tube assembly (7) to the DPF. Tighten the connection to a torque of 30 N·m (265 lb in). End By: a. If the DPF has had an ash service, it will be necessary to use the electronic service tool in order to perform the "DPF Ash Cleaning" procedure. b. If the DPF required replacing and a new DPF has been installed, it will be necessary to use the electronic service tool in order to perform the "DPF Replacement Reset" procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343606

Diesel Particulate Filter - Remove - Through Flow Diesel Particulate Filter SMCS - 108F-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bellows Protector

The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter.

Illustration 1

g03020017

Illustration 2 Typical example

g03013138

Illustration 3

g03013381

Typical example

1. If necessary, remove the Original Equipment Manufacturer's (OEM) exhaust tube assembly from outlet (4). Refer to the OEM for the correct procedure. 2. Make temporary alignment marks on DPF (6) and clamps (11) in Positions (A), (B), (C) and (D) in order to ensure that the DPF is installed in the original position. 3. If the DPF is installed onto the flywheel housing, install Tooling (A) in Position (E) in order to maintain correct alignment of flexible exhaust pipe assembly (8). 4. Disconnect the flexible exhaust pipe assembly (8). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. 5. Make a temporary mark on Diesel Particulate Filter (DPF) (6) in order to show the direction of the flow for the exhaust gases. 6. Disconnect the wiring harness from connection (1) for temperature sensor (9). Note: Make temporary identification marks on all connections for assembly purposes. 7. Disconnect the wiring harness from connection (2) for temperature sensor (3) Note: Make temporary identification marks on all connections for assembly purposes. 8. Disconnect pressure sensor tube assembly (5) from the DPF.

Note: Make temporary identification marks on the tube assembly for assembly purposes. 9. Disconnect pressure sensor tube assembly (7) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 10. Remove bolts (10) from clamps (11). Remove the clamps from the DPF in order to allow removal of the DPF. 11. Attach a suitable lifting device to the DPF . The weight of the DPF is approximately 15 kg (33 lb). 12. Use the suitable lifting device in order to remove the DPF from bracket (12). 13. If necessary, remove temperature sensor (3) and temperature sensor (9). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343612

Diesel Particulate Filter - Remove - Wall Flow Diesel Particulate Filter SMCS - 108F-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bellows Protector

Illustration 1 Flexible exhaust pipe assembly with bellows protector Tooling (A) in position. Typical example

g03370358

Illustration 2

g03370799

Typical example

1. If necessary, remove the Original Equipment Manufacturer's (OEM) exhaust tube assembly from outlet (6). Refer to the OEM for the correct procedure. 2. Make temporary alignment marks on DPF (4) and clamps (5) in Positions (A), (B), (C) and (D) in order to ensure that the DPF is installed in the original position. 3. If the DPF is installed onto the flywheel housing, install Tooling (A) in Position (E) in order to maintain correct alignment of flexible exhaust pipe assembly (12). 4. Disconnect the flexible exhaust pipe assembly (12). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. Note: Do not remove the bellows protector prior to installing the flexible exhaust pipe assembly. 5. Make a temporary mark on Diesel Particulate Filter (DPF) (4) in order to show the direction of the flow for the exhaust gases. 6. Disconnect the wiring harness from connection (1) for temperature sensor (2). Note: Make temporary identification marks on all connections for assembly purposes. 7. Disconnect the wiring harness from connection (11) for temperature sensor (3) Note: Make temporary identification marks on all connections for assembly purposes.

8. Disconnect pressure sensor tube assembly (7) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 9. Disconnect pressure sensor tube assembly (9) from the DPF. Note: Make temporary identification marks on the tube assembly for assembly purposes. 10. Remove bolts (8) from clamps (5). Remove the clamps from the DPF in order to allow removal of the DPF. 11. Attach a suitable lifting device to the DPF . The weight of the DPF is approximately 15 kg (33 lb). 12. Use the suitable lifting device in order to remove the DPF from brackets (10). 13. If necessary, remove temperature sensor (2) and temperature sensor (3). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.

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Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884932

Starter Electric Starting Motor - Remove and Install SMCS - 1453-010

Removal Procedure

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

1. Turn the battery disconnect switch to the OFF position. 2. Place identification marks on the harness assembly that is connected to the electric starting motor and the solenoid.

Illustration 1

g02844537

Typical example

3. Disconnect the harness assembly from the electric starting motor and the solenoid. 4. Support electric starting motor (3). 5. Remove bolts (2) from electric starting motor (3). 6. Remove electric starting motor (3). 7. If a gasket is installed, remove gasket (4).

Installation Procedure

Illustration 2

g02844537

Typical example

1. If necessary, position a new gasket (4) onto starter (3). 2. Position starter (3) onto flywheel housing (1). Note: Ensure that the starter is seated correctly in the starter motor pocket. 3. Install bolts (2) to starter (3). Tighten the bolts to a torque of 45 N·m (33 lb ft) 4. Connect the harness assembly to the starter and the solenoid. 5. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884933

Electronic Unit Injector - Install SMCS - 1290-012

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training. Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Illustration 1

g02704596

Injector code

1. If the original electronic unit injector (3) is installed, ensure that the electronic unit injector is installed into the original location. 2. If a replacement electronic unit injector is installed, the correct seven digit injector code that is located in Position (A) must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. Note: Record the seven digit injector code in Position (A) before the electronic unit injector is installed. 3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.

Illustration 2

g02851878

4. If necessary, install studs (9) to the cylinder head. Tighten the studs to a torque of 20 N·m (177 lb in) 5. If the original electronic unit injector (3) is to be reused, remove the protective cap from the nozzle and install a new sealing washer (10). Note: Ensure that the nozzle for the electronic unit injector is not damaged during installation of the new sealing washer. 6. Remove the plug from the electronic unit injector port in the cylinder head. 7. Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head. 8. Position clamp (6) onto electronic unit injector (3). Align the assembly of electronic unit injector (3) to the bore for the electronic unit injector in the cylinder head. Note: Ensure that the clamp is correctly positioned onto the electronic unit injector. 9. Push only on injector clamp (6) in order to install electronic unit injector (3). Do not apply pressure on any other part of the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head. 10. Install washer (8) and nut (4) onto stud (9). Tighten the nut finger tight. Note: Ensure that the washer is correctly orientated.

11. Remove the plugs from the new fuel injection line. Install the fuel injection line nuts hand tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct installation procedure. Note: Ensure that the ends of the fuel injection line are seated into the electronic unit injector and the fuel manifold. Note: Do not torque the fuel injection line nuts before the final torque has been applied to the electronic unit injector clamp nuts (4). 12. When nuts (4) are installed, the nuts must be tightened in two stages. Follow Step 12.a through 12.b for the correct torque sequence. a. Tighten nuts (4) to an initial torque of 15 N·m (133 lb in). b. Tighten nuts (4) to a final torque of 25 N·m (221 lb in). 13. If necessary, repeat Step 1 through Step 12.b in order to install the remaining electronic unit injectors. 14. Tighten the fuel injection line nuts to a torque of 25 N·m (221 lb in). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for further information.

Illustration 3

g02706897

15. Install a new O-ring seal (7) to the connection on hose assembly (2).

16. Install hose assembly (2) to electronic unit injector (3). 17. Install clip (1) to electronic unit injector (3). 18. If necessary, repeat Step 15 through Step 17 in order to connect the remaining hose assemblies (2). 19. Connect wiring harness assemblies (5) to the electronic unit injectors. Slide the locking tab into the locked position 20. If necessary install the exhaust gas recirculation valve. Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. 21. If necessary install the diesel particulate filter supporting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. 22. Install the wiring harness assembly. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 23. Replace the primary fuel filter. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure. 24. Replace the secondary fuel filter. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure. 25. Turn the fuel supply to the ON position. 26. Turn the battery disconnect switch to the ON position. 27. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884934

Electronic Unit Injector - Remove SMCS - 1290-011

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Note: Place identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will prevent fluid loss. Plugging all hose assemblies and tube assemblies will to keep contaminants from entering the system. Note: Plug or cap all open ports with new plugs or caps.

Illustration 1

g02701543

Illustration 2

g02701718

1. Disconnect wiring harness assembly (5) from electronic unit injector (3). Note: Make a temporary mark on the wiring harness assembly in order to ensure that the wiring harness assembly is connected to the correct electronic unit injector during assembly. 2. Remove clip (1) from electronic unit injector (3). 3. Disconnect hose assembly (2) from electronic unit injector (3). Remove O-ring seal (7) from the hose assembly. 4. Use Tooling (A) in order to cap electronic unit injector (3) immediately. Use Tooling (A) in order to plug hose assembly (2) immediately. 5. Remove nut (4) and washer (8) from clamp (6). Note: Note the orientation of the washer. 6. Make a temporary mark on the electronic unit injector in order to ensure that the electronic unit injector is reinstalled in the original location. 7. Remove the electronic unit injector and clamp (6) from the cylinder head. Note: Always handle electronic unit injectors with care. 8. Remove clamp (6) from electronic unit injector (3).

9. If electronic unit injector (3) is to be reused, Follow Step 10 through Step 11 in order to remove sealing washer (10). 10. Use a suitable tool in order to remove sealing washer (10) from electronic unit injector (3). If sealing washer (10) is not present on the electronic unit injector, ensure that the sealing washer is removed from the cylinder head. Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way during removal of the sealing washer. 11. Install Tooling (A) to the nozzle for electronic unit injector (3) immediately. 12. If necessary, repeat Step 1 through Step 10 in order to remove the remaining electronic unit injectors. In some applications removal of the clean emissions bracket and exhaust gas recirculation valve will be necessary in order to remove number four electronic unit injector. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" and Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedures. 13. If necessary, remove studs (9) from the cylinder head.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04881532

Engine Lifting Bracket - Install SMCS - 1122-012

Installation Procedure Follow the installation procedure for the configuration of engine lifting brackets that are installed.

Option 1

Illustration 1 View of the engine lifting bracket on the front of the engine

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Illustration 2

g03001176

View of the engine lifting brackets on the rear of the engine

1. Position lifting bracket (1) onto fan drive (3). Refer to Illustration 1. 2. Install bolts (2) finger tight to lifting bracket (1). Tighten the bolts to a torque of 45 N·m (33 lb ft). 3. Position lifting bracket (4) onto the cylinder head. Refer to Illustration 2. 4. Install bolts (7) finger tight to lifting bracket (4). Tighten the bolts to a torque of 65 N·m (48 lb ft). 5. Position lifting bracket (5) onto the cylinder head. Refer to Illustration 2. 6. Install bolts (6) finger tight to lifting bracket (5). Tighten the bolts to a torque of 65 N·m (48 lb ft).

Option 2

Illustration 3 View of the engine lifting bracket on the front of the engine

g03001576

Illustration 4

g03001603

View of the engine lifting brackets on the rear of the engine

1. Position lifting bracket (8) onto fan drive (10). Refer to Illustration 3. 2. Install bolts (9) finger tight to lifting bracket (8). Tighten the bolts to a torque of 45 N·m (33 lb ft). 3. Position lifting bracket (11) onto the flywheel housing. Refer to Illustration 4. 4. Install bolt (13) finger tight to lifting bracket (11). Tighten the bolt to a torque of 110 N·m (81 lb ft). 5. Position lifting bracket (12) onto the flywheel housing. Refer to Illustration 4. 6. Install bolt (14) finger tight to lifting bracket (12). Tighten the bolts to a torque of 110 N·m (81 lb ft).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04881531

Engine Lifting Bracket - Remove SMCS - 1122-011

Removal Procedure Follow the removal procedure for the configuration of engine lifting brackets that are installed.

Option 1

Illustration 1 View of the engine lifting bracket on the front of the engine

g03001156

Illustration 2 View of the engine lifting brackets on the rear of the engine

1. Remove bolts (2) from lifting bracket (1). 2. Remove lifting bracket (1) from fan drive assembly (3). 3. Remove bolts (7) from lifting bracket (4). 4. Remove lifting bracket (4) from the cylinder head. 5. Remove bolts (6) from lifting bracket (5). 6. Remove lifting bracket (5) from the cylinder head.

Option 2

g03001176

Illustration 3 View of the engine lifting bracket on the front of the engine

g03001576

Illustration 4 View of the engine lifting brackets on the rear of the engine

1. Remove bolts (9) from lifting bracket (8). 2. Remove lifting bracket (8) from fan drive assembly (10). 3. Remove bolt (13) from lifting bracket (11). 4. Remove lifting bracket (11) from the flywheel housing. 5. Remove bolt (14) from lifting bracket (12). 6. Remove lifting bracket (12) from the flywheel housing.

g03001603

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884935

Engine Oil Cooler - Install SMCS - 1378-012

Installation Procedure 1. Ensure that all components are free from wear and damaged. If necessary, replace any components that are worn or damaged.

www.FPTIndustrialEngineParts.com

Illustration 1

g02707318

2. If necessary, follow Step 2.a through Step 2.d in order to assembly the engine oil cooler. a. Ensure that engine oil cooler matrix (12) is clean, free from damage and restriction. Replace engine oil cooler matrix (12) if damaged or restricted. b. Ensure that housing (10) is clean and free from damage. Replace housing (10) if damaged. c. Position new gaskets (11) onto engine oil cooler matrix (12). Install engine oil cooler matrix (12) to housing (10). d. Install bolts (13) and bolts (14) to the assembly of oil cooler (3). Tighten bolts (13) and bolts (14) to a torque of 25 N·m (221 lb in).

Illustration 2 Tightening sequence for the engine oil cooler. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

g02871598

Illustration 3

g02706998

3. Clean the gasket surfaces of the cylinder block. 4. Position a new gasket (4) onto the engine oil cooler. 5. Install assembly of engine oil cooler (5) to the cylinder block. Install bolts (1) to the assembly of oil cooler (3). Note: Ensure that the bolts of different lengths are installed in the correct position. 6. Tighten bolts (3) to a torque of 25 N·m (221 lb in) in sequence that is shown in Illustration 2. 7. Position bracket (9) onto engine oil cooler (3). Install bolt (8) to bracket (9). Tighten the bolt to a torque of 15 N·m (133 lb in). 8. Install boost pressure chamber cover (4). Refer to Disassembly and Assembly, "Turbocharger - Install" for the correct procedure. 9. If necessary, install the turbo charger oil drain tube assembly. Refer to Disassembly and Assembly, "Turbocharger - Install" for the correct procedure. 10. Install a new O-ring seal (7) (not shown) to tube assembly (5). 11. Install tube assembly (5) to engine oil cooler (3). 12. Install bolts (6) to tube assembly (5). Tighten the bolts to a torque of 25 N·m (221 lb in).

13. Connect the coolant hoses to tube assembly (5). 14. Install the Alternator. Refer to Disassembly and Assembly, "Alternator - Install" for the correct procedure. 15. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. 16. If the engine oil was drained during the engine oil cooler removal procedure, refill the lubrication system. Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change" for the correct procedure. 17. Check the level of the engine lubricating oil. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884936

Engine Oil Cooler - Remove SMCS - 1378-011

Removal Procedure Start By: a. Remove the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

2. If the engine oil has become contaminated with coolant, the engine oil and filter must be replaced. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.

Illustration 1

g02706998

Illustration 2

g02871078

3. Disconnect the coolant hoses from tube assembly (5). 4. Remove bolts (6) from tube assembly (5). Remove tube assembly (5) from engine oil cooler assembly (3). 5. Remove O-ring seal (7) (not shown) from tube assembly (5). 6. Remove bolt (8) and bracket (9) from the engine oil cooler assembly. 7. Remove boost pressure chamber cover (4). Refer to Disassembly and Assembly, "Turbocharger - Remove" for the correct procedure. 8. Remove bolts (1) from the engine oil cooler. Do not remove the bolts in Position (X). Remove the engine oil cooler assembly from the cylinder block. Note: The bolts are different lengths. Note the position of the different lengths bolts. 9. Remove gasket (2) (not shown).

Illustration 3

g02707318

10. If necessary, follow Step 10.a through Step 10.c in order to disassemble the engine oil cooler. a. Remove bolts (13) and bolts (14) from the engine oil cooler assembly (3). b. Remove cooler matrix (12) from housing (10). c. Remove gaskets (11).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884937

Engine Oil Filter Base - Remove and Install SMCS - 1306-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1126

Filter Cartridge Remover

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02675998

1. Disconnect wiring harness assembly (1) from engine oil pressure switch (3). 2. Place a suitable container below engine oil filter (7) in order to catch any oil that might be spilled. 3. Use Tooling (A) in order to remove engine oil filter (7). Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure. 4. Remove bolts (6) from oil filter base (1). Note: Note the position of the different length bolts for installation purposes. 5. Remove engine oil filter base (4) from the cylinder block. 6. Remove gasket (5) (not shown). 7. If necessary, remove plug (2) from engine oil filter base (4). 8. If necessary, remove plug (11) from engine oil filter base (4). 9. If necessary, remove plug (10) from engine oil filter base (4). 10. If necessary, remove plug (9) from engine oil filter base (1). Remove O-ring seal (8) (not shown) from plug (9).

11. If necessary, remove the engine oil pressure switch. Refer to Disassembly and Assembly, "Engine Oil Pressure Switch - Remove and Install".

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

390-1126

Filter Cartridge Remover

Loctite 506

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02675998

1. Clean the gasket surface of the engine oil filter base (4). Clean the gasket surface of the cylinder block. 2. If necessary, install new O-ring seal (8) (not shown) to plug (9). Install plug (9) to engine oil filter base (1). Tighten the plug to a torque of 40 N·m (30 lb ft). 3. If necessary, install new plug (10) to engine oil filter base (4). Tighten the plug to a torque of 40 N·m (30 lb ft). 4. If necessary, install new plug (11) to engine oil filter base (4). Tighten the plug to a torque of 10 N·m (89 lb in). 5. If necessary, install new plug (2) to engine oil filter base (4). Tighten the plug to a torque of 40 N·m (30 lb ft). 6. Apply Tooling (B) onto the threads of bolts (6). 7. Position new gasket (5) (not shown) onto engine oil filter base (4). Install bolts (6) to engine oil filter base (4). Note: Ensure that the different length bolts are installed in the correct position. 8. Install the assembly of the engine oil filter base to the cylinder block. Tighten bolts (6) to a torque of 25 N·m (221 lb in). 9. If necessary, install the engine oil pressure switch. Refer to Disassembly and Assembly, "Engine Oil Pressure Switch - Remove and Install" for the correct procedure. 10. Connect wiring harness assembly (1) to engine oil pressure switch (3). 11. Use Tooling (A) in order to install new engine oil filter (7). Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure. 12. Check the level of the engine oil. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884938

Engine Oil Pan - Remove and Install - Cast Iron Engine Oil Pan SMCS - 1302-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Ensure that the engine lubricating oil is drained. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure. Note: In order to remove a cast iron oil pan, the engine must be removed from the machine. The engine should be mounted in a suitable stand and placed in the inverted position.

Illustration 1

g02835137

1. Mount the engine in a suitable stand and place in the inverted position. 2. If necessary, remove dipstick (2) from engine oil pan (3). 3. Remove sealing washer (5) (not shown) from oil drain plug (6). 4. Remove bolts (4) from engine oil pan (3). Note: Support the weight of the engine oil pan. 5. Remove the engine oil pan from the cylinder block. 6. Remove gasket (1) (not shown).

Illustration 2

g02835177

Typical example

7. If necessary, follow Step 7.a through Step 7.d in order to remove oil suction pipe (8) from the cylinder block. a. Remove Allen head cap screw (9) from oil suction pipe (8). b. Remove bolts (10) from the oil suction pipe. c. Remove the oil suction pipe from the cylinder block. d. Remove O-ring (7) from oil suction pipe (8).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description Technologic 15

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 3

g02835177

Typical example

2. If necessary, follow Step 2.a through Step 2.f in order to install oil suction pipe (8). a. Install new O-ring seal (7) to oil suction pipe (8). b. Install the oil suction pipe to the cylinder block. c. Apply Tooling (A) onto the threads of Allen head cap screw (9). Install the Allen head cap screw to the oil suction pipe. d. Apply Tooling (A) onto the threads of bolts (10). Install bolts (10) to the oil suction pipe support. e. Tighten Allen head cap screw (9) to a torque of 10 N·m (89 lb in). f. When M8 bolts are installed, tighten bolts (10) to a torque of 25 N·m (221 lb in). When M10 bolts are installed, tighten bolts (10) to a torque of 45 N·m (33 lb ft). 3. Clean the mating surface of the cylinder block.

Illustration 4

Illustration 5 Initial tightening sequence

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g02835539

Illustration 6

g02835357

Secondary tightening sequence

4. Position gasket (1) (not shown) onto engine oil pan (4). 5. Position spacer (2) onto the engine oil pan. 6. Position the engine oil pan onto the cylinder block. Use a suitable tool to support the weight of the engine oil pan. 7. Install bolts (4) finger tight. Note: Ensure that the rear of the engine oil pan is aligned with the rear of the cylinder block. 8. Tighten bolts (4) in the initial sequence that is shown in Illustration 5. Tighten bolts (7) to a torque of 45 N·m (33 lb ft). 9. Tighten bolts (4) in the final sequence that is shown in Illustration 6. Tighten bolts (7) to a torque of 45 N·m (33 lb ft). 10. Install a new sealing washer (5) to oil drain plug (6). 11. Install oil drain plug (6) to the engine oil pan . Tighten the oil drain plug to a torque of 50 N·m (37 lb ft). 12. Remove the engine from the suitable stand. 13. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884939

Engine Oil Pan - Remove and Install - Pressed Steel Oil Pan SMCS - 1302-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02823478

1. Remove oil drain plug (6). Drain the engine oil into a suitable container for storage or disposal. 2. Remove sealing washer (5) (not shown) from oil drain plug (5). 3. Remove two M10 bolts (7) and remove M8 bolts (3) from engine oil pan (4). Note: Support the weight of the engine oil pan. 4. Remove spacer (2) from the engine oil pan. 5. Remove the engine oil pan from the cylinder block. 6. Remove gasket (1) (not shown).

Illustration 2

g02823476

7. If necessary, follow Step 7.a through Step 7.d in order to remove oil suction pipe (9) from the cylinder block. a. Remove Allen head cap screw (10) from oil suction pipe (9). b. Remove bolts (11) from the oil suction pipe. c. Remove the oil suction pipe from the cylinder block. d. Remove O-ring (8) from oil suction pipe (9).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description Technologic 15

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from damage. If necessary, replace any components that are worn or damaged.

Illustration 3

g02823476

2. If necessary, follow Step 2.a through Step 2.f in order to install oil suction pipe (9). a. Install new O-ring seal (8) to oil suction pipe (9). b. Install the oil suction pipe to the cylinder block. c. Apply Tooling (A) onto the threads of Allen head cap screw (10). Install the Allen head cap screw to the oil suction pipe. d. Apply Tooling (A) onto the threads of bolts (11). Install bolts (11) to the oil suction pipe support. e. Tighten Allen head cap screw (10) to a torque of 10 N·m (89 lb in). f. When a M8 bolts are installed, tighten bolts (11) to a torque of 25 N·m (221 lb in). When a M10 bolts are installed, tighten bolts (11) to a torque of 45 N·m (33 lb ft).

3. Clean the mating surface of the cylinder block.

Illustration 4

g02823478

Illustration 5

g02826556

4. Position gasket (1) (not shown) onto engine oil pan (4). 5. Position spacer (2) onto the engine oil pan. 6. Position the engine oil pan onto the cylinder block. Use a suitable tool to support the weight of the engine oil pan. 7. Install bolts (3) and install bolts (7) finger tight. 8. Tighten bolts (3) and bolts (7) in the sequence that is shown in Illustration 5. Tighten bolts (3) to a torque of 25 N·m (221 lb in). Tighten bolts (7) to a torque of 45 N·m (33 lb ft). 9. Install a new sealing washer (5) to oil drain plug (6). 10. Install oil drain plug (6) to the engine oil pan . Tighten the oil drain plug to a torque of 50 N·m (37 lb ft). 11. Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884940

Engine Oil Pressure Switch - Remove and Install SMCS - 1924

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02673736

1. Disconnect harness assembly (2) from engine oil pressure switch (3). 2. Using a deep socket remove engine oil pressure switch (3) from oil filter head (1). 3. Remove O-ring seal (4) from the engine oil pressure switch.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02673736

1. Install a new O-ring seal (4) onto engine oil pressure switch (3). 2. Install engine oil pressure switch (3) to oil filter head (1). 3. Using a deep socket tighten the oil pressure switch to a torque of 25 N·m (221 lb in). 4. Connect harness assembly (2) to engine oil pressure switch (3). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05344269

Engine Oil Pump - Install SMCS - 1304-012

Installation Procedure Table 1 Required Tools Tool A

Part Number

Part Description

Qty

Dial Indicator

Magnetic Base and Stand

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that bushing is free from wear or damage. Refer to Specifications, "Engine Oil Pump" for more information. If necessary, replace the bushing.

Illustration 1

g02986456

2. Ensure that engine oil pump (2) is clean and free from wear or damage. Refer to Specifications, "Engine Oil Pump" for more information. If necessary, replace the engine oil pump. 3. Lubricate the rotors of the engine oil pump (2) with clean engine oil. 4. Align engine oil pump gear (3) with crankshaft gear (4). Install the engine oil pump to the cylinder block. 5. Install bolts (1). Tighten the bolts to a torque of 11 N·m (97 lb in). 6. Use Tooling (A) to check the backlash between oil pump gear (3) and crankshaft gear (4). Ensure that the backlash is within specified values. Refer to Specifications, "Gear Group (Front)" for further information. End By: a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove and Install". CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05344252

Engine Oil Pump - Remove SMCS - 1304-011

Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove and Install".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

1. Remove bolts (1) from engine oil pump (2). 2. Remove the engine oil pump from the cylinder block.

g02986438

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884943

Engine Oil Relief Valve - Remove and Install SMCS - 1315-010

Removal Procedure

www.FPTIndustrialEngineParts.com

Illustration 1

1. Remove bolts (2) from engine oil relief valve (1). 2. Remove engine oil relief valve (1) from the cylinder block. 3. Remove O-ring seal (3) from engine oil relief valve (1).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

2. Install new O-ring seal (3) to engine oil relief valve (1). 3. Install engine oil relief valve (1) to the cylinder block.

g02953956

4. Install bolts (2) to engine oil relief valve (1). Tighten the bolts to a torque of 10 N·m (89 lb in)

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884944

Exhaust Cooler (NRS) - Remove and Install SMCS - 1087; 108C-010

Removal Procedure Start By: a. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

Sulfuric Acid Burn Hazard may cause serious personal injury or death. The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

Note: Plug or cap all open ports with new plugs or caps. 1. If necessary, remove the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.

Illustration 1

g02717244

2. Position hose clamp (3) away from the coolant inlet in Position (A). Disconnect hose (4) from exhaust cooler assembly (2). 3. Reposition hose clamp (7) and hose clamp (10) in order to allow removal of hose (8). Disconnect hose (8) from exhaust cooler assembly (2). 4. Loosen V-band clamp (9) and position the clamp away from the Exhaust Gas Recirculation (EGR) valve assembly (1). 5. Remove bolts (5) from exhaust cooler assembly (2). 6. Remove exhaust cooler assembly (2) from the induction manifold. 7. Remove gasket (6). 8. Remove clamp (9) from the exhaust cooler assembly.

Installation Procedure 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged. Note: Remove plugs and caps that were previously installed prior to assembly.

Illustration 2

g02717358

2. Ensure that the NRS exhaust cooler is free from restriction and external damage. Ensure that the NRS exhaust cooler and tube assemblies are free from wear and damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the correct inspection procedure. Note: The NRS exhaust cooler should not be internally cleaned. 3. Clean the sealing face on the EGR valve assembly (1) is clean and free from damage. 4. Install a new clamp (9) to NRS mixer chamber (1). Note: Ensure that the clamp is correctly orientated to prevent contact with any other engine components. 5. Position a new gasket (6) onto the inlet manifold. 6. Position exhaust cooler assembly (2) onto the induction manifold. Install bolts (5) finger tight. Note: Ensure that the exhaust cooler assembly (2) can still move freely. 7. Tighten clamp (9) to a torque of 10 N·m (89 lb in) 8. Tighten bolts (5) to a torque of 25 N·m (221 lb in)

9. Connect hose (4) to exhaust cooler assembly (2) in Position (A). Position hose clamp (3) onto the coolant inlet. 10. Install hose assembly (8) to exhaust cooler assembly (2). Position hose clamp (7) and position hose clamp (10) and tighten securely. 11. If necessary, install the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. End By: a. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05341777

Exhaust Gas Recirculation Valve - Remove and Install SMCS - 108N-010

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Plug or cap all open ports with new plugs or caps. 1. If necessary, remove the diesel particulate mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.

Illustration 1

g02912798

Illustration 2

g02898616

Illustration 3

g02898617

2. If necessary, remove bolts (1) and heat shield (2) from exhaust gas recirculation (EGR) valve (4). 3. Slide the locking tab into the unlocked position and disconnect harness assembly (3) from EGR valve (4). 4. Loosen clamp (6) and position the clamp away from EGR valve (4). 5. Disconnect hose assembly (5) from EGR valve (4). 6. Remove bolt (18) from the bracket for tube assembly (19). 7. Remove bolt (20) and tube assembly (19) from EGR valve (4). 8. Remove O-ring seal (21) (not shown). 9. If necessary, slide hose clamp (17) along hose (16). Disconnect tube (19) from hose (16). 10. Apply releasing fluid prior to and during the removal of bolts (12) and bolts (14). 11. Remove bolts (12) and remove bolts (14). Remove flexible tube assembly (13) from the exhaust manifold. 12. Remove bolts (11) from EGR valve (4). Note: Note the position of different length bolts.

13. Remove from EGR valve (4) from the induction manifold. 14. If necessary, remove bolt (9) and remove tube assembly (7) from EGR valve (4). Remove O -ring seal (8) (not shown).

Installation Procedure

NOTICE Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 4 CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

g02898617

Illustration 5

g02898616

2. If necessary, install new O-ring seal (8) (not shown) to EGR valve (4). Install tube assembly (7) to EGR valve (4). 3. Install new clamp (6) to EGR valve (4). 4. Position a new clamp (6) onto EGR valve (4). 5. Install bolts (11) to EGR valve (4) finger tight. 6. Position clamp (6). Tighten the clamp to a torque of 10 N·m (89 lb in). 7. Tighten bolts (11) to a torque of 25 N·m (221 lb in). Note: Ensure that the bolts are installed into the correct position. 8. If necessary, install tube (19) to hose (16). Slide hose clamp (17) into position and tighten securely. 9. Install new O-ring seals (21) (not shown) to tube assembly (19). 10. Install tube assembly (19) to EGR valve (4). 11. Install bolt (18) and bolt (20) finger tight. Tighten the bolt 12. Tighten bolt (20) to a torque of 10 N·m (89 lb in).

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13. Tighten bolt (18) to a torque of 25 N·m (221 lb in). 14. Position new gasket (15) onto flexible tube assembly (13). 15. Position flexible tube assembly (13) onto the exhaust manifold. Install bolts (14) finger tight. Note: Ensure that the flexible tube assembly can move freely. 16. Position gasket (10) (not shown) between flexible tube assembly (13) and EGR valve (4). Install bolts (12) finger tight. Note: Ensure that the flexible tube assembly can move freely and the gasket is correctly positioned. 17. Tighten bolts (12) to a torque of 25 N·m (221 lb in). 18. Tighten bolts (14) to a torque of 25 N·m (221 lb in). 19. Install hose assembly (5) onto pipe (7). Position hose clamp and tighten the clamp securely.

Illustration 6

g02912798

20. If necessary, position heat shield (2) onto EGR valve (4) and install bolts (1). Tighten the bolts to a torque of 10 N·m (89 lb in).

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21. Connect harness assembly (3) to EGR valve (3) and slide the locking tab into the locked position. 22. If necessary, install the diesel particulate mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. End By: a. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. b. When the EGR valve is cleaned or a new replacement is installed, it will be necessary to use the electronic service tool in order to perform the "EGR Valve Learn Reset" procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05341789

Exhaust Manifold - Remove and Install SMCS - 1059-010

Removal Procedure Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" for the correct procedure.

Illustration 1

g02725206

Illustration 2

g02725251

Tighten sequence of exhaust manifold

1. Remove tube assembly (1). Refer to Disassembly and Assembly, "Air Control Valve - Remove and Install" for the correct procedure. 2. Loosen nuts (5) in reverse numerical order. Refer to Illustration 2. Note: Loosening the bolts in reverse numerical order will help prevent distortion of the exhaust manifold. 3. Remove nuts (5) and remove exhaust manifold (3) from the cylinder head. 4. Remove exhaust manifold gasket (6) (not shown). 5. If necessary, remove studs (2) from the exhaust manifold. 6. If necessary, remove studs (4) from the cylinder head.

Installation Procedure 1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket surface of the cylinder head. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g02725206

Illustration 4

g02725251

2. If necessary, install studs (2) to exhaust manifold (3). Tighten the stud to a torque of 18 N·m (159 lb in). 3. Position a new exhaust manifold gasket (6) (not shown) onto studs (4). Note: Ensure that the exhaust manifold gasket is correctly oriented. 4. Position exhaust manifold (3) onto studs (4).

5. Install nuts (5) to studs (4) finger tight. Tighten the nuts in the sequence that is shown in Illustration 4 in two stages. Tighten the nuts to an initial torque of 10 N·m (89 lb in). Tighten the nuts to a final torque of 27 N·m (239 lb in). 6. Install tube assembly (1). Refer to Disassembly and Assembly, "Air Control Valve - Remove and Install" for the correct procedure. End By: a. Install the turbocharger to the exhaust manifold. Refer to Disassembly and Assembly, "Turbocharger - Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884947

Fan - Remove and Install SMCS - 1356-010

Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

Illustration 1

g02829456

Typical example

1. Remove nuts (1). 2. Remove fan (2). Note: Note the orientation of the fan. 3. Remove fan adapter (3). 4. Remove fan pulley (4). 5. If necessary, remove studs (5) from fan drive (6).

Installation Procedure 1. Ensure that all the components are free from wear and damage. If necessary, replace any components that are worn or damaged. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 2

g02829456

Typical example

2. If necessary, install studs (5) to fan drive (6). Tighten studs (5) to a torque of 11 N·m (97 lb in). 3. If studs (5) have not been previously removed from fan drive (6). Check for the correct installation of the studs to the fan drive. Tighten studs (5) to a torque of 25 N·m (221 lb in). 4. Install fan pulley (4). 5. Install fan adapter (3). 6. Install fan (2). Note: Ensure that the fan is correctly oriented. 7. Inspect the condition of locking nuts (1). If necessary, replace the locking nuts. Install locking nuts (1). Tighten locking nuts (1) to a torque of 22 N·m (195 lb in). End By: a. Install the Alternator Belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876094

Fan Drive - Remove and Install SMCS - 1359-010; 1386-010

Removal Procedure 1. If necessary, remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.

Illustration 1

g02827145

2. If necessary, remove nuts (5) from studs (6). 3. Remove the alternator belt and the alternator belt tensioning bracket. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure. 4. Remove fan drive pulley (4). 5. Remove bolts (3) and remove the fan drive assembly (7) from the cylinder head. 6. If necessary, follow Step 6.a through Step 6.b in order to disassemble the fan drive assembly. a. Remove studs (6) from fan drive (7). b. Remove bolts (2) and remove lifting bracket (1) from fan drive (7).

Installation Procedure 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

g02827145

2. If necessary, follow Step 2.a through Step 2.b in order to assemble the fan drive.

a. Install studs (6) to fan drive (7). Tighten the studs to a torque of 18 N·m (159 lb in) b. Install lifting bracket (1) onto fan drive (7). Refer to Disassembly and Assembly, "Engine Lifting Group - Remove and Install" for the correct procedure. 3. Position fan drive (7) onto the cylinder head. Install bolts (3) and tighten the bolts to a torque of 25 N·m (221 lb in). 4. Position fan drive pulley (4) onto studs (6). 5. If necessary, install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure. 6. Install the alternator belt tensioning bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure. 7. Install the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure. 8. Install nuts (5) and tighten the nuts to a torque of 25 N·m (221 lb in). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05341788

Flexible Exhaust Pipe - Remove and Install SMCS - 1061-010

Removal Procedure for the Flexible Exhaust Pipe as an Assembly

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools in order to disassemble or assemble any part of the flexible exhaust system. The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows. Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.

Illustration 1

g02354623

Typical example

1. The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior to disassembly. The components that require correct lateral alignment are shown at Positions (A, B, and C). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 2

g02354616

Typical example

2. Follow Steps 2.a through Step 2.d in order to remove the flexible exhaust as an assembly from the Clean Emission Module (CEM) and the turbocharger. a. Use suitable material in order to encase flexible exhaust pipe (3). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe (3) between Position (D) and Position (E). Use cable straps in order to retain the suitable material. Note: Ensure that the flexible exhaust pipe is supported at all times. b. Loosen ball clamp (2) from the flexible exhaust pipe assembly. c. Loosen the bolt for V-band clamp (4). Note: If V-band clamp (4) remain tight on the flanges, apply releasing fluid on the Vband clamp. Lightly tap the bolt on the V-band clamp with a soft faced hammer in order to assist removal. Do not use a prybar in order to remove V-band clamp. d. Remove the assembly of the flexible exhaust pipe from the CEM (1) and the turbocharger (5). Note: Ensure that the assembly of the flexible exhaust pipe is supported as the clamps are removed.

Disassembly Procedure for the Flexible Exhaust Pipe Assembly 1. If any part of the flexible exhaust pipe assembly is damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.

Illustration 3

g02469602

Typical example

2. If necessary, follow Step 2.a through Step 2.d in order to disassemble the flexible exhaust pipe assembly. a. Make temporary marks in Position (F) on all components of bellows (3) and tube assembly (6) in order to show correct orientation and alignment.

Note: Do not scribe the components in order to mark the position of the flexible exhaust pipe assembly. b. Loosen clamp (7) and remove tube assembly (6) from bellows (3). c. Loosen ball clamp (8) and remove the ball clamp. d. Remove bellows (3) from elbow (9). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.

Assembly Procedure for the Flexible Exhaust Pipe Assembly Table 1 Required Tools Tool

Part Number

Part Description

Qty

Drill Bit 3 mm (0.118 inch) Ø

Drill Bit 6.5 mm (0.256 inch) Ø

1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 4

g02469603

Typical example

2. If the flexible exhaust pipe assembly was previously disassembled. Follow Step 2.a through Step 2.i in order to assemble the flexible exhaust pipe assembly.

NOTICE Use the correct personal protective equipment when removing the clamp.

a. If original bellows are to be reinstalled, place the internal area in Position (G) of the bellows on a suitable support. Use Tooling (A) in order to drill a pilot hole through the spot weld in Position (H) on clamp (7).

Note: Do not center punch the spot weld on clamp (7). b. Use Tooling (B) in order to drill out the spot weld in Position (H) on clamp (7). Remove clamp (7) from the bellows. c. Remove all burrs from the internal and external areas of bellows (3). Ensure that debris does not enter the bellows.

Illustration 5

g02354619

Typical example

d. Position a new clamp (7) onto bellows (3). Hand tighten clamp (7). Ensure that the center of the clamp is central to Slots (J) on the bellows. The clamp must be flush with the end of bellows (3). Note: Ensure that the bellows are not subjected to any undue stress. e. If new bellows (3) are installed, clamp (7) will be pre-installed to the bellows. Note: Ensure that the bellows are not subjected to any undue stress. f. Position a new ball clamp (8) onto elbow (9). g. Position bellows (3) onto elbow (9). Align the bellows and the elbow with temporary marks. h. Tighten ball clamp (8) hand tight.

Note: Ensure that the bellows are not subjected to any undue stress. i. Install tube assembly (6), align the tube assembly with the temporary marks on the bellows. Tighten clamp (7) hand tight.

Installation Procedure for the Flexible Exhaust Pipe as an Assembly NOTICE Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.

1. Check the flexible exhaust pipe assembly for damage. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.

Illustration 6 Typical example

g02354616

2. Position a new ball clamp (2) onto the flexible exhaust pipe assembly. 3. Install V-band clamp (4) onto turbocharger (5). 4. Install assembly of the flexible exhaust pipe onto CEM (1) and turbocharger (5). Note: Ensure that the assembly of the flexible exhaust pipe is supported at all times. 5. Tighten V-band clamp (4) hand tight. 6. Tighten ball clamp (2) hand tight.

NOTICE Failure to reinstall the bellows into the original position will result in a failure of the bellows and possible emissions failure.

7. Align the assembly of the flexible exhaust pipe with the temporary marks. Ensure that bellows (3) are not subjected to any undue stress.

Illustration 7 Typical example

g02250353

8. If a new bellows assembly has been installed, ensure that all components of the flexible exhaust pipe are not subjected to any undue stress and are correctly aligned. 9. Tighten ball clamp (2) to a torque of 35 N·m (26 lb ft). 10. Tighten clamp (7) to a torque of 55 N·m (40 lb ft). 11. Tighten ball clamp (8) to a torque of 35 N·m (26 lb ft). 12. Tighten V-band clamp (4) to a torque of 12 N·m (106 lb in). 13. Cut cable straps from the suitable material that was encasing bellows (3) between Position (A) and Position (B). Remove the suitable material from bellows (3).

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

i06061560

Flexible Exhaust Pipe - Remove and Install - Flexible Exhaust Pipe Between DOC and the SCR SMCS - 1061-010

Removal Procedure

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE Use the correct personal protective equipment when removing the clamp.

Illustration 1 Typical example

g03796494

1. Use suitable material in order to encase bellows (5). Use cable straps in order to retain the suitable material. Encasing the flexible exhaust pipe will prevent damage of the bellows. 2. Make temporary marks in Position (A) and Position (B) for installation purposes. 3. Sufficiently loosen ball clamp (3) and V-band clamp (5) in order to allow the assembly of flexible exhaust pipe (4) to be removed. 4. Remove flexible exhaust pipe (4) from Selective Catalyst Reduction (SCR) (1) and Diesel Oxidation Catalyst (DOC) (8). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 5. Remove gasket (2) (not shown) and gasket (7) (not shown).

Disassembly Procedure NOTICE Use the correct personal protective equipment when removing the clamp.

Illustration 2

g03796524

1. If necessary, follow Step 2.f through Step 1.g in order to disassemble the assembly of flexible exhaust pipe (4). a. Make temporary marks on the assembly of flexible exhaust pipe (4) for installation purposes. b. Sufficiently loosen ball clamp (15) and remove elbow (17) from bellows (5). c. Remove gasket (16). d. Sufficiently loosen V-clamp (13) and remove bellows (5) from tube assembly (12). Note: Ensure that the bellows are not subjected to any undue stress.

e. Remove gasket (14). f. Sufficiently loosen V-clamp (10) and remove tube assembly (12) from tube assembly (9). g. Remove gasket (11).

Assembly Procedure 1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.

NOTICE Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.

Illustration 3

g03796524

2. If necessary, follow Step 2.a through Step 2.g in order to assemble the flexible exhaust pipe (4). a. Install a new gasket (11) onto tube assembly (9). Install V-clamp (10) onto the tube assembly. b. Install tube assembly (9) onto tube assembly (12) and align with temporary marks. Tighten V-clamp (10) hand tight. c. Install a new gasket (14) to tube assembly (12). Install V-clamp (13) onto the tube assembly.

d. Install bellows (5) to tube assembly (12) and align with temporary marks. Tighten Vclamp (13) hand tight. Note: Ensure that the bellows are not subjected to any undue stress. e. Install a new gasket (16) to elbow (17). Install a new ball clamp (15) to the elbow. f. Install elbow (17) to bellows (5) and align with temporary marks. Tighten ball clamp (15) hand tight. g. Do not tighten ball clamp (15), V-clamp (13), or V-clamp (10) until the assembly of flexible exhaust pipe (4) has been installed to the SCR and the DOC.

Installation Procedure 1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information.

Illustration 4

g03796930

Typical example

2. If the assembly of flexible exhaust pipe (4) as previously disassembled, ensure that the clamps are sufficiently loose in order to aid assembly. 3. Install a new gasket (2) (not shown) and a new gasket (7) (not shown) onto SCR (1) and DOC (8). 4. Install a new ball clamp (3) onto SCR (1). 5. Install V-band clamp (5) onto DOC (8) 6. Install the assembly of flexible exhaust pipe (4) onto SCR (1) and DOC (8) and align with temporary marks in Position (A) and Position (B).

Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress. 7. Sufficiently tighten ball clamp (3) and V-band clamp (5) to hold the assembly of flexible exhaust pipe (4). Ensure that the assembly of flexible exhaust pipe is correctly aligned to the temporary marks in Position (A) and Position (B). 8. Tighten ball clamp (3) to a torque of 35 N·m (310 lb in). 9. Tighten V-band clamp (6) to a torque of 12 N·m (106 lb in). 10. Tighten V-band clamp (10) and V-band clamp (13) to a torque of 13 N·m (115 lb in). 11. Remove the suitable material from bellows (5).

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05825376

Flexible Exhaust Pipe - Remove and Install - Flexible Exhaust Pipe from the Turbocharger and the Diesel Oxidation Catalyst (DOC) SMCS - 1061-010

Removal Procedure

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

Illustration 1

g03795627

Typical example

1. Remove exhaust temperature sensor (3) from flexible exhaust pipe (5). Refer to Disassembly and Assembly, "Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure. 2. Remove nitrogen oxide sensor (4) from flexible exhaust pipe (5). Refer to Disassembly and Assembly, "Nitrogen Oxide Sensor - Remove and Install" for the correct procedure. 3. Loosen V-band clamp (2) and V-band clamp (6) in order to allow flexible exhaust pipe (5) to be removed from Diesel Oxidation Catalyst (DOC) (1) and turbocharger (7). 4. Remove flexible exhaust pipe (5), V-band clamp (2), and V-band clamp (6).

Installation Procedure NOTICE

Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.

1. Check the flexible exhaust pipe assembly for damage. Refer to Special Instruction, REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for more information. If any part of the flexible exhaust pipe assembly is damaged, replace the flexible exhaust pipe as an assembly.

Illustration 2

g03795627

Typical example

2. Position a new V-band clamp (2) onto DOC (1). 3. Position a new V-band clamp (6) onto turbocharger (7). 4. Install flexible exhaust pipe (5) onto turbocharger (7) and DOC (1). Install V-band clamp (2) and V-band clamp (6) onto the flexible exhaust pipe. Ensure that the V-band clamps are correctly positioned onto the flexible exhaust pipe. Note: Ensure that the assembly of the flexible exhaust pipe is supported at all times. 5. Tighten V-band clamp (2) and V-band clamp (6) to a torque of 15 N·m (133 lb in).

6. Install exhaust temperature sensor (3) to flexible exhaust pipe (5). Refer to Disassembly and Assembly, "Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure. 7. Install nitrogen oxide sensor (4) to flexible exhaust pipe (5). Refer to Disassembly and Assembly, "Nitrogen Oxide Sensor - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876098

Flow Control Valve - Remove and Install SMCS - 135V-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position.

Illustration 1

g02539836

3. Clean the area around flow control valve (2) and fuel injection pump. Ensure that the area is free from contamination before beginning disassembly. 4. Disconnect harness assembly (3) from flow control valve (2). 5. Make temporary marks on the flow control valve and the fuel injection pump for installation purpose. 6. Remove Allen heads screws (1) from the flow control valve. 7. Remove the flow control valve from the fuel injection pump. 8. Use Tooling (A) in order to plug the fuel injection pump. 9. Remove O-ring seal (4) (not shown).

Installation Procedure 1. Ensure that all component at free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly.

Illustration 2

g02539836

2. Position a new O-ring seal (4) (not shown) onto the flow control valve assembly. 3. Check O-ring seal (4) (not shown) is correctly positioned. Ensure that O-ring seal is not damaged. 4. Lubricate O-ring seal (4) (not shown) with clean fuel. Note: Ensure that the O-ring seals are not damaged or misaligned. 5. Remove Tooling (A) from the fuel injection pump. 6. Install flow control valve (3) to the fuel injection pump. 7. Install Allen head screws (2) from the flow control valve repair kit. 8. Tighten Allen head screws (2) equally until the flow control valve is seated correctly onto the fuel injection pump. Note: Ensure that the Allen screws are tightened equally. Failure to ensure that the Allen screws are tightened equally will result in damage to the fuel injection pump.

9. Tighten the Allen head screws to a torque of 9 N·m (80 lb in). 10. Connect harness assembly (1) to flow control valve (3). 11. Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure. 12. Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure. 13. Turn the fuel supply to the ON position. 14. Turn the battery disconnect switch to the ON position. 15. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information. End By: a. After replacement of the flow control valve, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05354383

Flywheel - Install SMCS - 1156-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Guide Stud M12 x 1.25 by 100mm

8T-3052

Degree Wheel

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 1

g02659159

Typical example

Always wear protective gloves when handling parts that have been heated.

1. If the flywheel ring gear was removed, follow Step 1.a through Step 1.c in order to install a new ring gear (3) to flywheel (1). a. Identify the orientation of teeth (4) on new ring gear (3). Note: The chamfered side of ring gear teeth (4) must face toward the starting motor when the flywheel is installed. The chamfered side of ring gear teeth ensures the correct engagement of the starting motor. b. Heat flywheel ring gear (3) in an oven to a maximum temperature of 250 °C (482 °F) prior to installation. Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of ring gear (3) is correct and quickly install the ring gear onto flywheel (1). 2. Inspect the crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove and Install".

Illustration 2

g02659160

Typical example

3. Install a suitable lifting device to flywheel (1). The flywheel can weigh 75 kg (165 lb). 4. Install Tooling (A) in Position (X) on the crankshaft. 5. Use the suitable lifting device to position flywheel (1) onto Tooling (A). 6. Install new bolts (2) hand tight to flywheel (1). 7. Remove Tooling (A) and install remaining new bolts (2) hand tight to flywheel (1). 8. Remove the lifting device from flywheel (1). 9. Use a suitable tool to prevent the flywheel from rotating. Tighten bolts (2) to a torque of 30 N·m (266 lb in). Use Tooling (B) to rotate bolts (2) through an additional 90 degrees in a clockwise direction in order to achieve the required final torque. 10. Check the run out of the flywheel. Refer to System Operation, Testing and Adjusting, "Flywheel" for further information. End By: a. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884951

Flywheel - Remove SMCS - 1156-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Guide Stud M12 x 1.25mm by 100mm

Start By: a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02657336

1. Remove bolts from Position (X) from flywheel (1). Discard the bolts. 2. Install Tooling (A) in Position (X) to flywheel (1). 3. Install a suitable lifting device onto flywheel (1). Support the weight of the flywheel. The flywheel can weigh 75 kg (165 lb). 4. Remove remaining bolts (2). Discard the bolts. 5. Use the suitable lifting device to remove the flywheel from the engine.

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Illustration 2

g02657439

6. Inspect flywheel (1) and ring gear (3) for wear and damage. Replace any worn or damaged components. 7. To remove flywheel ring gear (3), follow Step 7.a through Step 7.b. a. Place the flywheel assembly on a suitable support. b. Use a hammer and a punch in order to remove ring gear (3) from flywheel (1). Note: Identify the orientation of the teeth on the flywheel ring gear.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884952

Flywheel Housing - Remove and Install - Non-Stressed Cylinder Block SMCS - 1157-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description Guide Stud M8 by 100 mm

Qty 2

Start By: a. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove and Install" for the correct procedure. b. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02659276

Illustration 2

g02659298

1. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure. 2. If necessary install the diesel particulate filter supporting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. 3. Remove bolts (3) from Position (X) from flywheel housing (1). 4. Install Tooling (A) into Position (X) on flywheel housing (1). 5. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 6. Remove bolts (2) from flywheel housing (1). 7. Remove bolts (4) from flywheel housing (1). 8. Use the suitable lifting device in order to remove flywheel housing (1) from the cylinder block.

Illustration 3

g02882157

Illustration 4

g02661536

9. If necessary, remove dowels (5). 10. If necessary, remove bolts (7) and inspection cover (6) from flywheel housing (1).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

Guide Stud M8 by 100 mm

Loctite 5970

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.

Illustration 5

g02882197

Illustration 6

g02659298

Illustration 7

g02659276

2. Clean the rear face of the cylinder block. If necessary, install dowels (5) to the cylinder block. 3. If necessary, install dowels (5) to the cylinder block. 4. Apply a 3mm bead of Tooling (B) in Position (Y) to the cylinder block as shown in Illustration 5. 5. Install Tooling (A) into the cylinder block in Positions (X). 6. Install a suitable lifting device onto the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 7. Use the suitable lifting device to align flywheel housing (1) with Tooling (A). Install the flywheel housing to the cylinder block. 8. Install bolts (4) and bolts (2) finger tight. 9. Remove Tooling (A). Install bolts (3) finger tight. 10. Tighten bolts (4) and bolts (2) to a torque of 110 N·m (81 lb ft). 11. Tighten bolts (3) to a torque of 35 N·m (26 lb ft). 12. Check the alignment of flywheel housing (1) with the crankshaft. Refer to System Operation, Testing and Adjusting, "Flywheel Housing - Inspect" for more information.

Illustration 8

g02661536

13. If necessary, install inspection cover (6) and bolts (7) to flywheel housing (1). Tighten the bolts to a torque of 25 N·m (221 lb in). 14. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure. End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure. b. Install the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884953

Flywheel Housing - Remove and Install - Stressed Cylinder Block SMCS - 1157-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description Guide Stud M8 by 100 mm

Qty 2

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02879298

Illustration 2

g02879337

1. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure. 2. Remove bolts (3) from Position (X) from flywheel housing (1). 3. Install Tooling (A) into Position (X) on flywheel housing (1). 4. Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 5. Remove bolts (2) from flywheel housing (1). 6. Remove bolts (4) from flywheel housing (1). 7. Use the suitable lifting device in order to remove flywheel housing (1) from the cylinder block.

Illustration 3

g02879456

8. If necessary, remove dowels (5).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

Guide Stud M8 by 100 mm

Loctite 5970

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.

Illustration 4

g02881996

Illustration 5

g02879298

Illustration 6

g02879337

2. Clean the rear face of the cylinder block. 3. If necessary, install dowels (5) to the cylinder block. 4. Apply a 3mm bead of Tooling (B) in Position (Y) to the cylinder block as shown in Illustration 4. 5. Install Tooling (A) into the cylinder block in Positions (X). 6. Install a suitable lifting device onto the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb). 7. Use the suitable lifting device to align flywheel housing (1) with Tooling (A). Install the flywheel housing to the cylinder block. 8. Install bolts (4) and bolts (2) finger tight. 9. Remove Tooling (A). Install bolts (3) finger tight. 10. Tighten bolts (4) and bolts (2) to a torque of 110 N·m (81 lb ft). 11. Tighten bolts (3) to a torque of 35 N·m (26 lb ft). 12. Check the alignment of flywheel housing (1) with the crankshaft. Refer to System Operation, Testing and Adjusting, "Flywheel Housing - Inspect" for more information.

13. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure. End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure. b. Install the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05289217

Front Cover - Remove and Install SMCS - 1166-010

Removal Procedure Start By: A. If the engine is equipped with a fan, remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure. B. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather Remove and Install" for the correct procedure. C. Remove the camshaft position sensor. Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure. D. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install" for the correct procedure.

Illustration 1

g02727693

Illustration 2

g02727966

1. Remove bolts (1) from front cover (3) . Note: Note the position of the different length bolts. 2. Remove front cover (3) from the front housing. 3. Remove gasket (2) (not shown). 4. Remove the crankshaft front seal using a suitable tool. Ensure that the front cover (3) is not damaged during the removal of the crankshaft front seal. 5. If necessary, follow Step 5.a through Step 5.c in order to remove crankcase pressure relief valve (5) from the front cover. a. Remove bolts (4) from crankcase pressure relief valve (5) . b. Remove crankcase pressure relief valve (5) from the front cover (3) . c. Remove O-ring seal (6) from crankcase pressure relief valve (5) . 6. If necessary, remove studs (7) from front cover (3) .

Installation Procedure Table 1

Required Tools Tool

Part Number

B C

Part Description

Qty

Guide Stud M8 by 70 mm

390-1125

Front Cover Alignment Tool - Crankshaft

390-1132

Front Cover Alignment Tool - Crankcase Breather

Illustration 3

g02931736

1. If necessary, follow Step 1.a through Step 1.c in order to install crankcase pressure relief valve (5) to the front cover. a. Install O-ring seal (6) to crankcase pressure relief valve (5) . b. Install crankcase pressure relief valve (5) to the front cover (3) . c. Install bolts (4) to crankcase pressure relief valve (5) . Tighten the bolts to a torque of 10 N·m (89 lb in). 2. If necessary, install studs (7) to front cover (3) . Tighten the studs to a torque of 10 N·m (89 lb in)

3. Thoroughly clean the gasket surface of the front housing. 4. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 4

g02931738

Illustration 5

g02932042

5. Install Tooling (A) into the holes in Positions (X) in the front housing. 6. Position a new gasket (2) onto Tooling (A) . 7. Position front cover (3) onto Tooling (A) . 8. Install bolts (1) in the available locations finger tight. 9. Remove Tooling (A) and install remaining bolts (1) . 10. Install the breather drive (9) and install nut (10) to fuel injection pump shaft (8) . 11. Use a suitable tool in order to prevent the engine from rotating. Tighten nut (10) to a torque of 80 N·m (59 lb ft). 12. Install Tooling (B) into the aperture for the crankshaft front seal. 13. Install Tooling (C) into the aperture for the crankcase breather.

Illustration 6

g02727967

14. Tighten bolts (1) in the sequence that is shown in Illustration 6 in two stages. Tighten the bolts to an initial torque of 8 N·m (71 lb in). Tighten the nuts to a final torque of 25 N·m (221 lb in). 15. Remove Tooling (B) and remove Tooling (C) . 16. Install the crankshaft front seal to the front cover. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install" for the correct procedure. End By: a. Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather Remove and Install" for the correct procedure. b. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install" for the correct procedure. c. Install the camshaft position sensor. Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure. d. If the engine was equipped with a fan, install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876211

Fuel Filter Base - Remove and Install SMCS - 1262-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair

of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

1. Turn the battery disconnect switch to the OFF position. 2. Turn the fuel supply to the OFF position. 3. Drain the secondary filter. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.

Illustration 1

g03011036

4. Make temporary identification marks on plastic tube assembly (1) and plastic tube assembly (2) in order to show the correct position of the plastic tube assemblies. 5. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled. 6. Disconnect plastic tube assembly (1) and plastic tube assembly (2) from fuel filter base (3). 7. Use Tooling (A) in order to plug plastic tube assembly (1) and plastic tube assembly (2)

8. Use Tooling (A) in order to cap the connection on fuel filter base (3). 9. Slide locking tab in to the unlock position. Disconnect harness assembly (5) from fuel temperature sensor (4).

Illustration 2

g03011037

10. Remove cannister (8) from fuel filter base (3). Remove secondary filter (7). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure. 11. Remove nuts (6) from fuel filter base (3). Remove the fuel filter base from the mounting bracket. Note: Do not disassemble the fuel filter base.

Illustration 3

g03011038

12. If necessary, follow Step 1.c through Step 12.c in order to remove the bracket for secondary fuel filter. a. Remove bolts (11) fuel filter bracket (10). b. Remove fuel filter bracket (10) from the valve mechanism cover. c. If necessary, remove studs (9). from fuel filter bracket (10).

Refer to System Operation, Testing and Adjusting , "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.

Illustration 4

g03011038

1. If necessary, follow Step 1.a through Step 1.c in order to install the bracket for secondary fuel filter. a. If necessary, install studs (9) to fuel filter bracket (10). Tighten studs (9) to a torque of 18 N·m (159 lb in). b. Position fuel filter bracket (10) onto the valve mechanism cover. Install bolts (11) to fuel filter bracket (10).

c. Tighten bolts (11) to a torque of 25 N·m (221 lb in).

Illustration 5

g03011037

2. Ensure that fuel filter base (3) is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly. 3. Position fuel filter base (3) on the mounting bracket. Install nuts (6). Tighten the bolts to a torque of 25 N·m (221 lb in). 4. If necessary, install a new fuel filter (7) to canister (8). Install cannister (8) to fuel filter base (3). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.

Illustration 6

g03011036

5. Remove the plugs from the plastic tube assemblies. Remove the caps from the ports in the fuel filter base.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Allowing contamination to enter the fuel system will cause serious damage to the engine.

6. Connect plastic tube assembly (1) and plastic tube assembly (2) to the fuel filter base. 7. Connect harness assembly (5) to fuel temperature sensor (4). Slide locking tab in to the lock position. 8. Turn the fuel supply to the ON position. 9. Turn the battery disconnect switch to the ON position. End By:

a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884955

Fuel Injection Lines - Install SMCS - 1252-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

LASER 4920 1/2 Inch Drive HP Fuel Line Socket Set

Note: The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic

Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.

Illustration 1

g02699457

Illustration 2

g02849442

1. Remove the relevant plug from fuel manifold (24) and fuel injection pump (29). 2. Remove the caps from new fuel injection line (28). 3. Position fuel injection line (28) onto fuel injection pump (29) and fuel manifold (24). Loosely install nuts for the fuel injection line onto the fuel manifold and the fuel injection pump. 4. Use Tooling (B) to tighten the nuts on fuel injection line (23) to a torque of 25 N·m (221 lb in). Note: Ensure that fuel injection lines do not contact any other engine component. 5. Remove the caps from the port of the electronic unit injector and from the appropriate port in fuel manifold (16). 6. Loosely connect the nuts at both ends of fuel injection line (12) to the electronic unit injector and to the appropriate port in fuel manifold (16). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold. 7. Repeat Step 5 through Step 6 in order to install the remaining fuel injection lines. 8. Position clamp (22) onto fuel injection lines (12) and install clamp bolt (20). Tighten the bolt to a torque of 10 N·m (89 lb in).

Note: Ensure that the rubber separator is correctly installed around the fuel injection lines. Ensure that fuel injection lines do not contact any other engine component. 9. Repeat Step 8 for the remaining fuel injection lines. 10. Use Tooling (B) to tighten the nuts on fuel injection line (12) to a torque of 25 N·m (221 lb in). 11. Position bracket (25) onto the valve mechanism cover. Install bolt (26) and tighten the bolt to a torque of 10 N·m (89 lb in). 12. If necessary, reinstall the front engine lifting eye (31). Install bolts (30) and tighten the bolts to a torque of 45 N·m (33 lb ft).

Illustration 3 CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

g02849446

Illustration 4

g02699461

Illustration 5

g02699462

13. Position bracket (19) onto the valve mechanism cover. Install bolts (20) and tighten the bolts to a torque of 25 N·m (221 lb in). 14. Install the fuel filter base mounting bracket (21) (not shown). Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure. 15. Position the wiring harness assembly (11) over fuel injection lines (12). 16. Install bolt (6) to wiring harness assembly (11). Tighten the bolt to a torque of 10 N·m (89 lb in) 17. Install cable straps (1) to the wiring harness and brackets (25). Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specifications. 18. Connect wiring harness assembly (9) to fuel metering valve (10). Slide the locking tab for wiring harness assembly (9) into the locked position. 19. Connect wiring harness assembly (14) to oil pressure switch (13). 20. Connect wiring harness assembly (3) to pressure sensor (2). Slide the locking tab for wiring harness assembly (3) into the locked position. 21. Connect wiring harness assembly to fuel temperature sensor (4). Slide the locking tab for wiring harness assembly into the locked position.

22. Connect wiring harness assembly (15) to crankshaft position sensor (16). Slide the locking tab for wiring harness assembly (15) into the locked position. 23. Connect wiring harness assembly (17) to camshaft position sensor (18). Slide the locking tab for wiring harness assembly (17) into the locked position. 24. Install cable straps to the wiring harness assembly in the relevant positions. Ensure that the cable straps meet the OEM specifications. 25. Install the OEM wiring harness assembly to connection (5) and connection (8). 26. If necessary, install the Diesel Particulate Filter (DPF). Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure. 27. Turn the fuel supply to the ON position. 28. Turn the battery disconnect switch to the ON position. 29. Remove trapped air from the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884956

Fuel Injection Lines - Remove SMCS - 1252-011

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description

Qty

Capping Kit

LASER 4920 1/2 Inch Drive HP Fuel Line Socket Set

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Note: Put identification marks on all hoses on all hose assemblies and on wires and all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will help to prevent fluid loss and helps to keep contaminants from entering the system. 1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 3. If necessary, remove the Diesel Particulate Filter (DPF). Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" for the correct procedure.

Illustration 1

g02656817

Illustration 2

g02683476

4. Disconnect the Original Equipment Manufacturers (OEM) wiring harness assembly from connection (5) and connection (8). 5. Cut cable straps (1) from the wiring harness assemblies. 6. Slide the locking tab for wiring harness assembly (3) into the unlocked position. Disconnect wiring harness assembly (3) from pressure sensor (2). 7. Disconnect wiring harness assembly (14) from oil pressure switch (13). 8. If necessary, cut cable straps in order to remove the wiring harness assemblies. 9. Slide the locking tab for wiring harness assembly (15) into the unlocked position. Disconnect wiring harness assembly (15) from crankshaft position sensor (16). 10. Slide the locking tab for wiring harness assembly (17) into the unlocked position. Disconnect wiring harness assembly (17) from camshaft position sensor (18). 11. Slide the locking tab for wiring harness assembly (9) into the unlocked position. Disconnect wiring harness assembly (9) from the fuel metering valve (10). 12. Disconnect the wiring harness assembly from fuel temperature sensor (4). 13. Remove bolt (6) from wiring harness assembly (11). 14. Position the wiring harness assembly (11) away from fuel injection lines (12).

Illustration 3

g02848956

Illustration 4

g02683858

15. Remove the fuel filter base mounting bracket (21) (not shown). Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure. 16. Remove bolt (23) from tube clamp (22). Remove tube clamp (22) from fuel injection lines (12). Note: Make temporary marks to identify the position of the tube clamps. 17. Repeat Step 16 in order to remove the remaining tube clamps. 18. Remove bolt (26). Remove bracket (25) from the valve mechanism cover. 19. Clean the area around the nuts for fuel injection lines (12). Ensure that the area is free from contamination before beginning disassembly. 20. Use Tooling (B) in order to disconnect fuel injection line (12) from the electronic unit injector (27). Note: It may be necessary to remove the front engine lifting eye in order to gain access to number one high-pressure pipe nut. 21. Use Tooling (B) in order to disconnect fuel injection line (12) from fuel manifold (24). 22. Remove fuel injection line (12). Discard the fuel injection lines.

23. Use Tooling (A) in order to cap all open ports immediately in fuel manifold (24) and electronic unit injectors (27). 24. Repeat Step 19 through Step 23 in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.

Illustration 5

g02688011

25. Clean the area around the nuts for fuel injection line (28). Ensure that the area is free from contamination before beginning disassembly. 26. Disconnect fuel injection line (28) from fuel injection pump (29). 27. Disconnect fuel injection line (28) from fuel manifold (24). 28. Remove fuel injection line (28). Discard the fuel injection line. 29. Use Tooling (A) in order to cap all open ports immediately in fuel manifold (24) and in fuel injection pump (29). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05500649

Fuel Injection Pump - Install SMCS - 1251-012

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.

Illustration 1

g02937680

Illustration 2

g02937736

1. If necessary, install studs (9) into front cover (10) . Tighten the studs to a torque of 18 N·m (159 lb in) 2. Install new O-ring seal (11) onto fuel injection pump (6) . 3. Carefully install fuel injection pump (6) into front housing (10) . Ensure that the bore in front housing (10) is not damaged as the fuel injection pump is installed. 4. Install nuts (8) onto studs (9) . Tighten the nuts to a torque of 25 N·m (221 lb in).

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Illustration 3

g02709437

5. Remove the appropriate caps in order to install a new fuel injection line (7) . Install new fuel injection line (7) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. 6. Remove the appropriate plugs and caps and connect plastic tube assembly (2) , plastic tube assembly (3) , plastic tube assembly (4) plastic tube assembly (5) to fuel injection pump (6) . 7. Connect harness assembly (1) to the solenoid on fuel injection pump (6) . 8. Install the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install" for the correct procedure. 9. Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure. 10. Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure. 11. Turn the fuel supply to the ON position. 12. Turn the battery disconnect switch to the ON position. 13. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884958

Fuel Injection Pump - Remove SMCS - 1251-011

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

Start By: a. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Remove" for the correct procedure.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position. 3. Disconnect harness assembly (1) from the solenoid on fuel injection pump (6). Note: The harness assemblies should be positioned away from fuel injection pump in order to avoid an obstruction to the fuel injection pump.

Illustration 1

g02709437

4. Place a suitable container below the fuel injection pump in order to catch any fuel that might be spilled. 5. Clean the fuel injection pump and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.

6. Remove fuel injection line (7) that connects fuel injection pump (6) to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure. Note: Discard the fuel injection line. 7. Use Tooling (A) in order to cap the open port in the fuel injection pump immediately. 8. Use Tooling (A) in order to cap the open port in the fuel manifold immediately. 9. Make temporary identification marks on all plastic tube assemblies for installation purposes. 10. Disconnect plastic tube assembly (2), plastic tube assembly (3), plastic tube assembly (4) plastic tube assembly (5) from fuel injection pump (6). 11. Use Tooling (A) in order to cap the open ports in the fuel injection pump immediately. 12. Use Tooling (A) in order to plug the plastic tube assemblies immediately.

Illustration 2

g02709476

Fuel injection pump viewed from the rear

13. Remove nuts (8) from fuel injection pump (6). Note: The fuel injection pump should be supported by hand as the nuts are removed. 14. Carefully remove the fuel injection pump from front housing (10).

15. Remove O-ring (11) (not shown) from the fuel injection pump. 16. If necessary, remove studs (9) from front housing (10).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05341772

Fuel Injection Pump Gear - Install SMCS - 1251-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear of damage. If necessary, replace any components that are worn or damaged. 2. If Tooling (A) and Tooling (B) are not installed, install Tooling (A) and install Tooling (B). Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Remove" for the correct procedure.

Illustration 1

g02937163

3. If necessary, install locating pin (6) into fuel injection pump shaft (7). 4. Ensure that locating pin (6) is 45 degrees from vertical and parallel to the center of Torx head plug (5), refer to Illustration 1. 5. Position gear (8) onto fuel injection pump shaft (7). 6. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure. 7. Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather Install" for the correct procedure.

Illustration 2

g02937277

8. Remove Tooling (B) from the front housing. 9. Install new O-ring seal (1) to plug (2). 10. Install plug (2). Tighten the plug to a torque of 25 N·m (221 lb in). 11. Install new O-ring seal (3) to plug (4). 12. Install plug (4). Tighten the plug to a torque of 30 N·m (266 lb in). 13. If equipped, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05341744

Fuel Injection Pump Gear - Remove SMCS - 1251-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

Snap-on 650 Small Pry Bar

Start By: a. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position.

Illustration 1

g02937156

Illustration 2

g02937157

Camshaft timing ring removed for clarity.

3. Follow Step 3.a through Step 3.e in order to install the camshaft timing tool. a. If equipped, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure. b. Remove plug (2) in Position (W) from the front housing. c. Remove O-ring seal (1) from plug (2). d. Rotate the engine until Hole (X) in the camshaft gear is aligned with Position (W) in the front housing. e. Install Tooling (B) through Position (W) and into Hole (X) in the camshaft gear. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g02934298

4. Follow Step 4.a through Step 4.c in order to install the crankshaft positioning tool. a. Remove plug (4) from Position (X) in the cylinder block. b. Remove O-ring seal (3) from plug (4). c. Install Tooling (A) into the cylinder block in Position (Z). Note: Tooling (A) must be located in Hole (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 3.

Illustration 4

g02937163

5. Before removing fuel injection pump gear (8) ensure that alignment pin (6) is 45 degrees from vertical and parallel to the center of Torx head plug (5), refer to Illustration 4. 6. Use Tooling (C) in order to remove the fuel injection pump gear from the fuel injection pump shaft (7). 7. If necessary, remove locating pin (6) from fuel injection pump shaft (7).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05825341

Fuel Manifold (Rail) - Remove and Install SMCS - 1702-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Note: Plug or cap all open ports with new plugs or new caps. 1. Thoroughly clean the area around fuel manifold (12).

Illustration 1 CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

g03784524

Illustration 2

g03784525

2. Disconnect the wiring harness from fuel pressure sensor (3). 3. Disconnect hose assembly connection (9) from fuel injection pump (8). 4. Disconnect hose assembly connection (6) from fuel distribution block (5). 5. Remove bolts (1) from fuel manifold (2). Remove the fuel manifold from the valve mechanism cover (4). 6. If necessary, follow Step 6.a through Step 6.e in order to remove plastic tube assembly (7). a. Release hose clamp (10) on plastic tube assembly (7). b. Disconnect plastic tube assembly (7) from the fuel manifold (2). c. Use Tooling (A) to cap the open port in fuel manifold (2) with a new cap. d. Remove seal (11). e. Use Tooling (A) to plug the open end of plastic tube assembly (7) with a new plug. 7. If necessary, remove fuel pressure relief valve (12) and O-ring seal (13) (not shown) from the fuel manifold. 8. If necessary, remove fuel pressure sensor (3) from the fuel manifold.

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1. Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Note: Do not install a fuel manifold that has not been plugged. All plugs and caps must be left in place until the fuel injection lines are about to be installed.

Illustration 3

g03784524

Illustration 4

g03784525

2. If necessary, install fuel pressure relief valve (12) and new O-ring seal (13) (not shown) to fuel manifold (2). Tighten fuel pressure relief valve (12) to a torque of 100 N·m (74 lb ft). 3. If necessary, install fuel pressure sensor (3) to the fuel manifold. Tighten fuel pressure sensor (3) to a torque of 70 N·m (52 lb ft). 4. If necessary, follow Step 4.a through Step 4.d in order to install tube assembly (7) to fuel manifold (2). a. Position hose clamp (10) onto plastic tube assembly (7). b. Install new seal (11) into plastic tube assembly (7). c. Install plastic tube assembly (7) to fuel manifold (2). Note: Ensure that the plastic tube assembly is correctly orientated. d. Tighten hose clamp (10) securely. 5. Position fuel manifold (2) onto valve mechanism cover (4). Install bolts (1) to fuel manifold (2) finger tight.

6. Install new fuel injection lines finger tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the installation procedure. Note: Do not torque the nuts for the fuel injection lines at this stage of the assembly procedure. 7. Tighten bolts (1) to a torque of 25 N·m (221 lb in). 8. Tighten the nuts for the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct torque. 9. Remove the plug from connection (9) and install plastic tube assembly (7) to the fuel injection pump (8). 10. Remove the plug from connection (6) and install plastic tube assembly (7) to distribution block (5). 11. For the remaining installation procedure for the fuel injection lines, refer to Disassembly and Assembly, "Fuel Injection Lines - Install". End By: a. If a new fuel manifold is installed, it will be necessary to use the electronic service tool in order to perform the"Rail Pressure Valve Learn Reset" procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05339813

Fuel Priming Pump - Remove and Install SMCS - 1258-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair

1. Turn the fuel supply to the OFF position.

Illustration 1

g02988817

Typical example

2. Make a temporary identification mark on plastic tube assemblies (1) in order to show the correct position of the tube assemblies. 3. Place a suitable container below the fuel priming pump in order to catch any fuel that might be spilled. Drain primary filter (7). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace". 4. Disconnect plastic tube assemblies (1). Use Tooling (A) to plug the tube assemblies with new plugs. 5. Use Tooling (A) cap open connectors (2) on the fuel priming pump with new caps. 6. Remove primary filter (6) from fuel priming pump (4). Refer to Operation and Maintenance, "Fuel System Primary Filter (Water Separator) Element - Replace".

7. Remove bolts (7) from fuel priming pump (4). Remove fuel priming pump (4) from the mounting bracket. 8. If necessary, follow Steps 8.a through 8.d in order to disassemble fuel priming pump (4). a. Remove connectors (2) from fuel priming pump (4). Use Tooling (A) to plug fuel priming pump (4). b. Use Tooling (A) to cap connectors (2). c. Remove plugs (5) from fuel priming pump (4). Use Tooling (A) to plug fuel priming pump (4). d. Remove O-ring seals (3) from connectors (2) and plugs (5).

Installation Procedure (Mechanical Priming Pump) NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that fuel priming pump (4) is clean and free from wear or damage. If necessary, replace the fuel priming pump.

Illustration 2

g02988817

Typical example

2. If necessary, follow Steps 2.a through 2.f in order to assemble fuel priming pump (4). a. Install new O-ring seals (3) to plugs (5). b. Remove caps from connectors (2). Install new O-ring seals (3) connectors (2). c. Remove plugs from fuel priming pump (4). d. Install connectors (2) to fuel priming pump (4). e. Install plugs (5) to fuel priming pump (4). f. Tighten the plugs and the connectors to a torque of 20 N·m (14 lb ft). 3. Position fuel priming pump (4) on the mounting bracket. Install bolts (7) to the fuel priming pump . Tighten the bolts to a torque of 44 N·m (32 lb ft). 4. Remove the plugs from the plastic tube assemblies. Remove the caps from the connectors. 5. Connect plastic tube assemblies (1) to connectors (2). Note: Ensure that the plastic tube assemblies are installed in the original positions. 6. Install a new primary filter (6) to fuel priming pump (4). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".

7. Turn the fuel supply to the ON position. 8. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime". CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876212

Fuel Temperature Sensor - Remove and Install SMCS - 1922-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Turn the fuel supply to the OFF position. 2. Turn the battery disconnect switch to the OFF position.

Illustration 1

g02876777

3. Disconnect harness assembly (3) from fuel temperature sensor (2). 4. Use a deep socket in order to remove fuel temperature sensor (2) from fuel filter base (1). 5. Use Tooling (A) to plug the open port of the fuel injection pump. 6. Remove sealing washer (4) (not shown) from fuel temperature sensor (2).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are free from wear and damage. Replace any components that are worn or damaged.

Illustration 2

g02876777

2. Install new sealing washer (4) (not shown) onto fuel temperature sensor (2). 3. Remove the plug from the fuel filter base (1). 4. Install fuel temperature sensor (2) to the fuel filter base. Use a deep socket to tighten the fuel temperature sensor to a torque of 22 N·m (195 lb in). 5. Connect harness assembly (3) to fuel temperature sensor (2). 6. Turn the fuel supply to the ON position. 7. Turn the battery disconnect switch to the ON position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884962

Glow Plugs - Remove and Install SMCS - 1412-010

Removal Procedure Start By: a. Remove the combined inlet manifold temperature and pressure sensor. Refer to Disassembly and Assembly, "Inlet Manifold Temperature and Pressure Sensor - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Turn the battery disconnect switch to the OFF position. 2. If necessary, remove the Exhaust Gas Recirculation (EGR) valve. Refer to Disassembly and Assembly, " Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.

Illustration 1

g02837996

3. Disconnect wiring harness (1) from the glow plugs (2). Note: Make temporary identification marks on the wiring harness assembly for installation purposes. 4. Clean the area around the glow plugs. Ensure that the area is free from contamination before removal of the glow plugs. 5. Use a deep socket in order to remove glow plugs (2) from the cylinder head.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02837996

1. Before installing glow plugs (5), ensure that the glow plugs are operating correctly. Refer to Troubleshooting, "Glow Plug Starting Aid - Test" “Check the Operation of the Glow Plugs” for the correct procedure. 2. Ensure that the threads of the glow plugs are clean and free from damage. Replace any damaged glow plugs. 3. Install glow plugs (2) into the cylinder head . Tighten the glow plugs to a torque of 9 N·m (80 lb in). 4. Connect wiring harness (1) to glow plugs (2). 5. Turn the battery disconnect switch to the ON position. 6. If necessary, install the Exhaust Gas Recirculation (EGR) valve. Refer to Disassembly and Assembly, " Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. End By: a. Install the combined inlet manifold temperature and pressure sensor. Refer to Disassembly and Assembly, "Inlet Manifold Temperature and Pressure Sensor - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884963

Housing (Front) - Install SMCS - 1151-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Loctite 5970 Silicone Sealant

Guide Bolt M8 x 1.25 by 35 mm

Loctite 506

1U-6396

O-Ring Assembly Compound

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shorten component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 1

g03022878

2. If a new front housing is being installed, it will be necessary to remove plug (7) in Position (Y) for engines that are equipped with any accessory drive in order to maintain the lubrication of the accessory drive. 3. If the accessory drive was removed but will not be installed, the oil gallery in Position (Y) must be plugged. Follow Step 3.a through Step 3.c in order to maintain engine oil circulation. a. Apply Tooling (C) to plug (7). b. Install plug (7) into front housing (1). c. Tighten plug (7) to a torque of 15 N·m (133 lb in).

Illustration 2

g02951196

Illustration 3 Front housing sealant path.

g02729111

Illustration 4

g02729108

4. Thoroughly clean the gasket surface of the front housing (1) and the cylinder block. 5. If necessary, install dowels (6) (not shown) to the cylinder block. 6. Install Tooling (B) into the cylinder block in Positions (X). 7. Apply a 3mm bead of Tooling (A) to front housing (1) as shown in Illustration 3. 8. Install front housing (1) onto Tooling (B) and dowels (6) (not shown). 9. Apply Tooling (C) onto the threads of bolts (5). 10. Install bolts (5) into front housing (1) in available location finger tight. 11. Remove Tooling (B) from the cylinder block.

Illustration 5

g02951436

12. Install remaining bolts (5). Tighten the bolts in the sequence that is shown in Illustration 5 to a torque of 25 N·m (221 lb in). 13. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Install" for the correct procedure. 14. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump Install" for the correct procedure. 15. Install the engine oil pan . Refer to Disassembly and Assembly, "Engine Oil Pan - Remove" for the correct procedure. 16. If necessary, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.

Illustration 6

g02951696

17. If necessary, follow Step 17.a through Step 17.c in order to install engine oil filler (2). a. Install new O-ring seal (4) (not shown) onto engine oil filler (2). b. Install engine oil filler (2) into front housing (1). c. Install bolts (3) into engine oil filler (2). Tighten the bolts to a torque of 25 N·m (221 lb in).

Illustration 7

g03025197

18. If necessary, install cover plate (8) to the front housing. Follow Step 18.a through Step 18.c in order to install the cover plate. a. Install new O-ring seal (10) to cover plate (8). Apply Tooling (D) to O-ring seal (10). b. Install cover plate (8) to the front housing. c. Install bolts (9) to the cover plate and tighten the bolts to a torque of 25 N·m (221 lb in). 19. If necessary, install the fan drive. Refer to Disassembly and Assembly, "Fan Drive Remove and Install" for the correct procedure. End By: a. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884964

Housing (Front) - Remove SMCS - 1151-011

Removal Procedure Start By: a. Remove the engine oil pan . Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. b. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure. c. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shorten component life.

Dispose of all fluids according to local regulations and mandates.

1. If necessary, remove the fan drive. Refer to Disassembly and Assembly, "Fan Drive Remove and Install" for the correct procedure.

Illustration 1

g02729108

2. Remove bolts (5) from front housing (1). Note: Note the positions of the different length bolts for installation purposes. 3. Remove front housing (1) from the cylinder block and dowels (6) (not shown). 4. Dowels (6) (not shown) should only be removed if damaged. 5. If necessary, follow Step 5.a through Step 5.c in order to remove engine oil filler (2). a. Remove bolts (3) from engine oil filler (2). b. Remove engine oil filler (2) from front housing (1). c. Remove O-ring seal (4) (not shown).

Illustration 2

g03025257

Illustration 3

g03025256

6. If necessary, follow Step 6.a through Step 6.c in order to remove cover plate (8) from the front housing. a. Remove bolts (9) from cover plate (8). b. Remove cover plate (8) from front housing (1). c. Remove O-ring seal (10) from the cover plate. 7. If necessary, remove plug (7) in Position (Y) from the front housing.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05350944

Idler Gear - Install SMCS - 1206-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

Loctite 242 Thread Lock

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02937163

Illustration 2

g02939977

3. If necessary, Apply Tooling (C) to lubricating jet (11) and install the lubricating jet into front housing (13). Tighten the lubricating jet to a torque of 18 N·m (159 lb in). 4. Ensure that locating pin (6) is 45 degrees from vertical and parallel to the center of Torx head plug (5), refer to Illustration 1. 5. Position gear (9) into the front housing. Ensure that the teeth on all gears mesh correctly. 6. Install idler hub (10) to gear (9). Ensure that the temporary marks are aligned and the idler hub (10) is correctly installed into the front housing. 7. Install bolt (12) to idler hub (10). Tighten the bolt to a torque of 50 N·m (37 lb ft) 8. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.

Illustration 3

g02937277

9. Remove Tooling (B) from the front housing. 10. Install new O-ring seal (1) to plug (2). 11. Install plug (2). Tighten the plug to a torque of 25 N·m (221 lb in). 12. Remove Tooling (A) from the cylinder block. 13. Install new O-ring seal (3) to plug (4). 14. Install plug (4). Tighten the plug to a torque of 30 N·m (266 lb in). 15. If equipped, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05350941

Idler Gear - Remove SMCS - 1206-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

435-3146

Timing Pin (Camshaft)

Start By: a. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure. Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the idler gear.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shorten component life.

Illustration 1

g02937156

Illustration 2

g02937157

Camshaft timing ring removed for clarity.

1. Follow Step 1.a through Step 1.e in order to install the camshaft timing tool. a. If equipped, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure. b. Remove plug (2) in Position (W) from the front housing. c. Remove O-ring seal (1) from plug (2). d. Rotate the engine until Hole (X) in the camshaft gear is aligned with Position (W) in the front housing. e. Install Tooling (B) through Position (W) and into Hole (X) in the camshaft gear.

Illustration 3

g02934298

2. Follow Step 2.a through Step 2.c in order to install the crankshaft positioning tool. a. Remove plug (4) from Position (X) in the cylinder block. b. Remove O-ring seal (3) from plug (4). c. Install Tooling (A) into the cylinder block in Position (Z). Note: Tooling (A) must be located in Hole (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 3.

Illustration 4

g02937163

Illustration 5

g02939977

3. Before removing the idler gear ensure that alignment pin (6) on the fuel injection pump gear is 45 degrees from vertical and parallel to the center of Torx head plug (5), refer to Illustration 4. 4. Make temporary identification marks on idler hub (10) for installation purposes. 5. Remove bolt (12) from idler hub (10). 6. Remove the idler hub (10) and gear (9) from front housing (13). 7. Remove idler hub (10) from gear (9). 8. If necessary, remove lubricating jet (11) from front housing (13).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884967

Idler Pulley - Remove and Install SMCS - 1358-010

Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02710322

Typical example

1. If necessary, remove bolts (1) and remove engine lifting bracket (2). 2. Remove bolt (4) and remove idler pulley (3).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components of the idler pulley are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

g02710444

Typical example

2. Install bolts (4) to idler pulley (3). Position idler pulley (3) onto the cylinder head. 3. Tighten bolt (4) to a torque of 40 N·m (30 lb ft). 4. If necessary, install bolts (1) to engine lifting bracket (2). Position the engine lifting bracket onto the idler pulley. 5. Tighten bolt (1) to a torque of 40 N·m (30 lb ft). End By: a. Install a new alternator belt. Refer to Disassembly and Assembly, "Alternator Belt Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343632

Inlet and Exhaust Valve Guides - Remove and Install SMCS - 1104-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

444-0978

Valve Guide Driver

Start By: a. Remove the inlet valves and the exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".

NOTICE Removal and installation of the valve guide and valve seat must be carried out by personnel with the correct training. Also special machinery is required. For more information, refer to your authorized Caterpillar dealer.

Illustration 1

g03003636

1. Use Tooling (A) in order to remove valve guides (2) from cylinder head (1). 2. Repeat the Step 1 for the remaining valve guides.

Installation Procedure Table 2 Required Tools Tool A B

Part Number

Part Description

Qty

444-0978

Valve Guide Driver

435-3148

Stop Collar

442-7298

Valve Guide Reamer

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean the parent bores in the cylinder head for the valve guides.

Illustration 2

g03003639

2. Lubricate a new valve guide (2) and place the valve guide in position. Carefully tap the valve guide in order to start the installation. Use Tooling (A) to install the valve guide into the cylinder head. 3. Repeat Step 2 for the remaining valve guides. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g03005596

4. Check protrusion (X) of valve guides (2). The valve guides should protrude 8.5 ± 0.15 mm (0.33465 ± 0.00591 inch) above the valve spring recess. Refer to Specifications, "Cylinder Head Valves" for more information. 5. After installation of valve guides (2), the valve guides must be reamed to the finished diameter. Follow Steps 5.a through 5.c in order to ream the valve guides. a. Lubricate the bores of valve guides (2) with clean engine oil. b. Use Tooling (B) in order to ream the valve guides. Ensure that even pressure is applied to Tooling (B). c. Ensure that the cylinder head is clean and free from machining debris. 6. Check the finished diameter of valve guides (2). Refer to Specifications, "Cylinder Head Valves" for more information. 7. Check the depths of the valves below the face of the cylinder head. Refer to System Operation, Testing and Adjusting, "Valve Depth - Inspect" for more information. End By: a. Install the inlet valves and the exhaust valves. Refer to Disassembly and Assembly , "Inlet and Exhaust Valves - Remove and Install". CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343626

Inlet and Exhaust Valve Springs - Remove and Install SMCS - 1108-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A(1) B (1)

Part Description

Qty

445-2702

Housing

442-7300

Engine Turning Tool

442-7299

Valve Spring Compressor

This Tool is used in the aperture for the electric starting motor.

Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, "Inlet and Exhaust

Valves - Remove and Install" for the procedure to remove the valve springs from a cylinder head that has been removed from the engine. Note: Ensure that the appropriate piston is at the top center position before the valve spring is removed. Failure to ensure that the piston is at the top center position may allow the valve to drop into the cylinder bore.

NOTICE Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

1. Follow Steps 1.a through 1.d in order to position the appropriate piston at top center. a. Install Tooling (B) in position on the cylinder head in order to compress a valve spring for the appropriate piston. b. Use Tooling (B) in order to compress valve spring (3) and open the valve slightly. Note: Do not compress the spring so that valve spring retainer (2) touches the valve stem seal. c. Use Tooling (A) in order to rotate the crankshaft carefully, until the piston touches the valve. Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.

d. Continue to rotate the crankshaft and gradually release the pressure on Tooling (B) until the piston is at the top center position. The valve is now held in a position that allows the valve spring to be safely removed.

NOTICE Do not turn the crankshaft while the valve springs are removed.

Note: Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. If all valve springs require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders, 1 with 4 and 2 with 3. Ensure that all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders.

Illustration 1

g03001601

Typical example

2. Apply sufficient pressure to Tooling (B) in order to allow removal of valve keepers (1). Remove valve keepers (1). Note: Do not compress the spring so that valve spring retainer (2) touches the valve stem seal.

3. Slowly release the pressure on Tooling (B). 4. Remove valve spring retainer (2) and remove valve spring (3). 5. If necessary, remove the valve stem seal in order to remove valve spring seat (4). 6. Repeat Steps 2 through 5 in order to remove the remaining valve spring from the appropriate cylinder. 7. Remove Tooling (B).

Installation Procedure Table 2 Required Tools Tool

Part Description

Qty

445-2702

Housing

442-7300

Engine Turning Tool

442-7299

Valve Spring Compressor

443-4514

Valve Stem Seal Installer

A(1)

(1)

Part Number

This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Do not turn the crankshaft while the valve springs are removed.

1. Inspect the valve springs for the correct length. Refer to Specifications, "Cylinder Head Valves " for more information.

Illustration 2

g03001601

Typical example

2. If necessary, valve spring seat (4) onto cylinder head. 3. If necessary, use Tooling (C) in order to install a new valve stem seal onto the valve guide. Note: The outer face of the valve guide must be clean and dry before installing the valve stem seal. 4. Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) onto valve spring (3).

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

5. Install Tooling (B) in the appropriate position on the cylinder head in order to compress the valve spring.

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

6. Apply sufficient pressure to Tooling (B) in order to install valve keepers (1). Install valve spring keepers (1). Note: Do not compress the spring so that valve spring retainer (2) touches the valve stem seal. 7. Carefully release the pressure on Tooling (B). Note: Ensure that the valve keepers are correctly seated. 8. Repeat Steps 3 to 7 for the remaining valves.

The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.

9. Remove Tooling (B). End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install". CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05343630

Inlet and Exhaust Valves - Remove and Install SMCS - 1105-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

442-7299

Valve Spring Compressor

Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head Remove".

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean the bottom face of the cylinder head. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Specifications, "Cylinder Head Valves" for the correct dimensions. 2. Place a temporary identification mark on the heads of the valves in order to identify the correct position. Inlet valves have a recess in the center of the head.

Note: Do not stamp the heads of the valve. Stamping or punching the heads of the valves could cause the valves to fracture. 3. Use a suitable lifting device to position the cylinder head with the valve springs upward. The weight of the cylinder head is approximately 56 kg (125 lb). Note: Ensure that the cylinder head is kept on a clean, soft surface in order to prevent damage to the machined face.

Illustration 1 Typical example

g03003297

Illustration 2

g03003337

Typical example

4. Install Tooling (A) in position on the cylinder head in order to compress the appropriate valve spring.

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

5. Apply sufficient pressure to Tooling (A) in order to remove valve keepers (1). Note: Do not compress the spring so that valve spring retainer (2) touches valve stem seal (4). 6. Slowly release the pressure on Tooling (A). 7. Remove valve spring retainer (2). Remove valve spring (3). 8. Repeat Steps 4 to 7 for the remaining valves. 9. Remove Tooling (A).

10. Remove valve stem seals (4) and valve spring seats (4). 11. Use a suitable lifting device to carefully turn over the cylinder head. 12. Remove valves (6).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

442-7299

Valve Spring Compressor

443-4514

Valve Stem Seal Installer

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages, and all lubrication passages in the cylinder head are free from debris. Follow Steps 1.a through 1.e in order to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged. a. Inspect the cylinder head for wear and for damage. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head Inspect". b. Inspect the valve seats for wear and for damage. Refer to Specifications, "Cylinder Head Valves" for further information. c. Inspect the valve guides for wear and for damage. Refer to Specifications, "Cylinder Head Valves" and Systems Operation, Testing and Adjusting, "Valve Guide Inspect" for further information. d. Inspect the valves for wear and for damage. Refer to Specifications, "Cylinder Head Valves". e. Inspect the valve springs for the correct length. Refer to Specifications, "Cylinder Head Valves".

Illustration 3

g03003337

2. Lubricate the stems of valves (6) with clean engine oil. Install valves (6) in the appropriate positions in the cylinder head. Check the depth of the valves below the face of the cylinder head. Refer to Systems Operation, Testing and Adjusting, "Valve Depth - Inspect" for more information. 3. Use a suitable lifting device to carefully turn over the cylinder head. The weight of the cylinder head is approximately 56 kg (125 lb). Note: Ensure that all of the valves remain in place. 4. Install valve spring seats (5). 5. Use Tooling (B) in order to install new valve stem seals (4) onto each of the valve guides. Note: The outer face of the valve guides must be clean and dry before installing the valve stem seals. 6. Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) onto valve spring (3). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 4

g03003297

Typical example

7. Install Tooling (A) in the appropriate position on the cylinder head in order to compress valve spring (3).

NOTICE Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.

8. Apply sufficient pressure to Tooling (A) in order to install valve keepers (1).

Note: Do not compress the spring so that valve spring retainer (2) touches valve stem seal (4).

9. Carefully release the pressure on Tooling (A). 10. Repeat Steps 6 to 9 for the remaining valves. 11. Remove Tooling (A) from the cylinder head. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884969

Inlet Manifold - Remove and Install SMCS - 1058-010

Removal Procedure Start By: a. Remove the exhaust gas recirculation valve. Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. b. Remove the exhaust cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) Remove and Install" for the correct procedure. c. Remove the exhaust back pressure sensor bracket and tube assembly. Refer to Disassembly and Assembly, "Pressure Sensor (Exhaust Back Pressure) - Remove and Install" for the correct procedure. d. Remove the throttle valve. Refer to Disassembly and Assembly, "Throttle Valve (Intake Air) - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Plug the apertures in the cylinder head in order to prevent the entry of loose parts into the engine.

Illustration 1

g02729114

Illustration 2

g02919516

1. Slide the locking tab into the unlocked position and disconnect harness assembly (1) from the inlet manifold temperature and pressure sensor. 2. Position exhaust gas temperature connection (3) away from bracket (2). 3. Remove bolts (7) from inlet manifold (6). 4. Remove the inlet manifold from adaptor plate (10). 5. Remove gasket (8). 6. If necessary, remove studs (4) from inlet manifold (5). 7. If necessary, remove diffuser (5) from inlet manifold (6). 8. If necessary, follow Step 8.a through Step 8.d in order to remove adaptor plate (10). a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure. b. Remove bolts (9) from adaptor plate (10). c. Remove adaptor plate (10) from the cylinder head. d. Remove O-ring seals (11) (not shown).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Guide Stud M8 x 1.25mm by 90mm

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Remove the plugs that were installed during the disassembly procedure prior to installing components. Care must be taken to ensure that loose parts and debris do not enter the engine.

1. Clean all gasket surfaces.

Illustration 3

g02921858

Illustration 4

g02922116

2. If necessary, follow Step 2.a through Step 2.d in order to install adaptor plate (10). a. Install new O-ring seals (11) into adaptor plate (10). b. Position adaptor plate assembly (10) onto the cylinder head. c. Install bolts (9) finger tight. Tighten the bolts evenly in the sequence that is shown in Illustration 4 to a torque of 25 N·m (221 lb in). d. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 5

g02922816

Illustration 6

g02922879

3. If necessary, install studs (4) into inlet manifold (6). Tighten the studs to a torque of 5 N·m (44 lb in). 4. If necessary, install diffuser (5) into inlet manifold (6).

5. Install Tooling (A) in Positions (X) in adaptor plate assembly (10). Refer to Illustration 4. 6. Position new gasket (8) onto Tooling (A). 7. Install inlet manifold (6) onto Tooling (A). 8. Position bracket (2) onto inlet manifold (6) and install bolt (7) finger tight. 9. Position tube and bracket assembly (13) onto inlet manifold (6) and install bolt (7) finger tight. 10. Install sealing washers (14) (not shown) and banjo bolt (15) to tube and bracket assembly (13). Refer to Disassembly and Assembly, "Pressure Sensor (Exhaust Back Pressure) Remove and Install" for the correct procedure. 11. Position bracket (12) onto inlet manifold (6) and install bolt (7) finger tight. Connect tube and bracket assembly (13 ) onto bracket (12). Refer to Disassembly and Assembly, "Pressure Sensor (Exhaust Back Pressure) - Remove and Install" for the correct procedure. 12. Remove Tooling (A). 13. Install remaining bolts (7) in available positions.

Illustration 7

g02924860 CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 8

g02924916

14. Tighten bolts (7) in the sequence that is shown in Illustration 7 to a torque of 27 N·m (239 lb in). 15. Install exhaust gas temperature connection (3) into bracket (2). 16. Connect harness assembly (1) to the inlet manifold temperature and pressure sensor and slide the locking tab into the locked position. End By: a. Install the throttle valve. Refer to Disassembly and Assembly, "Throttle Valve (Intake Air) Remove and Install" for the correct procedure. b. Install the remaining components for the exhaust back pressure sensor. Refer to Disassembly and Assembly, "Pressure Sensor (Exhaust Back Pressure) - Remove and Install" for the correct procedure. c. Install the exhaust cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) Remove and Install" for the correct procedure. d. Install the exhaust gas recirculation valve. Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05346319

Inlet Manifold Pressure Sensor - Remove and Install SMCS - 1058-010-PXS

Removal Procedure

www.FPTIndustrialEngineParts.com CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

1. Disconnect the wiring harness assembly (not shown) from inlet manifold temperature sensor (1). 2. Remove Allen head bolt (2) from inlet manifold temperature sensor (1). 3. Remove inlet manifold temperature sensor (1) from inlet manifold temperature sensor housing (4). 4. Remove seal (3) (not shown). 5. If necessary, follow Step 5.a through Step 5.f in order to remove inlet manifold temperature sensor housing (7) and tube assembly (6).

Illustration 2

g03364176

a. Loosen nut (6) on tube assembly (7). b. Remove bolt (5) from inlet manifold temperature sensor housing (7). c. Disconnect tube assembly (7) from inlet manifold temperature sensor housing (4). d. Remove inlet manifold temperature sensor housing (4) from inlet manifold (8). e. Remove banjo bolt (10) and sealing washers (9) (not shown). f. Remove tube assembly (7).

Installation Procedure

Illustration 3

g03364176

1. If necessary, follow Step 1.a through Step 1.f in order to install the inlet manifold temperature sensor housing (4) and tube assembly (7). a. Install new sealing washers (9) (not shown) and banjo bolt (10) to tube assembly (7). b. Position tube assembly onto induction manifold (8) and loosely install banjo bolt (10). c. Position inlet manifold temperature sensor housing (4) onto inlet manifold (8). Tighten nut (6) finger tight. d. Install bolt (5). Tighten the bolt to a torque of 10 N·m (89 lb in). e. Tighten nut (6) to a torque of 10 N·m (89 lb in). f. Tighten banjo bolt (10) to a torque of 10 N·m (89 lb in). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 4

g03364100

2. Install new seal (3) (not shown) to inlet manifold temperature sensor (1). 3. Install inlet manifold temperature sensor (1) to inlet manifold temperature sensor housing (4). 4. Install Allen head bolt (2). Tighten the Allen head bolt to a torque of 10 N·m (89 lb in)

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05346316

Inlet Manifold Temperature Sensor - Remove and Install SMCS - 1921-010

Removal Procedure

1. Disconnect the wiring harness assembly (not shown) from inlet manifold temperature sensor (3). 2. Remove inlet manifold temperature sensor (3) from inlet manifold (1). 3. Remove seal (2) (not shown) from the inlet manifold temperature sensor.

Installation Procedure

Illustration 2

g03366344

1. Install new seal (2) (not shown) to the inlet manifold temperature sensor (3). 2. Install inlet manifold temperature sensor (3) to inlet manifold (1). Tighten the inlet manifold temperature sensor to a torque of 25 N·m (221 lb in). 3. Connect the wiring harness assembly (not shown) to inlet manifold temperature sensor (3). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884972

Lifter Group - Remove and Install SMCS - 1209-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1U-7262

Telescoping Magnet

Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02729121

1. If the crankshaft is installed, rotate the crankshaft in order to gain access to the appropriate lifters. 2. Use Tooling (A) in order to remove lifters (1) from the cylinder block. Note: Place a temporary identification mark on each lifter in order to identify the correct location.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

1U-7262

Telescoping Magnet

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTICE Replace all lifters when a new camshaft is installed.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. Clean the lifters. Follow Step 2.a through Step 2.c in order to inspect the lifters. Replace any worn lifters or damaged lifters. a. Inspect the seat of the pushrod in the lifter for visual wear and damage. b. Inspect the shank of the lifter for wear and damage. Refer to Specifications, "Lifter Group" for more information. c. Inspect the face of the lifter that runs on the camshaft for visual wear and damage.

Illustration 2

g02729121

3. If the crankshaft is installed, rotate the crankshaft in order to allow access for the installation of appropriate lifters (1).

4. Lubricate lifters (1) with clean engine oil. 5. Use Tooling (A) to install lifters (1) to the cylinder block. Ensure that used lifters are installed in the original location. Note: The lifters should be free to rotate. End By: a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05346205

Oxygen Sensor - Remove and Install - Catalytic Converter SMCS - 1096-010

Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF Position.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02725166

1. Disconnect harness assembly (1). 2. Remove oxygen sensor (2) from exhaust tube assembly (3). 3. Remove sealing washer (4) from the oxygen sensor.

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bostik Pure Nickel Anti-Seize Compound

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02725166

1. Install a new sealing washer (4) (not shown) to oxygen sensor (2). 2. Apply Tooling (A) to the threads of oxygen sensor (4) (not shown). 3. Install oxygen sensor (2) to exhaust tube assembly (3). Tighten the oxygen sensor to a torque of 50 N·m (37 lb ft). 4. Connect harness assembly (1). End By: a. Turn the battery disconnect switch to the ON Position. b. When a new oxygen sensor is installed, it will be necessary to use the Electronic Service Tool (EST) in order to perform the "Lambda Sensor Replacement Reset", "Lambda Sensor Learn Reset" and "Lambda Sensor Temperature Learn Reset" procedures. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884975

Piston Cooling Jets - Remove and Install SMCS - 1331-010

Removal Procedure Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure. b. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02895676

1. Remove banjo bolt (2) and piston cooling jet (1) from the cylinder block. 2. Repeat Step 1 in order to remove the remaining piston cooling jets.

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g02895676

1. Clean the piston cooling jets and inspect the piston cooling jets for damage. Replace any damaged piston cooling jets. The procedure for checking that the alignment of the piston cooling jets is described in Specifications, "Piston Cooling Jet Alignment". 2. Install banjo bolt (2) to piston cooling jet (1). Install the piston cooling jet assembly into the recess in the cylinder block. 3. Tighten banjo bolt (2) to a torque of 18 N·m (159 lb in). 4. Repeat Step 2 through Step 3 for the remaining piston cooling jets. End By: a. Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install" for the correct procedure. b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876910

Pistons and Connecting Rods - Assemble SMCS - 1225-016

Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1P-1857

Retaining Ring Pliers

1U-6683

Ring Expander

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g03003219

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. Position the spring for oil control ring (3) into the oil ring groove in piston (4). The central wire must be located inside the end of the spring. 3. Position the oil control ring with the word "TOP" in the upward position. Use Tooling (B) to install oil control ring (3) over the piston and the spring. Note: Ensure that the central wire is 180 degrees from the ring gap. 4. Use Tooling (B) to install intermediate compression ring (2) into the second groove in piston (4). The word "TOP" must be upward. 5. Use Tooling (B) to install top compression ring (1) into the top groove in piston (4). The word "TOP" must be upward. 6. Position the piston ring gaps at approximately 120 degrees away from each other. Note: A new piston assembly is supplied with new piston rings.

Illustration 2

g03001779

(A) Cut away for piston cooling jet (9) Upper shell for connecting rod (X) Identification marks (Y) Location tag on connecting rod shells (Z) Location tag in connecting rod for shells (not shown) (10) Lower shell for connecting rod cap

7. Use Illustration 2 as an assembly guide. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g03001216

8. Lubricate bushing (8) for piston pin (6) in the connecting rod with clean engine oil. Lubricate the bore for the piston pin in piston (4) with clean engine oil. 9. Install piston pin (6) to piston (4). Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of 45° ± 5°C (113° ± 9°F). 10. Use Tooling (A) in order to install circlips (5) to the piston pin bore in piston (4). Note: Ensure that the circlips are seated in the grooves in the piston. 11. Install upper bearing shell (9) into connecting rod (7). Ensure that the locating tab for the upper bearing shell is correctly seated in slot in the connecting rod. 12. Install lower bearing shell (10) into connecting rod cap (11). Ensure that the locating tab for the lower bearing shell is correctly seated in the slot in the connecting rod cap.

13. Temporarily install connecting rod cap (11) and bolts (12) to connecting rod (7) when the assembly is out of the engine. Ensure that the etched number on connecting rod cap matches the etched number on connecting rod. Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Tighten bolts (12) to a torque of 20 N·m (177 lb in). 14. Repeat Step 1 through Step 13 for the remaining piston and connecting rod assemblies. Note: Fracture split connecting rods should not be left without the connecting rod caps installed. End By: a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876180

Pistons and Connecting Rods - Disassemble SMCS - 1225-015

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1P-1857

Retaining Ring Pliers

1U-6683

Ring Expander

Start By: a. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Remove" for the correct procedure. Note: Make a temporary mark on the components of the piston and connecting rod assembly. Making temporary marks will ensure that the components of each piston and connecting rod assembly can be reinstalled in the original location. Mark the underside of the piston on the front pin boss. Do not interchange components.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g03001216

1. Remove lower bearing shell (10) from connecting rod cap (11). Remove upper bearing shell (9) from connecting rod (7). Keep the bearing shells together. 2. Place the piston and connecting rod assembly on a suitable surface with the connecting rod upward. Use Tooling (A) in order to remove circlips (5). 3. Remove piston pin (6) from bushing (8) in connecting rod (7). Remove connecting rod (7 ) from piston (4). Note: If the piston pin cannot be removed by hand, heat the piston to a temperature of 45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston. Note the orientation of connecting rod (7) and piston (4). 4. Place the piston on a suitable surface with the crown upward. Use Tooling (B) in order to remove compression ring (1), compression ring (2), and oil control ring (3) from piston (4).

Note: Make temporary identification marks to Identify the position and orientation of compression ring (1), and compression ring (2), and oil control ring (3). 5. Inspect the connecting rod for wear and damage. If necessary, replace connecting rod (7) . 6. Repeat Step 1 through Step 5 in order to disassemble the remaining pistons and connecting rods.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04873289

Pistons and Connecting Rods - Install SMCS - 1225-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1U-6684

Piston Ring Compressor

8T-3052

Degree Wheel

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components. Note: Discard all used connecting rod bolts. 2. Apply clean engine oil to the cylinder bore, piston, piston rings, connecting rod shell, and the shell in the connecting rod cap. 3. Rotate crankshaft until the required crankshaft journal is at bottom center position. Lubricate the crankshaft journal with clean engine oil.

Illustration 1

g02999358

Typical example

4. Lightly lubricate Tooling A with clean engine oil. Install Tooling (A) onto piston (4) Note: Ensure that the piston assembly is installed into the correct cylinder. Also, ensure the correct orientation of the assembly, refer to Illustration 2.

Illustration 2

g02999579

(4) Piston (A) Cut out for piston cooling jet (Y) Piston cooling jet (X) Connecting rod identification marks

5. Ensure that Tooling (B) is installed correctly and that piston (4) can easily slide from the tool. Note: Ensure alignment of the connecting rod assembly to the crankshaft journal. 6. Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin.

Illustration 3

g03001177

Typical example

7. Ensure that etched number in Position (X) on connecting rod cap (1) matches etched number in Position (X) on connecting rod (3). Ensure the correct orientation of connecting rod cap (1). The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Install the connecting rod cap (1) and install new bolts (2). 8. Tighten the new bolts to 50 N·m (37 lb ft). Turn the bolts for an additional 70 degrees in a clockwise direction. Use Tooling (C) in order to achieve the correct final torque.

9. Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. 10. Repeat Step 1 through Step 9 in order to install the remaining pistons and connecting rod assemblies End By: a. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install" for the correct procedure. b. If necessary, install the balancer. Refer to Disassembly and Assembly, "Balancer - Install" for the correct procedure. c. Install the oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04871278

Pistons and Connecting Rods - Remove SMCS - 1225-011

Removal Procedure Table 1 Required Tools Tool

Part Number

8S-2269

Part Description Ridge Reamer

Qty 1

Start By: a. Remove the oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan Remove and Install" for the correct procedure. b. If necessary, remove the balancer. Refer to Disassembly and Assembly, "Balancer Remove" for the correct procedure. c. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Rotate crankshaft until the required connecting rod is at bottom dead center. 2. Using tooling (A), remove carbon build-up from the top of the cylinder bore.

Illustration 1

g03001196

Typical example

Note: Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture. 3. The connecting rod and the connecting rod cap should have an etched number in Position (X). The number on the connecting rod and the connecting rod cap must match. Ensure that connecting rod (3) and connecting rod cap (1) are marked for the correct location. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number and orientation of the assembly. 4. Remove the bolts (2) and remove connecting rod cap (1) from connecting rod (3). 5. Rotate crankshaft so that the required piston is at top center position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 2

g02998516

Typical example

6. Carefully push piston (4) and the connecting rod out of the cylinder bore. Lift piston (4) out of the top of the cylinder block. Note: Do not apply force to the fracture split surfaces of the connecting rod as damage may result. 7. Temporarily install connecting rod cap (1) and bolts (2) to connecting rod (3) when the assembly is out of the engine. Ensure that the etched number on connecting rod cap matches the etched number on connecting rod. Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Tighten bolts (2) to a torque of 20 N·m (177 lb in). 8. Repeat Step 1 through Step 7 in order to remove the remaining pistons and connecting rods. Fracture split connecting rods should not be left without the connecting rod caps installed. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884976

Power Take-Off Drive - Remove and Install SMCS - 1165-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02901518

Illustration 2

g02901685

1. If necessary, remove the Original Equipment Manufacturer's (OEM) driven equipment from power take-off drive (1). Refer to the OEM for the correct procedure. 2. Remove bolts (2) from power take-off drive (1). Note: Note the positions of the different length bolts. 3. Remove the power take-off drive (1) from the cylinder block. 4. Remove O-ring seal (3) from power take-off drive (1). 5. Note the position of dowel (4) and dowel (5) in the power take-off drive. Do not remove the dowels unless the dowels are damaged.

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

1U-6396

O-Ring Assembly Compound

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 3

g02901518

Illustration 4

g02901685

2. If necessary, install dowel (4) and dowel (5) into power take-off drive (1). 3. Install a new O-ring seal (3) onto power take-off drive (1). 4. Apply Tooling (A) onto O-ring seal (3). 5. Position power take-off drive (1) onto the cylinder block. Note: Ensure that the drive gear for the power take-off drive is correctly engaged with the gear on the crankshaft. 6. Equally tighten bolts (2) in order to pull power take-off drive (1) into the cylinder block 7. Tighten bolts (2) to a torque of 25 N·m (221 lb in) 8. Ensure that there is tactile backlash between the idler gear and the accessory drive gear. 9. If necessary, install the OEM driven equipment to power take-off drive (1). Refer to the OEM for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05346261

Pressure Sensor (DPF) - Remove and Install SMCS - 1439-PXS

Removal Procedure

1. Disconnect the harness connector from Diesel Particulate Filter (DPF) differential pressure sensor (2). 2. Remove clip (4) from hose assembly (6). Remove clip (5) from hose assembly (7). 3. Disconnect hose assembly (6) and hose assembly (7) from DPF differential pressure sensor (2). 4. Remove bolt (3) from DPF differential pressure sensor (2). 5. Remove DPF differential pressure sensor (2) from bracket (1).

Installation Procedure

Illustration 2

g03005940

1. Position DPF differential pressure sensor (2) onto bracket (1). 2. Install bolt (3) finger tight to DPF differential pressure sensor (2). Tighten the bolt to a torque of 9 N·m (80 lb in) 3. Position a new clip (4) onto hose assembly (6). 4. Install hose assembly (6) and clip (4) onto DPF differential pressure sensor (2). Tighten clip (4) securely.

Note: Do not over tighten clip (4). 5. Position a new clip (5) onto hose assembly (7). 6. Install hose assembly (7) and clip (5) onto DPF differential pressure sensor (2). Tighten clip (5) securely. Note: Do not over tighten clip (5). 7. Connect the harness assembly to DPF differential pressure sensor (2). End By: a. When a new DPF differential pressure sensor is installed, use the Electronic Service Tool (EST) in order to perform the "DPF Differential Pressure Sensor Replacement" procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884977

Pressure Sensor (Exhaust Back Pressure) - Remove and Install SMCS - 1439

Removal Procedure

Illustration 1

g02917036

Illustration 2

g02915178

1. Slide the locking tab into the unlocked position and disconnect harness assembly (3) from exhaust back pressure sensor (5). 2. Using a deep socket in order to remove exhaust back pressure sensor (5) from adaptor bracket (7). 3. Remove O-ring (6) (not shown) from exhaust back pressure sensor (5). 4. If necessary, follow Step 4.a through Step 4.j in order to remove tube assembly (6). a. If necessary, remove the diesel particulate mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. b. If necessary, remove the exhaust gas recirculation cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure. c. If necessary, remove the exhaust gas temperature sensor. Refer to Disassembly and Assembly, "Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure. d. Disconnect harness assembly (4) from the retaining clip. e. Loosen nut (8) and disconnect tube assembly (9).

f. Remove bolt (2) and remove adaptor bracket (7) from the induction manifold. g. Remove banjo bolt (10) from tube assembly (9). h. Remove bolt (1) from the bracket for tube assembly (9). i. Remove tube assembly (9) from the exhaust manifold. j. Remove and sealing washers (11) (not shown).

Installation Procedure 1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 3

g02915178

Illustration 4

g02917036

2. If necessary, follow Step 2.a through Step 2.i in order to install tube assembly (6). a. Install a new sealing washer (11) (not shown) to banjo bolt (10). b. Install banjo bolt assembly (10) into tube assembly (9). Install the remaining new sealing washer (11) (not shown) to banjo bolt assembly (10). c. Install tube assembly (9) onto the exhaust manifold and exhaust back pressure sensor bracket (7). Tighten banjo bolt assembly (10) finger tight. d. Install bolt (1) to the bracket for tube assembly (6). e. Position adaptor bracket (7) onto the induction manifold and install bolt (2). f. Tighten nut (8) finger tight. g. Tighten bolt (1) and bolt (2) to a torque of 25 N·m (221 lb in). h. Tighten banjo bolt (10) to a torque of 15 N·m (133 lb in). i. Tighten nut (8) to a torque of 15 N·m (133 lb in). 3. Install new O-ring seal (6) (not shown) to exhaust back pressure sensor (5). 4. Install exhaust back pressure sensor (5). Tighten the sensor to a torque of 15 N·m (133 lb in)

5. Connect harness assembly (3) to exhaust back pressure sensor (5) and slide the locking tab into the locked position. 6. If necessary, install the exhaust gas temperature sensor. Refer to Disassembly and Assembly, "Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure. 7. If necessary, install the exhaust gas recirculation cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure. 8. If necessary, install the diesel particulate mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. 9. Install harness assembly (4) onto exhaust back pressure sensor bracket (7). 10. Install bolt (2) to exhaust back pressure sensor (4). Tighten the bolt to a torque of 25 N·m (221 lb in). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884978

Rocker Shaft - Assemble SMCS - 1102-016

Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from wear and damage. Refer to Specifications, "Rocker Shaft" for more information. If necessary, replace any components that are worn or damaged.

Illustration 1

g02942879

2. Lubricate the bore of rocker arm assemblies (2) for the inlet valve with clean engine oil. 3. Lubricate the bore of rocker arm assemblies (3) for the exhaust valve with clean engine oil. 4. Lubricate rocker shaft (5) with clean engine oil. 5. Install rocker shaft (5) into rocker shaft housing (4). Hole (X) must be in the upper most position in order for grub screw (1) to secure rocker shaft (5) in the correct position. 6. Install rocker arm assembly (2) for number 1 inlet valve to the rocker shaft. Install rocker arm assembly (3) for number 1 exhaust valve to rocker shaft (5). Note: The rocker arm assembly for the inlet valve is shorter than the rocker arm assembly for the exhaust valve. Used components should be installed in the original location. 7. Repeat Step 6 in order to assemble the remaining components to rocker shaft (5). 8. Install new grub screw (1) to rocker shaft housing (4). Tighten the grub screw to a torque of 15 N·m (133 lb in) Note: Ensure that Hole (X) is in the upper most position. End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.

www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884979

Rocker Shaft - Disassemble SMCS - 1102-015

Disassembly Procedure Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Make an identification mark on each rocker arm assembly in order to show the location.

Note: The components must be reinstalled in the original location. Do not interchange components.

Illustration 1

g02942776

2. Remove grub screw (1) from rocker shaft housing (4). 3. Remove rocker shaft (5) from rocker shaft housing (4). 4. Remove rocker arm assembly (3) for the exhaust valve from rocker shaft (5). Remove rocker arm assembly (2) for the inlet valve from rocker shaft (5). Note: The rocker arm assembly for the inlet valve is shorter than the rocker arm assembly for the exhaust valve. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884980

Rocker Shaft and Pushrod - Install SMCS - 1102-012; 1208-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free from damage. If necessary, replace any components that are worn or damaged. 2. If Tooling (A) is not installed, install Tooling (A). Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove" for the correct procedure.

Illustration 1

g02942696

Illustration 2

g02942756

3. If necessary, install dowel (7) (not shown). 4. Apply clean engine oil to wear caps (3). Install the wear caps to the valve stems. Note: If the wear caps were previously used, the wear caps must be installed in the original location. 5. Apply clean engine oil to both ends of push rods (5). Install the push rods into the cylinder head. Note: If the push rods have previously been used, the push rods must be installed in the original location. Note: Ensure that the push rods are seated in the cups of the lifters 6. Position rocker shaft assembly (4) onto the cylinder head. 7. Install bolts (6) to rocker shaft assembly (4). Tighten the bolts in the numerical sequence that is shown in Illustration 2 to a torque of 10 N·m (89 lb in). Note: Ensure that the rocker arms are seated in the cups of the push rods. Note: Ensure that the wear caps are not displaced from the valve stems when the rocker shaft assembly is installed.

Illustration 3

g02942738

8. Remove Tooling (A) from the cylinder block. 9. Install new O-ring seal (1) onto plug (2). 10. Install plug (2) into Position (Z) in the cylinder block. Tighten the plug to a torque of 30 N·m (266 lb in). End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884981

Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

390-1131

Timing Pin (Crankshaft)

Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Illustration 1

g02942738

1. Follow Step 1.a through Step 1.c in order to install the crankshaft positioning tool. a. Remove plug (4) from Position (X) in the cylinder block. b. Remove O-ring seal (3) from plug (4). c. Install Tooling (A) into the cylinder block in Position (Z). Note: Tooling (A) must be located in Hole (Y) in the crankshaft. Note: Ensure that Tooling (A) is located in the correct drilling in the crankshaft as shown in Illustration 1.

Illustration 2

g02942696

Illustration 3

g02942756

2. Remove bolts (6) from rocker shaft (4) in the reverse numerical sequence shown in Illustration 3. 3. Remove rocker shaft (4) from the cylinder head. 4. Make temporary identification marks on push rods (5). Remove the push rods from the cylinder head. 5. Remove wear caps (3) from the valve stems. Identify the position of the wear caps in order for the wear caps to be installed in the original location. 6. If necessary, remove dowel (7) (not shown).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876090

Support and Mounting (CEM) - Remove and Install - Option 1 SMCS - 0635

CEM Assembly Removal Procedure Start By: a. Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove " for the correct procedure.

Illustration 1

g03013176

Typical example

Make a temporary Mark on all components on the support assembly (1) and all bolts, in order to aide alignment during installation.

Illustration 2

g03015096

Typical example

1. Remove bolts (2) from bracket (3). 2. Remove bolts (4) from bracket (3). 3. Remove bolts (7) from bracket (3) and remove bracket (3) from the engine. The weight of bracket (3) is approximately 10 kg (22 lb). 4. If necessary, remove bolts (9) (not shown) and remove bracket (8) from the engine. 5. If necessary, remove bolts (6) and remove bracket (5) from the engine.

CEM Assembly Installation Procedure

Illustration 3

g03013176

Illustration 4

g03015096

1. If necessary, using temporary Marks position bracket (8) and install bolts (9) (not shown). Tighten bolts (9) hand tight. 2. If necessary, using temporary Marks position bracket (5) and install bolts (6). Tighten bolts (6) hand tight. 3. Position bracket (3) and loosely install bolts (4) loosely install bolts (2), and loosely install bolts (7). 4. Using temporary Marks, align support assembly (1) and tighten bolts. 5. Tighten bolts (9) to a torque of 25 N·m (221 lb in) 6. Tighten bolts (6) to a torque of 25 N·m (221 lb in) 7. Tighten bolts (2) to a torque of 45 N·m (33 lb ft) 8. Tighten bolts (4) to a torque of 25 N·m (221 lb in) 9. Tighten bolts (7) to a torque of 25 N·m (221 lb in) End By: a. Install the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install " for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04888987

Support and Mounting (CEM) - Remove and Install - Option 2 SMCS - 0635

CEM Assembly Removal Procedure Start By: a. Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove " for the correct procedure.

Illustration 1

g03017437

Make a temporary Mark on all components on both support assemblies (1) and all bolts, in order to aide alignment during installation. 1. Remove bolts (3) from bracket (2) and remove bracket (2) from the engine. 2. Remove bolts (5) from bracket (4) and remove bracket (4) from the engine.

CEM Assembly installation Procedure

Illustration 2

g03017437

1. Position bracket (2) and loosely install bolts (3). Position bracket (4) and loosely install bolts (5). 2. Using temporary Marks, align bracket (2) and tighten bolts (3) to a torque of 25 N·m (221 lb in) 3. Using temporary Marks, align bracket (4) and tighten bolts (5) to a torque of 25 N·m (221 lb in) End By: a. Install the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install " for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04889558

Support and Mounting (CEM) - Remove and Install - Option 3 SMCS - 0635

CEM Assembly Removal Procedure Start By: a. Remove the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove " for the correct procedure.

Illustration 1

g03019496

Make a temporary Mark on all components on support assemblies (1) and all bolts, in order to aide alignment during installation.

Illustration 2

g03020379

1. Remove bolts (3) from bracket (2). 2. Remove bolts (7) from bracket (2). 3. Remove bolts (6) from bracket (2) and remove bracket (2) from the engine. The weight of bracket (2) is approximately 10 kg (22 lb). 4. If necessary, remove bolts (4) from bracket (5). remove bracket (5) from the engine. 5. Remove bolts (8) from bracket (9) and remove bracket (9) from the engine.

CEM Assembly Installation Procedure

Illustration 3

g03019496

Illustration 4

g03020379

1. If necessary, using temporary Marks position bracket (5) onto the engine install bolts (4). Tighten bolts (4) hand tight. 2. If necessary, using temporary Marks position bracket (9) onto the engine. Tighten bolts (8) hand tight. 3. Position bracket (2) and loosely install bolts (3), loosely install bolts (6), and loosely install bolts (7). 4. Using temporary Marks align assembly (1) and tighten the bolts. 5. If necessary, tighten bolts (4) to a torque of 25 N·m (221 lb in). 6. If necessary, tighten bolts (8) to a torque of 25 N·m (221 lb in). 7. Tighten bolts (6) to a torque of 25 N·m (221 lb in). 8. Tighten bolts (7) to a torque of 25 N·m (221 lb in). 9. Tighten bolts (3) to a torque of 45 N·m (33 lb ft). End By: a. Install the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install " for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884982

Temperature Sensor (DPF) - Remove and Install SMCS - 1919-FI

Removal Procedure NOTICE Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.

NOTICE The temperature sensors for the Diesel Particulate Filter (DPF) are of different lengths and should be installed in the original position.

Illustration 1

g02728556

1. Disconnect the harness assembly from connection (1). 2. Make temporary identification marks on temperature sensor (2) for installation purpose. Remove the temperature sensor from Diesel Particulate Filter (DPF) (3). 3. If necessary, repeat Step 1 through Step 2 in order to remove the remaining temperature sensor from the DPF.

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bostik Pure Nickel Anti-Seize Compound

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 2

g02728556

2. Use tooling (A) in order to lubricate the thread of temperature sensor (2). 3. Install temperature sensor (2) to DPF (3). Tighten temperature sensor to a torque of 50 N·m (37 lb ft) Note: Ensure correct positioning of the temperature sensor. 4. Connect harness assembly (1). 5. If necessary, repeat Step 2 through Step 4 in order to install the remaining temperature sensor to the DPF. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i05346218

Temperature Sensor (Exhaust) - Remove and Install SMCS - 1439-010; 1919-010

Removal Procedure 1. If necessary, remove the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.

Illustration 1

g02876918

2. Disconnect harness assembly (2) (not shown) from exhaust temperature sensor connection (1). 3. Slide exhaust temperature sensor connection (1) out of bracket (3). 4. Remove exhaust temperature sensor (5) from exhaust manifold (4).

Installation Procedure 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

g02876918

2. Install exhaust temperature sensor (5) to exhaust manifold (4). Tighten the exhaust temperature sensor to a torque of 45 N·m (33 lb ft) Note: Ensure that the harness for the exhaust temperature sensor is correctly routed. 3. Slide exhaust temperature sensor connection (1) into bracket (3). 4. Connect harness assembly (2) (not shown) to exhaust temperature sensor connection (1).

5. If necessary, install the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884987

Throttle Valve (Intake Air) - Remove and Install - Rear Facing Inlet Elbow SMCS - 5506-010

Removal Procedure

Illustration 1

g02906277

Illustration 2

g02906317

1. Loosen the hose clamp and disconnect the hose assembly from elbow (1). 2. Slide the locking tab into the unlocked position and disconnect harness assembly (7) from throttle valve (8). 3. Loosen hose clamp (2) and disconnect hose assembly (4) from elbow (1). 4. Remove bolts (5) and remove nuts (3) from the elbow. 5. Remove the air inlet elbow from studs (9). 6. Remove gasket (6) (not shown). 7. Remove throttle valve (8) from studs (9). 8. Remove gasket (6) (not shown). 9. If necessary, remove studs (9). Refer to Disassembly and Assembly, "Inlet Manifold Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g02906404

10. If necessary, remove adaptor (12) and sealing washer (11) from elbow (1).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description Technologic 15

Qty 1

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 4

g02906404

Illustration 5

g02906317

Illustration 6

g02906277

2. If necessary, install studs (9). Refer to Disassembly and Assembly, "Inlet Manifold Remove and Install" for the correct procedure. 3. If necessary, install new sealing washer (11) to adaptor (12) and apply Tooling (A) to the threads of adaptor (12). Tighten the adaptor to a torque of 20 N·m (177 lb in). 4. Install gasket (10) to studs (9). 5. Install throttle valve (8) to studs (9). 6. Install gasket (6) to studs (9). 7. Install elbow (1) to studs (9). 8. Install bolts (5) finger tight. 9. Install nuts (3) finger tight. 10. Tighten bolts (5) and nuts (3) to a torque of 10 N·m (89 lb in). 11. Position hose clamp (2) onto hose assembly (4). Install hose assembly (4) to adaptor (12) and tighten hose clamp (2) securely. 12. Install harness assembly (7) to throttle valve (8). Slide the locking tab into the locked position.

13. Install the clamp to the air inlet hose and connect the air inlet hose to elbow (1).

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884985

Throttle Valve (Intake Air) - Remove and Install - Side Facing Inlet Elbow SMCS - 5506-010

Removal Procedure

Illustration 1

g02909057

1. Loosen the hose clamp and disconnect the hose assembly from elbow (3). 2. Slide the locking tab into the unlocked position and disconnect harness assembly (1) from throttle valve (2). 3. Loosen hose clamp (6) and disconnect hose assembly (7) from elbow (3). 4. Remove plug (4) from elbow (3). Remove sealing washer (5) (not shown) from the plug.

Illustration 2

g02909137

Illustration 3

g02909198

5. Remove nuts (9) from studs (13). 6. Remove bolts (8). Note: Bolt (8) in Position (X) must be removed with air inlet elbow (3) in order to prevent the bolt from falling into the induction system. 7. Remove gasket (12). 8. Remove throttle valve (2) from studs (13). 9. Remove gasket (14) (not shown). 10. If necessary, remove adaptor (11) and sealing washer (10) from elbow (3). 11. If necessary, remove studs (13). Refer to Disassembly and Assembly, "Inlet Manifold Remove and Install" for the correct procedure.

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Technologic 15

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 4

g02909198

Illustration 5

g02909137

2. If necessary, install studs (13). Refer to Disassembly and Assembly, "Inlet Manifold Remove and Install" for the correct procedure. 3. Install gasket (14) (not shown) onto studs (13). 4. If necessary, follow Step 4.a through Step 4.b in order to install adaptor (11). a. Install new sealing washer (10) to adaptor (11). b. Apply Tooling (A) to adaptor (11). Install adaptor assembly (11) to air inlet elbow (3). Tighten the adaptor to a torque of 20 N·m (177 lb in). 5. Install throttle valve (2) onto studs (13). 6. Install gasket (12) onto studs (13).

Illustration 6

g02909057

7. Install bolt (8) in Position (X) to elbow (3). Install elbow (3) onto studs (13) and tighten bolt (8) in Position (X) finger tight. Install remaining bolt (8). 8. Install nuts (9) to studs (13). 9. Tighten bolts (8) and nuts (9) to a torque of 10 N·m (89 lb in). 10. Install new sealing washer (5) (not shown) to plug (4). 11. Apply Tooling (A) to plug (4) and install the plug to air inlet elbow (3). Tighten the plug to a torque of 50 N·m (37 lb ft). 12. Install the clamp to the air inlet hose and connect the air inlet hose to air inlet elbow (3). 13. Connect harness assembly (1) onto throttle valve (2). Slide the locking tab into the locked position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884989

Turbocharger - Install - Side Mounted Turbochargers SMCS - 1052-012

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced. 2. Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.

Illustration 1

g02862040

3. If necessary, follow Step 3.a through Step 3.f in order to install boost pressure chamber cover (29). a. Position gasket (23) (not shown) onto boost pressure chamber cover (29). b. Position boost pressure chamber cover onto the engine oil cooler and install bolts (26). Tighten the bolts to a torque of 10 N·m (89 lb in) c. Install a new sealing washer (28) to banjo bolt (27). Install the banjo bolt assembly to hose assembly (22) and install the remaining sealing washer (28). Install hose assembly (22) to boost pressure chamber cover (29) finger tight. d. Install tube assembly (22) into clip (21). e. Install a new sealing washer (25) to banjo bolt (24). Install the banjo bolt assembly to hose assembly (6) and install the remaining sealing washer (24). Install hose assembly (6) to boost pressure chamber cover (29) finger tight. f. Install the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.

Illustration 2

g02862480

4. Clean the gasket surfaces of exhaust manifold (19). If necessary, install studs (17) to exhaust manifold (19) and turbocharger (11). Tighten the studs to a torque of 15 N·m (133 lb in). 5. Position a new gasket (20) (not shown) onto turbocharger (11). 6. Position turbocharger (11) onto exhaust manifold (19) and install washers (16) and new nuts (15). Tighten the nuts to a torque of 28 N·m (248 lb in). Note: Do not use the actuator rod to lift the turbocharger.

Illustration 3

g02859585

Illustration 4

g02859796

7. If necessary install new O-ring seals (8) onto tube assembly (9). Install tube assembly (9) into the cylinder block. 8. Position a new gasket (7) (not shown) onto tube assembly (9). 9. Position tube assembly (9) onto the turbocharger. Install bolts (10) to tube assembly (9). Tighten the bolts to a torque of 10 N·m (89 lb in). 10. Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant. 11. If necessary, install a new sealing washer (13) onto connection (14). Install connection assembly (14) to the cylinder block. Tighten the connection assembly to a torque of 22 N·m (195 lb in). 12. Position tube assembly (12) onto connection assembly (14). Loosely install nut (15). 13. Position a new sealing washer (1) (not shown) onto banjo bolt (2). Install banjo bolt (2) onto tube assembly (12) and install remaining new sealing washer (1) to banjo bolt (2). Tighten the banjo bolt to torque of 22 N·m (195 lb in). 14. Tighten nut (15) to torque of 22 N·m (195 lb in). 15. Connect hose assembly (6) to the wastegate actuator. Tighten the hose clamp securely. 16. Connect hose assembly (4) to the turbocharger. Tighten the hose clamp securely.

Illustration 5

g02862956

17. Tighten banjo bolt (28) to a torque of 12 N·m (106 lb in). Note: Ensure that the hose assembly does not come into contact with any other engine components. 18. Tighten banjo bolt (24) to a torque of 12 N·m (106 lb in). Note: Ensure that the hose assembly does not come into contact with any other engine components. 19. Connect the hose assemblies to the turbocharger inlet and the turbocharger outlet. Tighten the hose clamps securely. 20. Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884988

Turbocharger - Install - Top Mounted Turbochargers SMCS - 1052-012

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02868256

2. If necessary, follow Step 2.a through Step 2.g in order to install boost pressure chamber cover (33). a. Position gasket (27) (not shown) onto boost pressure chamber cover (33). b. Position boost pressure chamber cover onto the engine oil cooler and install bolts (30). Tighten the bolts to a torque of 10 N·m (89 lb in) c. Install a new sealing washer (32) to banjo bolt (31). Install the banjo bolt assembly to hose assembly (26) and install the remaining sealing washer (32). Install hose assembly (26) to boost pressure chamber cover (33) finger tight. d. Install tube assembly (26) into clip (25). e. Install a new sealing washer (29) to banjo bolt (28). Install the banjo bolt assembly to hose assembly (8) and install the remaining sealing washer (28). Install hose assembly (8) to boost pressure chamber cover (33) finger tight. f. Tighten banjo bolt (28) and banjo bolt (32) to a torque of 12 N·m (106 lb in). g. Install the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.

Illustration 2

g02868099

Illustration 3

g02719524

3. Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced. 4. If necessary, follow Step 4 through Step 4.f in order to install tube assembly (9). a. Install new O-ring seal (19) (not shown) to tube assembly (9). b. Install tube assembly (9) to the cylinder block. c. Install bolt (17) to tube assembly (9). Tighten the bolt to a torque of 25 N·m (221 lb in). d. Install O-ring seal (15) (not shown) to tube assembly (18). e. Install tube assembly (18) to the oil cooler assembly. Install bolts (16) to tube assembly (18). Tighten the bolts to a torque of 25 N·m (221 lb in). f. Fill the coolant from the coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. 5. Clean the gasket surface of exhaust manifold (24). If necessary, install studs (22) to exhaust manifold (24) and turbocharger (14). Tighten the studs to a torque of 15 N·m (133 lb in). 6. Install a new gasket (23) (not shown) to the exhaust manifold.

7. Position turbocharger (14) onto exhaust manifold (24) and install washers (21) and new nuts (20). Tighten the nuts to a torque of 28 N·m (248 lb in). Note: Do not use the actuator rod to lift the turbocharger.

Illustration 4

g02847785

8. Position a new gasket (13) (not shown) onto tube assembly (9). 9. Position tube assembly (9) onto the turbocharger. 10. Install bolts (12) finger tight. 11. Tighten bolts (12) to a torque of 10 N·m (89 lb in). 12. Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant. 13. Position a new sealing washer (2) (not shown) onto banjo bolt (1). Install banjo bolt (1) onto tube assembly (11) and install remaining new sealing washer (2) to banjo bolt (1). 14. Position tube assembly (11) onto the cylinder block. Loosely install nut (10). 15. Position tube assembly (11) onto the turbocharger. Loosely install banjo bolt (1). 16. Tighten banjo bolt (1) to a torque of 35 N·m (26 lb ft).

Note: Ensure that the tube assembly does not come into contact with any other engine component. 17. Tighten nut (10) to a torque of 25 N·m (221 lb in). 18. Connect hose assembly (8) to the wastegate actuator. Install hose clamp (7) to hose assembly (8). Tighten the hose clamp securely. Note: Ensure that hose clamp is correctly positioned on the hose assembly. 19. Connect hose assembly (4) to the turbocharger. Install hose clamp (5) to hose assembly (4). Tighten the hose clamp securely. Note: Ensure that hose clamp is correctly positioned on the hose assembly. 20. Connect the hose assemblies to turbocharger inlet (6) and for turbocharger outlet (3). Securely tighten the hose clamps. End By: a. Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884990

Turbocharger - Remove - Side Mounted Turbochargers SMCS - 1052-011

Removal Procedure Start By: a. Remove the flexible exhaust pipe from the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02859585

Illustration 2

g02859796

1. Loosen hose clamps and disconnect the hose assemblies from turbocharger inlet (5) and from turbocharger outlet (3). 2. Remove banjo bolt (2) from tube assembly (12). Remove sealing washers (1) (not shown). 3. Loosen nut (15) and remove tube assembly (12) from turbocharger (11) and the cylinder block. 4. If necessary, remove connection (14) from the cylinder block. Remove sealing washer (13) (not shown). 5. Loosen the hose clamp on hose assembly (4). Disconnect hose assembly (4) from the turbocharger. 6. Loosen the hose clamp on hose assembly (6). Disconnect hose assembly (6) from the wastegate actuator. 7. Remove bolts (10) from tube assembly (9). 8. Remove gasket (7) (not shown). 9. If necessary, remove tube assembly (9) from the cylinder block. Remove O-ring seals (8) (not shown).

Illustration 3

g02861996

10. Remove nuts (18) and washers (16) (not shown). Remove turbocharger from the exhaust manifold (19). Note: Do not use the actuator rod to lift the turbocharger. 11. Remove gasket (20) (not shown). 12. If necessary, remove the studs (17) from the turbocharger and exhaust manifold.

Illustration 4

g02862040

13. If necessary, follow Step 13.a through Step 13.f in order to remove boost pressure chamber cover (29). a. Remove the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure. b. Remove banjo bolt (24) and remove sealing washers (25) (not shown) from hose assembly (6). c. Remove banjo bolt (28) and remove sealing washers (27) (not shown) from hose assembly (22). d. Release the tube assembly (22) from clip (21) and position the hose assembly away from boost pressure chamber cover (29). e. Remove bolts (26) and remove boost pressure chamber cover (29) from the oil cooler. f. Remove gasket (23) (not shown). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884991

Turbocharger - Remove - Top Mounted Turbochargers SMCS - 1052-011

Removal Procedure Start By: a. Remove the flexible exhaust pipe from the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02719477

Illustration 2

g02868099

1. Loosen hose clamps and disconnect the hose assemblies from turbocharger inlet (6) and from turbocharger outlet (3). 2. Remove banjo bolt (1) from tube assembly (11). Remove sealing washers (2) (not shown). 3. Loosen nut (10) and remove tube assembly (11) from turbocharger (14) and the cylinder block. 4. Remove hose clamp (5) from hose assembly (4). Disconnect hose assembly (4). 5. Remove hose clamp (7) from hose assembly (8). Disconnect hose assembly (8) from the wastegate actuator. 6. Remove bolts (12) from tube assembly (9). 7. Remove gasket (13) (not shown). 8. If necessary, follow Step 8.a through Step 8.e in order to remove tube assembly (9) from the cylinder block. a. Drain the coolant from the coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. b. Remove bolts (16) and position tube assembly (18) away from the oil cooler. c. Remove O-ring seal (15) (not shown) from tube assembly (18).

d. Remove bolt (17) and remove tube assembly (9) from the cylinder block. e. Remove O-ring seal (19) (not shown) from tube assembly (9).

Illustration 3

g02719524

9. Remove nuts (20) and washers (21) (not shown). Remove turbocharger (14) from exhaust manifold (24). Note: Do not use the actuator rod to lift the turbocharger. 10. Remove gasket (23) (not shown). 11. If necessary, remove the studs (22) from turbocharger (14) and exhaust manifold (24).

Illustration 4

g02868256

12. If necessary, follow Step 12.a through Step 12.f in order to remove boost pressure chamber cover (33). a. Remove the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure. b. Remove banjo bolt (28) and remove sealing washers (29) (not shown) from hose assembly (8). c. Remove banjo bolt (32) and remove sealing washers (31) (not shown) from hose assembly (26). d. Release the tube assembly (26) from clip (25) and position the hose assembly away from boost pressure chamber cover (33). e. Remove bolts (30) and remove boost pressure chamber cover (33) from the oil cooler. f. Remove gasket (27) (not shown). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884992

Valve Mechanism Cover - Remove and Install SMCS - 1107-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description Capping Kit

Qty 1

Start By: a. If the Diesel Particulate Filter (DPF) assembly is mounted above the valve mechanism cover, removal of the DPF assembly and mounting bracket will be necessary. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedures. b. Remove the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) Remove and Install" for the correct procedure. c. Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure. d. Remove the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install (Secondary Fuel Filter)" for the correct procedure.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Plug or cap all open ports and tube assemblies.

Illustration 1

g02671257

1. If necessary, remove the exhaust gas recirculation valve (EGR Valve). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. 2. Remove bolts (2) and bolt (3) from valve mechanism cover (1). 3. Remove valve mechanism cover (1) from the cylinder head.

Illustration 2

g02671282

Typical example

4. Remove gasket (4).

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 3 Typical example

g02671282

Illustration 4

g02908978

1. Thoroughly clean all gasket surfaces of valve mechanism cover (1). Note: Ensure that the recess for the gasket is free from oil. 2. Clean the gasket surfaces of the cylinder head. 3. Install a new gasket (4) to valve mechanism cover (1). Note: Ensure that the gasket is fully seated into the groove of the valve mechanism cover. 4. Position valve mechanism cover (1) onto the cylinder head. 5. Install bolts (2) and bolt (3) to the valve mechanism cover. 6. Temporarily install the bolts used to secure the fuel manifold in Positions (X) finger tight. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 5

g02671296

7. Tighten the bolts in the numerical sequence that is shown in Illustration 5. Tighten the bolts 1 through 7 to a torque of 10 N·m (89 lb in) Tighten the bolt 8 to a torque of 27 N·m (239 lb in) Repeat Step 7 in order to ensure the correct torque. 8. Remove the bolts used to secure the fuel manifold in Positions (X). 9. If necessary, install the exhaust gas recirculation valve (EGR Valve). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure. b. Install the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base Remove and Install (Secondary Fuel Filter)" for the correct procedure. c. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) Remove and Install" for the correct procedure. d. If the Diesel Particulate Filter (DPF) assembly is mounted above the valve mechanism cover, install the DPF assembly and mounting bracket. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedures. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884995

Wastegate Solenoid - Remove and Install SMCS - 1057-010

Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF position.

Illustration 1

g02720973

Illustration 2

g02720986

1. Disconnect harness assembly (4) from wastegate solenoid (5). 2. Place temporary marks on all hose assemblies in order to identify the position on the wastegate regulator (5). 3. Remove hose clamp (2). Disconnect hose assembly (3) from wastegate solenoid (5). 4. Remove hose clamp (6). Disconnect hose assembly (7) from wastegate solenoid (5). 5. Remove hose clamp (9). Disconnect hose assembly (8) from wastegate solenoid (5). 6. Remove Allen head bolts (1) and remove the wastegate solenoid from bracket (10). 7. If necessary, remove bolt (11) and remove bracket (10) from the water temperature regulator housing.

Installation Procedure 1. Ensure that all components of wastegate regulator are clean and free from wear and damage. If necessary, replace the wastegate regulator as an assembly if any of the components are worn or damaged.

Illustration 3

g02721016

Illustration 4

g02720973

2. If necessary, position bracket (10) onto the water temperature regulator housing. Ensure that the bracket is correctly located onto the spigot in Position (A). 3. Install bolt (11) and tighten the bolt to a torque of 10 N·m (89 lb in). 4. Position wastegate solenoid (5) onto bracket (10). Install Allen head bolts (1) to wastegate solenoid (5). Tighten Allen head bolts (1) to a torque of 10 N·m (89 lb in). 5. Position hose (8) onto the wastegate solenoid. Tighten hose clamp (9) securely. 6. Position hose (7) onto the wastegate solenoid. Tighten hose clamp (6) securely. 7. Position hose (3) onto the wastegate solenoid. Tighten hose clamp (2) securely. 8. Ensure that the hoses do not come into contact with any other engine components. 9. Connect harness assembly (4) to the wastegate solenoid. End By: a. Turn the battery disconnect switch to the ON position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884997

Water Pump - Install SMCS - 1361-012

Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that the water pump is clean and free from wear and damage. If necessary, replace the water pump. Clean the seal surface of the water pump.

Illustration 1

g02663458

Illustration 2

g02663598

2. Clean the seal surface on the cylinder block. 3. Install a new seal (3) to the water pump (2). 4. Install the water pump (2) to the cylinder block. Note: Ensure that the water pump is correctly orientated. 5. Install bolts (1) to the water pump. Tighten the bolts to a torque of 25 N·m (221 lb in). 6. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. End By: a. Install the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04884998

Water Pump - Remove SMCS - 1361-011

Removal Procedure Start By: a. Remove the alternator belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

Illustration 1

g02663376

Illustration 2

g02663417

2. Remove bolts (1) from water pump (2). 3. Remove water pump (2) from the cylinder block. 4. Remove seal (3). CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04876229

Water Separator and Fuel Filter (Primary) - Remove and Install SMCS - 1261-010-PY; 1263-010

Removal Procedure Table 1 Required Tools Tool

Part Number

388-1289

Part Description

Qty

Capping Kit

1. Turn the battery disconnect switch to the OFF position. 2. Turn the fuel supply to the OFF position.

Illustration 1

g03011667

3. Make temporary identification marks on plastic tube assemblies in order to show the correct position of the plastic tube assemblies. 4. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled. 5. Disconnect the plastic tube assembly from connecting (1). Use Tooling (A) in order to plug the plastic tube assemblies. Use Tooling (A) in order to cap the connection (1). 6. Disconnect the plastic tube assembly from connecting (2). Use Tooling (A) in order to plug the plastic tube assemblies. Use Tooling (A) in order to cap the connection (2). 7. Disconnect the Original Equipment Manufactures (OEM) harness assembly (6) from water in fuel sensor (5). 8. Remove bolts (2) (not shown) and remove the assembly of primary fuel filter (4) from the mounting bracket.

Illustration 2

g03011668

9. If necessary, follow Step 9.a through Step 9.g in order to disassembly the assembly of primary fuel filter (4). a. Remove vent screw assembly (7) and remove O-ring seal (8). Use Tooling (A) in order to plug the primary fuel filter (4). Use Tooling (A) in order to cap vent screw assembly (7). b. Remove connection (1) and remove O-ring seal (10). Use Tooling (A) in order to plug the primary fuel filter (4). Use Tooling (A) in order to cap connection (1). c. Remove connection (2) and remove O-ring seal (13). Use Tooling (A) in order to plug the primary fuel filter (4). Use Tooling (A) in order to cap connection (1). d. Remove plug (12) and remove O-ring seal (13). Use Tooling (A) in order to plug the primary fuel filter (4). e. Remove plug (15) and remove O-ring seal (14). Use Tooling (A) in order to plug the primary fuel filter (4). f. Remove water in fuel sensor (6) and remove O-ring seal (17). g. Remove the filter element from fuel filter canister (16). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element Replace" for the correct procedure.

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting , "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.

Illustration 3

g03011668

2. If necessary, follow Step 2.a through Step 2.i in order to assembly primary fuel filter (1).

a. Install a new filter element to fuel filter canister (16). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element Replace" for the correct procedure. b. Remove cap from connection (1). Install a new O-ring seal (10) to connection (1). c. Remove plug from primary fuel filter (4). Install connection (1) to primary fuel filter (4). Tighten the connection to a torque of 20 N·m (177 lb in). d. Remove cap from connection (2). Install a new O-ring seal (13) to connection (2). e. Remove plug from primary fuel filter (4). Install connection (2) to primary fuel filter (4). Tighten the connection to a torque of 20 N·m (177 lb in). f. Install a new O-ring seal (13) to plug (12). Install plug (12) to primary fuel filter (4). Tighten the plug to a torque of 20 N·m (177 lb in). g. Install a new O-ring seal (14) to plug (15). Install plug (15) to primary fuel filter (4). Tighten the plug to a torque of 20 N·m (177 lb in). h. Remove cap from vent screw assembly (7). Install a new O-ring seal (8) to vent screw assembly (7). Install vent screw assembly (7) to primary fuel filter (4). Tighten the vent screw assembly securely. i. Install a new O-ring seal (17) to water in fuel sensor (5). Install water in fuel sensor (5) to primary fuel filter (4). Tighten water in fuel sensor (5) hand tight.

Illustration 4

g03011667

3. Position the assembly of primary fuel filter (4) onto the mounting bracket. 4. Install bolts (3) (not shown) to the assembly of primary fuel filter (4). Tighten the bolts to a torque of 50 N·m (37 lb ft).

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

5. Remove plug from the plastic tube assembly. Remove cap from connecting (1) on primary fuel filter (4). Connect the plastic tube assembly to connecting (1) on primary fuel filter (4). 6. Remove plug from the plastic tube assembly. Remove cap from connecting (2) on primary fuel filter (4). Connect the plastic tube assembly to connecting (2) on primary fuel filter (4). 7. Connect the OEM harness assembly (6) to water in fuel sensor (5). 8. Turn the fuel supply to the ON position. 9. Turn the battery disconnect switch to the ON position. End By: a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Industrial Engine Media Number -UENR0621-05

Publication Date -01/08/2013

Date Updated -27/04/2018

i04885001

Thermostat - Water Temperature Regulator Remove and Install SMCS - 1355-010

Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system to a level below the water temperature regulator, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure. 2. Remove the wastegate regulator valve. Refer to Disassembly and Assembly, "Wastegate Solenoid - Remove and Install" for the correct procedure.

Illustration 1

g02829476

Typical example

3. Loosen the hose clamps from the upper radiator hose and disconnect the upper radiator hose from water temperature regulator housing (1). 4. Loosen clamp (3) and disconnect exhaust gas recirculation (EGR) cooler hose (2) from water temperature regulator housing (1). Position the EGR cooler hose away from the water temperature regulator housing. 5. Slide the locking tab into the unlocked position and disconnect the wiring harness from coolant temperature sensor (4). 6. Remove bolts (6) and remove bolts (7) from water temperature regulator housing (1). 7. Remove water temperature regulator housing (1) from the cylinder head. 8. Remove gasket (5) (not shown). 9. If necessary, remove the coolant temperature sensor. Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.

Installation Procedure NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure that all components are clean and free of wear and damage. If necessary, replace any components that are worn or damaged. 2. Check the water temperature regulator for correct operation. Refer to System Operation, Testing, and Adjusting, "Water Temperature Regulator - Test" for the procedure to test the water temperature regulator. If the water temperature regulator is not operating correctly, the complete assembly must be replaced. 3. If necessary, install the coolant temperature sensor. Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.

Illustration 2

g02829476

Typical example

4. Position gasket (5) (not shown) onto water temperature regulator housing (1). Note: Ensure that the gasket is correctly orientated. 5. Install bolts (7) to water temperature regulator housing (1). 6. Position water temperature regulator housing (1) onto the cylinder head.

7. Install bolts (6) to the water temperature regulator housing finger tight. 8. Tighten the bolts (6) and bolts (7) to a torque of 25 N·m (221 lb in). 9. Connect hose (2) to the water temperature regulator housing and tighten clamp (3) securely. 10. Connect the upper radiator hose to water temperature regulator housing (1) and tighten the hose clamps securely. 11. Connect the wiring harness to coolant temperature sensor (4). Slide the locking tab into the locked position. 12. Install the wastegate solenoid. Refer to Disassembly and Assembly, "Wastegate Solenoid Remove and Install" for the correct procedure. 13. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedures. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989113

DEF Injector and Mounting - Remove and Install SMCS - 108I-010

Removal Procedure Table 1 Required Tools Tool

Part Number

473-2944

Part Description

Qty

Capping Kit

De-ionized Water

NOTICE Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training. Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.

NOTICE Care must be taken to ensure that Diesel Emission Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g03799260

2. Ensure that the area around Diesel Emission Fluid (DEF) injector (7) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF injector with Tooling (B) and a suitable tool. 3. Disconnect the harness assembly from connection (3) on DEF injector (7). Use Tooling (A) to cap the harness assembly and the DEF injector. 4. Remove the Diesel Emission Fluid (DEF) line from connection (1) on the DEF injector (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. 5. Use Tooling (A) to cap connection (1) on DEF injector (7) and the DEF line. 6. Remove the coolant line from connection (2) and coolant line from connection (6) on DEF injector (7). 7. Use Tooling (A) to caps connection (2) and connection (6) on DEF injector (7).

8. Sufficiently loosen the Torx head bolt for V-band clamp (4) and remove DEF injector (7) and the V-band clamp from DOC (5).

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

De-ionized Water

1. Ensure that the DEF injector and the DOC are free from wear or damage. Replace any component that is worn or damaged.

Illustration 2

g03799267

Illustration 3

g03799260

2. Ensure that surfaces (8), DOC (5), and DEF injector (7) is clean and free from damage and wear. 3. Position V-band clamp (4) onto DEF injector (7). Ensure that the V-band clamp is correctly orientated. 4. Install DEF injector (7) and align with peg (9) with Slot (X) in DOC (5). 5. Tighten the Torx head bolt for V-band clamp (4) hand tight. Ensure that the DEF injector and the V-band clamp are correctly seated onto the DOC.

Illustration 4

g03799285

6. Tighten the Torx head bolt for V-band clamp (4) to a torque of 11.5 N·m (102 lb in). 7. Remove the caps from the harness assembly and connection (3) on DEF injector (7). Connect harness assembly to the connection on the DEF injector. 8. Prior to the installation of the DEF supply line, follow Step 8.a through Step 8.h in order to flush the DEF supply line. a. Turn the battery disconnect switch to the ON position. b. Connect the electronic service tool. Refer to Troubleshooting, "Electronic Service Tools" for the correct procedure. c. Remove cap from the DEF supply line. Place the open end of the DEF supply line in a suitable container, with a capacity greater than 2 L (0.44 Imp gal). d. Select the DEF dosing system accuracy test. Refer to Troubleshooting, "DEF Dosing System Accuracy Test" for the correct procedure. e. Hold the DEF supply line above the suitable container. Run the DEF dosing system accuracy test for maximum of 90 second. Ensure that the DEF supply line is not immersed in the DEF fluid in the suitable container. f. Turn the battery disconnect switch to the OFF position. g. Use Tooling (B) to clean any DEF fluid from the end of the DEF supply line.

h. Remove the cap from connection (1) on DEF injector (7). Connect DEF supply line to connection (1) on the DEF injector. 9. Remove the caps from connection (2) and connection (6) on DEF injector (7). Install the coolant lines to the connection on the DEF injector. Ensure that the coolant lines are correctly installed. 10. Lightly tap the full circumference of the V-band clamp with a soft faced hammer in order to correctly seat the V-band clamp. Repeat Step 6 until the Torx head bolt reaches the correct torque value. 11. Turn the battery disconnect switch to the ON position. 12. Use the electronic service tool to perform a pressure test on the DEF system and check for leaks. Refer to Troubleshooting, "DEF Dosing System Verification Test" for further information. 13. Turn the battery disconnect switch to the OFF position. Disconnect the electronic service tool. 14. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Engi nes for Ca terpilla r Built Machines Media Num ber -UENR4535-07

Publication Date -01/06/2015

Date Updated - 28/08/2020

i05989111

Diesel Exhaust Fluid Lines - Remove and Install SMCS - 108K-010-LI

Removal Procedure Table 1 Required Tools Tool

Part Number

473-2944

Part Description

Qty

Capping Kit

De-ionized Water

Illustration 1

g03799358

Illustration 2

g03799340

Typical examples

3. Ensure that the area around Manifold (DEF Heater) (3), Diesel Exhaust Fluid (DEF) pump (4), Diesel Exhaust Fluid injector (5) and Diesel Exhaust Fluid (DEF) line (1), and Diesel Exhaust Fluid (DEF) line (2), and Diesel Exhaust Fluid (DEF) line (6) are clean and free dirt and debris. If necessary, use Tooling (B) and a suitable tool to clean the area around the DEF components. 4. Refer to the Original Equipment Manufacture (OEM) for the correct location of the manifold DEF heater (3), Diesel Exhaust Fluid (DEF) pump (4), and Diesel Exhaust Fluid injector (5). Refer to the OEM for the correct routing of the diesel exhaust fluid lines. 5. Disconnect the Original Equipment Manufacture (OEM) harness assemblies from harness assembly (7), harness assembly (8), and harness assembly (9) for the Diesel Exhaust Fluid (DEF) lines. 6. Make temporary marks on cable straps for installation purposes. Cut the cable straps. Ensure that all cable straps are removed. 7. Disconnect diesel exhaust fluid line (1) and diesel exhaust fluid line (2) from manifold DEF heater (3). 8. Use Tooling (A) to cap manifold DEF heater (3). Use Tooling (A) to plug diesel exhaust fluid line (1) and diesel exhaust fluid line (2). 9. Disconnect of the other end of diesel exhaust fluid line (1) and diesel exhaust fluid line (2) from DEF pump (4). 10. Use Tooling (A) to cap DEF pump (4). Use Tooling (A) to plug diesel exhaust fluid line (1) and diesel exhaust fluid line (2). 11. Disconnect diesel exhaust fluid line (6) from DEF injector (5) and DEF pump (4).

12. Use Tooling (A) to cap DEF injector (5). Use Tooling (A) to plug diesel exhaust fluid line (6) at both ends.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

De-ionized Water

1. Ensure that all diesel exhaust fluid components are free from wear or damage. Replace any diesel exhaust fluid component that is worn or damaged.

Illustration 3 Typical examples

g03799358

Illustration 4

g03799340

Typical examples

2. Refer to the OEM for the correct routing of the diesel exhaust fluid lines. 3. Remove the caps from manifold DEF heater (3) and plug from DEF line (1) and DEF line (2). 4. Connect DEF line (1) and DEF line (2) to manifold DEF heater (3). 5. Remove the caps from DEF pump (4) and plugs from DEF line (1) and DEF line (2). Connect the DEF lines to the DEF pump. Ensure that the DEF lines are correctly orientated. 6. Remove cap from DEF line (6). Connect the DEF line to DEF pump (4). 7. Connect the OEM harness assemblies to harness assembly (7), harness assembly (8), and harness assembly (9) for the DEF lines. 8. Install new cable straps to the OEM harness assemblies for harness assembly (7) and harness assembly (8). Ensure that the cable straps are installed in the original positions. Note: Ensure that the cable straps meet OEM specification. 9. Prior to the installation of DEF supply line (6) to DEF injector (5), follow Step 9.a through Step 9.h in order to flush the DEF supply line. a. Turn the battery disconnect switch to the ON position. b. Connect the electronic service tool. Refer to Troubleshooting, "Electronic Service Tools" for the correct procedure. c. Remove cap from DEF supply line (6). Place the open end of the DEF supply line in a suitable container, with a capacity greater than 2 L (0.44 Imp gal).

d. Select the DEF dosing system accuracy test. Refer to Troubleshooting, "DEF Dosing System Accuracy Test" for the correct procedure. e. Hold DEF supply line (6) above the suitable container. Run the DEF dosing system accuracy test for maximum of 90 second. Ensure that the DEF supply line is not immersed in the DEF fluid in the suitable container. f. Turn the battery disconnect switch to the OFF position. g. Use Tooling (B) to clean any DEF fluid from the end of DEF supply line (6). h. Remove the caps from DEF injector (5). Connect DEF supply line (6) to DEF injector (5). 10. Turn the battery disconnect switch to the ON position. 11. Use the electronic service tool to perform a pressure test on the DEF system and check for leaks. Refer to Troubleshooting, "DEF Dosing System Verification Test" for further information. 12. Turn the battery disconnect switch to the OFF position. Disconnect the electronic service tool. 13. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989112

Diesel Exhaust Fluid Pump - Remove and Install SMCS - 108J-010

Removal Procedure Table 1 Required Tools Tool

Part Number

473-2944

Part Description

Qty

Capping Kit

De-ionized Water

Dispose of all fluids according to local regulations and mandates.

1. Refer to the Original Equipment Manufacture (OEM) for the location of the DEF pump. 2. Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information. 3. Turn turning the battery disconnect switch to the OFF position.

Illustration 1

g03799801

4. Ensure that the area around DEF fluid pump (1) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF fluid pump with Tooling (B) and a suitable tool. 5. Disconnect harness assembly (3) from Original Equipment Manufacture (OEM) harness assembly (4). 6. Make temporary marks on DEF lines for installation purposes. Remove the DEF line from connection (5) and the DEF line from connection (6) from DEF fluid pump (1). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.

7. Use Tooling (A) to plug the DEF lines. Tooling (A) to cap connection (5) and connection (6). 8. Remove bolts (7) from DEF pump (1). Support the weight of the DEF pump as the bolts are removed. Remove the DEF pump. 9. If necessary, remove DEF filter (2) (not shown). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Filter - Clean/Replace" for the correct procedure.

Installation Procedure Table 2 Required Tools Tool

Part Number

473-2944

Part Description

Qty

Capping Kit

De-ionized Water

1. Ensure that the DEF pump is free from wear or damage. Replace the DEF pump as an assembly if any component of the DEF pump is not free from wear or damage.

Illustration 2

g03799801

2. If necessary, install a new DEF filter (2) (not shown). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Filter - Clean/Replace" for the correct procedure. 3. Install DEF pump (1) and install bolts (7) to diesel exhaust fluid pump. Support the weight of the DEF pump as the bolts are installed. Tighten the bolts to a torque of 16 N·m (142 lb in). 4. Remove plugs from the DEF lines. Remove the caps from connection (5) and connection (6). 5. Install the DEF line to connection (5) and the DEF line to connection (6). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Note: Ensure that the DEF lines are connected into the correct positions. 6. Connect harness assembly (3) to OEM harness assembly (4).

Illustration 3

g03799808

7. After the installation of the DEF lines on to the DEF pump. Follow Step 7.a through Step 7.k in order to flush DEF supply line (8) at DEF injector (9). a. Ensure that the area around DEF injector (9) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF injector with Tooling (B) and a suitable tool. b. Disconnect DEF line (8) from DEF injector (9). c. Use Tooling (A) to cap DEF injector (9) and DEF line (8). d. Turn the battery disconnect switch to the ON position. e. Connect the electronic service tool. Refer to Troubleshooting, "Electronic Service Tools" for the correct procedure. f. Remove cap from the DEF supply line. Place the open end of the DEF supply line in a suitable container, with a capacity greater than 2 L (0.44 Imp gal). g. Select the DEF dosing system accuracy test. Refer to Troubleshooting, "DEF Dosing System Accuracy Test" for the correct procedure. h. Hold the DEF supply line above the suitable container. Run the DEF dosing system accuracy test for maximum of 90 second. Ensure that the DEF supply line is not immersed in the DEF fluid in the suitable container. i. Turn the battery disconnect switch to the OFF position. j. Use Tooling (B) to clean any DEF fluid from the end of the DEF supply line. k. Remove the caps from DEF injector (9). Connect DEF supply line (8) to the DEF injector. 8. Turn the battery disconnect switch to the ON position. 9. Use the electronic service tool to perform a pressure test on the DEF system and check for leaks. Refer to Troubleshooting, "DEF Dosing System Verification Test" for further information. 10. Turn the battery disconnect switch to the OFF position. Disconnect the electronic service tool. 11. Turn the battery disconnect switch to the ON position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989114

Diesel Exhaust Fluid Tank - Remove and Install SMCS - 108T-010

Removal Procedure Table 1 Required Tools Tool

Part Number

473-2944

Part Description

Qty

Capping Kit

De-ionized Water

Dispose of all fluids according to local regulations and mandates.

1. Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information. 2. Refer to the Original Equipment Manufacture (OEM) for the location of the diesel exhaust fluid tank. 3. Drain the coolant from the cooling system to a level below the solenoid valve, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.

Illustration 1 Typical example

g03732064

4. Ensure that the area around manifold DEF heater (3) is clean and free dirt and debris. If necessary, clean the area around the manifold DEF heater. If necessary, clean the area around the manifold DEF heater. Clean the area around the manifold DEF heater with Tooling (B) and a suitable tool. 5. Make temporary mark on cable straps (13) for installation purposes. Cut the cable straps from the harness assemblies and the diesel emission fluid lines. 6. Disconnect the Original Equipment Manufacture (OEM) harness assemblies from harness assembly (5), harness assembly (11), and harness assembly (14). Use Tooling (A) to cap the harness assemblies. 7. Remove diesel emission fluid line (7) and diesel emission fluid line (6) from manifold DEF heater (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. 8. Loosen the hose clamps and disconnect the hose assembly (8) and hose assembly (9) from manifold DEF heater (3). Use Tooling (A) to cap hose assemblies and the manifold DEF heater. 9. Remove bolt (4) and bolt (12) for strap (2) and strap (10). Remove the straps from diesel exhaust fluid tank (1). 10. Remove diesel exhaust fluid tank (1) from the mounting bracket.

Installation Procedure 1. Ensure that all components are free from wear or damage. Replace any component that is worn or damaged.

Illustration 2

g03732064

Typical example

2. Install diesel exhaust fluid tank (1) onto the mounting bracket. 3. Install strap (2) and strap (10) onto diesel exhaust fluid tank (1). Ensure that the straps are correctly installed onto the diesel exhaust fluid tank. 4. Install bolt (4) and bolt (12) for strap (2) and strap (10). Hand tighten the bolts. Ensure that the straps are correctly located onto the diesel exhaust fluid tank. 5. Tighten bolt (4) and bolt (12) to strap (2). Refer to the OEM for the correct torque procedure and the correct value. 6. Install diesel emission fluid line (7) and diesel emission fluid line (6) to manifold DEF heater (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.

7. Remove the caps from hose assembly (8) and hose assembly (9) to manifold DEF heater (3). Connect the hose assemblies to the manifold DEF heater. Ensure that the hose assemblies are installed into the correct positions. Tighten the hose clamps. Refer to the OEM for the correct torque value. 8. Remove the caps from harness assembly (5), harness assembly (11), and harness assembly (14). Connect the OEM harness assemblies to the harness assemblies. Ensure that the harness assemblies are installed into the correct position. 9. Install new cable straps (13) to the harness assemblies and the diesel emission fluid lines. Ensure that the cable straps are install in the original position. Note: Ensure that the cable straps meet OEM specifications. 10. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure. 11. Turn the battery disconnect switch to the ON position. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i08217167

Manifold (DEF Heater) - Remove and Install SMCS - 3206-CLT

Removal Procedure Table 1 Required Tools Tool

Part Number

473-2944

Part Description Capping Kit

Qty 1

1. Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information. 2. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

Illustration 1

g03730127

3. Remove the Diesel Emission Fluid (DEF) line from connection (3) (not shown) from manifold Diesel Exhaust Fluid (DEF) heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.

4. Remove the diesel emission fluid line from connection (6) from manifold DEF heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. 5. Use Tooling (A) to cap connection (6) and connection (3) (not shown). 6. Use Tooling (A) to plug the DEF lines. 7. Loosen the hose clamps on the hose assemblies. Disconnect the hose assemblies from connection (4) and connection (5) from manifold DEF heater (7). 8. Use Tooling (A) to cap connection (4) and connection (5). 9. Use Tooling (A) to plug the hose assemblies. 10. Disconnect the harness assembly from harness assembly (9). 11. Remove Torx screws (1) from ring (2). Remove the ring from manifold DEF heater (7). 12. Remove manifold DEF heater (7) from DEF tank (10). 13. Remove O-ring seal (8) from manifold DEF heater (7).

Illustration 2

g03730136

14. If necessary, follow Step 4a through Step 5 to remove filter (12) from manifold DEF heater (7). a. Remove Torx screw from filter (12). b. Remove filter (12).

Illustration 3

g03730140

15. If necessary, follow Step 15a through Step 15d to disassemble DEF tank (10). a. Ensure that the area around cap on the DEF tank is clean. Drain DEF tank (10). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Tank - Flush" the correct procedure. b. Remove plug (16) from DEF tank (10). Remove O-ring seal (15) from the plug. c. Remove filler cap (13) from DEF tank (10). d. Use a suitable tool, to press locking tabs (17) and remove filter screen (14) from the neck of DEF tank (10).

Installation Procedure Table 2

Required Tools Tool

Part Number

247-5377

B C

Part Description

Qty

Torque Wrench

T15 Torx 1/4" Hexagon Drive

T25 Torx 1/4" Hexagon Drive

1. Ensure that the manifold DEF heater, DEF tank, filter, and filter screen are free from wear, damage, clean, and free from restriction. Replace any component that is not free from wear, damage, and free from restriction. 2. If necessary, clean DEF filler screen. Refer to Operation and Maintenance Manual, "DEF Filler Screen - Clean" the correct procedure.

Illustration 4

g03730140

3. If necessary, follow Step 3a through Step 3c to assemble DEF tank (10). a. Install a new O-ring seal (15) to plug (16). Install the plug to DEF tank (10). Tighten the plug to a torque of 6 N·m (53 lb in). b. Install filter screen (14) to the neck of DEF tank (10).Ensure that locking tabs (17) are correctly engaged into the neck of DEF tank. c. Install filler cap (13) to DEF tank (10).

Illustration 5

g03730136

4. If necessary, follow Step 4a through Step 4b to install filter (12) to manifold DEF heater (7). a. Install filter (12) to manifold DEF heater (7). Ensure that the filter is correctly positioned onto the manifold DEF heater. b. Install Torx screw to filter (12). Use Tooling (A) and Tooling (B) to tighten the Torx screw to a torque of 1.24 N·m (11 lb in).

Illustration 6

g03730127

5. Install a new O-ring seal (8) to manifold DEF heater (7). 6. Install manifold DEF heater (7) to DEF tank (10).Ensure that the manifold DEF heater is correctly seated into DEF tank. 7. Install ring (2) to manifold DEF heater (7). Ensure that the ring is correctly orientated and correctly seated onto the manifold DEF heater. 8. Install new Torx screws (1) to ring (2). Use Tooling (A) and Tooling (C) to tighten Torx screws to a torque of 2.8 N·m (25 lb in). 9. Remove the caps from the connections on the manifold DEF heater. Remove caps from DEF lines.

10. Install the DEF line to connection (3) (not shown) on manifold DEF heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. 11. Install the diesel emission fluid line to connection (6) on manifold DEF heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. 12. Remove the cap connection (4) and connection (5). 13. Connect the hose assemblies to connection (4) and connection (5) on manifold DEF heater (7). Tighten the hose clamps to a torque of 7 N·m (62 lb in). 14. Connect the harness assembly to harness assembly (9). 15. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. 16. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Engi nes for Ca terpilla r Built Machines Media Num ber -UENR4535-07

Publication Date -01/06/2015

Date Updated - 28/08/2020

i08058888

Manifold (DEF Heater) Sensor - Assemble - Temperature, Level, Quality DEF Manifold Sensor SMCS - 107D-016; 108K-016; 1439-016

Assembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

326-8203

Cable Strap Tension Tool

Deionized Water

Loctitie LB8104

NOTICE Care must be taken to ensure that Diesel Exhaust Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

1. Ensure that all components are free from damage and wear. Replace any component that is worn or damaged.

Illustration 1

g06499866

Typical example

2. Ensure new O-ring (10) is installed to new DEF sensor (4). Apply Tooling (C) to the new O-ring seal. Note: Do not use hydrocarbon-based lubricant.

Illustration 2

g06501315

Typical example

Illustration 3

g06501321

Typical example

3. Place DEF heater (3) in a suitable support. Install DEF sensor (4) to the DEF header in Position (X) in the orientation noted on removal. Ensure that the DEF sensor locates into clamp (2) and clamp (6) as the DEF sensor is installed. Install spacer (9) between DEF heater (3) and DEF sensor (4) in the position and orientation noted on removal.

4. Ensure new O-ring (8) is located in new nut (7) and apply Tooling (C) to the new O-ring seal. Install the new nut to DEF sensor (4) and tighten the nut finger tight. Note: Do not use hydrocarbon-based lubricant. 5. Using suitable tool tighten nut (7) to a torque of 4.5 N·m (40 lb in)

Illustration 4

g06496948

Typical example

6. Install new cable tie (1) to clamp (2) and new cable tie (5) to clamp (6) in the positions noted on removal. Use Tooling (A) to tighten the new cable ties to 222 N (50 lb). Note: Ensure that the new cable straps meet the Original Engine Manufacturers (OEM) specification.

Illustration 5

g06496977

7. Ensure that there is an air gap between gas bubble evacuation port (12) on the DEF sensor (4) and bracket (11). If necessary, adjust bracket (11) to achieve 5 mm (0.2 inch) gap between the gas bubble evacuation port and the bracket. 8. Using Tooling (B) clean any excess assembly lubricant from the DEF sensor prior to installing the DEF heater to the DEF tank. End By: a. Install the manifold DEF heater. Refer to Disassembly and Assembly, "Manifold (DEF Heater) Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Engi nes for Ca terpilla r Built Machines Media Num ber -UENR4535-07

Publication Date -01/06/2015

Date Updated - 28/08/2020

i08058886

Manifold (DEF Heater) Sensor - Disassemble - Temperature, Level, Quality DEF Manifold Sensor SMCS - 107D-015; 108K-015; 1439-015

Disassemble Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Deionized water

Start By: a. Remove the manifold DEF heater. Refer to Disassembly and Assembly, "Manifold (DEF Heater) Remove and Install" for the correct procedure.

Illustration 1

g06496948

Typical example

1. If necessary, use Tooling (A) to clean the Diesel Exhaust Fluid (DEF) deposits from manifold DEF heater (3) and DEF sensor (4) 2. Using a suitable tool cut cable strap (1) and cable strap (5), remove the cable straps. Note: Note cable strap positions for installation purposes. Note: Discard cable straps once removed.

Illustration 2

g06499816

Typical example

3. Place the DEF heater (3) in a suitable support, using a suitable tool loosen nut (7) on DEF sensor (4). 4. Remove nut (7) and O-ring seal (8) from DEF sensor (4). Note: Ensure that the O-ring seal is removed from the upper sealing face of the DEF header.

Illustration 3

g06501321

Typical example

5. If necessary, use a suitable tool to remove DEF sensor (4) from clamp (2) and clamp (6), ensure that the clamps are not damaged. Whilst removing the DEF sensor from the DEF header. Ensure spacer (9) is supported as the DEF sensor is removed from the DEF header. Note: Note DEF sensor orientation for installation purposes. Note: Note spacer position and orientation for installation purposes. 6. Ensure O-ring seal (10) is removed from the lower sealing face of the DEF header.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989149

Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor on Engine SMCS - 191N-010

Removal Procedure 1. Ensure that the nitrogen oxide sensor is not dropped or knocked. If the nitrogen oxide sensor, has been dropped or knocked the nitrogen oxide sensor must be replaced as an assembly. 2. Turn the battery disconnect switch to the OFF position.

Illustration 1 Typical example

g03820428

Illustration 2

g03820394

Illustration 3

g03731236

Typical example

3. Remove nitrogen oxide sensors (6) from exhaust elbow (7) and exhaust tube assembly (8). Ensure that the harness assembly is not damaged as the nitrogen oxide sensor is removed. Place the probe of the nitrogen oxide sensor in a plastic bag and secure the plastic bag with a cable strap. 4. If necessary, follow Step 4.a through Step 4.c in order to remove nitrogen oxide sensor Electronic Control Module (ECM) (2). a. Disconnect Original Equipment Manufacture (OEM) harness assembly (3) from the nitrogen oxide sensor ECM (2). b. Cut cable straps (1) from the harness assembly. Note the position of all cable straps for installation purposes. Note: Ensure that the harness assembly is not damaged as the cable straps are cut. c. Remove bolts (4) nitrogen oxide sensor ECM (2). Remove the nitrogen oxide sensor ECM from bracket (5).

Installation Procedure Table 1 Required Tools

Tool

Part Number

Part Description

Qty

Bostik Pure Nickel Anti-Seize Compound

22 mm Crows Foot

1. Ensure that the nitrogen oxide sensor is free from wear or damage. Replace the nitrogen oxide sensor as an assembly if worn or damaged. 2. Check the threads of the mounting point for nitrogen oxide sensor in the exhaust elbow and exhaust tube assembly. Replace the exhaust elbow and exhaust tube assembly if the mounting point is worn or damage.

Illustration 4 Typical example

g03820428

Illustration 5

g03820394

Illustration 6

g03731236

Typical example

3. If necessary, follow Step 3.a through Step 3.c in order to install nitrogen oxide sensor ECM (2). a. Position nitrogen oxide sensor ECM (2) onto bracket (5). Ensure that the nitrogen oxide sensor ECM is correctly orientated onto the bracket. b. Install bolts (4) to nitrogen oxide sensor ECM (2). Support the nitrogen oxide sensor ECM as the bolts are installed. Tighten the bolts to a torque of 10 N·m (89 lb in). c. Connect OEM harness assembly (3) to nitrogen oxide sensor ECM (2). 4. New nitrogen oxide sensor (6) are pre-lubricated. When installing an existing nitrogen oxide sensor (6), lightly lubricate the thread of the nitrogen oxide sensor with Tooling (A). Note: Ensure that the nitrogen oxide sensor is not contaminated. 5. Remove the probe of nitrogen oxide sensor (6) from the plastic bag. Install the nitrogen oxide sensor to exhaust elbow (7) and exhaust tube assembly (8). Ensure that the harness assembly is not damaged as the nitrogen oxide sensor is installed. 6. Use Tooling (B) to tighten nitrogen oxide sensor (6) to a torque of 50 N·m (37 lb ft). 7. Install new cable straps (1) to the harness assembly. Ensure that the cable straps are installed into the original position.

Note: Ensure that the cable straps meet OEM specifications. 8. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

i06061565

Selective Catalytic Reduction (SCR) Canister - Remove and Install SMCS - 1091-010-KY

Removal Procedure

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 1

g03824061

Illustration 2

g03824491

1. Loosen clamp (2) and disconnect tube assembly (1) from Selective Catalytic Reduction (SCR) outlet (3). 2. Loosen clamp (6) and disconnect tube assembly (7) from SCR inlet (5). 3. Make temporary alignment marks in Position (A), Positions (B), Positions (C) and Position (D), in order to identify the correct position of clamps (8) and SCR (10). 4. Remove the nuts (4) from clamps (8). Position the clamps away from the SCR in order to allow removal of the SCR. 5. If necessary, remove bolts (9) and clamp assemblies (8).

Installation Procedure

Illustration 3

g03824491

Illustration 4

g03824061

1. If necessary, install clamp assemblies (8) and loosely install bolts (9). 2. Position SCR (10) onto clamp assemblies (8). Loosely install nuts (4). 3. Alignment temporary marks in Position (A), Positions (B), Positions (C) and Position (D) that were made on clamps (8) and SCR (10). 4. Tighten nuts (4) to a torque of 22 N·m (195 lb in). 5. Install tube assembly (7) to SCR inlet (5). Install clamp (6). Tighten the clamp to a torque of 12 N·m (106 lb in). 6. Install tube assembly (I) to SCR outlet (3). Install clamp (2). Tighten the clamp to a torque of 12 N·m (106 lb in). 7. Tighten bolts (9) to a torque of 22 N·m (195 lb in).

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989130

Solenoid Valve (DEF Heater Coolant) - Remove and Install SMCS - 5479-CLT

Removal Procedure 1. Turn the battery disconnect switch to the OFF position. 2. Refer to the Original Equipment Manufacture (OEM) for the location of the solenoid valve. 3. Drain the coolant from the cooling system to a level below the solenoid valve, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.

Illustration 1

g03727977

4. Disconnect the harness assembly from connection (3) on solenoid valve (2). 5. Loosen hose clamp (5) and remove hose assembly (4) from solenoid valve (2). 6. Loosen hose clamp (6) and remove hose assembly (7) from solenoid valve (2). 7. Remove bolts (1) and remove solenoid valve (2).

Installation Procedure 1. Ensure that the solenoid valve is free from wear or damage. Replace the solenoid valve as an assembly if any component of the solenoid valve is not free from wear or damage.

Illustration 2

g03727977

2. Install solenoid valve (2) and install bolts (1). Tighten the bolts to a torque of 22 N·m (195 lb in). 3. Install hose assembly (4) to solenoid valve (2). Tighten hose clamp (5) to a torque of 7 N·m (62 lb in). 4. Install hose assembly (7) to solenoid valve (2). Tighten hose clamp (6) to a torque of 7 N·m (62 lb in). 5. Connect the harness assembly to connection (3) on solenoid valve (2). 6. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure. 7. Turn the battery disconnect switch to the ON position.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05989160

Support and Mounting (CEM) - Remove and Install Flywheel Housing Mounted CEM SMCS - 0635

Removal Procedure Start By: a. Remove the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Clean Emission Module (CEM) - Remove" for the correct procedure. b. Remove the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.

Illustration 1

g03795579

Typical example

Make temporary marks on bracket (1) and bracket (2) for installation purposes. 1. Remove bolts (3) from bracket (1). Support the bracket as the bolts are removed. Remove the bracket from flywheel housing (5). 2. Remove bolts (4) from bracket (2). Support the bracket as the bolts are removed. Remove the bracket from flywheel housing (5).

Installation Procedure 1. Ensure that all the components are free from wear or damage.

Illustration 2

g03795579

Typical example

2. Position bracket (2) onto flywheel housing (5). Install bolts (4) to the bracket. Support the bracket as the bolts are installed. 3. Position bracket (1) onto flywheel housing (5). Install bolts (3) to the bracket. Support the bracket as the bolts are installed. 4. Tighten bolts (3) and bolts (4) to a torque of 45 N·m (33 lb ft). End By: a. Install the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Clean Emission Module (CEM) - Remove" for the correct procedure. b. Install the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i06060398

Support and Mounting (CEM) - Remove and Install - Top Mounted DOC SMCS - 0635

Illustration 1

g03798717

1. If necessary, cut cable straps (4) from harness assembly (5). Position the harness assembly away from bracket (1). 2. Remove bolts (2) and bolts (3) from bracket (1). 3. Remove bracket (1).

Illustration 2

g03798718

4. Remove bolts (7) and bolts (8) from bracket (6). 5. Remove bracket (6) from bracket (9) and bracket (11). 6. Remove bolts (10) from bracket (11). Remove the bracket from the cylinder head.

Illustration 3

g03798719

7. Remove engine lifting brackets (12). Refer to Disassembly and Assembly, "Engine Lifting Bracket - Remove" for the correct procedure. 8. Remove bolts (13) from bracket (6). Support the bracket as the bolts are removed. 9. Remove bracket (6) from the cylinder head.

Installation Procedure 1. Ensure that all the components are free from wear or damage. Replace any component that is worn or damaged.

Illustration 4

g03798719

2. Position bracket (6) onto the cylinder head. 3. Install bolts (13) to bracket (6). Support the bracket as the bolts are installed. 4. Tighten bolts (13) to a torque of 45 N·m (33 lb ft). 5. Install engine lifting brackets (12). Refer to Disassembly and Assembly, "Engine Lifting Bracket - Remove" for the correct procedure.

Illustration 5

g03798718

Illustration 6

g03798717

6. Position bracket (11) onto the cylinder head. Install bolts (10) to the bracket. Hand tighten the bolts. 7. Position bracket (6) onto bracket (9) and bracket (11). Install bolts (7) and bolts (8) to the brackets. Hand tighten the bolts. Support the bracket as the bolts are installed. 8. Position bracket (1) onto bracket (6) and the front bracket. 9. Install bolts (2) and bolts (3) to bracket (1) hand tighten the bolts. 10. Tighten bolts (3) to a torque of 45 N·m (33 lb ft). 11. Tighten bolts (2) to a torque of 45 N·m (33 lb ft). 12. Tighten bolts (7), bolts (8), and (10) to a torque of 25 N·m (221 lb in). 13. If necessary, position the harness assembly onto bracket (1). Install new cable straps (4) to the harness assembly Note: Ensure that the cable straps meet the Original Equipment Manufacture (OEM) specification. End By: a. Install the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Clean Emission Module (CEM) - Remove" for the correct procedure.

b. Install the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i05825500

Temperature Sensor (Exhaust) - Remove and Install Exhaust Manifold Temperature Sensor for NRS SMCS - 1439-010; 1919-010

Removal Procedure

Illustration 1

g02876918

1. Disconnect harness assembly (2) (not shown) from exhaust temperature sensor connection (1). 2. Slide exhaust temperature sensor connection (1) out of bracket (3). 3. Remove exhaust temperature sensor (5) from exhaust manifold (4).

Installation Procedure 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

g02876918

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i06062308

Temperature Sensor (Exhaust) - Remove and Install Temperature Sensor Exhaust After SCR SMCS - 1439-010; 1919-010

Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF Position.

Illustration 1

g03823099

1. Disconnect harness assembly for temperature sensor (1). 2. Remove the temperature sensor from Selective Catalytic Reduction (SCR) assembly (2).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bostik Pure Nickel Anti-Seize Compound

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

Illustration 2

g03823099

2. Apply Tooling (A) to the threads of temperature sensor (1). 3. Install the temperature sensor to Selective Catalytic Reduction (SCR) assembly (2). Tighten the temperature sensor to a torque of 45 N·m (33 lb ft). End By: a. Turn the battery disconnect switch to the ON Position.

Disassembly and Assembly C3.4B Engines for Caterpillar Built Machines Media Number -UENR4535-07

Publication Date -01/06/2015

Date Updated -28/08/2020

i06062306

Temperature Sensor (Exhaust) - Remove and Install Temperature Sensor Exhaust before SCR SMCS - 1439-010; 1919-010

Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF Position.

Illustration 1

g03823064

1. Disconnect harness assembly for temperature sensor (1). 2. Remove the temperature sensor from Selective Catalytic Reduction (SCR) assembly (2).

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

Bostik Pure Nickel Anti-Seize Compound

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Illustration 2

g03823064

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. 2. Apply Tooling (A) to the threads of temperature sensor (1). 3. Install the temperature sensor to Selective Catalytic Reduction (SCR) assembly (2). Tighten the temperature sensor to a torque of 45 N·m (33 lb ft). End By: a. Turn the battery disconnect switch to the ON Position.

CAT C3.4B Industrial Engine Electrical System

FPT INDUSTRIAL

Printed in U.S.A.

SCHEMATIC SYMBOLS AND DEFINITIONS INTERNAL PASSAGEWAYS

VALVES ENVELOPES

Two Position

One Position

Three Position

PORTS

Two-way

Three-Way

FLOW IN ONE DIRECTION

FLOW ALLOWED IN EITHER DIRECTION

Infinite Positioning

Two Position

PARALLEL FLOW

PUMPS

Unidirectional

Three Position

BASIC HYDRAULIC COMPONENT SYMBOLS

FIXED DISPLACEMENT

CROSS FLOW

Pump or Motor

Variability

Fluid Conditioner

Spring (Adjustable)

Spring

Pressure Compensation

Control Valves

Line Restriction (Variable)

Restriction

Line Restriction (Fixed)

Line Restriction Variable and Pressure Compensated

2-Section Pump

Attachment

Pump: Variable and Pressure Compensated

Bidirectional

VARIABLE DISPLACEMENT NON- COMPENSATED

CYLINDERS

Four-Way

Unidirectional

Bidirectional

CONTROL AB

P T

Single Acting

FIXED DISPLACEMENT

Shifted Position

Normal Position

MOTORS

Double Acting

Infinite Position

CHECK

ACCUMULATORS Basic Symbol

Spring Loaded

Shuttle

Unidirectional

VARIABLE DISPLACEMENT NON- COMPENSATED

Pilot Controlled

Spring Loaded Gas Charged

Unidirectional

PILOT CONTROL

Bidirectional

ROTATING SHAFTS

RELEASED PRESSURE

External Return

Bidirectional

Unidirectional

Internal Return

Bidirectional

REMOTE SUPPLY PRESSURE

Simplified

Complete

MAIN AUX.

Internal Supply Pressure

Hydraulic Pneumatic Energy Triangles

COMBINATION CONTROLS LINES Solenoid

Solenoid or Manual

Solenoid and Pilot

Solenoid and Pilot or Manual

Servo

Thermal

Detent

Crossing

MEASUREMENT Joining

MANUAL CONTROL

Push-pull Lever

Manual Shutoff

Temperature

Pressure

Flow

FLUID STORAGE RESERVOIRS

General Manual

Push Button

Pedal

Spring

Vented

Pressurized

Return Above Fluid Level

Return Below Fluid Level

ELECTRICAL SYMBOLS

HYDRAULIC SYMBOLS - ELECTRICAL

Transducer (Fluid)

Transducer (Gas / Air)

Generator

Electric Motor

Pressure Switch

Pressure Switch (Adjustable)

Temperature Switch

Electrical Wire

Pressure Switch

Temperature Switch

BASIC ELECTRICAL COMPONENT SYMBOLS

Level Switch

Flow Switch

Circuit Breaker

HARNESS AND WIRE SYMBOLS Wire, Cable, or Harness Assembly Identification: Includes Harness Identification Letters and Harness Connector Serialization Codes (see sample).

Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it. Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). No circle indicates that the wire cannot be disconnected from the component.

L-C12 3E-5179

AG-C4 111-7898

Part Number: for Connector Plug

Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine.

Receptacle Pin or Socket Number

Plug

Ground (Case): This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.

Harness Identification Letter(s): (A, B, C, AA, AB, AC, ...) Harness Connector Serialization Code: The "C" stands for "Connector" and the number indicates which connector in the harness (C1, C2, C3, ...)

Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.

Sender: A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid: A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. Magnetic Latch Solenoid: An electrical component that is activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.

L-C12 3E-5179 5A Fuse (5 Amps)

9X-1123

Component Part Number

325-AG135 PK-14 Harness identification code: This example indicates wire group 325, wire 135 in harness "AG".

Wire Gauge Wire Color

1 2

Deutsch connector: Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.

1 2

Sure-Seal connector: Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.

WASTEGATE REGULATOR RETURN

INJECTOR 1

2 3 4 6 7

TV POSITION SENSOR POWER +5V NRS POSITION SENSOR POWER +5V

8 9

SENSOR POWER +5V

10 FRP SENSOR POWER +5V 11 EGP SENSOR POWER +5V 12 CAM SPEED SENSOR POWER +5V 13 CAM SPEED SENSOR SIGNAL 14 FUEL METERING VALVE SUPPLY INJECTOR SUPPLY CYL 1 INJECTOR SUPPLY CYL 4

ECM 15

ECM 60

FUEL METERING VALVE

10 PIN CONNECTOR

5 OIL PRESSURE SWITCH

ELECTRONIC CONTROL MODULE (ECM) J2 INJECTOR SUPPLY CYL 3 INJECTOR SUPPLY CYL 2

ECM 6

A B H G

INJECTOR 2

D C E H

INJECTOR 3

J K

INJECTOR 4

15 16 17 18 19

OIL PRESSURE SWITCH

ECM 28 ECM 14 ECM 13

ECM 26 ECM 41 ECM 11

SECONDARY SPEED/TIMING SENSOR

2 3

FUEL RAIL PRESSURE

SENSOR

ECM 59

ECM 44

PRIMARY SPEED/TIMING SENSOR

20 21 22 ENGINE FUEL TEMP GROUND 23 NRS POSITION SENSOR GROUND 24 SENSOR GROUND 25 FRP SENSOR GROUND 26 EGP SENSOR GROUND 27 CAM SPEED SENSOR 28

29 30 INJECTOR RETURN CYL 3 31 INJECTOR RETURN CYL 1 32 33 THROTTLE VALVE RETURN 34 NRS RETURN VALVE 35 36 TV POSITION SENSOR 37 ENGINE FUEL TEMP SIGNAL 38 NRS POSITION SENSOR SIGNAL PRESSURE SENSOR SIGNAL FRP SENSOR SIGNAL EPG SENSOR SIGNAL CRANK SPEED SENSOR RETURN INJECTOR RETURN CYL 2 INJECTOR RETURN CYL 4

THROTTLE VALVE SUPPLY NRS VALVE SUPPLY

TV POSITION SENSOR SIGNAL TEMPERATURE SENSOR SIGNAL COOLANT TEMP SENSOR SIGNAL COOLANT TEMP SENSOR GROUND CRANK SPEED SENSOR SUPPLY

ECM 57 ECM 58

ECM 38 ECM 23

COOLANT TEMPERATURE

SENSOR

ENGINE FUEL TEMPERATURE

ELECTRONIC CONTROL MODULE (ECM) J2

SENSOR

ECM 25

ECM 10 ECM 40

INTAKE MANIFOLD AIR PRESSURE SENSOR

SENSOR GROUND TEMPERATURE SENSOR SIGNAL SENSOR POWER +5V PRESSURE SENSOR SIGNAL

3 4

62 PIN CONNECTOR ECM ECM ECM ECM ECM ECM ECM

60 6 14 26 41 11 28

1 2 3 4 5 6 7 8

ECM ECM ECM ECM

59 44 58 13

9 10 11 12

ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM

58 57 23 38 10 40 25 55 12 27 43

13 14 15 16

ECM 15

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

17 18 19 20

ECM 58 JI ECM 81 JI ECM 82 ECM 4 SWITCHED BATTERY +

FUEL METERING VALVE RETURN 60 61 62

ECM 50 ECM 35

ECM 24

35 36 37 38

ECM 49 ECM 34

39 40 41 42 43

ECM 8 ECM 53 ECM 37

GLOW PLUG CONTROL UNIT 8 3 41 4

25 26 27 28 29 30 31 32 33 34

ECM 9 ECM 39

21 22 23 24

6 1 7 2

ECM 55 ECM 58

ECM 15 ECM ECM ECM ECM ECM

60 6 14 26 41

19 6 17 18

1 2 3 4

INTAKE MANIFOLD AIR TEMPERATURE SENSOR

1 2

ECM 12 ECM 27

28 59 44 58 13 58 57 23 38

1 2

ECM 43

EXHAUST PRESSURE SENSOR

JI ECM 82

JI ECM 81

EXHAUST TEMPERATURE SENSOR

D SWITCHED BATTERY + ECM 4

ECM 10 ECM 40 ECM 25 ECM 55 ECM 12 ECM 27 ECM 43 ECM 58 JI ECM 81 JI ECM 82 ECM 4 SWITCHED BATTERY + ECM 50

WASTE GATE REGULATOR

ECM 50 ECM 35

1 5 6

ECM 9 ECM 39

ECM 24

NOx REDUCTION SYSTEM

Industrial Engine J1 Connections

VALVE

ECM 35

ECM 35 ECM 39 ECM 24

ECM 49

ECM 34 ECM 8 ECM 53

ECM 37

1 2 3

BATTERY + VIA MAIN RELAY (a) BATTERY -1 BATTERY + VIA MAIN RELAY (b)

4 5 6

BATTERY -2 BATTERY + VIA MAIN RELAY (c)

7 8 9 10 11 12 13

INTAKE THROTTLE VALVE

ECM 49

ECM 8 ECM 53 ECM 37

48 49 50 51 52

BATTERY -3 OXYGEN SENSOR HEATING STARTER REQUEST PTO MODE - ON/OFF PTO MODE - RESUME

53 54 55 56 57 58

COOLANT PRESSURE SWITCH RESERVE SENSOR SUPPLY 1 RESERVE SENSOR SUPPLY 2

59 60

14 15

DPF DIFFERENTIAL SENSOR POWER RESERVE SENSOR SUPPLY 3

16 17

THROTTLE 1 POWER (+5V) THROTTLE 2 POWER FAN SPEED SENSOR 2 SUPPLY AIR INLET TEMPERATURE SIGNAL AIR INLET SENSOR GROUND

18 19 20

ECM 34

21 22 23 24

FAN SPEED 2 GLOW PLUG UNIT FEED BACK SIGNAL

25 26 27 28

CAN C 1 (LOW) ENGINE SPEED OUTPUT SIGNAL STARTER RELAY LOW SIDE

29 30 31 32 33

(+5V)

WAIT TO START LAMP SHUTDOWN LAMP GLOW PLUG RELAY STARTER RELAY HIGH SIDE IGNITION KEYSWITCH + TORQUE LIMITATION (MULTIPLE STATE SWITCH) MPSTS 1 / SWITCH TO BATTERY + MPSTS 4 DPF DIFF PRESSURE SENSOR SIGNAL MPSTS 2 ANALOG THROTTLE 1

61 62

ANALOG THROTTLE 2

63 64 65 66

OXYGEN SENSOR VOLTAGE SIGNAL OXYGEN SENSOR CURRENT PUMP

67 68 69 70

CAN 2 (HIGH) CAN C 1 (HIGH)

DPF DISABLE LAMP REVERSE OUTPUT 1

THROTTLE ARBITRATION SWITCH

RESERVE GROUND 5 REGENERATION INHIBIT PWM THROTTLE 1 ISO K LOW OIL PRESSURE LAMP FUEL FILTER HEATER RELAY DO NOT CONNECT 11 (OUTPUT INSTEAD OF LOW VOLTAGE CONTROL) EVAPORATOR RELAY FAN REVERSE REGENERATION ACTIVE LAMP

MAIN RELAY OXYGEN SENSOR 1 HEATING DISCREET STAGE (OPTIONAL)

WATER IN FUEL SWITCH SIGNAL PTO MODE - RAISE

77 78 79 80

IDLE VALIDATION SWITCH 1/CUSTOMER FAN OVERRIDE TORQUE LIMITATION GROUND (MULTIPLE STATE SWITCH)

AIR SHUT OFF

CYLINDER 4 GLOW PLUG CYLINDER 3 GLOW PLUG

60 61

CYLINDER 2 GLOW PLUG

FAN SPEED SENSOR 2 GROUND

CYLINDER 1 GLOW PLUG

35 36 37 38 39

RESERVE GROUND 4 DPF DIFFER EN AL PRESSURE SENSOR GROUND RESERVE GROUND 6 THROTTLE POSITION SENSOR 1 GROUND

81 82 83 84 85

THROTTLE POSITION SENSOR 2 GROUND

INLET TURBINE TEMPERATURE SENSOR (EXHAUST) EXHAUST GAS TEMPERATURE SENSOR 2 GROUND EXHAUST GAS TEMPERATURE SENSOR 2 SIGNAL OXYGEN SENSOR GROUND OXYGEN SENSOR CURRENT ADJUST

RESERVE GROUND 3

MPTS3/ SWITCH TO GROUND

GLOW PLUG CONTROL GROUND

RESERVE INPUT 1

IDLE VALIDATION SWITCH 2

REGENERATION FORCE/SWITCH TO BATTERY

USER DEFINED SHUTDOWN SWITCH/SWITCH TO BATTERY

LIN INTERFACE PRE-SUPPLY PUMP

CAN 2 (LOW) CAN 1 (HIGH)

WARNING LAMP

ENGINE BRAKE ACTUATOR

CAN

DPF LAMP

CYLINDER 1 GLOW PLUG

CYLINDER 2 GLOW PLUG

GROUND 81 SIGNAL 82

46 47

71 72 73 74 75

57 58

GLOW PLUG CONTROL RETURN 22 GLOW PLUG CONTROL GROUND 41 GLOW PLUG CONTROL 52 EXHAUST TEMP SENSOR EXHAUST TEMP SENSOR

25 55 10 40

COMBINED INLET AIR TEMPERATURE AND AIR PRESSURE SENSOR

ECM 11 ECM ECM ECM ECM ECM ECM ECM ECM ECM

62 PIN CONNECTOR

SENSOR

PTO MODE - LOWER STARTER HSD DIAGNOSTIC GROUND (OPTIONAL)

1 (LOW)

DO NOT CONNECT 10 (PARALLEL A43) EXHAUST GAS TEMPERATURE SENSOR 1 GROUND EXHAUST GAS TEMPERATURE SENSOR 1 SIGNAL INLET TURBINE TEMPERATURE SENSOR GROUND (EXHAUST)

PWM THROTTLE 1 GROUND

SWITCHED BATTERY + (WASTEGATE REGULATOR) BATTERY +

CYLINDER 3 GLOW PLUG

CYLINDER 4 GLOW PLUG

(+) BATTERY

SYMBOL

(+) BATTERY SWITCHED STARTING CIRCUIT

CIRCUIT NOT CONNECTED

SENSOR / ACTUATOR SUPPLY

ELECTRICAL CONNECTION TO MACHINE STRUCTURE

SIGNAL TO ECM CONTROL (POSITIVE) FROM ECM CONTROL (RETURN) FROM ECM CAT DATA LINK H#

J1939 DATA LINK

DESCRIPTION CIRCUIT CONNECTED

(-) BATTERY / SENSOR RETURN

COLOR RED

WHITE

ORANGE

YELLOW

INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT

PINK

CONNECTOR

BLACK

CIRCUIT GROUPING DESIGNATION

RS-232/RS-485 DATA LINK

ATCH WIRE, CABLE, COMPONENT

ETHERNET

SPLICE

HIGHWAYS

BLADE, SPADE, RING OR SCREW TERMINAL

ABBREV

GRAY

PURPLE

BROWN

GREEN

BLUE

THIS SCHEMATIC IS FOR THE C3.4B INDUSTRIAL ENGINE ELECTRICAL SYSTEM MEDIA NUMBER: KENR9132-02

Components are shown installed on a fully operable machine with the key and engine off, transmission shifter in neutral and with parking brake set. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations. Note: Refer to the Parts Manual using a specific serial number prefix in SIS before ordering parts from this schematic.

ECM VIEW ALL CALLOUTS

ECM

FRONT VIEW VIEW ALL CALLOUTS

ALTERNATOR

INTAKE THROTTLE VALVE

LOCATION OF FUEL MANIFOLD PRESSURE SENSOR

FUEL MANIFOLD PRESSURE SENSOR

INTAKE THROTTLE VALVE

COOLANT TEMPERATURE SENSOR

COOLANT TEMPERATURE SECONDARY SPEED/TIMING SENSOR

GLOW PLUG CONTROL UNIT

BREATHER HEATER

INLET AIR TEMPERATURE SENSOR

HARNESS CONNECTORS VIEW ALL CALLOUTS

10 PIN CONNECTOR

62 PIN CONNECTOR

10 PIN CONNECTOR

5 9 62

57 60

LEFT SIDE VIEW VIEW ALL CALLOUTS

10 PIN CONNECTOR

62 PIN CONNECTOR

FUEL TEMPERATURE SENSOR

OIL PRESSURE SWITCH

FUEL METERING VALVE

HARNESS CONNECTION PLUGS

EXHAUST TEMPERATURE SENSOR

PRIMARY SPEED/TIMING SENSOR

WATER IN FUEL SWITCH

EXHAUST TEMPERATURE CONNECTOR

CAT C3.4B ENGINE PARTS FPT INDUSTRIAL ENGINE PARTS Phone 269 673 1638 email: engineparts2@gmail.com website: www.CATC34B.com

RIGHT SIDE VIEW NOx REDUCTION CONTROL VALVE

VIEW ALL CALLOUTS

OXYGEN SENSOR

INLET MANIFOLD PRESSURE AND TEMPERATURE SENSOR EXHAUST TEMPERATURE SENSOR CONNECTOR EXHAUST PRESSURE SENSOR WASTE GATE REGULATOR NRS CONTROL VALVE

STARTING MOTOR

WASTE GATE REGULATOR CONTROL VALVE

DFP DPF TEMPERATURE SENSOR DIESEL OXIDATION CATALYST TEMPERATURE SENSOR

OUTLET CONNECTION FOR DIFFERENTIAL PRESSURE SENSOR

INLET CONNECTION FOR DIFFERENTIAL PRESSURE SENSOR

WALL FLOW DFP

DIESEL OXIDATION CATALYST TEMPERATURE SENSOR

DIFFERENTIAL PRESSURE SENSOR

THROUGH FLOW DFP

TEMPERATURE SENSOR AFTER DOC

CAT C3.4B Cat C3.4B Diesel Engine with electronic high pressure common rail fuel system

PARTS SPECIFICATIONS AND BOLT TIGHTENING TORQUE VALUES

FPT INDUSTRIAL

www.FPTIndustrialEngineParts.com

Printed in U.S.A

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

Date Updated -15/07/2016

i05282770

Alternator SMCS - 1405 S/N - CJ31-UP S/N - CJG1-UP

12V Alternator

Illustration 1

g03357091

Typical example (1) Terminal "D+" (3) Terminal "W"

(2) Terminal "B+" Tighten the nut on the terminal to the following torque. ... 11 N·m (97 lb in) Tighten the nut for the alternator pulley to the following torque. ... 50 N·m (37 lb ft) Output The output of the alternator ... 65 Amp

12V Alternator

Illustration 2

g03357125

Typical example (3) Terminal "W"

(1) Terminal "D+" Tighten the nut on the terminal to the following torque. ... 3.25 N·m (28.76 lb in) (2) Terminal "B+" Tighten the nut on the terminal to the following torque. ... 11 N·m (97 lb in)

Tighten the nut for the alternator pulley to the following torque. ... 50 N·m (37 lb ft) Output The output of the alternator ... 80 Amp

12V Alternators

Illustration 3 Typical example (1) Terminal "W" (2) Terminal "D+"

g03357160

(3) Terminal "B+" Tighten the nut on the terminal to the following torque. ... 7.75 N·m (68.60 lb in) Tighten the nut for the alternator pulley to the following torque. ... 50 N·m (37 lb ft) Output The outputs of the alternators ... 100 Amp, and 120 Amp

24V Alternator

Illustration 4

g02620019

Typical example (3) Terminal "W"

(1) Terminal "B+" Tighten the nut on the terminal to the following. ... 7.75 N·m (68.60 lb in) (2) Terminal "D+"

Tighten the nut on the terminal to the following. ... 3.25 N·m (28.76 lb in) Tighten the nut for the alternator pulley to the following torque. ... 50 N·m (37 lb ft) Output The outputs of the alternators ... 65 Amp

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

Date Updated -15/07/2016

i04555081

Balancer SMCS - 1220

Illustration 1 Typical example

g02727673

Tighten the bolts in the sequence that is shown in illustration 1 to the following torque. ... 70 N·m (52 lb ft) Backlash values Backlash between the balancer gears ... 0.075 to 0.165 mm (0.00295 to 0.00650 inch) Backlash between the balancer gear and the crankshaft gear ... 0.110 to 0.210 mm (0.00433 to 0.00827 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

Date Updated -15/07/2016

i05246996

Boost Pressure Sensor - If equipped

Illustration 1

g03344803

Typical example

Illustration 2

g03344804

Typical example

(1) Tighten the fastener to the following torque. ... 15 N·m (11 lb ft) (2) Tighten the fastener to the following torque. ... 10 N·m (89 lb in) (3) Tighten the sensor to the following torque. ... 10 N·m (89 lb in) (4) Tighten the fastener to the following torque. ... 15 N·m (11 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

Date Updated -15/07/2016

i04411212

Camshaft Bearings

Illustration 1

g02608336

Typical example

(1) The diameter of the installed camshaft bearing ... 54.083 to 54.147 mm (2.12925 to 2.13177 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239470

Camshaft SMCS - 1210

Illustration 1 Typical example

g02844377

(1) Bolts Torque for the bolts ... 25 N·m (18 lb ft) (2) End play of a camshaft ... 0.1 to 0.3 mm (0.00394 to 0.01181 inch) Maximum permissible end play of a worn camshaft ... 0.3 mm (0.01181 inch) (3) The diameters of the camshaft journals are given in the following tables. Table 1 Camshaft Journals from the Front End of the Engine

Standard Diameter

1 Front

53.995 to 54.045 mm (2.12578 to 2.12775 inch)

2, 3 and 4

49.975 to 50.025 mm (1.96752 to 1.96948 inch)

5 Rear

39.975 to 40.025 mm (1.57382 to 1.57578 inch)

Check the camshaft lobes for visible damage. If a new camshaft is installed, you must install new lifters.

Publication Date -01/04/2013

i04332830

Connecting Rod Bearing Journal SMCS - 1202; 1219; 1225 The original size of the connecting rod bearing journal on the crankshaft ... 71.970 to 71.990 mm (2.83346 to 2.83425 inch) Maximum permissible wear of a bearing journal on the crankshaft when a new connecting rod is installed ... 0.04 mm (0.00157 inch) Width of the connecting rod bearing journals on the crankshaft ... 37.962 to 38.038 mm (1.4946 to 1.4976 inch) Radius of the fillet of the connecting rod bearing journals ... 1.6 to 1.7 mm (0.06299 to 0.06693 inch) Surface finish of connecting rod bearing journals ... Ra 0.3 microns maximum Surface finish of radii ... Ra 0.3 microns maximum

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04479212

Connecting Rod SMCS - 1218

Illustration 1

g02859356

Typical example

(1) The bearing shell for the connecting rod For the correct procedure to install the bearing shell for the connecting rod, refer to Disassembly and Assembly, "Pistons and Connecting Rods - Assemble". Table 1 Thickness of Connecting Rod Bearing at the Center

1.955 to 1.968 mm (0.07697 to 0.07748 inch)

Thickness of Bearing Cap at the Center

1.955 to 1.968 mm (0.07697 to 0.07748 inch)

Bearing Clearance

Illustration 2

0.080 to 0.035 mm (0.00315 to 0.00138 inch)

g02844317

Typical example (A) Class of weight (B) Part number (C) Date of production (DD/MM) (D) Date of production (Year) (E) Serial number markings on the connecting rod and connecting rod cap

The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged connecting rod. Ensure that the correct cap for the connecting rod is installed with the correct

connecting rod. Ensure that the serial numbers (E) for both components match. Refer to illustration 2 for more information. (2) Torque of the setscrews for the connecting rod ... 50 N·m (37 lb ft) Tighten the setscrews (2) for the connecting rod for an additional 70 degrees. The setscrews for the connecting rod must be replaced after this procedure.

Illustration 3

g02859357

Typical example

(3) Diameter of the finished bore for the piston pin ... 36.01 to 36.02 mm (1.41771 to 1.41811 inch) (4) Distance between the parent bores ... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)

(5) Diameter for the finished bore for the connecting rod bearing ... 67.833 to 67.848 mm (2.67059 to 2.67118 inch) Refer to table 2 for the length of connecting rod. Table 2 Specifications for the Connecting Rod Length Of The Connecting Rod 161.8 to 162.2 mm (6.37 to 6.38 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04346352

Coolant Temperature Sensor

Illustration 1

g02621136

Typical example

(1) Tighten the coolant temperature sensor to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239495

Crankcase Breather SMCS - 1317 For the correct procedures to remove and install the crankcase breather, refer to Disassembly and Assembly, "Crankcase Breather - Remove" and Disassembly and Assembly, "Crankcase Breather Install".

Illustration 1 Typical example

(1) Tighten the studs to the following torque. ... 8 N·m (71 lb in) (2) Tighten the insert to the following torque. ... 85 N·m (63 lb ft) (3) Tighten the nuts to the following torque. ... 10 N·m (89 lb in)

g02721003

Illustration 2

g02621860

Typical example

(4) Tighten the clamps to the following torque. ... 5 N·m (44 lb in)

Product: ENGINE - MACHINE Model: C3.4B ENGINE - MACHINE CJG Configuration: C3.4B Industrial Engine CJG00001-UP

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240730

Crankshaft Pulley SMCS - 1205

Illustration 1 Typical example

g02501059

(1) Tighten the bolts to the following torque. ... 45 N·m (33 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04343435

Crankshaft SMCS - 1202

Illustration 1

g02841976

Typical example (1) Crankshaft gear (2) Crankshaft (3) Crankshaft thrust washers

Maximum permissible temperature of the gear for installation on the crankshaft ... 180 °C (356 °F) The end play of a new crankshaft ... 0.1 to 0.41 mm (0.00394 to 0.01614 inch) Standard thickness of thrust washer ... 2.69 to 2.75 mm (0.10591 to 0.10827 inch)

Illustration 2

g02841978

Typical example (4) Journal 1 (5) Journal 2 (6) Journal 3 (7) Journal 4 (8) Journal 5

Refer to table 1 for the run out of the crankshaft journals. Table 1 Journal

Run out of the Journals

(1)

Mounting

(2)

0.03 mm (0.00118 inch)

(3)

0.03 mm (0.00118 inch)

(4)

0.03 mm (0.00118 inch)

(5)

Mounting

Inspect the crankshaft for wear or for damage. Refer to Specifications, "Connecting Rod Bearing Journal" for more information on the connecting rod bearing journals and connecting rod bearings. Refer to Specifications, "Main Bearing Journal" for information on the main bearing journals and for information on the main bearings.

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04332590

Cylinder Block SMCS - 1201

Illustration 1 Typical example

g02488336

(1) Cylinder block (2) Cylinder bore ... 99.00 to 99.02 mm (3.8976 to 3.8984 inch) (3) Camshaft bearings Diameter of the bushing in the cylinder block for the number 1 camshaft bearing ... 59.222 to 59.248 mm (2.33157 to 2.33259 inch) Diameter of the bore in the cylinder block for numbers 2, 3 and 4 camshaft journals ... 50.069 to 50.119 mm (1.97122 to 1.97319 inch) Diameter of the bore in the cylinder block for the number 5 camshaft journal ... 40.069 to 40.119 mm (1.57752 to 1.57949 inch) (4) Main bearings Bore in the cylinder block for the number 1, 2, 3 and 4 main bearings ... 80.588 to 80.614 mm (3.17275 to 3.17377 inch) Bore in the cylinder block for the number 5 main bearings ... 87.588 to 87.614 mm (3.44834 to 3.44936 inch) (5) Main bearing cap bolts Use the following procedure in order to install the main bearing cap bolts: 1. Apply clean engine oil to the threads of the main bearing cap bolts. 2. Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block. 3. Evenly tighten the main bearing cap bolts. Initial torque for the main bearing cap bolts. ... 50 N·m (37 lb ft) Final torque for the main bearing cap bolts. ... 80 N·m (59 lb ft) 4. After torquing the bolts for the main bearing caps, the bolts must be rotated for an additional 90 degrees. Note: Ensure that the crankshaft can rotate freely.

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04335069

Cylinder Head Valves SMCS - 1105

Illustration 1 Typical example

g01335203

When the valve springs (1) are replaced the valve springs must be replaced in pairs. The free length for the valve spring ... 44.6 mm (1.75590 inch) Table 1 The load for the valve spring

The length of the valve spring

270 N (61 lb)

34 mm (1.33858 inch)

528 N (119 lb)

23.8 mm (0.93701 inch)

Illustration 2

g01335204

(2) Valve face angle Inlet ... 30 degrees Exhaust ... 30 degrees (3) Valve stem diameter Inlet ... 7.985 to 8.000 mm (0.31437 to 0.31496 inch) Exhaust ... 7.985 to 8.000 mm (0.31437 to 0.31496 inch) Clearance Clearance of the inlet valve stem ... 0.040 to 0.053 mm (0.00157 to 0.00209 inch) Clearance Clearance of the exhaust valve stem ... 0.040 to 0.053 mm (0.00157 to 0.00209 inch) (4) Length of valve

Inlet valve and exhaust valve ... 132.75 to 133.15 mm (5.22637 to 5.24212 inch) (5) Valve head Diameter of inlet valve head ... 41.43 to 41.69 mm (1.63110 to 1.64134 inch) Diameter of exhaust valve head ... 37.27 to 37.53 mm (1.46732 to 1.47756 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05329586

Cylinder Head SMCS - 1100

Illustration 1

g03005658

Typical example

Lubricate the threads and the underside of the head bolts with clean engine oil. Tighten the M15 bolts in the sequence that is shown in illustration 1 to the following torque. ... 130 N·m (96 lb ft) Tighten the M12 bolts in the sequence that is shown in illustration 1 to the following torque. ... 65 N·m (48 lb ft) Tighten the M15 bolts in the sequence that is shown in illustration 1 to the additional amount. ... 90 degrees Tighten the M12 bolts in the sequence that is shown in illustration 1 to the additional amount. ... 90 degrees Tighten the M15 bolts in the sequence that is shown in illustration 1 to the additional amount. ... 70 degrees Tighten the M12 bolts in the sequence that is shown in illustration 1 to the additional amount. ... 60 degrees Minimum thickness of cylinder head ... 90 mm (3.54330 inch)

Illustration 2

g02490336

Note: The maximum distortion of the bottom face of the cylinder head is given in table 1. Table 1 Dimension Width (A) Length (B) Diagonal Line (C)

Maximum Permissible Distortion 0.05 mm (0.00197 inch) 0.05 mm (0.00197 inch) 0.05 mm (0.00197 inch)

Illustration 3

g02328933

Typical example

(D) Valve guide height from the top of the valve guide to the valve spring seat ... 8.5 ± 0.13 mm (0.335 ± 0.0051 inch) (E) Outside diameter of the valve guides ... 12.950 to 12.985 mm (0.50984 to 0.51122 inch) (F) Length of the valve guides ... 56 mm (2.20472 inch) (G) Internal diameter of the valve guides ... 8.023 to 8.038 mm (0.31587 to 0.31646 inch) (H) Valve depths Inlet ... 0.3 to 0.7 mm (0.01181 to 0.02756 inch) The service limit for the depth of the inlet valve ... 0.9 mm (0.03543 inch) Exhaust ... 0.3 to 0.7 mm (0.01181 to 0.02756 inch) The service limit for the exhaust valve depth ... 1 mm (0.03937 inch)

Illustration 4

g02474819

Typical example

(J) Diameter of the parent bore in the cylinder head ... 12.960 to 12.995 mm (0.51024 to 0.51161 inch) (K) Seat angle Inlet ... 59.5 degrees Exhaust ... 59.5 degrees

Illustration 5

g02847819

Typical example

(L) Seat surface finish ... Ra 0.5 microns (M) Concentricity of valve seat to valve guide parent bore Maximum Total Indicated Reading (TIR) ... 0.05 mm (0.00197 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05287843

Diesel Particulate Filter - Through Flow Diesel Particulate Filter (DPF)

Illustration 1 Typical example (2) Diesel Particulate Filter (DPF) (3) Clamps (4) Mounting bracket

(1) Tighten the bolts to an initial torque. ... 8 N·m (71 lb in) (1) Tighten the bolts to a second torque. ... 16 N·m (12 lb ft) (1) Tighten the bolts to a final torque. ... 25 N·m (18 lb ft)

g03358495

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05287571

Diesel Particulate Filter - Wall Flow Diesel Particulate Filter (DPF) SMCS - 108F S/N - CJG1-UP

Illustration 1 Typical example (3) Diesel Particulate Filter (DPF) (4) Clamps (5) Clamps (6) Mounting bracket

(1) Tighten the bolts to the following torque. ... 9 N·m (80 lb in) (2) Tighten the bolts to an initial torque. ... 8 N·m (71 lb in) (2) Tighten the bolts to a second torque. ... 16 N·m (12 lb ft) (2) Tighten the bolts to a final torque. ... 25 N·m (18 lb ft)

g03358816

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05241792

Electronic Control Module SMCS - 1901

Tighten the M6 fasteners to the following torque ... 8 N·m (71 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i06719934

Engine Design SMCS - 1201

Illustration 1 Cylinder and valve location (A) Exhaust valve (B) Inlet valve

Bore ... 99 mm (3.90 inch)

g06090557

Stroke ... 110 mm (4.33 inch) Displacement ... 3.4 L (207 in3) Cylinder arrangement ... In-line Type of combustion ... Direct injection Compression ratio Turbocharged aftercooled ... 17.5:1 Number of cylinders ... 4 Valves per cylinder ... 2 Firing order ... 1, 3, 4, 2 When the crankshaft is viewed from the flywheel end of the engine, the crankshaft rotates in the following direction: ... Counterclockwise When the camshaft is viewed from the flywheel end of the engine, the camshaft rotates in the following direction: ... Counterclockwise Note: The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240694

Engine Lifting Bracket SMCS - 1122

Illustration 1

g02488718

Typical example

(1) Tighten the bolts on the front engine lifting bracket to the following torque. ... 45 N·m (33 lb ft)

Illustration 2

g02488736

Typical example

(2) Tighten the bolts on the rear engine lifting brackets to the following torque. ... 65 N·m (48 lb ft)

Illustration 3

g03342585

Typical example

(3) Tighten the bolts on the rear engine lifting brackets to the following torque. ... 110 N·m (81 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240850

Engine Oil Cooler SMCS - 1378

Illustration 1 Typical example

g02871598

Tighten the setscrews in the sequence shown in illustration 1 to the following torque. ... 22 N·m (16 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240691

Engine Oil Filter Base SMCS - 1306

Illustration 1

g02659546

Typical example

(1) Tighten the plug to the following torque. ... 30 N·m (22 lb ft) (2) Tighten the plug to the following torque. ... 30 N·m (22 lb ft) (3) Tighten the engine oil pressure switch to the following torque. ... 35 N·m (26 lb ft) (4) Tighten the bolts to the following torque. ... 25 N·m (18 lb ft) (5) Tighten the filter to the following torque. ... 30 N·m (22 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04790655

Engine Oil Pan - Aluminum Oil Pan SMCS - 1302

Illustration 1

g02906220

Typical example

(1) Tighten the drain plug to the following torque. ... 50 N·m (37 lb ft) Tighten the fasteners (2) in sequence that is shown in illustration 2. Tighten the M8 fasteners to an initial torque of 7.5 N·m (66 lb in). Tighten the M10 fasteners to an initial torque of 13.5 N·m (10 lb ft). Tighten the fasteners (2) in sequence that is shown in illustration 2. Tighten the M8 fasteners to a final torque of 25 N·m (18 lb ft). Tighten the M10 fasteners to a final torque of 45 N·m (33 lb ft).

Illustration 2 Tightening sequence

g02906221

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05288769

Engine Oil Pan - Cast Iron Oil Pan SMCS - 1302

Illustration 1

g02676701

Typical example

(1) Tighten the drain plug to the following torque. ... 50 N·m (37 lb ft) Tighten the fasteners (2) to a torque of 70 N·m (52 lb ft). Tighten the fasteners in sequence that is shown in illustration 2.

Illustration 2

g02904098

Tightening sequence for the deep tunnel oil pan

Tighten the fasteners (2) to a torque of 70 N·m (52 lb ft). Tighten the fasteners in sequence that is shown in illustration 3.

Illustration 3 Tightening sequence for the flat bottom oil pan

g02904216

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04789574

Engine Oil Pan - Pressed Steel Oil Pan SMCS - 1302

Illustration 1 Typical example

g02904316

Illustration 2 Tightening sequence for the pressed steel oil pan

g02904337

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04333169

Engine Oil Pressure SMCS - 1924 The minimum oil pressure at normal operating temperature and at an engine speed of 750 rpm is the following value. ... 200 kPa (29 psi) The minimum oil pressure at normal operating temperature and at an engine speed of 2400 rpm is the following value. ... 400 kPa (58 psi)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04346369

Engine Oil Pump SMCS - 1304

Illustration 1 Typical example

g02501357

(1) Tighten the bolts to an initial torque. ... 15 N·m (11 lb ft) (1) Tighten the bolts to a final torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04426264

Exhaust Cooler (NRS) SMCS - 1079; 108C

Illustration 1

g02621805

Typical example

(1) Tighten the nuts to the following torque. ... 25 N·m (18 lb ft) (2) Tighten the fastener to the following torque. ... 3.5 N·m (31 lb in) (3) Tighten the fastener to the following torque. ... 10 N·m (89 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239430

Exhaust Gas Valve (NRS) SMCS - 3139; 5137; 5479

Illustration 1

g02626260

Typical example

(1) Tighten the setscrews to the following torque. ... 10 N·m (89 lb in) (2) Tighten the setscrews to the following torque. ... 40 N·m (30 lb ft) (3) Tighten the setscrews to the following torque. ... 20 N·m (15 lb ft) (4) Tighten the setscrews to the following torque. ... 20 N·m (15 lb ft) (5) Tighten the setscrews to the following torque. ... 20 N·m (15 lb ft) (6) Tighten the setscrew to the following torque. ... 20 N·m (15 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239453

Exhaust Manifold SMCS - 1059

Illustration 1

g02909156

Typical example

(1) Tighten the studs to the following torque. ... 18 N·m (13 lb ft)

Illustration 2

g02725251

Typical example

(2) Tighten the nuts to an initial torque. Tighten the nuts in the sequence that is shown in Illustration 2. ... 10 N·m (89 lb in) (2) Tighten the nuts to a final torque. Tighten the nuts in the sequence that is shown in Illustration 2. ... 27 N·m (20 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240729

Fan Drive SMCS - 1359

Illustration 1 Typical example

g02844797

(1) Tighten the bolts that secure the fan drive to the engine to the following torque. ... 25 N·m (18 lb ft) (2) Tighten the fasteners for the fan support to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05287664

Flexible Exhaust Pipe SMCS - 1061 S/N - CJ31-UP S/N - CJG1-UP

Illustration 1

g03180056

Typical example (1) Tube assembly (4) Bellows (6) Elbow

(2) Tighten the ball clamp to the following torque. ... 35 N·m (26 lb ft) (3) Tighten the clamp to the following torque. ... 55 N·m (41 lb ft) (5) Tighten the ball clamp to the following torque. ... 35 N·m (26 lb ft) (7) Tighten the V-band clamp to the following torque. ... 12 N·m (106 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04346112

Flywheel Housing SMCS - 1157

Illustration 1

g02501136

Typical example

Tighten the setscrews in the sequence that is shown in illustration 1 to an initial torque. ... 20 N·m (15 lb ft)

Illustration 2

g02727691

Typical example

Tighten setscrews (1), (2), (3), (4), (5), (6), (7) and (8) in the sequence that is shown in illustration 2 to a final torque. ... 110 N·m (81 lb ft) Tighten setscrews (9) and (10) in the sequence that is shown in illustration 2 to a final torque. ... 35 N·m (26 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i07037489

Flywheel SMCS - 1156

Illustration 1

g02501156

Typical example

(1) Flywheel ring gear Heat the flywheel ring gear to the following temperature. ... 180° C (356° F) Note: Do not use an oxyacetylene torch to heat the flywheel ring gear. (2) Flywheel (3) Bolt Tighten the flywheel bolts to the following torque: ... 140 N·m (103 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240669

Front Housing and Covers SMCS - 1162; 1166

Illustration 1 Typical example

g02909257

Illustration 2

g02951436

Typical example

(1) Tighten the setscrews in the sequence that is shown in illustration 2 to the following torque. ... 25 N·m (18 lb ft)

Illustration 3 Typical example

g02909258

Illustration 4

g02727967

Typical example

(2) Tighten the setscrews for the front cover in the sequence that is shown in illustration 4 to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240680

Fuel Filter Base - Primary Fuel Filter Base SMCS - 1261; 1262

NOTICE Refer to Systems Operation, Testing, and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

If necessary, install a new fuel filter element to canister (2). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.

Illustration 1

g02606186

Typical example

(1) Tighten the water in fuel sensor to the following torque. ... 2.5 N·m (22 lb in) Note: Tighten water in fuel sensor until the O-ring seal comes into contact with the bowl of the water separator. Tighten the water in fuel sensor an additional 180 degrees. (3) Tighten the connection to the following torque. ... 20 N·m (15 lb ft) (4) Tighten the setscrews to the following torque. ... 44 N·m (32 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240679

Fuel Filter Base - Secondary Fuel Filter Base SMCS - 1261; 1262

If necessary, install a new fuel filter element to canister (6). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.

Illustration 1

g02621258

Typical example

(1) Tighten the connections to the following torque. ... 25 N·m (18 lb ft) (2) Tighten the screw to the following torque. ... 2.5 N·m (22 lb in) (3) Tighten the screw to the following torque. ... 17 N·m (13 lb ft) (4) Tighten the setscrews to the following torque. ... 25 N·m (18 lb ft) (5) Tighten the fuel temperature sensor to the following torque. ... 22 N·m (16 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240674

Fuel Injection Lines SMCS - 1252

Refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" before adjustments and repairs are performed.

Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.

Illustration 1

g02501177

Typical example

(1) Tighten the screws to the following torque. ... 10 N·m (89 lb in) (2) ( 3) Torque for the nuts on the fuel injection lines ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05293114

Fuel Injection Nozzles SMCS - 1254 Refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" before adjustments and repairs are performed.

NOTICE Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Illustration 1

g03342579

Typical example (2) Clamp (4) Washer (5) O ring seal

(3) Tighten the studs in the cylinder head to the following torque. ... 20 N·m (15 lb ft) (1) Tighten the injector fastening nut to an initial torque. ... 15 N·m (11 lb ft) (1) Tighten the injector fastening nut to a final torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240671

Fuel Injection Pump SMCS - 1251; 1290

Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.

Illustration 1

g02621683

Typical example

Tighten the studs (not shown) to the following torque. ... 18 N·m (13 lb ft) (1) Tighten the nuts to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04424550

Fuel Manifold (Rail) SMCS - 1702 S/N - CJ31-UP S/N - CJG1-UP Refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" before adjustments and repairs are performed.

Illustration 1

g02621238

Typical example

(1) Tighten the fuel pressure relief valve to the following torque. ... 100 N·m (74 lb ft) (2) Tighten the bolts to the following torque. ... 25 N·m (18 lb ft) (3) Tighten the bolts to the following torque. ... 10 N·m (89 lb in) (4) Tighten the fuel pressure sensor to the following torque. ... 70 N·m (52 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240675

Gear Group (Front) SMCS - 1206

Illustration 1 Typical example

(1) Fuel injection pump drive gear Initial torque for the nut ... 18 N·m (13 lb ft) Final torque for the nut ... 90 N·m (66 lb ft) Number of teeth ... 24 (2) Idler gear Torque for the bolt for the idler gear ... 50 N·m (37 lb ft)

g02659957

Width of idler gear and bearing assembly ... 20.8 mm (0.81890 inch) Inside diameter of idler gear bearings ... 36.990 to 37.075 mm (1.45630 to 1.45964 inch) Outside diameter of idler gear hub ... 36.950 to 36.975 mm (1.45472 to 1.45571 inch) Clearance of idler gear bearing on hub ... 0.015 to 0.125 mm (0.00059 to 0.00492 inch) The end play of the idler gear ... 0.3 to 0.483 mm (0.01181 to 0.01902 inch) Number of teeth ... 31 (4) Camshaft gear Torque for the bolts for the camshaft gear ... 25 N·m (18 lb ft) Number of teeth ... 72 (5) Crankshaft gear Bore diameter of crankshaft gear ... 50.88 to 50.92 mm (2.00315 to 2.00472 inch) Outside diameter of crankshaft hub ... 50.984 to 51.000 mm (2.00724 to 2.00787 inch)

Number of teeth ... 36 (6) Oil pump idler gear Inside diameter of oil pump idler gear bearing ... 16.012 to 16.043 mm (0.63039 to 0.63161 inch) Outside diameter of oil pump idler gear shaft ... 15.987 to 16.000 mm (0.62941 to 0.62992 inch) End play of the oil pump idler gear ... 0.05 to 0.15 mm (0.00197 to 0.00591 inch) (7) Oil pump gear Inside diameter of oil pump gear bearing ... 15.932 to 15.957 mm (0.62724 to 0.62823 inch) Outside diameter of oil pump gear shaft ... 15.987 to 16.013 mm (0.62941 to 0.63043 inch) End play of the oil pump gear ... 0.05 to 0.15 mm (0.00197 to 0.00591 inch) Backlash values Backlash between the fuel injection pump gear (1) and the idler gear (2) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch)

Backlash between the idler gear (2) and the accessory drive gear (if equipped) (3) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch) Backlash between the idler gear (2) and the camshaft gear (4) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch) Backlash between the camshaft gear (4) and the crankshaft gear (5) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch) Backlash between the crankshaft gear (5) and the oil pump idler gear (6) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch) Backlash between the oil pump idler gear (6) and the oil pump gear (7) ... 0.07 to 0.17 mm (0.00276 to 0.00669 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04425773

Glow Plugs SMCS - 1412

Illustration 1 Typical example

g02621690

(1) Tighten the glow plugs to the following torque. ... 9 N·m (80 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04550539

Inlet Manifold Temperature and Pressure Sensor - If equipped SMCS - 1058-NS; 1439-TMS; 1439-PXS

Illustration 1

g02722054

Typical example

(1) Tighten the screw for the inlet manifold air pressure and temperature sensor to the following torque. ... 10 N·m (89 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05246995

Inlet Manifold Temperature Sensor - If equipped SMCS - 1921 S/N - CJ31-UP S/N - CJG1-UP

Illustration 1

g03344802

Typical example

Tighten the sensor to the following torque. ... 15 N·m (11 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04332521

Lifter Group SMCS - 1209

Illustration 1

g02488296

Typical example (B) 26 mm (1.02362 inch) (D) 38 ± 0.25 mm (1.49606 ± 0.00984 inch)

(A) Diameter of the lifter body ... 14.780 ± 0.04 mm (0.58189 ± 0.00157 inch) (C) Height of the lifter body ... 67 ± 0.25 mm (2.63779 ± 0.00984 inch) (E) Diameter of the lifter body ... 14.970 ± 0.02 mm (0.58937 ± 0.00079 inch) (F) Diameter of the lifter body ... 14.780 ± 0.04 mm (0.58189 ± 0.00157 inch) Bore diameter in the cylinder block ... 15.4 to 15.6 mm (0.60630 to 0.61417 inch) Clearance Clearance of the lifter ... 0.020 to 0.054 mm (0.00079 to 0.00213 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04332763

Main Bearing Journal SMCS - 1202; 1203 The original size of the main bearing journal ... 83.980 to 84.000 mm (3.30629 to 3.30708 inch) Maximum permissible wear of the main bearing journals ... 0.040 mm (0.0016 inch) Radius of the fillet of the main bearing journals ... 3.875 to 4.125 mm (0.15256 to 0.16240 inch) Surface finish of bearing journals and crank pins ... Ra 0.2 microns Surface finish of radii ... Ra 0.4 microns Width of new main bearing journal where the thrust washer is installed ... 35.235 to 35.165 mm (1.3872 to 1.3844 inch) Width of new main bearing journal where the thrust washer is not installed ... 35.25 to 35.15 mm (1.38779 to 1.38386 inch)

The shell for the main bearings The shells for the main bearings are available for remachined journals which have the following oversize dimensions. Oversize bearing shell ... 0.127 mm (0.005 inch) Oversize bearing shell ... 0.254 mm (0.010 inch) Oversize bearing shell ... 0.508 mm (0.020 inch) Thickness at center of the shells of oversize bearing shell 0.25 mm (0.010 inch) ... 2.226 to 2.232 mm (0.08764 to 0.08787 inch)

Thickness at center of the shells of oversize bearing shell 0.50 mm (0.020 inch) ... 2.353 to 2.359 mm (0.09264 to 0.09287 inch) Thickness at center of the shells of oversize bearing shell 0.76 mm (0.030 inch) ... 2.480 to 2.486 mm (0.09764 to 0.09787 inch) Width of the main bearing shells ... 26.32 to 26.58 mm (1.03622 to 1.04645 inch) Clearance between the bearing shell and the main bearing journals ... 0.032 to 0.102 mm (0.00126 to 0.00402 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04555069

Oxygen Sensor SMCS - 1096; 7400

Illustration 1

g02844456

Typical example

(1) Tighten the sensor to the following torque. ... 50 N·m (37 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i06865154

Piston and Rings SMCS - 1214; 1215

Illustration 1

g01155119

Typical example

(1) Top compression ring Width of top compression ring ... 2.068 mm to 2.097 mm (0.08142 inch to 0.08256 inch) Ring gap ... 0.112 mm to 0.157 mm (0.00441 inch to 0.00618 inch)

Note: When you install a new top compression ring, make sure that the word "TOP" is facing the top of the piston. New top piston rings have a black identification mark. The identification mark must be on the left of the ring end gap when the top piston ring is installed on an upright piston. (2) Intermediate compression ring Width of intermediate compression ring ... 1.970 mm to 1.990 mm (0.07756 inch to 0.07835 inch) The clearance between a new intermediate compression ring and the piston groove in a new piston ... 0.06 mm to 0.16 mm (0.00236 inch to 0.00630 inch) Ring gap ... 0.060 mm to 0.100 mm (0.00236 inch to 0.00394 inch) Note: When you install a new intermediate compression ring, make sure that the word "TOP" is facing the top of the piston. New intermediate rings have a blue identification mark. The identification mark must be on the left of the ring end gap when the top piston ring is installed on an upright piston. (3) The oil control ring Width of oil control ring ... 2.470 mm to 2.490 mm (0.09724 inch to 0.09803 inch) The clearance between a new oil control ring and the groove in a new piston ... 0.015 mm to 0.05 mm (0.00059 inch to 0.00197 inch) Ring gap ... 0.050 mm to 0.090 mm (0.00197 inch to 0.00354 inch) Note: When you install a new oil control ring, make sure that the word "TOP" is facing the top of the piston. New oil control rings have a red identification mark. The identification mark must be on the left of the ring end gap when the top piston ring is installed on an upright piston. The oil control ring is a two-piece ring that is spring loaded. A pin is used to hold both ends of the spring of the oil control ring in position. The ends of the spring of the oil control ring must be installed opposite the end gap of the oil control ring. Note: Ensure that the ring end gaps of the piston rings are spaced 120 degrees from each other.

Piston Note: An arrow which is marked on the piston crown must be toward the front of the engine.

Illustration 2

g02659840

Typical example (4) Piston (5) Cylinder bore

Measure the piston height. Refer to Systems Operation, Testing and Adjusting, "Piston Height Inspect" for the correct procedure. Refer to table 1 to select the correct gasket. Table 1 Engine Gasket Thickness (A)

Piston Height (B)

0.80 mm (0.03150 inch) 0.70 mm (0.02756 inch) Width of top groove in the piston ... 2.21 mm (0.08701 inch) Width of second groove in new piston ... 2.05 mm to 2.07 mm (0.08071 inch to 0.08150 inch) Width of third groove in new piston ... 2.54 mm to 2.56 mm (0.10000 inch to 0.10079 inch) Piston pin Diameter of a new piston pin ... 35.996 mm to 35.999 mm (1.41716 inch to 1.41728 inch)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04335149

Piston Cooling Jet SMCS - 1331

Illustration 1 Typical example

g02490436

(1) Tighten the bolt to the following torque. ... 18 N·m (13 lb ft)

Piston Cooling Jet Alignment

Illustration 2

g01352578

(2) Piston cooling jet (3) Rod (4) Cylinder block

Use the following procedure in order to check the alignment of the piston cooling jet. 1. Insert rod (3) into the end of the piston cooling jet (2). Rod (3) has a diameter of 1.70 mm (0.067 inch). Rod (3) must protrude out of the top of the cylinder block. 2. Dimension (A) is 50.75 mm (1.9980 inch) and dimension (B) is 9.35 mm (0.3681 inch). Dimension (A) and dimension (B) are tangential to the cylinder bore (4). 3. The position of the rod (3) must be within dimension (C). Dimension (C) is 14 mm (0.5512 inch).

Note: Ensure that the rod (3) cannot damage the piston cooling jet when the alignment is checked. The piston cooling jets cannot be adjusted. If a piston cooling jet is not in alignment, the piston cooling jet must be replaced.

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240876

Pressure Sensor (NOx Reduction System) SMCS - 1439

Illustration 1

g02724012

Typical example

Illustration 2

g03342627

Typical example

(1) Tighten the fastener to the following torque. ... 15 N·m (11 lb ft) (2) Tighten the sensor to the following torque. ... 15 N·m (11 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04823040

Rocker Shaft SMCS - 1102

Illustration 1 Typical example

g02842156

(1) Inlet rocker arm Diameter of the rocker arm bore ... 19.020 to 19.033 mm (0.74882 to 0.74933 inch) (2) Exhaust rocker arm Diameter of the rocker arm bore ... 19.020 to 19.033 mm (0.74882 to 0.74933 inch) Clearance Maximum clearance of both the rocker arm bores. ... 0.020 to 0.054 mm (0.00079 to 0.00213 inch) (3) Diameter of the rocker shaft ... 18.979 to 19.000 mm (0.74720 to 0.74803 inch)

Illustration 2

g02681778

Tightening sequence

Tighten the fasteners in the sequence that is in illustration 2. Tighten the fasteners to the following torque. ... 10 N·m (89 lb in) Sat Jul 17 15:02:45 UTC+0530 2021

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239559

Speed/Timing Sensor SMCS - 1907; 1912

Illustration 1 Typical example

g02620180

Illustration 2

g02620181

Typical example

(1) Tighten the screw for the crankshaft position sensor to the following torque. ... 10 N·m (89 lb in) (2) Tighten the screw for the camshaft position sensor to the following torque. ... 10 N·m (89 lb in)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04415750

Starter Motor SMCS - 1451; 1453

12 V Starting Motor 3.2 kW

Illustration 1

g02614019

Typical example

(1) Tighten the solenoid terminal to the following torque. ... 5.8 N·m (51 lb in) (2) Tighten the positive terminal nut to the following torque. ... 15 N·m (11 lb ft) (3) Tighten the negative terminal nut to the following torque. ... 12 N·m (106 lb in)

12 V Starting Motor 4.2 kW

Illustration 2

g02678770

Typical example

(1) Tighten the positive terminal nut to the following torque. ... 15 N·m (11 lb ft) (2) Tighten the solenoid terminal to the following torque. ... 15 N·m (11 lb ft) (3) Tighten the negative terminal nut to the following torque. ... 18 N·m (13 lb ft)

24 V Starting Motor 4.5 kW

Illustration 3

g02678817

Typical example

(1) Tighten the positive terminal nut to the following torque. ... 15 N·m (11 lb ft) (2) Tighten the solenoid terminal to the following torque. ... 5.8 N·m (51 lb in) (3) Tighten the negative terminal nut to the following torque. ... 18 N·m (13 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04550534

Temperature Sensor (DOC Inlet) SMCS - 1439; 1919

Illustration 1

g02722047

Typical example

(1) Tighten the temperature sensor to the following torque. ... 45 N·m (33 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04550469

Temperature Sensor (DPF Inlet) SMCS - 1439

Illustration 1

g02722006

Typical example

(1) Tighten the temperature sensor to the following torque. ... 45 N·m (33 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05240937

Temperature Sensor (NOx Reduction System) SMCS - 1439

Illustration 1

g03342646

Typical example

Illustration 2 Typical example

(1) Tighten the sensor to the following torque. ... 45 N·m (33 lb ft) Operating voltage ... 5 VDC

g02722380

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i05239446

Turbocharger SMCS - 1052

Illustration 1

g02626265

Typical example

(1) Actuator The test pressure for the wastegate actuator ... 170 kPa (24.6568 psi) The movement for the rod actuator ... 10 mm (0.3937 inch)

Illustration 2 Typical example

(2) Tighten the studs to the following torque. ... 15 N·m (11 lb ft) (3) Tighten the nuts to the following torque. ... 25 N·m (18 lb ft)

g02626267

Illustration 3 Typical example

(4) Tighten the bolt to the following torque. ... 22 N·m (16 lb ft) (5) Tighten the bolts to the following torque. ... 25 N·m (18 lb ft)

g02626269

Illustration 4

g02626270

Typical example

(6) Tighten the setscrew to the following torque. ... 25 N·m (18 lb ft) (7) Tighten the nut to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04335229

Valve Mechanism Cover SMCS - 1107

Illustration 1

g02490536

Typical example

Tighten the M6 fasteners (1), (2), (3), (4), (5), (6) and (7) in the sequence shown in illustration 1 to an initial torque. ... 5 N·m (44 lb in) Tighten the M8 fastener (8) in the sequence shown in illustration 1 to an initial torque. ... 10 N·m (89 lb in)

Illustration 2

g02727663

Typical example

Tighten the M6 fasteners (1), (2), (3), (4), (5), (6) and (7) in the sequence shown in illustration 2 to a final torque. ... 10 N·m (89 lb in) Tighten the M8 fasteners (8), (9) and (10) in the sequence shown in illustration 2 to a final torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04335189

Water Pump SMCS - 1361

Illustration 1 Typical example

g02490498

(1) Tighten the setscrews to the following torque. ... 25 N·m (18 lb ft)

Specifications C3.4B Industrial Engine Media Number -UENR0619-02

Publication Date -01/04/2013

i04335212

Thermostat - Water Temperature Regulator and Housing SMCS - 1355; 1393

Illustration 1

g02842121

Typical example

Torque for the vent plug ... 40 N·m (30 lb ft) Torque for the bolts (1) and (2) that fasten the housing to the cylinder head ... 25 N·m (18 lb ft)

Illustration 2

g00906121

Typical example

Thermostat Opening temperature ... 77° to 81°C (171° to 196°F) Maximum open length of 11.5 mm (0.45276 inch) is achieved at the following temperature. ... 130° C (266° F)

CAT C3.4B Cat C3.4B Diesel Engine with electronic high pressure common rail fuel system

SYSTEMS OPERATIONS

FPT INDUSTRIAL

www.FPTIndustrialEngineParts.com

Printed in U.S.A

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04174031

Air Inlet and Exhaust System SMCS - 1050

Illustration 1 Air inlet and exhaust system (1) Aftercooler core (2) Air filter (3) Diesel particulate filter

g02720982

(4) Turbocharger (5) Wastegate actuator (6) Boost pressure chamber (7) Exhaust gas valve (NRS) (8) Wastegate regulator (9) Exhaust cooler (NRS) (10) Inlet manifold (11) Throttle valve

The components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The air inlet and exhaust system consists of the following components: • Air cleaner • Exhaust cooler (NRS) • Exhaust gas valve (NRS) • Turbocharger • Aftercooler • Inlet manifold • Cylinder head, injectors, and glow plugs • Valves and valve system components • Piston and cylinder • Exhaust manifold • Diesel oxidation catalyst • Diesel particulate filter • Throttle valve Air is drawn in through the air cleaner into the air inlet of the turbocharger by the turbocharger compressor wheel. The air is compressed to a pressure of about 150 kPa (22 psi) and the compression heats the air to about 120° C (248° F) before the air is forced to the aftercooler. As the air flows through the aftercooler the temperature of the compressed air lowers to about 55° C (131° F). Cooling of the inlet air assists the combustion efficiency of the engine. Increased combustion efficiency helps achieve the following benefits: • Lower fuel consumption • Increased power output • Reduced NOx emission • Reduced particulate emission

From the aftercooler, air is forced into the inlet manifold. Air flow from the inlet manifold to the cylinders is controlled by inlet valves. There is one inlet valve and one exhaust valve for each cylinder. The inlet valve opens when the piston moves down on the intake stroke. When the inlet valve opens, cooled compressed air from the inlet port is forced into the cylinder. The complete cycle consists of four strokes: • Inlet • Compression • Power • Exhaust On the compression stroke, the piston moves back up the cylinder and the inlet valve closes. The cool compressed air is compressed further. This additional compression generates more heat. Note: If the cold starting system is operating, the glow plugs will also heat the air in the cylinder. Just before the piston reaches the top center (TC) position, the ECM operates the electronic unit injector. Fuel is injected into the cylinder. The air/fuel mixture ignites. The ignition of the gases initiates the power stroke. Both the inlet and the exhaust valves are closed and the expanding gases force the piston downward toward the bottom center (BC) position. From the BC position, the piston moves upward. This initiates the exhaust stroke. The exhaust valve opens. The exhaust gases are forced through the open exhaust valve into the exhaust manifold.

Illustration 2 Typical example

g02720984

The NOx Reduction System (NRS) operates with the transfer of the hot exhaust gas from the exhaust manifold to the assembly of the exhaust gas valve. The assembly of the exhaust gas valve consists of an exhaust gas valve and an electronically controlled actuator. As the electronically controlled actuator (7) starts to open the flow of exhaust gas from the exhaust gas valve mixes with the air flow from the charge air aftercooler. The mixing of the exhaust gas and the air flow from the charge air aftercooler reduces the oxygen content of the gas mixture. This results in a lower combustion temperature, so decreases the production of NOx. As the demand for more exhaust gas increases the electronically controlled actuator opens further. The further opening of the actuator increases the flow of exhaust gas from the exhaust gas valve. As the demand for exhaust gas decreases, the electronically controlled actuator closes. This decreases the flow of exhaust gas from the exhaust gas valve. The hot exhaust gas is then cooled in the exhaust cooler (6). The cooled gas then travels from the exhaust cooler (6) to the inlet manifold. Exhaust gases from the exhaust manifold enter the inlet of the turbocharger in order to turn the turbocharger turbine wheel. The turbine wheel is connected to a shaft that rotates. The exhaust gases pass from the turbocharger through the following components: exhaust outlet, Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and exhaust pipe.

Turbocharger

Illustration 3

g00302786

Typical example of a cross section of a turbocharger (1) Air intake (2) Compressor housing (3) Compressor wheel (4) Bearing (5) Oil inlet port (6) Bearing (7) Turbine housing (8) Turbine wheel (9) Exhaust outlet (10) Oil outlet port (11) Exhaust inlet

The turbocharger is mounted on the outlet of the exhaust manifold. The exhaust gas from the exhaust manifold enters the exhaust inlet (11) and passes through the turbine housing (7) of the turbocharger. Energy from the exhaust gas causes the turbine wheel (8) to rotate. The turbine wheel is connected by a shaft to the compressor wheel (3). As the turbine wheel rotates, the compressor wheel is rotated. The rotation of the compressor wheel causes the intake air to be pressurized through the compressor housing (2) of the turbocharger.

Illustration 4

g02720975

Typical example (12) Line (boost pressure) (13) Wastegate actuator (14) Actuating lever

Illustration 5

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Typical example (15) Wastegate regulator

When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this additional fuel produces more exhaust gases. The additional exhaust gases cause the turbine and the compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, air is compressed to a higher pressure and more air is forced into the cylinders. The increased flow of air into the cylinders allows the fuel to be burnt with greater efficiency. The more efficient burning of fuel produces more power. A wastegate is installed on the turbine housing of the turbocharger. The wastegate is a valve that allows exhaust gas to bypass the turbine wheel of the turbocharger. The operation of the wastegate is dependent on the pressurized air (boost pressure) from the turbocharger compressor. The boost pressure acts on a diaphragm. The diaphragm is spring loaded in the wastegate actuator which varies the amount of exhaust gas that flows into the turbine. The wastegate regulator (15) is controlled by the engine electronic control module (ECM). The ECM uses inputs from a number of engine sensors to determine the optimum boost pressure. This will achieve the best exhaust emissions and fuel consumption at any given engine operating

condition. The ECM controls the wastegate regulator, that regulates the boost pressure to the wastegate actuator. When high boost pressure is needed for the engine performance, a signal is sent from the ECM to the wastegate regulator. This causes high pressure in the inlet manifold to act on the diaphragm within the wastegate actuator (13). The actuating rod (14) acts upon the actuating lever to close the valve in the wastegate. When the valve in the wastegate is closed, more exhaust gas is able to pass over the turbine wheel. This results in an increase in the speed of the turbocharger. When low boost pressure is needed for the engine performance, a signal is sent from the ECM to the wastegate regulator. This causes high pressure in the air inlet pipe (12) to act on the diaphragm within the wastegate actuator (13). The actuating rod (14) acts upon the actuating lever to open the valve in the wastegate. When the valve in the wastegate is opened, more exhaust gas from the engine is able to bypass the turbine wheel, resulting in a decrease in the speed of the turbocharger. The shaft that connects the turbine to the compressor wheel rotates in bearings (4) and (6). The bearings require oil under pressure for lubrication and cooling. The oil that flows to the lubricating oil inlet port (5) passes through the center of the turbocharger which retains the bearings. The oil exits the turbocharger from the lubricating oil outlet port (10) and returns to the oil pan.

Crankcase Breather NOTICE The crankcase breather gases are part of the engines measured emissions output. Any tampering with the breather system could invalidate the engines emissions compliance.

The crankcase breather has a centrifugal separator. The centrifugal separator has a special coating. Engine oil that has been separated from the breather gas is returned to the timing case. The crankcase breather is driven by the shaft of the fuel injection pump. A heated connection may be installed on the pipe for the crankcase breather. The purpose of the heated connection is to prevent the formation of ice in cold climates, that could lead to an obstruction of the pipe.

Valve System Components CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 6

g02720989

Valve system components (1) Rocker arm (2) Pushrod (3) Lifter (4) Camshaft

The valve system components control the flow of inlet air into the cylinders during engine operation. The valve system components also control the flow of exhaust gases out of the cylinders during engine operation. The crankshaft gear drives the camshaft gear. The camshaft must be timed to the crankshaft in order to get the correct relation between the piston movement and the valve movement. The camshaft has two camshaft lobes for each cylinder. The lobes operate either the inlet valve or the exhaust valve. As the camshaft turns, lobes on the camshaft cause the lifter to move the pushrod up and down. Upward movement of the pushrod against rocker arm results in a downward movement. This action opens a pair of valves which compresses the valve springs. When the camshaft has rotated to the peak of the lobe, the valves are fully open. When the camshaft rotates further, the two valve springs under compression start to expand. The valve stems are under tension of the springs. The stems are pushed upward. The continued rotation of the camshaft causes the rocker arm, the pushrods and the lifters to move downward until the lifter reaches the bottom of the lobe. The valves are now closed. The cycle is repeated for all the valves on each cylinder.

The rocker arm incorporates a hydraulic lash adjuster which removes valve lash from the valve mechanism. The hydraulic lash adjuster uses engine lubricating oil to compensate for wear of system components so that no service adjustment of valve lash is needed. The engine lubricating oil enters the hydraulic lash adjuster through a non-return valve. The engine lubricating oil increases the length of the hydraulic lash adjuster until all valve lash is removed. If the engine is stationary for a prolonged period the valve springs will cause the hydraulic lash adjuster to shorten so that when the engine is started engine valve lash is present for the first few seconds. After cranking restores oil pressure the hydraulic lash adjuster increases in length and removes the valve lash. When load is removed from a hydraulic lash adjuster during service work by the removal of the rocker shaft the hydraulic lash adjuster increases in length to the maximum extent. Refer to Systems Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. During reassembly of the rocker shaft the engine must be put into a safe position to avoid engine damage. After load is imposed on the lifters by reassembling the rocker assembly, the engine must be left in safe position for a safe period until the lifters have reduced to the correct length. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169549

Basic Engine SMCS - 1200

Introduction The eight major mechanical components of the basic engine are the following parts: • Cylinder block • Cylinder head • Pistons • Connecting rods • Crankshaft • Timing gear case and gears • Camshaft

Cylinder Block

Illustration 1

g02859296

Typical example

The cast iron cylinder block for the engine has four cylinders which are arranged in-line. The cylinder block is made of cast iron. The cylinder block provides support for the full length of the cylinder bores. The cylinder bores are machined into the block. The cylinders are honed to a specially controlled finish in order to ensure long life and low oil consumption. The cylinder block has five main bearings which support the crankshaft. Thrust washers are installed on both sides of number 3 main bearing in order to control the end play of the crankshaft. The thrust washers can only be installed one way. Passages supply the lubrication for the crankshaft bearings. These passages are machined into the cylinder block. Cooling passages are cast into the cylinder block in order to allow the circulation of coolant. The cylinder block has a bush that is installed for the front camshaft journal. The other camshaft journals run directly in the cylinder block. The engine has a cooling jet that is installed in the cylinder block for each cylinder. The piston cooling jet sprays lubricating oil onto the inner surface of the piston in order to cool the piston. A Multi-Layered Steel (MLS) cylinder head gasket is used between the engine block and the cylinder head in order to seal combustion gases, water, and oil.

Cylinder Head

Illustration 2

g02859418

Typical example (1) Valve keepers (2) Valve spring retainer (3) Valve spring

The engine has a cast iron cylinder head (4). There is one inlet valve and one exhaust valve for each cylinder. The port for the inlet valve is on the top of the cylinder head. The port for the exhaust valve is on the right side of the cylinder head. The valve stems move in valve guides that are pressed into the cylinder head. There is a renewable oil seal that fits over the top of the valve guide. The valve seats and the valve guides are replaceable.

Pistons, Rings, and Connecting rods CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Illustration 3

g02859336

Typical example

The pistons (3) have a Quiescent combustion chamber in the top of the piston in order to provide an efficient mix of fuel and air. The piston pin (9) is off-center in order to reduce the noise level. The position pin (9) is retained in the correct position by two circlips (8). The pistons (3) have two compression rings (1) and an oil control ring (2). The groove for the top ring has a hard metal insert in order to reduce wear of the groove. The piston skirt has a coating of graphite in order to reduce the risk of seizure when the engine is new. The correct piston height is important in order to ensure that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in order to conform to requirements for emissions. The connecting rods (4) are machined from forged steel. The connecting rods have bearing caps (6) that are fracture split. The bearing caps (6) on fracture split connecting rods (4) are retained with bolts (7). Connecting rods with bearing caps that are fracture split have the following characteristics:

• The splitting produces an accurately matched surface on each side of the fracture for improved strength. • The correct connecting rod must be installed with the correct bearing cap. Each connecting rod and bearing cap have a unique serial number. When a connecting rod is assembled the serial numbers for the connecting rod and bearing cap must match.

Crankshaft

Illustration 4

g02841976

Typical example (1) Crankshaft gear (2) Crankshaft (3) Crankshaft thrust washers

The crankshaft can be a spheroidal graphite iron casting. The crankshaft has five main journals. Thrust washers are installed on both sides of number 3 main bearing in order to control the end play of the crankshaft. The crankshaft changes the linear energy of the pistons and connecting rods into rotary torque in order to power external equipment. A gear at the front of the crankshaft drives the timing gears. The crankshaft gear turns the idler gear which then turns the following gears:

• Camshaft gear • Fuel injection pump and fuel transfer pump Lip type seals are used on both the front of the crankshaft and the rear of the crankshaft. A timing ring is installed to the crankshaft. The timing ring is used by the ECM in order to measure the engine speed and the engine position. A timing ring for the balancer can be installed to the crankshaft. The timing ring for the balancer drives the balancer.

Gears and Timing Gear Case

Illustration 5 Typical example

g02859276

The crankshaft oil seal is mounted in the cover of the timing case. The timing case is made of cast iron. The timing case cover is made from aluminum. The timing gears are made of steel. The crankshaft gear (5) drives the camshaft gear (4) and an idler gear (6) for the engine oil pump. The idler gear (6) for the engine oil pump drives the oil pump gear (7). The camshaft gear (4) drives the idler gear (2) and the accessory drive gear (3). The idler gear (2) drives the fuel injection pump gear (1). The camshaft gear rotates at half the engine speed. The fuel injection pump gear rotates at one and a half times engine speed.

Camshaft The engine has a single camshaft. The camshaft is made of cast iron. The camshaft lobes are chill hardened. The camshaft is driven at the front end. As the camshaft turns, the camshaft lobes move the valve system components. The valve system components move the cylinder valves. The camshaft gear must be timed to the crankshaft gear. The relationship between the lobes and the camshaft gear causes the valves in each cylinder to open at the correct time. The relationship between the lobes and the camshaft gear also causes the valves in each cylinder to close at the correct time.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05242096

Clean Emissions Module SMCS - 1062; 108B; 108E; 108F; 108M To meet current emissions legislation requirements, a small amount of certain chemical compounds that are emitted by the engine must not be allowed to enter the atmosphere. The Clean Emissions Module (CEM) that is installed to the engine is designed to convert these chemical compounds into less harmful compounds. The Engine Aftertreatment System for the engine consists of the following components. • Diesel Oxidation Catalyst (DOC) • Diesel Particulate Filter (DPF) The Diesel Oxidation Catalyst (DOC) oxidizes the carbon monoxide and the hydrocarbons that are not burnt in the exhaust gas into carbon dioxide and water. The Diesel Oxidation Catalyst (DOC) is a through flow device that will continue to operate during all normal engine operating conditions. The Diesel Particulate Filter (DPF) collects all solid particulate matter in the exhaust gas. The solid particulate matter that is collected by the DPF consists of soot (carbon) from incomplete combustion of the fuel and inorganic ash from the combustion of any oil in the cylinder.

Illustration 1

g03343187

A typical example of a CEM with a wall flow Diesel Particulate Filter (DPF)

For engines with a power rating of 55 kW or higher, a wall flow Diesel Particulate Filter (DPF) is used.

Illustration 2

g03343192

A typical example of a CEM with a through flow Diesel Particulate Filter (DPF)

For engines with a power rating of 55 kW or lower, a through flow Diesel Particulate Filter (DPF) is used.

The wall flow Diesel Particulate Filter (DPF) is designed to contain all the ash up to the ash service interval. Refer to Operation and Maintenance Manual for more information. No ash service is required for the through flow Diesel Particulate Filter (DPF). The engine aftertreatment system is designed to oxidize the soot in the DPF at the same rate as the soot is produced by the engine. The oxidization of the soot will occur when the engine is operating under normal conditions. The soot in the DPF is constantly monitored. The regeneration system is passive with an additional Oxy-Exotherm system. The Oxy-Exotherm system operates by injecting fuel after the main fuel injection period. The fuel is then burnt over a catalyst to raise the temperature of the exhaust gases to 650° C (1202° F). If the engine is operated in a way that produces more soot than the oxidized soot, the engine management system will automatically activate systems to raise the exhaust temperature. The raising of the exhaust temperature will ensure that more soot is oxidized than the soot that is produced by the engine. The oxidization of more soot returns the DPF to a reduced level of soot. The systems are then deactivated when the soot level has been reduced. The engine ECM must know how much soot is in the DPF. Measurement of soot is accomplished through the following means: • Soot Load Estimation Model that is based on engine operating conditions • Delta pressure measurement across the DPF used to estimate the soot load by evaluation of the flow resistance of the Diesel Particulate Filter (DPF) The Electronic Control Module (ECM) uses the soot measurement information to determine if the engine operating conditions need to be adjusted in order to oxidize the soot at an increased rate.

Product: ENGINE - MACHINE Model: C3.4B ENGINE - MACHINE CJG Configuration: C3.4B Industrial Engine CJG00001-UP

Publication Date -01/03/2013

i04173652

Cleanliness of Fuel System Components SMCS - 1250

Cleanliness of the Engine NOTICE It is important to maintain extreme cleanliness when working on the fuel system, since even tiny particles can cause engine or fuel system problems.

The entire engine should be washed with a high-pressure water system. Washing the engine will remove dirt and loose debris before a repair on the fuel system is started. Ensure that no highpressure water is directed at the seals for the injectors or electrical connectors.

Environment When possible, the service area should be positively pressurized. Ensure that the components are not exposed to contamination from airborne dirt and debris. When a component is removed from the system, the exposed fuel connections must be closed off immediately with suitable sealing plugs. The sealing plugs should only be removed when the component is reconnected. The sealing plugs must not be reused. Dispose of the sealing plugs immediately after use. Contact your nearest Caterpillar dealer in order to obtain the correct sealing plugs.

New Components High-pressure lines are not reusable. New high-pressure lines are manufactured for installation in one position only. When a high-pressure line is replaced, do not bend or distort the new line. Internal damage to the pipe may cause metallic particles to be introduced to the fuel.

All new fuel filters, high-pressure lines, tube assemblies, and components are supplied with sealing plugs. These sealing plugs should only be removed in order to install the new part. If the new component is not supplied with sealing plugs then the component should not be used. The technician must wear suitable rubber gloves. The rubber gloves should be disposed of immediately after completion of the repair in order to prevent contamination of the system.

Refueling In order to refuel the diesel fuel tank, the refueling pump and the fuel tank cap assembly must be clean and free from dirt and debris. Refueling should take place only when the ambient conditions are free from dust, wind, and rain. Only use fuel that is free from contamination. Ultra Low Sulfur Diesel (ULSD) must be used. The content of sulfur in Ultra Low Sulfur Diesel (ULSD) fuel must be below 15 PPM 0.0015%. Biodiesel may be used. The neat biodiesel must conform to the latest "EN14214 or ASTM D6751" (in the USA). The biodiesel can only be blended in mixture of up to 20% by volume in acceptable mineral diesel fuel meeting latest edition of "EN590 or ASTM D975 S15" designation. In United States, Biodiesel blends of B6 to B20 must meet the requirements listed in the latest edition of "ASTM D7467" (B6 to B20) and must be of an API gravity of 30-45. For more information, refer to Operation and Maintenance Manual, "Fluid Recommendations".

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169911

Cooling System SMCS - 1350

Introduction The cooling system has the following components: • Radiator • Water pump • Cylinder block • Oil cooler • Exhaust gas cooler (NRS) • Cylinder head • Water temperature regulator ( thermostat )

Coolant Flow

Illustration 1

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Typical example (1) Radiator (2) Thermostat - Water temperature regulator and housing (3) Exhaust gas cooler (NRS) (4) Cylinder head (5) Cylinder block (6) Water pump (7) Engine oil cooler

The coolant flows from the bottom of the radiator (1) to the engine oil cooler (7). The engine oil cooler (7) is installed on the right-hand side of the engine. The coolant flows from the engine oil cooler (7) to the water pump (6). The water pump (6) contains a rotary seal that uses the engine coolant as a lubricating medium. This will ensure that an adequate sealing film is created. The sealing film is maintained in order to reduce heat generation. Heat that is generated by the rotating sealing faces under normal operating conditions causes a small flow of coolant to be emitted into a chamber. The water pump pumps the coolant through a passage to the main coolant gallery in the cylinder block (5). Coolant flows around the outside of the cylinders then flows from the cylinder block (5) into the cylinder head (4). The coolant flows forward through the cylinder head (4). Some coolant is diverted into the exhaust gas cooler (NRS) (3) by a coolant pipe in the right-hand side of the cylinder block (5). The coolant

then flows from the exhaust gas cooler (NRS) (3) back to the housing of the thermostat - water temperature regulator (2). The coolant then flows into the housing of the thermostat - water temperature regulator (2). If the thermostat - water temperature regulator is closed, the coolant goes directly through a bypass to the inlet side of the water pump. If the thermostat - water temperature regulator is open, and the bypass is closed then the coolant flows to the top of the radiator (1).

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169852

Electrical System SMCS - 1400; 1550; 1900 The electrical system is a negative ground system. The charging circuit operates when the engine is running. The alternator in the charging circuit produces direct current for the electrical system.

Starting Motor The starting motor turns the engine via a gear on the engine flywheel. The starting motor speed must be high enough in order to initiate a sustained operation of the fuel ignition in the cylinders. The ignition switch is deactivated once the desired engine speed has been achieved. The circuit is disconnected. The armature will stop rotating. Return springs that are located on the shafts and the solenoid will disengage the pinion from flywheel ring gear back to the rest position. The armature of the starting motor and the mechanical transmissions may be damaged if the increases in the speed of the engine are greater than the pinion of the starting motor. Damage may occur when the engine is started or after the engine is started. An overrunning clutch prevents damage to the armature of the starting motor and mechanical transmissions.

Alternator The electrical outputs of the alternator have the following characteristics: • Three-phase • Full-wave • Rectified The alternator is an electro-mechanical component. The alternator is driven by a belt from the crankshaft pulley. The alternator charges the storage battery during the engine operation.

The alternator is cooled by an external fan which is mounted behind the pulley. The fan may be mounted internally. The fan forces air through the holes in the front of the alternator. The air exits through the holes in the back of the alternator. The alternator converts the mechanical energy and the magnetic field into alternating current and voltage. This conversion is done by rotating a direct current electromagnetic field on the inside of a three-phase stator. The electromagnetic field is generated by electrical current flowing through a rotor. The stator generates alternating current and voltage. The alternating current is changed to direct current by a three-phase, full-wave rectifier. Direct current flows to the output terminal of the alternator. The direct current is used for the charging process. A regulator is installed on the rear end of the alternator. Two brushes conduct current through two slip rings. The current then flows to the rotor field. A capacitor protects the rectifier from high voltages. The alternator is connected to the battery for charging and machine load requirements. A warning lamp can be connected via the ignition switch. This wiring is optional.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i06127161

Electronic Control System SMCS - 1900

Introduction The engine is designed for electronic control. The engine has an Electronic Control Module (ECM), a fuel injection pump and electronic unit injectors. All of these items are electronically controlled. There are also a number of engine sensors. The engine is equipped with an electronically controlled wastegate for the turbocharger. The ECM controls the engine operating parameters through the software within the ECM and the inputs from the various sensors. The software contains parameters that control the engine operation. The parameters include all of the operating maps and customer-selected parameters.

Illustration 1 Typical example

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(1) Valve for the NOx Reduction System (NRS) (2) Air cleaner (3) Air inlet temperature sensor (4) Oxygen sensor (5) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (6) Diesel Particulate Filter (DPF) inlet temperature sensor (7) Diesel Oxidation Catalyst (DOC) (8) Diesel Particulate Filter (DPF) (9) Exhaust Cooler for the NOx Reduction System (NRS) (10) Turbocharger (11) DPF differential pressure sensor (wall flow DPF only) (12) Engine intake throttle valve (13) Air-to-air aftercooler (14) Wastegate regulator (15) Engine exhaust gas pressure sensor (16) Engine exhaust gas temperature sensor (17) Crankshaft speed/timing sensor (18) Camshaft speed/timing sensor (19) Electronic unit injectors (20) Fuel injection pump (21) Fuel pressure sensor (22) Oil pressure switch (23) Coolant temperature sensor (24) ECM

(25) Engine (26) Glow plugs (27) Glow plug Control Unit (GCU) (28) Primary fuel filter with water-in-fuel sensor (29) Inlet manifold air temperature/pressure sensor (30) Secondary fuel filter with fuel temperature sensor (31) Fuel tank

Note: A separate intake manifold air pressure sensor and intake manifold temperature sensor are installed on the 55 kW (74 hp) engine.

Note: The ECM is not mounted on the engine. The electronic control system has the following components: • ECM • Pressure sensor • Temperature sensors • Crankshaft speed/timing sensor • Camshaft speed/timing sensor

• The suction control valve for the fuel injection pump • Wastegate solenoid • Electronic unit injectors

Sensor Locations for the Engine The illustrations in this section show the typical locations of the sensors for the industrial engine. Specific engines may appear different from the illustration due to differences in applications.

Illustration 2

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Sensors and electrical connector locations on the left side of the C3.4B engine (1) 10-pin engine interface connector (2) 62-pin engine interface connector (3) Fuel pressure sensor (4) Fuel temperature sensor (5) Inlet metering valve for the fuel injection pump (6) Oil pressure switch (7) Crankshaft speed/timing sensor (8) Water In Fuel (WIF) sensor

Illustration 3

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Close up views of the sensor locations on the left side of the C3.4B engine (1) 10-pin engine interface connector (2) 62-pin engine interface connector (3) Fuel pressure sensor (4) Fuel temperature sensor (5) Inlet metering valve for the fuel injection pump (6) Oil pressure switch (7) Crankshaft speed/timing sensor (8) Water In Fuel (WIF) sensor

Illustration 4 Typical example of sensors and electrical connector locations on the right side of the C3.4B engine (9) Inlet manifold air pressure and temperature sensor (10) Connector for the temperature sensor (NOx Reduction System) (11) Pressure sensor (NOx Reduction System) (12) Exhaust gas valve for the NOx Reduction System (NRS) (13) Wastegate regulator (14) Oxygen sensor

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Illustration 5 Typical example of sensors and electrical connection locations on the front of the C3.4B engine. (15) Intake throttle valve for the NOx Reduction System (NRS) (16) Coolant temperature sensor (17) Camshaft position sensor

Sensor Locations for the Clean Emissions Module

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Illustration 6 Typical example of the sensor locations (18) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (19) Diesel Particulate Filter (DPF) inlet temperature sensor (20) Inlet connection for the DPF differential pressure sensor (21) Outlet connection for the DPF differential pressure sensor

ECM

Illustration 7

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Typical example

The Electronic Control Module (ECM) (1) functions as a governor and a computer for the fuel system. The ECM receives signals from the sensors in order to control the timing and the engine speed. The electronic system consists of the ECM, the engine sensors, and inputs from the parent machine. The ECM is the computer. The personality module is the software for the computer. The personality module contains the operating maps. The operating maps define the following characteristics of the engine: • Engine rating • Torque curves • High and low idle speed (rpm) • Emissions • Injection timing Passwords restrict changes to authorized personnel. Refer to Troubleshooting for more information on the passwords.

The ECM has an excellent record of reliability. Any problems in the system are most likely to be the connectors and the wiring harness. The ECM should be the last item in troubleshooting the engine. The programmable software contains all the fuel setting information. The information determines the engine performance. Flash programming is the method of programming or updating the programmable software. Refer to Troubleshooting, "Flash Programming" for the instructions on the flash programming of the programmable software. The ECM is sealed and the ECM needs no routine adjustment or maintenance.

Engine Speed The electronic controls determine the injection timing, the amount of fuel that is delivered to the cylinders and the intake manifold pressure if an electronically controlled wastegate is installed. These decisions are based on the actual conditions and the desired conditions at any given time. The ECM has software that compares the desired engine speed to the actual engine speed. The actual engine speed is determined through the crankshaft speed/timing sensor and the camshaft speed/timing sensor. If the desired engine speed is greater than the actual engine speed, the ECM will instruct the electronic unit injector to inject more fuel in order to increase engine speed.

Timing Considerations Once the ECM has determined the amount of fuel that is required, the software must determine the timing of the fuel injection. Fuel injection timing is determined by the ECM after considering input from the following components: • Engine coolant temperature sensor • The sensor for the intake manifold air temperature • The sensor for the intake manifold pressure • Oxygen sensor At start-up, the ECM determines the top center position of the number 1 cylinder from the secondary speed/timing sensor on the camshaft. The ECM decides when fuel injection should occur relative to the top center position. The ECM optimizes engine performance by control of each of the electronic unit injectors so that the required amount of fuel is injected at the precise point of the engine's cycle. The electronic unit injectors are supplied high-pressure fuel from the fuel manifold. The ECM also provides the signal to the solenoid in the fuel injection pump. The solenoid in the fuel injection pump controls a valve in the fuel injection pump. This valve controls the volume of fuel that enters the plungers. By controlling the volume of fuel that enters the plungers, this controls the pressure in the fuel manifold. Fuel that is not required for the engine is diverted away from the fuel injection pump back to the fuel tank. The ECM adjusts injection timing and fuel pressure for the best engine performance, the best fuel economy, and the best control of exhaust emissions. The actual timing can be viewed with an electronic service tool. Also, the desired timing can be viewed with an electronic service tool.

Fuel Injection The programmable software inside the ECM sets certain limits on the amount of fuel that can be injected. The FRC Limit is a limit that is based on intake manifold air pressure and engine rpm. The FRC Limit is used to control the air/fuel ratio in order to control the engines exhaust emissions. When the ECM senses a higher intake manifold air pressure, the ECM increases the FRC Limit. A higher intake manifold air pressure indicates that there is more air in the cylinder. When the ECM increases the FRC Limit, the ECM allows more fuel into the cylinder. The Rated Fuel Limit is a limit that is based on the power rating of the engine and on the engine rpm. The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and torque curves of a specific engine model. These limits are in the programmable software and these limits cannot be changed. The ECM controls the following characteristics: • Boost pressure • Operation of the NOx reduction system

Diagnostic Codes When the ECM detects an electronic system problem, the ECM generates a diagnostic code. Logged diagnostic codes will be cleared from the "Logged Diagnostic Codes" screen when the code has not been active for 40 hours. Diagnostic codes are provided in order to indicate that the ECM has detected an electrical problem or an electronic problem with the engine control system. In some cases, the engine performance can be affected when the condition that is causing the code exists. If the operator indicates that a performance problem occurs, the diagnostic code may indicate the cause of the problem. Use a laptop computer to access the diagnostic codes. The problem should then be corrected.

Event Codes Event Codes are used to indicate that the ECM has detected an abnormal engine operating condition. The ECM will log the occurrence of the event code. This does not indicate an electrical malfunction or an electronic malfunction. If the temperature of the coolant in the engine is higher than the permitted limit, then the ECM will detect the condition. The ECM will then log an event code for the condition.

Speed/Timing Sensors

Illustration 8

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Typical example

The crankshaft speed/timing sensor generates a signal by detecting the movement of the teeth that are located on the crankshaft timing ring (1) . The signal that is generated by the speed/timing sensor is transmitted to the ECM. The ECM uses the signal from the speed/timing sensor to calculate the position of the crankshaft. The signal is also used to determine the engine speed.

Illustration 9

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Typical example

The camshaft speed/timing sensor generates a signal that is related to the camshaft position. The camshaft speed/timing sensor detects the movement of the position wheel on the front of the camshaft (2) . The signal that is generated by the speed/timing sensor is transmitted to the ECM. The ECM calculates the speed and the rotational position of the engine by using the signal.

Illustration 10 Schematic for speed/timing sensor

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When the engine is cranking, the ECM uses the signal from the speed/timing sensor on the camshaft. When the engine is running the ECM uses the signal from the speed/timing sensor on the crankshaft. This speed/timing sensor is the primary source of the engine position.

Pressure Sensors

Illustration 11

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Schematic for the pressure sensors for the greater than 56 kW (75 hp) C3.4B engine

Illustration 12 Schematic for the pressure sensors for the less than 56 kW (75 hp) C3.4B engine

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Illustration 13 Schematic for the DPF differential pressure sensor on certain C3.4B engines

Note: The DPF differential pressure sensor is only applicable to engines equipped with a wall flow DPF. The boost pressure sensor is an active sensor. The boost pressure sensor provides the ECM with a measurement of inlet manifold pressure in order to control the air/fuel ratio. This will reduce the engine smoke during transient conditions. An engine oil pressure switch is installed to the engine. While the engine is running and oil pressure is detected, the switch will be open. When no oil pressure is detected, the switch will be closed. The ECM can warn the operator of possible conditions that can damage the engine. This includes the detection of an oil filter that is blocked. The operating range for the engine oil pressure switch ... 30 to 90 kPa (4 to 13 psi)

Temperature Sensors

Illustration 14 Schematic for the temperature sensors for the greater than 56 kW (75 hp) C3.4B engine

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Illustration 15

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Schematic for the temperature sensors for the less than 56 kW (75 hp) C3.4B engine

The air inlet temperature sensor and the coolant temperature sensor are passive sensors. Each sensor provides a temperature input to the ECM. The ECM controls following operations: • Fuel delivery • Injection timing The sensors are also used for engine monitoring.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04175249

Fuel Injection SMCS - 1251; 1252; 1253; 1254; 1281

Introduction

Illustration 1 Typical example (1) Primary fuel filter (2) Secondary fuel filter (3) Fuel Injection Pump (4) Fuel transfer pump (5) Fuel manifold (rail) (6) Pressure relief valve (7) Electronic unit injector (8) Manifold connector (9) Fuel cooler (if equipped) (A) Fuel tank

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Fuel is drawn from the fuel tank to the 10 micron primary fuel filter and a water separator. The fuel then flows to the fuel transfer pump. The fuel transfer pump is part of the fuel injection pump. Fuel then flows from the fuel transfer pump to the 4 micron secondary fuel filter. Fuel flows from the secondary fuel filter to the fuel injection pump. At the fuel injection pump, the fuel is pumped at an increased pressure of up to 160 MPa (23200 psi) fuel manifold (rail). Fuel that has too high a pressure from the fuel manifold (rail) returns through the pressure relief valve to the return line. Fuel that is leak off from the electronic unit injectors flows to the return line. The fuel may then flow through a fuel cooler (if equipped) on the way back to the fuel tank.

High Pressure Fuel System

Illustration 2 Typical example (1) Fuel injection pump (2) Suction control valve for the fuel injection pump (3) Pressure relief valve (4) Fuel manifold (rail) (5) Electronic unit injector (6) Fuel pressure sensor (7) Fuel transfer pump

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The fuel injection pump (1) feeds fuel to the high-pressure fuel manifold (rail) (4). The fuel is at a pressure of up to 160 MPa (23200 psi). A pressure sensor (6) in the high-pressure fuel manifold (rail) (4) monitors the fuel pressure in the high-pressure fuel manifold (rail). The ECM controls a suction control valve (2) in the fuel injection pump in order to maintain the actual pressure in the high-pressure fuel manifold at the desired level. The high-pressure fuel is continuously available at each injector (5). The ECM determines the correct time for activation of the correct electronic unit injector (5) which allows fuel to be injected into the cylinder. The leakoff fuel from each injector passes through an external pipe above the electronic unit injectors. The leakoff fuel then flows to a connector block on the left-hand side of the engine. A pipe is connected from the connector block in order to return the leakoff fuel to the fuel tank.

Components of the Fuel Injection System The fuel injection system has the following mechanical components: • Primary filter/water separator • Fuel transfer pump • Secondary fuel filter • Fuel injection pump • Fuel injectors • Fuel manifold • Pressure relief valve • Fuel pressure sensor • Fuel temperature sensor • Water in fuel sensor The following list contains examples of both service and repairs when you must prime the system: • A fuel filter is changed. • A low-pressure fuel line is replaced. • The fuel injection pump is replaced. For the correct procedure to prime the fuel system, refer to Systems Operation, Testing and Adjusting, "Fuel System - Prime".

Primary Filter/Water Separator

Illustration 3

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Typical example

The primary filter/water separator (1) is located between the fuel tank and the fuel transfer pump. The primary filter/water separator (1) provides a 10 micron filtration level. The primary filter/water separator can either be engine mounted or supplied loose. The primary filter/water separator is supplied with water in fuel sensor. The water in fuel sensor has to be connected.

Secondary Fuel Filter

Illustration 4

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Typical example

The secondary fuel filter (1) is located after the fuel transfer pump. The secondary fuel filter (1) provides a 4 micron filtration level. The fuel temperature sensor measures the temperature of the fuel. The ECM receives the signal from the fuel temperature sensor. The ECM calculates the volume of fuel.

Fuel Pump Assembly

Illustration 5

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Typical example

The fuel pump assembly consists of a low-pressure transfer pump and a high-pressure fuel injection pump. The pump assembly is driven from a gear in the front timing case at one a half times the engine speed. The fuel injection pump (1) has one plunger that are driven by a camshaft. The stroke of the plunger is fixed but the volume of fuel that is provided by the fuel injection pump is controlled by the suction control valve. The injector will use only part of the fuel that is delivered by each stroke of the pistons in the pump. The suction control valve (2) for the fuel injection pump is controlled by the ECM. This maintains the fuel pressure in the fuel manifold (rail) at the correct level. A feature of the fuel injection pump allows fuel to return to the tank continuously. The fuel injection pump has the following operation: • Generation of high-pressure fuel The fuel output of the fuel injection pump is controlled by the ECM in response to changes in the demand of fuel pressure.

Shutoff The engine shuts off by preventing the electronic unit injectors from injecting. The ECM then closes the suction control valve to prevent the pressure in the fuel manifold (rail) from increasing.

Control

Illustration 6

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Typical example of the electrical control system for the fuel system (1) Electronic Control Module (ECM) (2) Electronic unit injectors CAT C3.4B Engine Parts (3) Suction control valve Contact phone: 269 673 1638 (4) Fuel injection pump Email: (5) Crankshaft position sensor EngineParts@HeavyEquipmentRestorationParts.com (6) Camshaft position sensor Alternate email: engineparts2@gmail.com (7) Coolant temperature sensor Website: www.CATC34B.com Related website: (8) Fuel temperature sensor www.HeavyEquipmentRestorationParts.com (9) Inlet manifold air temperature and pressure sensor www.FPTIndustrialEngineParts.com (10) Oil pressure switch

(11) Fuel pressure sensor (12) Pressure sensor for the NOx Reduction System (NRS) (13) Wastegate regulator (14) Water in fuel sensor (15) Throttle position sensor

The ECM determines the quantity, timing, and pressure of the fuel in order to be injected into the fuel injector. The ECM uses input from the sensors on the engine. These sensors include the speed/timing sensors and the pressure sensors. The ECM controls the timing and the flow of fuel by actuating the injector solenoid. The amount of fuel is injected is a function of fuel pressure in the fuel manifold and the duration of the signal to the injector solenoid. The ECM controls the fuel pressure by increasing or decreasing the flow of fuel from the fuel injection pump.

Fuel Injectors

Illustration 7 Typical example (1) Electrical connections

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(2) Bolt (3) Clamp (4) Combustion washer (5) O-ring (6) Fuel inlet

The fuel injectors contain no serviceable parts apart from the O-ring seal and the combustion washer. The clamp and setscrew are serviced separately. The injector nozzle and control piston volume are continuously connected to the fuel manifold (rail) through the high-pressure fuel line. The nozzle needle is controlled by the control piston, which in turn is controlled by the pressure in the control piston volume. The injector contains a solenoid valve that controls the spill flow from the control piston volume. The control piston volume has an inlet throttle and an outlet throttle. The sizing of the throttles determines the rate of pressure decay in the control volume and hence the rate of nozzle opening. By opening the solenoid valve, fuel flows out of the control volume lowering its internal pressure which allows nozzle pressure to lift the needle and control piston, this enables injection to occur. To end injection, the solenoid valve is closed. Closing the solenoid valve blocks off the control volume outlet orifice which causes the control volume pressure to increase. By increasing control volume pressure, this forces the control piston, and needle, back down until the needle reseats in the nozzle. The injection process ends. The needle valve has a close fit with the inside of the nozzle. This makes a positive seal for the valve. The electronic unit injectors can be instructed to inject fuel multiple times during the combustion process. A close pilot injection occurs before the main injection. The close pilot injection helps to reduce NOx and noise. The main injection period helps to increase the torque of the engine. The after injection period helps to reduce the amount of smoke that is produced.

Fuel Manifold

CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com www.FPTIndustrialEngineParts.com Related website: www.HeavyEquipmentRestorationParts.com

Illustration 8

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Typical example

The fuel manifold (2) stores high-pressure fuel from the fuel injection pump. The high-pressure fuel will flow to the injectors. The fuel pressure sensor (3) measures the fuel pressure in the fuel manifold (2). The pressure relief valve (1) will prevent the fuel pressure from getting too high.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338249

Glossary of Electronic Control Terms SMCS - 1900 Active Diagnostic Code - An active diagnostic code alerts the operator or the service technician that an electronic system malfunction is currently present. Refer to the term "Diagnostic Code" in this glossary. Aftertreatment - Aftertreatment is a system that is used to remove pollutants from exhaust gases. The system consists of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). Air-To-Air Aftercooler - An air-to-air aftercooler is a device that is used on turbocharged engines in order to cool inlet air that has undergone compression. The inlet air is cooled after the inlet air passes through the turbocharger. The inlet air is passed through an aftercooler (heat exchanger) that uses ambient air for cooling. The inlet air that has been cooled advances to the inlet manifold. Alternating Current (AC) - Alternating current is an electric current that reverses direction at a regular interval that is reoccurring. Before Top Center (BTC) - BTC is the 180 degrees of crankshaft rotation before the piston reaches the top center position in the normal direction of rotation. Boost Pressure - The difference between the turbocharger outlet pressure and atmospheric pressure is commonly referred to as boost pressure. The sensor for the intake manifold air pressure measures the amount of boost. Breakout Harness - The breakout harness is a test harness that is designed to connect into the engine harness. This connection allows a normal circuit operation and the connection simultaneously provides a Breakout T in order to measure the signals. Bypass Circuit - A bypass circuit is a circuit that is used as a substitute circuit for an existing circuit. A bypass circuit is typically used as a test circuit. CAN Data Link (see also J1939 CAN Data Link) - The CAN Data Link is a serial communications port that is used for communication with other microprocessor-based devices.

Clean Emissions Module - The Clean Emissions Module (CEM) includes all the components of the engine aftertreatment system. Code - Refer to "Diagnostic Trouble Code". Cold Mode - Cold mode is a mode for cold starting and for cold engine operation. This mode is used for engine protection, reduced smoke emissions, and faster warm-up time. Communication Adapter Tool - The communication adapter provides a communication link between the ECM and the Electronic Service Tool. Component Identifier (CID) - The CID is a number that identifies the specific component of the electronic control system that has experienced a diagnostic code. Coolant Temperature Sensor - The coolant temperature sensor detects the engine coolant temperature for all normal operating conditions and for engine monitoring. Customer Specified Parameters - A customer specified parameter is a parameter that can be changed in the ECM with the Electronic Service Tool. A customer specified parameters value is set by the customer. These parameters are protected by customer passwords. Data Link - The Data Link is a serial communication port that is used for communication with other microprocessor-based devices. Derate - Certain engine conditions will generate event codes. Also, engine derates may be applied. The map for the engine derate is programmed into the ECM software. The derate can be one or more of three types: reduction of rated power, reduction of rated engine speed and reduction of rated machine speed for OEM products. Desired Engine Speed - The desired engine speed is input to the electronic governor within the ECM. The electronic governor uses the signal from the throttle position sensor, the engine speed/timing sensor, and other sensors in order to determine the desired engine speed. Diagnostic Trouble Code - A diagnostic trouble code is sometimes referred to as a fault code. These codes indicate an electronic system malfunction. Diagnostic Lamp - A diagnostic lamp is sometimes called the check engine lamp. The diagnostic lamp is used to warn the operator of the presence of an active diagnostic code. The lamp may not be included in all applications. Diesel Oxidation Catalyst - The Diesel Oxidation Catalyst is also known as the (DOC). The DOC is a device in the exhaust system that oxidizes certain elements in the exhaust gases. These elements can include carbon monoxide (CO), hydrocarbons and the soluble organic fraction (SOF) of particulate matter. Diesel Particulate Filter - The Diesel Particulate Filter (DPF) filters particulates from the exhaust gases. When the particulates have built up on the internal surfaces of a wall flow DPF, the temperature of the exhaust gas is raised in order to burn off the particulates. This regeneration process prevents the DPF from becoming blocked. The regeneration process therefore allows the DPF to continue to operate efficiently. A through-flow DPF does not require an active regeneration. Digital Sensor Return - The common line (ground) from the ECM is used as ground for the digital sensors.

Digital Sensors - Digital sensors produce a pulse width modulated signal. Digital sensors are supplied with power from the ECM. Digital Sensor Supply - The power supply for the digital sensors is provided by the ECM. Direct Current (DC) - Direct current is the type of current that flows consistently in only one direction. Duty Cycle - Refer to "Pulse Width Modulation". Electronic Engine Control - The electronic engine control is a complete electronic system. The electronic engine control monitors the engine operation under all conditions. The electronic engine control also controls the engine operation under all conditions. Engine Control Module (ECM) - The ECM is the control computer of the engine. The ECM provides power to the electronics. The ECM monitors data that is input from the sensors of the engine. The ECM acts as a governor in order to control the speed and the power of the engine. Electronic Service Tool - The electronic service tool allows a computer (PC) to communicate with the ECM. Engine Monitoring - Engine Monitoring is the part of the electronic engine control that monitors the sensors. This also warns the operator of detected problems. Engine Oil Pressure Switch - The engine oil pressure switch measures engine oil pressure. The switch sends an electronic signal to the ECM that is dependent on the engine oil pressure. Engine Speed/Timing Sensor - An engine speed/timing sensor is a hall effect switch that provides a digital signal to the ECM. The ECM interprets this signal as the crankshaft position and the engine speed. Two sensors are used to provide the speed and timing signals to the ECM. The primary sensor is associated with the crankshaft and the secondary sensor is associated with the camshaft. Estimated Dynamic Timing - Estimated dynamic timing is the estimate of the actual injection timing that is calculated by the ECM. Event Code - An event code may be activated in order to indicate an abnormal engine operating condition. These codes usually indicate a mechanical problem instead of an electrical system problem. Failure Mode Identifier (FMI) - This identifier indicates the type of failure that is associated with the component. The FMI has been adopted from the SAE practice of J1587 diagnostics. The FMI follows the parameter identifier (PID) in the descriptions of the fault code. The descriptions of the FMIs are in the following list. 0 - The data is valid but the data is above the normal operational range. 1 - The data is valid but the data is below the normal operational range. 2 - The data is erratic, intermittent, or incorrect. 3 - The voltage is above normal or the voltage is shorted high. 4 - The voltage is below normal or the voltage is shorted low.

5 - The current is below normal or the circuit is open. 6 - The current is above normal or the circuit is grounded. 7 - The mechanical system is not responding properly. 8 - There is an abnormal frequency, an abnormal pulse width, or an abnormal time period. 9 - There has been an abnormal update. 10 - There is an abnormal rate of change. 11 - The failure mode is not identifiable. 12 - The device or the component is damaged. 13 - The device requires calibration. 14 - There is a special instruction for the device. 15 - The signal from the device is high (least severe). 16 - The signal from the device is high (moderate severity). 17 - The signal from the device is low (least severe). 18 - The signal from the device is low (moderate severity). 19 - There is an error in the data from the device. 20 - There is an error in the data from the device (high). 21 - There is an error in the data from the device (low). 31 - No FMI description Flash File - This file is software that is inside the ECM. The file contains all the instructions (software) for the ECM and the file contains the performance maps for a specific engine. The file may be reprogrammed through flash programming. Flash Programming - Flash programming is the method of programming or updating an ECM with an electronic service tool over the data link instead of replacing components. FRC - See "Fuel Ratio Control". Fuel Injection Pump - This item is sometimes referred to as the High Pressure Fuel Rail Pump. This is a device that supplies fuel under pressure to the fuel rail (high-pressure fuel rail). Fuel Manifold (Rail) - This item is sometimes referred to as the High Pressure Fuel Rail. The fuel rail supplies fuel to the electronic unit injectors. The fuel rail pump and the fuel rail pressure sensor work with the ECM in order to maintain the desired fuel pressure in the fuel rail. This pressure is determined by calibration of the engine in order to enable the engine to meet emissions and performance requirements. Fuel Manifold (Rail) Pressure Sensor - The fuel rail pressure sensor sends a signal to the ECM that is dependent on the pressure of the fuel in the fuel rail.

Fuel Ratio Control (FRC) - The FRC is a limit that is based on the control of the ratio of the fuel to air. The FRC is used for purposes of emission control. When the ECM senses a higher intake manifold air pressure (more air into the cylinder), the FRC increases the FRC Limit (more fuel into the cylinder). The Solenoid Valve for the Fuel Injection Pump - This is sometimes referred to as the High Pressure Fuel Rail Pump Solenoid Valve or the Suction Control Valve. This is a control device in the fuel injection pump. The ECM controls the pressure in the fuel rail by using this valve to divert excess fuel from the pump to the fuel tank. Glow Plug - The glow plug is an optional starting aid for cold conditions. One glow plug is installed in each combustion chamber in order to improve the ability of the engine to start. The ECM uses information from the engine sensors such as the engine temperature to determine when the glow plug relay must provide power to each glow plug. Each of the glow plugs then provides a hot surface in the combustion chamber in order to vaporize the mixture of air and fuel. This improves ignition during the compression stroke of the cylinder. Glow Plug Control Unit - The glow plug control unit is controlled by the ECM in order to provide high current to the glow plugs. Harness - The harness is the bundle of wiring (loom) that connects all components of the electronic system. Hertz (Hz) - Hertz is the unit of frequency in cycles per second. High Pressure Fuel Rail Pump - See "Fuel Injection Pump". High Pressure Fuel Rail - See "Fuel Manifold (Rail)". Injector Trim Codes - Injector trim codes are supplied with new injectors. The code is input through the electronic service tool into the ECM. The injector trim codes compensate for variances in manufacturing of the electronic unit injector and for the life of the electronic unit injector. Inlet Manifold Air Temperature/Boost Pressure Sensor - The inlet manifold air temperature/pressure sensor detects the air temperature and pressure in the inlet manifold. The ECM monitors the air temperature and other data in the inlet manifold in order to adjust injection timing and other performance functions. The pressure in the inlet manifold may be different to the pressure outside the engine (atmospheric pressure). The difference in pressure may be caused by an increase in air pressure by a turbocharger. Integrated Electronic Controls - The engine is designed with the electronic controls as a necessary part of the system. The engine will not operate without the electronic controls. J1939 CAN Data Link - This data link is a SAE standard diagnostic communications data link that is used to communicate between the ECM and other electronic devices. Logged Diagnostic Codes - Logged diagnostic codes are codes which are stored in the memory. These codes are an indicator of possible causes for intermittent problems. Refer to the term "Diagnostic Code" for more information. NOx Reduction System - The NOx Reduction System recycles a portion of the exhaust gases back into the inlet air in order to reduce the amount of nitrous oxide (NOx) in the exhaust gases. The recycled exhaust gas passes through a cooler before being introduced into the inlet air.

OEM - OEM is an abbreviation for the Original Equipment Manufacturer. This is the manufacturer of the machine or the vehicle that uses the engine. Open Circuit - An open circuit is a condition that is caused by an open switch, or by an electrical wire or a connection that is broken. When this condition exists, the signal or the supply voltage can no longer reach the intended destination. Oxygen Sensor - The oxygen sensor detects the level of oxygen. The level of oxygen is inputted to the combustion control. Parameter - A parameter is a value or a limit that is programmable. This helps determine specific characteristics or behaviors of the engine. Password - A password is a group of numeric characters or a group of alphanumeric characters that is designed to restrict access to parameters. Power Cycling - Power cycling refers to the action of cycling the keyswitch from any position to the OFF position, and to the START/RUN position. Pressure Limiting Valve (PLV) - The PLV is a valve in the fuel rail that prevents excessive pressure. The PLV will reduce the pressure to a safe level that will limit engine operation but the reduced pressure will not stop the engine. Programmable Software - The software is programmed into the ECM. The software contains all the instructions (software) for the ECM and the software contains the performance maps for a specific engine. The software may be reprogrammed through flash programming. Primary Speed/Timing Sensor - This sensor determines the position of the crankshaft during engine operation. If the primary speed/timing sensor fails during engine operation, the secondary speed/timing sensor is used to provide the signal. Pulse Width Modulation (PWM) - The PWM is a signal that consists of pulses that are of variable width. These pulses occur at fixed intervals. The ratio of "TIME ON" versus total "TIME OFF" can be varied. This ratio is also referred to as a duty cycle.

Illustration 1

g01858875

Rated Fuel Limit - This is a limit that is based on the power rating of the engine and on the engine rpm. The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and torque curves of a specific engine model. These limits are in the flash file and these limits cannot be changed. Reference Voltage - Reference voltage is a regulated voltage and a steady voltage that is supplied by the ECM to a sensor. The reference voltage is used by the sensor to generate a signal voltage. Relay - A relay is an electromechanical switch. A flow of electricity in one circuit is used to control the flow of electricity in another circuit. A small current or voltage is applied to a relay in order to switch a much larger current or voltage. Secondary Speed/Timing Sensor - This sensor determines the position of the camshaft during engine operation. If the primary speed/timing sensor fails during engine operation, the secondary speed/timing sensor is used to provide the signal. Sensor - A sensor is a device that is used to detect the current value of pressure or temperature, or mechanical movement. The information that is detected is converted into an electrical signal. Short Circuit - A short circuit is a condition that has an electrical circuit that is inadvertently connected to an undesirable point. An example of a short circuit is a wire which rubs against a vehicle frame and this rubbing eventually wears off the wire insulation. Electrical contact with the frame is made and a short circuit results.

Signal - The signal is a voltage or a waveform that is used in order to transmit information typically from a sensor to the ECM. Suction Control Valve (SCV) - The SCV is a control device in the high-pressure fuel pump. The ECM controls the pressure in the fuel rail by using this valve to control the amount of fuel that enters the chambers in the pump. Supply Voltage - The supply voltage is a continuous voltage that is supplied to a component in order to provide the electrical power that is required for the component to operate. The power may be generated by the ECM or the power may be battery voltage that is supplied by the engine wiring. System Configuration Parameters - System configuration parameters are parameters that affect emissions and/or operating characteristics of the engine. "T" Harness - This harness is a test harness that is designed to permit normal circuit operation and the measurement of the voltage simultaneously. Typically, the harness is inserted between the two ends of a connector. Throttle Position - The throttle position is the interpretation by the ECM of the signal from the throttle position sensor or the throttle switch. Throttle Position Sensor - The throttle position sensor is an electronic sensor that is connected to an accelerator pedal or a hand lever. This sensor sends a signal to the ECM that is used to calculate desired engine speed. Throttle Switch - The throttle switch sends a signal to the ECM that is used to calculate desired engine speed. Top Center Position - The top center position refers to the crankshaft position when the engine piston position is at the highest point of travel. The engine must be turned in the normal direction of rotation in order to reach this point. Wait To Start Lamp - This is a lamp that is included in the cold starting aid circuit in order to indicate when the wait to start period is active. The lamp will go off when the engine is ready to be started. The glow plugs may not have deactivated at this point in time. Warning Lamp - The warning lamp is used to warn the operator of the presence of an active diagnostic code. Wastegate - This is a device in a turbocharged engine that controls the maximum boost pressure that is provided to the inlet manifold. Wastegate Regulator - The wastegate regulator controls the pressure in the inlet manifold to a value that is determined by the ECM. The wastegate regulator provides the interface between the ECM and the mechanical system that regulates inlet manifold pressure to the desired value that is determined by the software.

Systems Operation C3.4B Industrial Engine

Introduction SMCS - 1000 The following model views show a typical C3.4B engine. Due to individual applications, your engine may appear different from the illustrations.

Illustration 1 Typical example (1) Clean Emissions Module (CEM) (2) Oil gauge (Dipstick) (3) Electronic Control Module (ECM) (4) Air inlet connection from charge cooler (5) Coolant outlet connection (6) Air intake from air filter (7) Alternator (8) Coolant intake connection (9) Air outlet connection from turbocharger (10) Turbocharger (11) Oil drain plug (12) Starting motor (13) Flywheel housing (14) Flywheel

g02317613

Illustration 2

g03343018

Typical example (15) Front lifting eye (16) Oil filler cap (17) Rear lifting eyes (18) Secondary fuel filter (19) Oil filter (20) Fuel priming pump (21) Primary fuel filter (22) Fuel injection pump (23) Crankcase breather (24) Water pump

Note: The primary fuel filter (21) may be supplied loose. Note: The Electronic Control Module (ECM) (3) will be mounted to the application. The C3.4B diesel engine is electronically controlled. The C3.4B engine has an Electronic Control Module (ECM) that receives signals from the fuel injection pump and other sensors in order to control the electronic unit injector. The fuel injection pump supplies fuel to the fuel manifold (Rail). The fuel manifold (Rail) distributes fuel to the electronic unit injectors.

The four cylinders are arranged in-line. The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. The port for the exhaust valve is on the right side of the cylinder head. The port for the inlet valve is on the top of the cylinder head. Each cylinder valve has a single valve spring. Each cylinder has a piston cooling jet that is installed in the cylinder block. The piston cooling jet sprays engine oil onto the inner surface of the piston in order to cool the piston. The pistons have a Quiescent combustion chamber in the top of the piston in order to achieve clean exhaust emissions. The piston pin is off-center in order to reduce the noise level. The pistons have two compression rings and an oil control ring. The groove for the top ring has a hard metal insert in order to reduce wear of the groove. The skirt has a layer of graphite in order to reduce the risk of seizure when the engine is new. The correct piston height is important in order to ensure that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in order to conform to requirements for emissions. The crankshaft has five main bearing journals. End play is controlled by thrust washers which are located on both sides of the number 3 main bearing. The timing case is made of cast iron. Some of the timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the number 1 piston is at a certain position, the marked teeth on the camshaft gear will align with the marks that are on the gear on the crankshaft. There are no timing marks on the rear face of the timing case. The crankshaft gear turns the camshaft gear which then turns the following gears: • the idler gear • the idler gear for the engine oil pump • the engine oil pump gear • the accessory drive gear • the fuel injection pump gear The camshaft runs at half the rpm of the crankshaft. The fuel injection pump runs at one and a half times the speed as the crankshaft. The fuel injection pump that is installed on the left side of the engine is gear-driven from the timing case. The internal fuel transfer pump is driven by the fuel injection pump. The fuel transfer pump draws low pressure fuel from the primary fuel filter. The fuel transfer pump delivers the fuel to the secondary filter. The fuel then travels to the fuel injection pump. The fuel injection pump increases the fuel to a maximum pressure of 160 MPa (23200 psi). The fuel injection pump delivers the fuel to the fuel manifold (Rail). The fuel injection pump is not serviceable. The engine uses speed sensors and the Electronic Control Module (ECM) to control the engine speed. For the specifications of the C3.4B engine, refer to the Specifications, "Engine Design".

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169606

Lubrication System SMCS - 1300 Lubricating oil from the oil pan flows through a strainer and a pipe to the suction side of the engine oil pump. Pressure for the lubrication system is supplied by the oil pump. The crankshaft gear drives a lower idler gear. The lower idler gear drives the oil pump gear. The pump has an inner rotor and an outer rotor. The axis of rotation of the rotors are off-center relative to each other. There is an interference fit between the inner rotor and the drive shaft. The inner rotor has four lobes which mesh with the five lobes of the outer rotor. When the pump rotates, the distance increases between the lobes of the outer rotor and the lobes of the inner rotor in order to create suction. When the distance decreases between the lobes, pressure is created. The lubricating oil flows from the outlet side of the oil pump through a passage to a plate type oil cooler. The oil cooler is located on the right side of the cylinder block. The lubricating oil flows from the oil cooler through a passage to the oil filter head. The oil then flows through a bypass valve that permits the lubrication system to function if the oil filter becomes blocked. Under normal conditions, the oil then flows to the oil filter. The oil flows from the oil filter through a passage that is drilled across the cylinder block to the oil gallery. The oil gallery is drilled through the total length of the left side of the cylinder block. Lubricating oil from the oil gallery flows through high-pressure passages to the main bearings of the crankshaft. Then, the oil flows through the passages in the crankshaft to the connecting rod bearing journals. The pistons and the cylinder bores are lubricated by the splash of oil and the oil mist. Lubricating oil from the main bearings flows through passages in the cylinder block to the journals of the camshaft. Then, the oil flows from the front journal of the camshaft at a reduced pressure to the cylinder head. The oil then flows through the center of the rocker shaft to the rocker arm levers. Oil flows to the hydraulic lash adjusters in the rocker arm levers. The valve stems, the valve springs and the valve lifters are lubricated by the splash and the oil mist. The hub of the idler gear is lubricated by oil from the oil gallery. The timing gears are lubricated by the splash from the oil.

Engines have piston cooling jets that are supplied with oil from the oil gallery. The piston cooling jets spray lubricating oil on the underside of the pistons in order to cool the pistons.

Systems Operation C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05292850

Power Sources SMCS - 4480

Introduction The engine supplies power to the ECM. The ECM powers the following components: • All sensors • The control valve for the fuel injection pump • The solenoid for the wastegate • Diagnostic connector • Electronic unit injectors The glow plugs are powered directly from the battery.

ECM Power Supply

Illustration 1

g02720990

Typical example

The power supply to the ECM and the system is drawn from the 24 V or the 12 V battery. The power supply for the ECM has the following components: • Battery • Disconnect switch • Ignition keyswitch • Fuses • Ground bolt • ECM connector • Machine interface connector The schematic for the ECM shows the main components for a typical power supply circuit. Battery voltage is normally connected to the ECM. The input from the ignition keyswitch turns on the ECM. The main relay will remain energized for a time period after the keyswitch has been turned to the OFF position. The wiring harness can be bypassed for troubleshooting purposes. The display screen on the electronic service tool can be used in order to check the voltage supply.

Power Supply for the Pressure Sensors

Illustration 2

g03360401

Schematic for the pressure sensors for the greater than 56 kW (75 hp) C3.4B engine

Illustration 3

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Schematic for the pressure sensors for the less than 56 kW (75 hp) C3.4B engine

Illustration 4

g03360405

Schematic for the DPF differential pressure sensor on certain C3.4B engines

Note: The DPF differential pressure sensor is only applicable to engines equipped with a wall flow DPF.

The ECM supplies 5 DC volts through the ECM connector to each sensor. The power supply is protected against short circuits. A short in a sensor or a wiring harness will not cause damage to the ECM.

Power supply for the Glow plugs

Illustration 5

g02381262

Typical example

The ECM supplies 5 DC volts through the ECM connector to the glow plug control unit. The glow plug control unit controls the glow plugs.

CAT C3.4B Cat C3.4B Diesel Engine with electronic high pressure common rail fuel system

TESTING AND ADJUSTING

FPT INDUSTRIAL

www.FPTIndustrialEngineParts.com

Printed in U.S.A

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338253

Electric Starting System - Test SMCS - 1450-081

General Information All electrical starting systems have four elements: • Keyswitch • Start relay • Starting motor solenoid • Starter - Starting motor The starting motor solenoid is a switch with a capacity of about 1000 A. The starting motor solenoid supplies power to the starter drive. The starting motor solenoid also engages the pinion to the flywheel. The starting motor solenoid has two coils. The pull-in coil draws about 40 A. The hold-in coil requires about 5 A. When the magnetic force increases in both coils, the pinion gear moves toward the ring gear of the flywheel. Then, the solenoid contacts close in order to provide power to the starting motor. When the solenoid contacts close, the ground is temporarily removed from the pull-in coil. Battery voltage is supplied on both ends of the pull-in coil while the starting motor cranks. During this period, the pull-in coil is out of the circuit. Cranking of the engine continues until current to the solenoid is stopped by releasing the keyswitch. Power which is available during cranking varies according to the temperature and condition of the batteries. Table 1 shows the voltages which are expected from a battery at the various temperature ranges. Table 1

Typical Voltage Of Electrical System During Cranking At Various Ambient Temperatures Temperature

10 to 27°C (50 to 80°F)

12 V System

24 V System

6 to 8 V

12 to 16 V

7 to 9 V

14 to 18 V

8 to 10 V

16 to 24 V

Table 2 shows the maximum acceptable loss of voltage in the battery circuit. The battery circuit supplies high current to the starting motor. The values in the table are for engines which have service of 2000 hours or more. Table 2 Maximum Acceptable Voltage Drop In The Starting Motor Circuit During Cranking Circuit

12 V System

24 V System

Battery post "-" to the starting motor terminal "-"

0.7 V

1.4 V

Drop across the disconnect switch

0.5 V

1.0 V

Battery post "+" to the terminal of the starting motor solenoid "+"

0.5 V

1.0 V

Solenoid terminal "Bat" to the solenoid terminal "Mtr"

0.4 V

0.8 V

Voltage drops that are greater than the amounts in table 2 are caused most often by the following conditions: • Loose connections • Corroded connections • Faulty switch contacts

Diagnosis Procedure The procedures for diagnosing the starting motor are intended to help the technician determine if a starting motor needs to be replaced or repaired. The procedures are not intended to cover all possible problems and conditions. The procedures serve only as a guide.

NOTICE If equipped with electric start, do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before cranking again. Never turn the disconnect switch off while the engine is running. Serious damage to the electrical system can result.

If the starting motor does not crank or cranks slow, perform the following procedure: 1. Measure the voltage of the battery. Measure the voltage across the battery posts with the multimeter when you are cranking the engine or attempting to crank the engine. Do not measure the voltage across the cable post clamps. a. If the voltage is equal to or greater than the voltage in table 1, then go to step 2. b. The battery voltage is less than the voltage in Table 1. A low charge in a battery can be caused by several conditions. Deterioration of the battery A shorted starting motor A faulty alternator Loose drive belts Current leakage in another part of the electrical system 2. Measure the current that is sent to the starting motor solenoid from the positive post of the battery. Note: If the following conditions exist, do not perform the test in step 2 because the starting motor has a problem. The voltage at the battery post is within 2 V of the lowest value in the applicable temperature range of table 1. The large starting motor cables get hot. Use a suitable ammeter in order to measure the current. Place the jaws of the ammeter around the cable that is connected to the "bat" terminal. Refer to Specifications, "Starter Motor" for the maximum current that is allowed for no load conditions. The current and the voltages that are specified in Specifications are measured at a temperature of 27°C (80°F). When the temperature is below 27°C (80°F), the voltage will be lower through the starting motor. When the temperature is below 27°C (80°F), the current through the starting motor will be higher. If the current is too great, a problem exists in the starting motor. Repair the problem or replace the starting motor. If the current is within the specification, proceed to step 3. 3. Measure the voltage of the starting motor. a. Use the multimeter in order to measure the voltage of the starting motor, when you are cranking or attempting to crank the engine.

b. If the voltage is equal to or greater than the voltage that is given in table 1, then the battery and the starting motor cable that goes to the starting motor are within specifications. Go to step 5. c. The starting motor voltage is less than the voltage specified in table 1. The voltage drop between the battery and the starting motor is too great. Go to step 4. 4. Measure the voltage. a. Measure the voltage drops in the cranking circuits with the multimeter. Compare the results with the voltage drops which are allowed in table 2. b. Voltage drops are equal to the voltage drops that are given in table 2 or the voltage drops are less than the voltage drops that are given in Table 2. Go to step 5 in order to check the engine. c. The voltage drops are greater than the voltage drops that are given in table 2. The faulty component should be repaired or replaced. 5. Rotate the crankshaft by hand in order to ensure that the crankshaft is not stuck. Check the oil viscosity and any external loads that could affect the engine rotation. a. If the crankshaft is stuck or difficult to turn, repair the engine. b. If the engine is not difficult to turn, go to step 6. 6. Attempt to crank the starting motor. a. The starting motor cranks slowly. Remove the starting motor for repair or replacement. b. The starting motor does not crank. Check for the blocked engagement of the pinion gear and flywheel ring gear. Note: Blocked engagement and open solenoid contacts will give the same electrical symptoms.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04371153

V-Belt - Test SMCS - 1357-081

NOTICE Ensure that the engine is stopped before any servicing or repair is performed.

To maximize the engine performance, inspect the poly v-belt for wear and for cracking. Replace the poly vbelt if the belt is worn or damaged. • Check the poly v-belt for cracks, splits, glazing, grease, displacement of the cord and evidence of fluid contamination. The poly v-belt must be replaced if the following conditions are present. • The poly v-belt has a crack in more than one rib. • More than one section of the poly v-belt is displaced in one rib of a maximum length of 50.8 mm (2 inch). To replace the poly v-belt, refer to Operation and Maintenance Manual, "Alternator and Fan Belts - Replace".

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i06260318

Charging System - Test SMCS - 1406-081 The condition of charge in the battery at each regular inspection will show if the charging system is operating correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed. A large amount of water would be more than 28 mL (1 oz) per cell per week or per every 100 service hours. There are no adjustments on maintenance free batteries. When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a permanent part of the system. Off-engine testing or bench testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, perform a test in order to prove that the units have been repaired to the original condition of operation.

Alternator The charging rate of the alternator should be checked when an alternator is charging the battery too much or not charging the battery enough. Alternator output should be 28 ± 1 V on a 24 V system and 14 ± 0.5 V on a 12 V system. No adjustment can be made in order to change the rate of charge on the alternator regulators. If the rate of charge is not correct, a replacement of the regulator is necessary. For individual alternator output, refer to Specifications, "Alternator".

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i01126605

Battery - Test SMCS - 1401-081 Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in good condition. The wire and cable connections must be clean, and both components must be tight.

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.

The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery.

NOTICE The charging unit will be damaged if the connections between the battery and the charging unit are broken while the battery is being charged. Damage occurs because the load from the battery is lost and because there is an increase in charging voltage. High voltage will damage the charging unit, the regulator, and other electrical components.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i03635721

Alternator - Test SMCS - 1405-081 Inspect the alternator for any visible faults. The faults could be the following items. • Frayed wires or damaged wires • Loose connections or damaged connections • Loose alternator pulley • Loose alternator or damaged alternator 1. Put the positive lead "+" of a suitable multimeter on the "B+" terminal of the alternator. Put the negative "-" lead on the ground terminal or on the frame of the alternator. Put a suitable ammeter around the positive output wire of the alternator. a. Turn the keyswitch to the ON position but do not start the engine. b. The system voltage matches the specification. Go to step 2. c. The system voltage is less than the specification. Check if the battery is in good condition. Refer to Systems Operation, Testing and Adjusting, "Battery - Test" for the correct procedure. Go to step 5.a if the battery is in good condition. 2. Put the positive lead "+" of a suitable multimeter on the "B+" terminal of the alternator. Put the negative "-" lead on the ground terminal or on the frame of the alternator. a. Start the engine and run the engine at least 75% of full throttle. Record the voltage on the multimeter. b. The voltage should be higher than the voltage in step 1.b. The voltage is less than the maximum voltage listed for the alternator. The alternator is partially charging. Go to step 3. The voltage is

more than the maximum voltage listed for the alternator. There is overcharging of the alternator. Check the alternator wiring. Refer to Systems Operation, Testing and Adjusting, "Charging System - Test" for the correct procedure. c. The value of the voltage is less than the voltage in step 1.b. Go to step 6. Note: Severely discharged batteries can cause low system voltage. This can occur even while the engine is running above idle, and the alternator is working properly. Correct low engine idle is important. All alternators that are installed on this engine are self-excited. The alternators must exceed the turn on speed before charging will begin. 3. Ensure that the batteries are not fully charged. a. Fully charged batteries have open circuit voltage above 12.5 V on 12 V systems or 25 V on 24 V systems. b. If the batteries are fully charged then crank the engine for 30 seconds. This reduces the battery voltage. c. Connect a current probe or an ammeter to a digital multimeter. The multimeter must have a peak hold feature. Ensure that the probe is zeroed. Clamp the probe around the output wire "B+". d. Set the multimeter to "peak hold" or "max mode". e. Turn on all electrical accessories. f. Start the engine and run the engine at least 75% of full throttle. The peak current will appear on the multimeter. g. The current is at least 90% of the peak output of the alternator. Go to step 4 or step 5. h. The current is less than 90% of the peak alternator output. Go to step 6. Note: This test procedure is for applications with a main disconnect switch. 4. Turn off all accessories. Turn the keyswitch to the OFF position. a. Connect a current probe or an ammeter to a digital multimeter. Ensure that the probe is zeroed. Clamp the current probe or an ammeter around the ground cable. Clamp the tool with the positive side away from the battery. Record the value of the electrical current. b. The current value is below 2 amperes. Go to step 4.d. c. The current value is above 2 amperes. Go to step 7. d. Turn the disconnect switch to the ON position. Connect an ammeter across the disconnect switch terminals. Connect the red lead to the terminal on the frame side. Connect the black lead to the terminal on the battery. If a multimeter is used for the test use the ten amp connections to avoid damage. e. Turn the disconnect switch to the OFF position. Record the value of the electrical current.

f. The current is below 0.05 amperes. The charging system is currently good. The fault is possibly an intermittent draw in the system. The batteries may be faulty. Check that no accessories were on during the test. Note: The standard acceptable draw is 0.05 amperes. A current that is greater than this value usually indicates a problem. However, some large machines with multiple control modules have a higher acceptable limit. g. The current value is above 0.05 amperes. There is a current draw in the system. Go to step 7. 5. Turn off all accessories. Turn the keyswitch to the OFF position. a. Connect a current probe or an ammeter to a digital multimeter. Ensure that the probe is zeroed. Clamp the current probe or an ammeter around the ground cable. Clamp the tool with the positive side away from the battery. Record the value of the electrical current. b. The current value is below 2 amperes. Go to step 4.d. c. The current value is above 2 amperes. Go to step 7. d. Remove the ground cable from the battery terminal. For systems with four batteries or 12 V systems with two batteries, disconnect the ground cables from both negative batteries. e. Connect an ammeter between the disconnected battery ground cable and one of the negative battery terminals. Connect the red lead to the cable. Connect the black lead to the terminal on the battery. If a multimeter is used for the test use the ten amp connections to avoid damage. f. The current is below 0.05 amperes. The charging system is currently good. The fault is possibly an intermittent draw in the system. The batteries may be faulty. Check that no accessories were on during the test. Note: The standard acceptable draw is 0.05 amperes. A current value above this figure usually indicates a problem. However, some large machines with multiple control modules have a higher acceptable limit. g. The current value is above 0.05 amperes. There is a current draw in the system. Go to step 7. 6. Check the condition of the poly v-belt and alternator pulley. a. If the poly v-belt is oily, clean the pulleys. Replace the poly v-belt. Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure. Inspect the poly vbelt for wear or for cracks. Refer to Systems Operation, Testing and Adjusting, "V- Belt - Test". If the poly v-belt is wet, dry the poly v-belt and the pulleys. Retest the system. b. Inspect the nut on the alternator pulley. Ensure that the nut is not loose. If the nut is loose, tighten the nut to the correct torque. Refer to Specifications, "Alternator" for the correct torque. c. If no faults are found from the procedures in step 6.a and step 6.b, inspect the charging system. Refer to Systems Operation, Testing and Adjusting, "Charging System - Test" for the correct procedure.

7. Turn the keyswitch to the OFF position. a. Connect a current probe or an ammeter to a digital multimeter. Ensure that the probe is zeroed. Clamp the current probe or an ammeter around the "B+" cable. Clamp the tool with the positive side away from the battery. Record the value of the electrical current. b. The current is less than two amperes. Go to step 7.d. c. The current is more than two amperes. There is an internal problem with the alternator. Replace the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure. d. Disconnect the wire for "B+" terminal from the alternator. Connect the red lead of the multimeter to the wire for the "B+" terminal. Connect the black lead of the multimeter to the "B+" terminal on the alternator. Set the multimeter to ten amp. Record the value of the electrical current. e. The current is below 0.015 amperes. The alternator is operating correctly. There is an electrical load on the machine. Go to step 8. f. The current is above 0.015 amperes. There is an internal fault with the alternator. Replace the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure. 8. Turn off all electrical accessories. Turn the keyswitch to the OFF position. a. Connect a current probe or an ammeter to a digital multimeter. Ensure that the probe is zeroed. Clamp the current probe or an ammeter to the main ground cable. Clamp the tool with the positive side away from the battery. b. Monitor the current and remove the fuses and circuit breakers one at a time. Check the current after each fuses or each of the circuit breakers are removed. After removing a fuse and checking the current, replace the fuse. Start with the main fuses and proceed to the smaller circuits. c. If removing a fuse causes a current drop, then the problem is within that circuit. d. Check if any components on the circuit are on. e. If all components are switched off, disconnect electrical components on that circuit one at a time and monitor the current. f. After all components on the circuit have been disconnected, check the current. If the problem still exists, check the wiring for corrosion. Check if there is a short to ground. Note: The standard current is 0.05 amperes. A current value above this figure usually indicates a problem. However, some large machines with multiple control modules have a higher acceptable limit.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338214

Crankshaft Pulley - Check SMCS - 1205-535 The crankshaft pulley is installed on the front of the crankshaft. Replace the crankshaft pulley if any of the following conditions exist: • There is movement of the crankshaft pulley. • There is a large amount of gear train wear that is not caused by lack of oil. • Analysis of the engine oil has revealed that the front main bearing is badly worn. • The engine has had a failure because of a broken crankshaft. Check the areas around the holes for the bolts in the crankshaft pulley for cracks or for wear and for damage. Use the following steps in order to check the alignment and the runout of the crankshaft pulley: 1. Remove any debris from the front face of the crankshaft pulley. Remove any debris from the circumference of the crankshaft pulley. 2. Mount the dial indicator on the front cover. Use the dial indicator to measure the outer face of the crankshaft pulley. Set the dial indicator to read 0.00 mm (0.00 inch). 3. Rotate the crankshaft at intervals of 45 degrees and read the dial indicator. 4. The difference between the lower measurements and the higher measurements that are read on the dial indicator at all four points must not be more than 0.18 mm (0.007 inch). If the reading on the dial indicator is more than 0.18 mm (0.007 inch), inspect the pulley for damage. If the pulley is damaged, use new parts for replacement.

5. Move the dial indicator so that the dial indicator will measure the circumference of the crankshaft pulley. Set the dial indicator to read 0.00 mm (0.00 inch). 6. Slowly rotate the crankshaft in order to measure the runout of the circumference of the crankshaft pulley. Use the highest reading and the lowest reading on the dial indicator. The maximum and the minimum readings on the dial indicator should not vary more than 0.12 mm (0.005 inch). If the reading on the dial indicator is more than 0.12 mm (0.005 inch), inspect the pulley for damage. If the pulley is damaged, use new parts for replacement.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04175270

Gear Group - Inspect SMCS - 1206-040

Illustration 1

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Typical example (3) Accessory drive gear (if equipped) (7) Oil pump gear

Note: If one or more of the gears need to be removed for repair, refer to Disassembly and Assembly, "Gear Group (Front) - Remove" in order to remove the gears. Refer to the Disassembly and Assembly, "Gear Group (Front) - Install" in order to install the gears. 1. Inspect the gears for wear or for damage. If the gears are worn or damaged, use new parts for replacement. 2. Measure the clearance between the crankshaft gear (5) and the camshaft gear (4). Refer to Specifications, "Gear Group (Front)" for the clearance measurement.

3. Measure the clearance between the idler gear (6) for the oil pump and the crankshaft gear (5). Refer to Specifications, "Gear Group (Front)" for the clearance measurement. 4. Measure the backlash between the fuel injection pump gear (1) and the idler gear (2). Refer to Specifications, "Gear Group (Front)" for the backlash measurement. 5. Measure the end play on idler gear (2). Refer to Disassembly and Assembly, "Idler Gear - Install" for the correct procedure. Refer to Specifications, "Gear Group (Front)" for the end play measurement.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04371152

Flywheel Housing - Inspect SMCS - 1157-040 Table 1 Required Tools Tool

Part Number

Part Description

Qty

8T-5096

Dial Indicator Group

Concentricity of the Flywheel Housing Note: This check must be made with the flywheel and the starter removed and the bolts for the flywheel housing tightened lightly.

Illustration 1

g01344313

Typical example

1. Install Tooling (A). See Illustration 1. 2. Set the pointer of the dial indicator to 0 mm (0 inch). 3. Check the concentricity at intervals of 45 degrees around the flywheel housing. 4. Calculate the difference between the lowest measurement and the highest measurement. This difference must not be greater than the limit that is given in Table 2.

Alignment of the Flywheel Housing Note: This check must be made with the flywheel and the starter removed and the bolts for the flywheel housing tightened to the correct torque.

Illustration 2

g01344315

Typical example

1. Install Tooling (A). See Illustration 2. 2. Set the pointer of the dial indicator to 0 mm (0 inch). 3. Check the alignment at intervals of 45 degrees around the flywheel housing. 4. Calculate the difference between the lowest measurement and the highest measurement. This difference must not be greater than the limit that is given in Table 2. Table 2 Limits for Flywheel Housing Runout and Alignment (Total Indicator Reading) Bore of the Housing Flange

Maximum Limit (Total Indicator Reading)

410 mm (16.14 inch)

0.25 mm (0.010 inch)

448 mm (17.63 inch)

0.28 mm (0.011 inch)

Sat Jul 17 15:09:47 UTC+0530 2021

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04371150

Flywheel - Inspect SMCS - 1156-040 Table 1 Required Tools Tool

Part Number

Part Description

Qty

8T-5096

Dial Indicator Group

Alignment of the Flywheel Face

Illustration 1

g01334421

Typical example

1. Install Tooling (A) in illustration 1, as shown. 2. Set the pointer of the dial indicator to 0 mm (0 inch). 3. Turn the flywheel. Read the dial indicator for every 45 degrees. Note: During the check, keep the crankshaft pressed toward the front of the engine in order to remove any end play. 4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference must not be greater than 0.03 mm (0.001 inch) for every 25 mm (1.0 inch) of the radius of the flywheel. The radius of the flywheel is measured from the axis of the crankshaft to the contact point of the dial indicator.

Flywheel Runout

Illustration 2

g01334422

Typical example

1. Install Tooling (A) in illustration 2, as shown. 2. Set the pointer of the dial indicator to 0 mm (0 inch). 3. Turn the flywheel. Read the dial indicator for every 45 degrees. 4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference must not be greater than 0.30 mm (0.012 inch).

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04371155

Piston Height - Inspect SMCS - 1214-040 Table 1 Required Tools Tool

Part Number

Part Description

Qty

1P-2403

Dial Indicator

1P-2402

Gauge Body

If the height of the piston above the cylinder block is not within the tolerance that is given in Specifications, "Piston and Rings", the bearing for the piston pin must be checked. Refer to Systems Operation, Testing and Adjusting, "Connecting Rod - Inspect". If any of the following components are replaced or remachined, the piston height above the cylinder block must be measured: • Crankshaft • Cylinder head • Connecting rod • Bearing for the piston pin The correct piston height must be maintained in order to ensure that the engine conforms to the standards for emissions. Note: The top of the piston should not be machined. If the original piston is installed, be sure that the original piston is assembled to the correct connecting rod and installed in the original cylinder.

Illustration 1 Typical example

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Illustration 2

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Typical example

1. Use Tooling (A) and Tooling (B) in order to measure the piston height above the cylinder block. Use the cylinder block face to zero Tooling (A). 2. Rotate the crankshaft until the piston is at the approximate top center. 3. Position Tooling (B) and Tooling (A) in order to measure the piston height above the cylinder block. The piston height should be measured at positions (X) or (Y). Slowly rotate the crankshaft in order to determine when the piston is at the highest position. Record this dimension. Compare this dimension with the dimensions that are given in Specifications, "Piston and Rings".

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338889

Cylinder Head - Inspect SMCS - 1100-040 1. Remove the cylinder head from the engine. 2. Remove the water temperature regulator housing. 3. Inspect the cylinder head for signs of gas or coolant leakage. 4. Remove the valve springs and valves. 5. Clean the bottom face of the cylinder head thoroughly. Clean the coolant passages and the lubricating oil passages. Make sure that the contact surfaces of the cylinder head and the cylinder block are clean, smooth, and flat. 6. Inspect the bottom face of the cylinder head for pitting, corrosion, and cracks. Inspect the area around the valve seat inserts and the holes for the fuel injection nozzles carefully. 7. Test the cylinder head for leaks at a pressure of 200 kPa (29 psi).

Illustration 1

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Flatness of the cylinder head (typical example) (A) Side to side (B) End to end (C) Diagonal

8. Measure the cylinder head for flatness. Use a straight edge and a feeler gauge to check the cylinder head for flatness. Measure the cylinder head from one side to the opposite side (A). Measure the cylinder head from one end to the opposite end (B). Measure the cylinder head from one corner to the opposite corner (C). Refer to Specifications, "Cylinder Head" for more information.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05391913

Cylinder Block - Inspect SMCS - 1201-040 1. Clean all of the coolant passages and the oil passages. 2. Check the cylinder block for cracks and damage. 3. Check the front camshaft bearing for wear. Refer to Specifications, "Camshaft Bearings" for the correct specification of the camshaft bearing. If a new bearing is needed, use a suitable adapter to press the bearing out of the bore. Ensure that the oil hole in the new bearing faces the front of the block. The oil hole in the bearing must be aligned with the oil hole in the cylinder block. The bearing must be aligned with the face of the recess.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04175235

Connecting Rod - Inspect SMCS - 1218-040 If the crankshaft or the cylinder block are replaced, the piston height for all cylinders must be measured. Refer to Specifications, "Piston and Rings" for the correct piston height. Inspect the connecting rod for wear or for damage. Refer to Specifications, "Connecting Rod" for the correct dimensions. Note: When the piston pin is installed, always install new retaining rings on each end of the piston pin.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i03633934

Piston Ring Groove - Inspect SMCS - 1214-040 Table 1 Required Tools Tool

Part Number

8H-8581

Part Description Feeler Gauge

Qty 1

Inspect the Piston and the Piston Rings 1. Check the piston for wear and other damage. 2. Check that the piston rings are free to move in the grooves and that the rings are not broken.

Inspect the Clearance of the Piston Ring 1. Remove the piston rings (2). Refer to Disassembly and Assembly, "Pistons and Connecting Rods Disassemble" for the correct procedure. Clean the grooves (1) and the piston rings (2).

Illustration 1

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Typical example (A) Feeler gauge (1) Piston grooves (2) Piston ring

2. Install new piston rings (2) in the piston grooves (1). Refer to Disassembly and Assembly Manual, "Pistons and Connecting Rods - Assemble" for the correct procedure. 3. Check the clearance for the piston ring by placing Tooling (A) between piston groove (1) and the top of piston ring (2) for the intermediate ring and the oil control ring. Refer to Specifications, "Piston and Rings" for the dimensions.

Inspect the Piston Ring End Gap

Illustration 2

g01344283

(A) Feeler Gauge (2) Piston ring (3) Cylinder ring ridge

1. Clean all carbon from the top of the cylinder bores. 2. Place each piston ring (2) in the cylinder bore just below the cylinder ring ridge (3). 3. Use Tooling (A) to measure piston ring end gap. Refer to Specifications, "Piston and Rings" for the dimensions. Note: The coil spring must be removed from the oil control ring before the gap of the oil control ring is measured.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04823051

Position the Valve Mechanism Before Maintenance Procedures SMCS - 1102; 1121; 1123; 1209

NOTICE Ensure that this procedure is carried out before the rocker shaft is removed.

Table 1 Required Tools Tool A (1) (1)

Part Number 5P-7306 5P-7305

Part Description

Qty

Housing

Engine Turning Tool

This Tool is used in the aperture for the electric starting motor.

Illustration 1

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Cylinder and valve location (A) Inlet valve (B) Exhaust valve

1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install" for the correct procedure.

Illustration 2

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Typical example

2. Select an exhaust rocker arm (1) . The exhaust rocker arm (1) can be on any cylinder. 3. Use Tooling (A) to rotate the crankshaft in the normal direction of rotation until the hydraulic lash adjuster starts to open the exhaust valve. Continue to rotate the crankshaft until the valve has opened to the maximum extent. This is the safe position. Note: Make temporary marks on the front pulley and the front housing once the engine is in the safe position.

NOTICE Ensure that the crankshaft is located in the safe position before the rocker shaft assembly is installed.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338356

Water Pump - Inspect SMCS - 1361-040 1. Inspect the water pump for leaks at vent hole. The water pump seal is lubricated by coolant in the cooling system. A normal condition is for a small amount of leakage to occur as the engine cools down and the parts contract. 2. Refer to Disassembly and Assembly, "Water Pump - Remove " and Disassembly and Assembly, "Water Pump - Install" for the correct procedures to remove and install the water pump. 3. Inspect the water pump shaft for unusual noise, excessive looseness and/or vibration of the bearings.

Product: ENGINE - MACHINE Model: C3.4B ENGINE - MACHINE CJG Configuration: C3.4B Industrial Engine CJG00001-UP

Publication Date -01/03/2013

i02414647

Thermostat - Water Temperature Regulator - Test SMCS - 1355-081-ON; 1355-081

Personal injury can result from escaping fluid under pressure. If a pressure indication is shown on the indicator, push the release valve in order to relieve pressure before removing any hose from the radiator.

1. Remove the water temperature regulator from the engine. Refer to Disassembly and Assembly Manual, "Water Temperature Regulator - Remove and Install". 2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the fully open temperature of the water temperature regulator. Stir the water in the pan. This will distribute the temperature throughout the pan. 3. Hang the water temperature regulator in the pan of water. The water temperature regulator must be below the surface of the water. The water temperature regulator must be away from the sides and the bottom of the pan. 4. Keep the water at the correct temperature for ten minutes. 5. After ten minutes, remove the water temperature regulator. Immediately measure the opening of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the minimum opening distance of the water temperature regulator at the fully open temperature. If the distance is less than the amount listed in the manual, replace the water temperature regulator.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338229

Engine Oil Cooler - Inspect SMCS - 1378-040

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Illustration 1

g02494121

Typical example

Perform the following procedure in order to inspect the engine oil cooler. 1. Place a container under the oil cooler in order to collect any engine oil or coolant that drains from the oil cooler. 2. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" for removal of the engine oil cooler. 3. Thoroughly clean the oil cooler (1) and the cylinder block.

Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

4. Inspect the oil cooler (1) for cracks and dents. Replace the oil cooler (1) if cracks or dents exist. Ensure that no restrictions for the flow of lubricating oil exist in the oil cooler (1). Dry the oil cooler (1) with low-pressure air. Flush the inside of the oil cooler (1) with clean lubricating oil. 5. Refer to Disassembly and Assembly, "Engine Oil Cooler - Install" for installation of the engine oil cooler. 6. Ensure that the lubrication and the cooling system of the engine is filled to the correct level. Operate the engine. Note: Refer to Operation and Maintenance Manual, "Refill Capacities" for additional information. Check for oil or coolant leakage.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169715

Cooling System - Test SMCS - 1350-040; 1350-081 Remember that temperature and pressure work together. When a diagnosis is made of a cooling system problem, temperature and pressure must be checked. The cooling system pressure will have an effect on the cooling system temperature. For an example, refer to Illustration 1. This will show the effect of pressure on the boiling point (steam) of water. This will also show the effect of height above sea level.

Illustration 1 Cooling system pressure at specific altitudes and boiling points of water

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

The coolant level must be to the correct level in order to check the coolant system. The engine must be cold and the engine must not be running. After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling system. Then remove the pressure cap. If the cooling system is equipped with a sight glass, the coolant should be to the correct level in the sight glass. On cooling systems without an indicator of the coolant level, fill the cooling system in order to be no more than 13 mm (0.5 inch) from the bottom of the filler pipe.

Making the Correct Antifreeze Mixtures Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze. Refer to Operation and Maintenance Manual, "Refill Capacities" for the correct procedure. The pure antifreeze increases the concentration of antifreeze in the cooling system. The increased concentration increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. The antifreeze mixture must consist of equal quantities of antifreeze and clean soft water. The corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% of antifreeze is used. Concentrations of more than 50% of antifreeze may have the adverse effect on the performance of the coolant.

Checking the Filler Cap One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

To check for the amount of pressure that opens the filler cap, use the following procedure: 1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the cooling system. Then, remove the filler cap. 2. Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface. Inspect the following components for any foreign substances: Filler cap Seal Surface for seal Remove any deposits that are found on these items, and remove any material that is found on these items. 3. Install the pressure cap onto a suitable pressurizing pump. 4. Observe the exact pressure that opens the filler cap. 5. Compare the pressure to the pressure rating that is found on the top of the filler cap. The pressure cap should open within 95 to 110 kPa (13.7788 to 15.9544 psi). The pressure cap has a nominal pressure rating of 100 kPa (14.504 psi). 6. If the filler cap is damaged, replace the filler cap.

Testing The Radiator And Cooling System For Leaks Use the following procedure to test the radiator and the cooling system for leaks.

Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

1. When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release from the cooling system. Then remove the filler cap. 2. Make sure that the coolant covers the top of the radiator core. 3. Put a suitable pressurizing Pump onto the radiator. 4. Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the operating pressure of the filler cap. 5. Check the radiator for leakage on the outside. 6. Check all connections and hoses of the cooling system for leaks. The radiator and the cooling system do not have leakage if all of the following conditions exist: You do NOT observe any leakage after 5 minutes. The dial indicator remains constant beyond 5 minutes. The inside of the cooling system has leakage only if the following conditions exist: The reading on the gauge goes down. You do NOT observe any outside leakage. Make any repairs, as required.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i03577882

Cooling System - Inspect SMCS - 1350-040 This engine has a pressure type cooling system. A pressure type cooling system gives two advantages: • The pressure type cooling system can operate safely at a higher temperature than the boiling point of water at different atmospheric pressure ranges. • The pressure type cooling system prevents cavitation in the water pump. Cavitation is the sudden generation of low pressure bubbles in liquids by mechanical forces. The generation of an air or steam pocket is much more difficult in a pressure type cooling system. Regular inspections of the cooling system should be made in order to identify problems before damage can occur. Visually inspect the cooling system before tests are made with the test equipment.

Visual Inspection Of The Cooling System 1. Check the coolant level in the cooling system. 2. Look for leaks in the system. Note: A small amount of coolant leakage across the surface of the water pump seals is normal. This leakage is required in order to provide lubrication for this type of seal. A hole is provided in the water pump housing in order to allow this coolant/seal lubricant to drain from the pump housing. Intermittent leakage of small amounts of coolant from this hole is not an indication of water pump seal failure. 3. Inspect the radiator for bent fins and other restriction to the flow of air through the radiator. 4. Inspect the drive belt for the fan. 5. Inspect the blades of the fan for damage.

6. Look for air or combustion gas in the cooling system. 7. Inspect the radiator cap for damage. The sealing surface must be clean. 8. Look for large amounts of dirt in the radiator core. Look for large amounts of dirt on the engine. 9. Shrouds that are loose or missing cause poor air flow for cooling.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05288851

Cooling System - Check SMCS - 1350-535

Engine And Cooling System Heat Problems 1. The following conditions indicate that a heat problem exists. a. Hot coolant is released through the pressure cap during the normal operation of the engine. Hot coolant can also be released when the engine is stopped. b. Hot coolant is released from the coolant system but not through the pressure cap during normal operation of the engine. Hot coolant can also be released when the engine is stopped. c. Coolant must be added frequently to the cooling system. The coolant is not released through the pressure cap or through an outside leak. 2. If any of the conditions in Step 1 exist, perform the following procedures: a. Run the engine at medium idle, which is approximately 1200 rpm, for 3 minutes after the high idle shuts off. Running the engine at medium idle will allow the engine to cool before the engine is stopped. b. Inspect the poly v-belt for wear or for damage. If necessary, replace the poly v-belt. Refer to Operation and Maintenance Manual, "Alternator and Fan Belts - Replace" for the correct procedure. 3. Refer to "Visual Inspection Of The Cooling System" in order to determine if a leak exists in the cooling system. a. Refer to "Testing The Radiator And Cooling System For Leaks" procedures.

4. If the coolant does not flow through the radiator and through other componentsof the cooling system, perform the following procedures. a. Perform the "Testing The Thermostat - Water Temperature Regulator " procedures. b. Clean the radiator and other components with hot water or steam at low pressure. Detergent in the water may also be used. Compressed air may be used to remove materials from the cooling system. Identify the cause of the restriction before you choose the method for cleaning. c. Straighten any fins of the radiator if the fins are bent. 5. Check the high idle of the engine. The engine may overheat if the high idle rpm is set too high.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i03577881

Increased Engine Oil Temperature - Inspect SMCS - 1348-040 Look for a restriction in the oil passages of the oil cooler. The oil temperature may be higher than normal when the engine is operating. In such a case, the oil cooler may have a restriction. Sat Jul 17 15:06:55 UTC+0530 2021

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i02414692

Excessive Engine Oil Consumption - Inspect SMCS - 1348-040

Engine Oil Leaks on the Outside of the Engine Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the engine oil pan and all lubrication system connections. Look for any engine oil that may be leaking from the crankcase breather. This can be caused by combustion gas leakage around the pistons. A dirty crankcase breather will cause high pressure in the crankcase. A dirty crankcase breather will cause the gaskets and the seals to leak.

Engine Oil Leaks into the Combustion Area of the Cylinders Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke. There are several possible ways for engine oil to leak into the combustion area of the cylinders: • Failed valve stem seals • Leaks between worn valve guides and valve stems • Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine oil) • Incorrect installation of the compression ring and/or the intermediate ring • Leaks past the seal rings in the turbocharger shaft • Overfilling of the crankcase • Wrong dipstick or guide tube • Sustained operation at light loads

Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04027269

Excessive Bearing Wear - Inspect SMCS - 1203-040; 1211-040; 1219-040 When some components of the engine show bearing wear in a short time, the cause can be a restriction in an oil passage. An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for the oil supply to the component. A restriction in an oil supply passage will not allow enough lubrication to reach a component. Early wear will result. Refer to Specifications for more information regarding component wear limits.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04484013

Engine Oil Pump - Inspect SMCS - 1304-040 1. Remove the oil pump from the engine. 2. Clean the engine oil pump. 3. Look for cracks in the metal or other damage to the engine oil pump. If necessary, replace the engine oil pump. 4. Install the oil pump on the engine. 5. Remove the engine oil pressure relief valve from the engine. 6. Inspect the engine oil pressure relief valve for wear of for damage. If necessary, replace the engine oil pressure relief valve.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04169630

Engine Oil Pressure - Test SMCS - 1304-081

Low Oil Pressure The following conditions will cause low oil pressure. • The oil level is low in the crankcase. • A restriction exists on the oil suction screen. • Connections in the oil lines are leaking. • The connecting rod or the main bearings are worn. • The rotors in the oil pump are worn. • The oil pressure relief valve is operating incorrectly. A worn oil pressure relief valve can allow oil to leak through the valve which lowers the oil pressure. The minimum oil pressure at a maximum engine speed of 2200 rpm and at normal operating temperature is 400 to 480 kPa (58.016 to 69.619 psi). A lower pressure is normal at low idle. A suitable pressure gauge can be used in order to test the pressure of the lubrication system.

High Oil Pressure High oil pressure can be caused by the following conditions. • The spring for the oil pressure relief valve is installed incorrectly.

• The plunger for the oil pressure relief valve becomes jammed in the closed position. • Excessive sludge exists in the oil which makes the viscosity of the oil too high.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04483849

Valve Guide - Inspect SMCS - 1104-040 Perform this test in order to determine if a valve guide should be replaced.

Illustration 1 Measure the radial movement of the valve in the valve guide. (1) Valve guide (2) Radial movement of the valve in the valve guide (3) Valve stem (4) Dial indicator (5) Valve head

g00314806

1. Place a new valve in the valve guide. 2. Place a dial indicator with a magnetic base on the face of the cylinder head. 3. Lift the edge of the valve head to a distance of 15 mm (0.591 inch). 4. Move the valve in a radial direction away from the dial indicator. Make sure that the valve moves away from the dial indicator as far as possible. Position the contact point of the dial indicator on the edge of the valve head. Set the position of the needle of the dial indicator to zero. 5. Move the valve in a radial direction toward the dial indicator as far as possible. Note the distance of movement which is indicated on the dial indicator. If the distance is greater than the maximum clearance of the valve in the valve guide, replace the valve guide. Refer to Specifications, "Cylinder Head Valves" for the clearances. The original valve guides are bored into the cylinder head. When new valve guides (1) are installed, new valves and new valve seat inserts must be installed. The cylinder head must be rebored in order to install the new valve guide. For more information, contact your distributor or your dealer.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338937

Valve Depth - Inspect SMCS - 1105-040 Table 1 Required Tools Tool

Part Number

Part Description

Qty

8T-0455

Liner Projection Tool Group

Illustration 1

g01343897

(1) Dial indicator (2) Gauge body (3) Gauge block

1. Use the Tooling (A) to check the depths of the inlet valves and the exhaust valves below the face of the cylinder head. Use the gauge block (3) to zero the dial indicator (1). 2. Ensure that the face of the valves are clean. Ensure that the bottom face of the cylinder head is clean. Ensure that the cylinder head is not distorted. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the procedure to measure flatness of the cylinder head.

Illustration 2

g01343900

Typical example Measurement of the valve depth (1) Dial indicator (2) Gauge body

3. Position gauge body (2) and dial indicator (1) in order to measure the valve depth. Measure the depth of the inlet valve and the exhaust valve before the valve springs are removed. 4. For the minimum and maximum limits for a new engine for the inlet valves and the exhaust valves, refer to Specifications, "Cylinder Head". 5. Check each valve for cracks. Check the stems of the valves for wear. Ensure that the valves are the correct fit in the valve guides. Refer to Systems Operation, Testing and Adjusting, "Valve Guide Inspect" for the procedure to inspect the valve guides. 6. Check the load on the valve springs. Refer to Specifications, "Cylinder Head Valves" for the correct lengths and specifications for the valve springs.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04821825

Engine Valve Lash - Inspect SMCS - 1102-040 Table 1 Required Tools Tool A(1) (1)

Part Number

Part Description

Qty

5P-7306

Housing

5P-7305

Engine Turning Tool

This Tool is used in the aperture for the electric starting motor.

Illustration 1

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Cylinder and valve location (A) Inlet valve (B) Exhaust valve

Too much valve lash can cause some broken valve stems, springs, and spring retainers. Damage to the valve mechanism will produce emissions in excess of the correct specification. The hydraulic lifter will compensate for all normal wear of the components of the valve train. Too much valve lash can be an indication of the following problems: • Worn camshaft and valve lifters • Worn rocker arms • Bent pushrods • Broken socket on the upper end of a pushrod • Loose adjustment screw for the valve lash • Issues with the hydraulic lash adjusters If the camshaft and valve lifters show rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause.

Valve Lash Check

Accidental engine starting can cause injury or death to personnel. To prevent accidental engine starting, turn the ignition switch to the OFF position and place a do not operate tag at the ignition switch location.

1. Find top center position for number one piston. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 1 Piston" for the correct procedure. 2. Check the rocker arms for an engine valve lash. There should be no engine valve lash.

Illustration 2

g02948536

Typical example

3. If there is an engine valve lash at any position the engine valve lash may be caused by a normal leakdown of the hydraulic lash adjuster. Push the affected rocker arm (1) against the pushrod. The rocker arm (1) should rotate as the pushrod is pushed up by the recovery of the hydraulic lifter. Once all motion has ceased test again for an engine valve lash. There should be no engine valve lash. 4. Use Tooling (A) to rotate the crankshaft in a clockwise direction. The crankshaft should be rotated 360 degrees. 5. Check the rocker arms for an engine valve lash. There should be no engine valve lash. 6. If there is an engine valve lash at any position the engine valve lash may be caused by a normal leakdown of the hydraulic lash adjuster. Push the affected rocker arm (1) against the pushrod. Monitor the rocker arm (1) for movement. The rocker arm (1) should rotate as the pushrod is pushed up by the recovery of the hydraulic lash adjuster. Once all motion has ceased test again for an engine valve lash. There should be no engine valve lash. 7. If an engine valve lash is found in any position, examine the valve mechanism components for excessive wear or damage. Examine the hydraulic lash adjusters for damage.

www.CATC34B.COM Cat C3.4B Engine Parts www.FPTIndustrialEngineParts.com

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04461759

Cat C3.4B Engine Compression - Test SMCS - 1215 The cylinder compression test should only be used in order to compare the cylinders of an engine. If one or more cylinders vary by more than 350 kPa (51 psi), the cylinder and related components may need to be repaired. A compression test should not be the only method which is used to determine the condition of an engine. Other tests should also be conducted in order to determine if the adjustment or the replacement of components is required. Before the performance of the compression test, make sure that the following conditions exist: • The battery is in good condition. • The battery is fully charged. • The starting motor operates correctly. • The valve lash is correct. • All glow plugs are removed. • The ECM is powered. • The fuel pressure sensor is connected. • The suction control valve is connected.

Illustration 1

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Typical example

1. Remove the glow plug (1). Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure. 2. Install a suitable gauge for measuring the cylinder compression in the hole for the glow plug (2). 3. Remove the fuse for the glow plugs. 4. Operate the starting motor in order to turn the engine. Record the maximum pressure which is indicated on the compression gauge. 5. Repeat steps 2 and 4 for all cylinders. 6. Install the fuse for the glow plugs.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i06803978

Diesel Particulate Filter - Clean SMCS - 108F-070

The wall flow Diesel Particulate Filters (DPF) require periodic removal of ash that accumulates from engine oil.

Cleaning Procedure

Follow this cleaning procedure for removal of the ash from the wall flow DPF. Refer to Operation and Maintenance Manual for the intervals of service hours for cleaning of the wall flow DPF. 1. Connect the engine to the electronic service tool before the wall flow DPF is removed from the engine. Once the engine is connected to the electronic service tool, then perform an ash service test. This test is a manual regeneration. The test could take an hour. Note: Allow the wall flow DPF to cool until the wall flow DPF can be safely removed. 2. Remove the wall flow DPF from the Clean Emissions Module (CEM). Refer to Disassembly and Assembly for the correct procedure. Note: Identify all engine fault codes if black soot is discovered on the outlet side of the center section on the wall flow DPF. Refer to Troubleshooting for problem identification and the disposition of the wall flow DPF. 3. Clean the wall flow DPF. Refer to Special Instruction, NEHS1109, "Compact DPF Cleaner" for the cleaning procedure. 4. Reinstall the wall flow DPF onto the Clean Emissions Module (CEM). Refer to Disassembly and Assembly for the correct procedure.

Reset the Engine Ash Model The engine ash model must be reset whenever the filter is cleaned or replaced. Resetting the ash model places the wall flow DPF volume back to the "Clean State". The resetting will allow the regeneration of the wall flow DPF to function properly. 1. Use the electronic service tool to access the following menus: Service Configuration Component Replacement Resets Ash Service Calibration 2. Choose the correct replacement type of diesel particulate filter in the menu that appears. The types of replacements for the diesel particulate filter are the following: "New filter replacement" "Remanufactured filter replacement" "Filter cleaned and reapplied" Note: If a new filter or a remanufactured filter is used, the new serial number must be programmed into the electronic service tool.

Note: For the "Filter cleaned and reapplied" option, use the electronic service tool to perform the "DPF Ash Cleaning" reset. Note: For the "New filter replacement" option, use the electronic service tool to perform the "DPF Replacement Reset". 3. The electronic service tool will display "Ash Service Calibration Successful" when the calibration has been completed.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04552042

Exhaust Cooler (NRS) - Test SMCS - 1061; 1087; 108C-081 Air Under Water Leak Test Procedure. 1. Follow steps 1.a to 1.i in order to test the coolant side of the exhaust gas cooler (NRS). a. Plug the coolant inlet of the exhaust gas cooler (NRS). b. Plug the coolant outlet port with tube and pressure regulator assembly. c. Make sure that the air pressure regulator is closed and connect compressed air to the pressure regulator. d. Use a suitable air supply in order to apply an air pressure of 250 kPa (36 psi) to the exhaust gas cooler (NRS). e. While the exhaust gas cooler (NRS) is still pressurized, submerge the cooler in water that is at ambient temperature. f. Allow the exhaust gas cooler (NRS) to settle in order for the air that is trapped to escape. g. Observe the exhaust gas cooler (NRS) for air bubbles that indicate a leak. If air bubbles are seen within 3 minutes, this indicates a leak with the exhaust gas cooler (NRS). Note the location or the origin of the leak. Record this information. h. If no bubbles are detected after 3 minutes, the exhaust gas cooler (NRS) is reusable. i. Remove the exhaust gas cooler (NRS) from the water. If the exhaust gas cooler (NRS) does not leak, the problem may be elsewhere in the cooling system or the engine. Refer the service manual in order to check for leakage. If the exhaust gas cooler (NRS) does leak, the exhaust gas cooler (NRS) should be replaced.

2. Follow steps 2.a to 2.i in order to test the gas side of the exhaust gas cooler (NRS). a. Plug the gas inlet of the exhaust gas cooler (NRS). b. Plug the gas outlet port with tube and pressure regulator assembly. c. Make sure that the air pressure regulator is closed and connect compressed air to the pressure regulator. d. Use a suitable air supply in order to apply an air pressure of 250 kPa (36 psi) to the exhaust gas cooler (NRS). e. While the exhaust gas cooler (NRS) is still pressurized, submerge the cooler in water that is at ambient temperature. f. Allow the exhaust gas cooler (NRS) to settle in order for the air that is trapped to escape. g. Observe the exhaust gas cooler (NRS) for air bubbles that indicate a leak. If air bubbles are seen within 3 minutes, this indicates a leak with the exhaust gas cooler (NRS). Note the location or the origin of the leak. Record this information. h. If no bubbles are detected after 3 minutes, the exhaust gas cooler (NRS) is reusable. i. Remove the exhaust gas cooler (NRS) from the water. If the exhaust gas cooler (NRS) does not leak, the problem may be elsewhere in the cooling system or the engine. Refer the service manual in order to check for leakage. If the exhaust gas cooler (NRS) does leak, the exhaust gas cooler (NRS) should be replaced.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05292997

Turbocharger - Inspect SMCS - 1052-040

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Before you begin inspection of the turbocharger, be sure that the inlet air restriction is within the specifications for your engine. Be sure that the exhaust system restriction is within the specifications for your engine. Refer to Systems Operation, Testing, and Adjusting, "Air Inlet and Exhaust System - Inspect". The condition of the turbocharger will have definite effects on engine performance. Use the following inspections and procedures to determine the condition of the turbocharger. • Inspection of the compressor and the compressor housing • Inspection of the turbine wheel and the turbine housing • Inspection of the wastegate

Inspection of the Compressor and the Compressor Housing

Illustration 1 Typical example (1) Turbine housing (2) Compressor housing

g02529616

1. Inspect the compressor wheel for damage from a foreign object. If there is damage, determine the source of the foreign object. Replace the turbocharger. If there is no damage, go to step 2. 2. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways. The assembly should turn freely. The compressor wheel should not rub the compressor housing. The turbocharger must be replaced if the compressor wheel rubs the compressor wheel housing. If there is no rubbing or scraping, go to step 3. 3. Inspect the compressor and the compressor wheel housing for oil leakage. An oil leak from the compressor may deposit oil in the aftercooler. If oil is found in the aftercooler, then drain and clean the aftercooler. a. Check the oil level in the crankcase. If the oil level is too high, adjust the oil level. b. Inspect the engine air cleaner element. Replace a dirty engine air cleaner element with a clean engine air cleaner element. Refer to Operation and Maintenance Manual, "Engine Air Cleaner Element (Dual Element) - Clean/Replace" or Operation and Maintenance Manual, "Engine Air Cleaner Element (Single Element) - Replace" for the correct procedure. Inspect the engine air cleaner service indicator. Refer to Operation and Maintenance Manual, "Engine Air Cleaner Service Indicator - Inspect" for the correct procedure. c. Inspect the engine crankcase breather. Clean the engine crankcase breather or replace the engine crankcase breather if the engine crankcase breather is plugged. d. Remove the pipe for the oil drain. Inspect the drain opening. Inspect the oil drain line. Inspect the area between the bearings of the rotating assembly shaft. Look for the oil sludge. Inspect the oil drain hole for the oil sludge. Inspect the oil drain line for the oil sludge in the drain line. If necessary, clean the oil drain line. Replace the oil drain line if there is any sign of damage to the oil drain line. e. If steps 3.a through 3.d did not reveal the source of the oil leakage, the turbocharger has internal damage. Replace the turbocharger.

Inspection of the Turbine Wheel and the Turbine Housing Remove the air piping from the turbine housing. 1. Inspect the turbine for damage by a foreign object. If there is damage, determine the source of the foreign object. Replace the turbocharger. If there is no damage, go to step 2. 2. Inspect the turbine wheel for the carbon and other foreign material. Inspect turbine housing (1) for carbon and foreign material. Replace the turbocharger, if necessary. If there is no buildup of carbon or foreign material, go to step 3. 3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways. The assembly should turn freely. The turbine wheel should not rub turbine wheel housing (1). Replace the turbocharger if the turbine wheel rubs turbine housing (1). If there is no rubbing or scraping, go to step 4.

4. Inspect the turbine and turbine housing (1) for oil leakage. Inspect the turbine and turbine housing (1) for oil coking. Some oil coking may be cleaned. Heavy oil coking may require replacement of the turbocharger. If the oil is coming from the turbocharger center housing go to step 4.a. Otherwise go to "Inspection of the Wastegate". a. Remove the pipe for the oil drain. Inspect the drain opening. Inspect the area between the bearings of the rotating assembly shaft. Look for the oil sludge. Inspect the oil drain hole for the oil sludge. Inspect the oil drain line for the oil sludge. If necessary, clean the drain line. b. If crankcase pressure is high, or if the oil drain is restricted, pressure in the center housing may be greater than the pressure of turbine housing (1). Oil flow may be forced in the wrong direction and the oil may not drain. Check the crankcase pressure and correct any problems. c. If the oil drain line is damaged, replace the oil drain line. d. Check the routing of the oil drain line. Eliminate any sharp restrictive bends. Make sure that the oil drain line is not too close to the engine exhaust manifold. e. If steps 4.a through 4.d did not reveal the source of the oil leakage, turbocharger (3) has internal damage. Replace the turbocharger.

Inspection of the Wastegate The wastegate actuator controls the amount of exhaust gas that is allowed to bypass the turbine side of the turbocharger. This valve then controls the rpm of the turbocharger. When the engine operates in conditions of a low boost (lug), a spring presses against a diaphragm in the canister. The load on the spring holds the wastegate closed. The turbocharger can then operate at maximum performance. When a boost pressure signal acts against the diaphragm in the wastegate, the pressure overcomes the spring and the wastegate actuator will open. The rpm of the turbocharger becomes limited. The rpm limitation occurs because a portion of the exhaust gases bypass the turbine wheel of the turbocharger. The following levels of boost pressure indicate a potential problem with the wastegate actuator or wastegate regulator: • Too high at full load conditions • Too low at all lug conditions The boost pressure controls the maximum rpm of the turbocharger, because the boost pressure controls the position of the wastegate. The following factors also affect the maximum rpm of the turbocharger: • The engine rating • The power demand on the engine • The high idle rpm

• Inlet air restriction • Exhaust system restriction Note: Check the operation of the wastegate regulator. Refer to Troubleshooting, "Solenoid Valve - Test".

Check the Wastegate for Proper Operation Table 1 Required Tools Tool

Part Number

Part Description

QTY

8T-5096

Dial Indicator Group

Illustration 2

g02529617

Typical example

1. Disconnect the pipe for the boost sensor (1) at the wastegate actuator (2). Connect an air supply to the wastegate actuator that can be adjusted accurately.

2. Install Tooling (A) to the turbocharger so that the end of the actuator rod (3) is in contact with Tooling (A). This will measure axial movement of the actuator rod (3). 3. Slowly apply air pressure to the wastegate so that the actuator rod (3) moves 10 mm (0.3937 inch). Refer to Specifications, "Turbocharger" for the correct pressure for the wastegate. Ensure that the dial indicator returns to zero when the air pressure is released. Repeat the test several times. This will ensure that an accurate reading is obtained. 4. If the operation of the wastegate is not correct, the turbocharger will need to be replaced. 5. Repeat steps 2 to 3 in order to repeat the pressure test. 6. If the air pressure is correct, remove the air supply. Remove Tooling (A). Install the pipe for the boost sensor (1).

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04170052

Air Inlet and Exhaust System - Inspect SMCS - 1050-040 A general visual inspection should be made to the air inlet and exhaust system. Make sure that there are no signs of leaks in the system. There will be a reduction in the performance of the engine if there is a restriction in the air inlet system or the exhaust system.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts. When working on an engine that is running, avoid contact with hot parts and rotating parts.

1. Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not blocked or collapsed.

2. Inspect the engine air cleaner element. Replace a dirty engine air cleaner element with a clean engine air cleaner element. Refer to Operation and Maintenance Manual, "Engine Air Cleaner Element (Dual Element) - Clean/Replace" or Operation and Maintenance Manual, "Engine Air Cleaner Element (Single Element) - Replace" for the correct procedure. 3. Check for dirt tracks on the clean side of the engine air cleaner element. If dirt tracks are observed, contaminants are flowing past the engine air cleaner element and/or the seal for the engine air cleaner element.

Illustration 1

g02857416

Typical example

4. Inspect the orifice in the boost pressure chamber (1) for blockages. If necessary, remove any blockages. Note: The boost pressure chamber is located on the side of the engine oil cooler.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04170049

Gear Group (Front) - Timing Gears SMCS - 1206-531

Illustration 1

g02859779

Typical example (3) Accessory drive gear (if equipped) (5) Crankshaft gear (6) Oil pump idler gear (7) Oil pump gear

1. Install the camshaft gear (4) onto the camshaft. Refer to Disassembly and Assembly, "Camshaft Gear Remove and Install" for the correct procedure. 2. Ensure that the crankshaft and the camshaft are locked in the correct position. Ensure that the fuel injection pump is in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump Remove" for the correct procedure.

3. Install the idler gear (2). Refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure. 4. Install the fuel injection pump and gear assembly (1). Refer to Disassembly and Assembly for the correct procedure. 5. Make sure that the timing marks on the gears are in alignment. If the timing marks are not aligned, refer to Disassembly and Assembly, "Gear Group (Front) - Remove and Install".

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05312509

Fuel System Pressure - Test SMCS - 1250-081; 1256-081 Table 1 Required Tools Tool

Part Number

Pressure gauge

438-4553

Pressure test kit

(1)

Part Description (1)

Qty 1 1

Pressure gauge needs to be able to measure pressure in a vacuum.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Note: Ensure that the engine is stopped before installing and removing Tooling (A) and (B) or carrying out any repair work on the fuel system.

Illustration 1

g02871337

Typical example (1) Primary fuel filter (2) Secondary fuel filter

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(3) Fuel injection pump

(4) Fuel manifold (rail) (5) Electronic unit injector (6) Check valve

Table 2 Position

Measurement

Minimum Pressure

Maximum Pressure

Inlet of fuel injection pump

50 kPa (7.25 psi)

Inlet of secondary fuel filter

400 kPa (58 psi)

650 kPa (94 psi)

Outlet of secondary fuel filter

400 kPa (58 psi)

650 kPa (94 psi)

Injector return line

30 kPa (4.35 psi)

80 kPa (11.6 psi)

Return line

20 kPa (2.9 psi)

1. Remove all relevant tube assemblies. Refer to Disassembly and Assembly for the correct procedures. 2. Install Tooling (A) at location (A) . Refer to illustration 1. Install Tooling (B) at locations (B) , (C) , (D) , and (E) . Refer to illustration 1. 3. Start the engine. Refer to Operation and Maintenance Manual for the correct procedure. 4. Use Tooling (A) and (B) to measure the pressure values in the order indicated in table 2 at both idle speed and at maximum engine speed with zero load. In both measurement conditions, the values measured must be between the minimum and maximum permissible pressure values. 5. Use Tooling (A) to measure the pressure value at position (A) . If the pressure value measured is lower than the minimum permissible pressure, check that the primary fuel filter is not restricted. Check that the tube assemblies upstream of the measurement point are not restricted. Check that there are no signs of air infiltration or damage in the tube assemblies and connectors upstream of the inlet of the fuel injection pump. Replace any damaged components. 6. Use Tooling (B) to measure the pressure value at position (B) . If the pressure value measured is lower than the minimum permissible pressure, check that the fuel injection pump functions correctly. Check for leaks in the circuit. If the pressure value measured is greater than the maximum permissible pressure, check that the lines between the secondary fuel filter and the fuel injection pump are not restricted. Replace any damaged components. 7. Use Tooling (B) to measure the pressure value at position (C) . If the pressure value measured is lower than the minimum permissible pressure, or if the difference between the value and the value measured in step 6 is greater than 150 kPa (22 psi), check if the secondary fuel filter is restricted. If the pressure

value measured is greater than the maximum permissible pressure, check that the tube assemblies between the secondary fuel filter and the fuel injection pump are not restricted. If the problem persists, check that fuel injection pump functions correctly. Replace any damaged components. 8. Use Tooling (B) to measure the pressure value at position (D) . If the pressure value measured is lower than the minimum permissible pressure, check that there is no leakage from the injector return line. Check that the check valve (6) that is integrated in the injector return line is functioning correctly. If the pressure value measured is greater than the maximum permissible pressure, check that there are no restrictions in the lines of the injector return line. Check that the check valve (6) that is integrated in the injector return line is functioning correctly. If the problem persists, check that the electronic unit injectors are functioning correctly with the electronic service tool. Replace any damaged components. 9. Use Tooling (B) to measure the pressure value at position (E) . If the pressure value measured is greater than the maximum permissible pressure, check that there are no restrictions in the fuel return lines. Check that the components of the high-pressure fuel system, such as the fuel injection pump, fuel manifold and electronic unit injectors are working correctly by using the electronic service tool test function to identify any faults relative to these components. Replace any damaged components. Note: Check that the manifold connector (7) is functioning correctly. Check that fuel flow is visible in the transparent pipe downstream of the connector (7) . 10. Remove Tooling (A) and (B) at locations (A) , (B) , (C) , (D) , and (E) . 11. Install all relevant tube assemblies. Refer to Disassembly and Assembly for the correct procedures.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04371154

Fuel System - Prime SMCS - 1258-548

Note: Refer to Systems Operation, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:

• The fuel tank is empty or the fuel tank has been partially drained. • The low-pressure fuel lines are disconnected. • A leak exists in the low-pressure fuel system. • The fuel filter has been replaced. Use the following procedures in order to remove air from the fuel system: 1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in the "ON" position.

Illustration 1

g02882651

Typical example

2. Open the screw (1) on the secondary fuel filter base. 3. Operate the hand priming pump. Count the number of operations of the pump. After approximately 80 depression of the pump stop. Note: As the fuel system is primed, the pressure will increase within the fuel system and this increase in pressure can be felt during priming.

4. Tighten the screw (1) to a torque of 2.5 N·m (22 lb in). 5. The fuel system should now be primed and the engine should be able to start. 6. Operate the engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of 5 minutes. Ensure that the fuel system is free from leaks. Note: Operating the engine for this period will help ensure that the fuel system is free of air. DO NOT loosen the high-pressure fuel lines in order to purge air from the fuel system. This procedure is not required. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the cooling, lubrication, or air systems. Replace any high-pressure fuel line that has leaked. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install". If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, "General hazard Information". If the engine will not start, refer to Troubleshooting, "Engine Cranks but will not Start".

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338389

Fuel Quality - Test SMCS - 1280-081 Note: Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training. Use the following procedure to test for problems regarding fuel quality: 1. Determine if water and/or contaminants are present in the fuel. Check the water separator. Drain the water separator, if necessary. A full fuel tank minimizes the potential for overnight condensation. Note: A water separator can appear to be full of fuel when the water separator is full of water. 2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of the fuel tank. Visually inspect the fuel sample for contaminants. The color of the fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or like sludge can be an indication of the growth of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates that the fuel may not be suitable for operating conditions. Refer to Operation and Maintenance Manual, "Fuel Recommendations" for more information. 3. If fuel quality is still suspected as a possible cause to problems regarding engine performance, disconnect the fuel inlet line. Temporarily operate the engine from a separate source of fuel that is known to be good. This will determine if the problem is caused by fuel quality. If fuel quality is determined to be the problem, drain the fuel system and replace the fuel filters. Engine performance can be affected by the following characteristics: Cetane number of the fuel

Viscosity of the fuel Lubricity of the fuel Air in the fuel Other fuel characteristics Refer to Operation and Maintenance Manual, "Fuel Recommendations" for more information on the cetane number of the fuel.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05292857

Fuel Injection Timing - Check SMCS - 1251-036 Table 1 Required Tools Tool A(1) B (1)

Part Number

Part Description

Qty

5P-7306

Housing

5P-7305

Engine Turning Tool

435-3146

Timing Pin (Camshaft)

This Tool is used in the aperture for the electric starting motor.

Illustration 1

g02862116

Typical example

1. If necessary, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive Remove and Install" for the correct procedure. Remove plug (1) from the engine. Use Tooling (A) in order to rotate the crankshaft in the normal direction of rotation. 2. Install Tooling (B) into Hole (X) in the engine. Use Tooling (B) in order to locate the camshaft in the correct position. Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the camshaft during repairs.

3. If the shaft for the fuel injection pump is not in the position shown in illustration 2, the timing of the fuel injection pump may be incorrect. If necessary, remove the fuel injection pump. Refer to Disassembly and Assembly for the correct procedure.

Illustration 2

g02906337

Typical example

4. Ensure that the camshaft is in correct position. If necessary, install the fuel injection pump. Refer to Disassembly and Assembly for the correct procedure. Ensure that the fuel injection pump shaft is in the correct position as shown in illustration 2. The Angle (Y) should be 45 degrees. 5. If necessary, remove Tooling (B). Install plug (1) to the engine.

6. If necessary, install the accessory drive . Refer to Disassembly and Assembly, "Accessory Drive Remove and Install" for the correct procedure.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i06844847

Finding Top Center Position for No. 1 Piston SMCS - 1105-531 Table 1 Required Tools Tool A(1) (1)

Part Number

Part Description

Qty

5P-7306

Housing

5P-7305

Engine Turning Tool

This Tool is used in the aperture for the electric starting motor.

1. Remover the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install" for the correct procedure. 2. Use Tooling (A) to rotate the crankshaft in the normal direction of rotation. 3. Rotate the crankshaft in the normal direction of rotation until the inlet valve of number 4 cylinder has opened and the exhaust valve of the same cylinder has not closed completely. The piston in the number 1 cylinder should be at the top center position.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i05292854

Air in Fuel - Test SMCS - 1280-081 Table 1 Required Tools Tool

Part Number

420-2523

Part Description Sight gauge

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Note: Ensure that the tools are stored with the caps in place. Store the tools in a clean plastic bag. 1. Ensure that the fuel level in the fuel tank is above the level of the suction pipe in the fuel tank. 2. Inspect the fuel system thoroughly for leaks. If necessary, repair the fuel system.

3. Check all low-pressure fuel lines from the fuel tank for restrictions. Replace any damaged components. 4. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. 5. Start the engine. Refer to Operation and Maintenance Manual, "Starting the Engine" for the correct procedure. Check if the problem has been resolved. Run the engine at low idle speed for 5 minutes. 6. Stop the engine. Refer to Operation and Maintenance Manual, "Stopping the Engine" for the correct procedure.

Illustration 1

g02879436

Typical example

7. If necessary, remove the low-pressure fuel line from the retaining clips. Remove the tube assembly (1) from the inlet of the fuel transfer pump. Note: Ensure that the low-pressure fuel lines are not deformed.

Illustration 2

g02895617

Typical example

8. Install Tooling (A) to the inlet of the fuel transfer pump and the end of tube assembly (1). Ensure that Tooling (A) is secured and clear of rotating parts. 9. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. 10. Start the engine. Refer to Operation and Maintenance Manual, "Starting the Engine" for the correct procedure. Refer to steps 10.a to 10.d for the procedure for testing the air in fuel. a. Run the engine a low idle speed. b. Run the engine for 2 minutes. There should be no air in the fuel flow through the sight tube. Small bubbles that are spaced more than 2.5 cm (1.0 inch) are acceptable. Do not manipulate the connections during the test for the air in fuel. c. The presence of large bubbles or a continuous stream of bubbles indicates a leak. d. Investigate potential leaks and rectify any potential leaks in the low-pressure fuel system. Check for leaks between the fuel tank and the inlet of the fuel injection pump. If necessary, replace the low-pressure fuel lines. 11. Remove Tooling (A) from the engine. Reconnect the low-pressure lines. 12. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

Testing and Adjusting C3.4B Industrial Engine Media Number -UENR0620-02

Publication Date -01/03/2013

i04338391

Fuel System - Inspect SMCS - 1250-040

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

A problem with the components that transport fuel to the engine can cause low fuel pressure. This can decrease engine performance. 1. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt. 2. Check that the valve in the fuel return line is open before the engine is started. 3. Check all low-pressure fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends. Verify that the fuel return line is not collapsed. 4. Install new fuel filters.

5. Cut the old filter open with a suitable filter cutter. Inspect the filter for excess contamination. Determine the source of the contamination. Make the necessary repairs.

TROUBLESHOOTING MANUAL FPT INDUSTRIAL

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Printed in U.S.A

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06219299

Acceleration Is Poor or Throttle Response Is Poor SMCS - 1000-035

Probable Causes • Diagnostic codes • Parameters in the Electronic Control Module (ECM) • Throttle Position Sensor/Throttle Switches • Air intake and exhaust system • Valve lash • Turbocharger • Fuel supply • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinder

Recommended Actions NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

Note: The procedures have been listed in order of probability. Complete the procedures in order. Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine speed, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results. Table 1 Troubleshooting Test Steps

Values

Results Result: A diagnostic code is present.

1. Diagnostic Codes Note: Certain diagnostic codes may cause poor performance.

Engine Derate or Diagnostic Codes

A. Use the electronic service tool to check for active or logged diagnostic codes.

Repair: Troubleshoot the diagnostic code. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: A diagnostic code is not present. Proceed to Test Step 2.

Result: The parameters are not correct. 2. Parameters in the Electronic Control Module (ECM) A. Use the electronic service tool to verify that the correct parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.

Parameters

Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information. Result: The parameters are correct. Proceed to Test Step 3.

3. Throttle Position Sensor/Throttle Switches A. Turn the start switch to the ON position. B. Run the engine until the speed is equal to the maximum no-load speed. C. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.

Electrical connections

Result: The throttle response is not as expected. Repair: If the maximum noload speed cannot be obtained refer to Troubleshooting, "Switch Circuits - Test (Throttle Switch)" and Troubleshooting, "Mode Selection - Test". If the engine speed is erratic

refer to Troubleshooting, "Speed Control - Test". Result: All responses are normal. Proceed to Test Step 4.

Result: There are restrictions in the air inlet or exhaust system. 4. Air Intake and Exhaust System A. Observe the engine warning lamp. Check for an air filter restriction indicator, if equipped. Replace plugged air filters. Refer to the Operation and Maintenance Manual. Restrictions B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".

Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information. Result: There are no restrictions in the air inlet or exhaust system. Proceed to Test Step 5.

Result: The valve lash is not correct. 5. Valve Lash Note: The valve lash can affect the performance of the engine. A. Check the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect".

Valve lash

Repair: Make any necessary repairs. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect". Result: The valve lash is correct. Proceed to Test Step 6.

7. Turbocharger Note: The turbocharger that is installed on the engine is a nonserviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced. A. Ensure that the mounting bolts for the turbocharger are tight.

Turbocharger

Result: There is a fault on the turbocharger. Repair: Repair the turbocharger or replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".

B. Check that the oil drain for the turbocharger is not blocked or restricted.

Result: The turbocharger is OK.

C. Check that the compressor housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.

Proceed to Test Step 8.

D. Check that the turbine housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged. E. Check that the turbine blades rotate freely in the turbocharger. F. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".

8. Fuel Supply A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only. B. Ensure that the vent in the fuel cap is not filled with debris.

Fuel system

Result: The fuel supply is not OK. Repair: Repair the fuel system or replace the fuel system components, as necessary. Result: The fuel supply is OK.

C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position. D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). E. Check the primary filter/water separator for water in the fuel. F. Check for fuel supply lines that are restricted. G. Check that the low-pressure fuel lines are tight and secured properly. H. Replace the primary and secondary fuel filters. I. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and

Proceed to Test Step 9.

Adjusting, "Fuel Quality - Test". J. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". K. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Prime".

Result: The results of the compression test are outside the specifications. Repair: Investigate the cause and rectify any faults. Note: Possible causes of low compression are shown in the following list:

9. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Cylinder compression

· Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 10.

Result: There are active diagnostic codes relating to the fuel injectors. 10. Electronic Unit Injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.

Diagnostic codes

Repair: Troubleshoot the active diagnostic codes. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: All injectors are OK. Proceed to Test Step 11.

11. Individual Malfunctioning Cylinders

Cylinders

A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Result: The test indicates a faulty cylinder. Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance. Result: The test indicates that all cylinders are OK.

If a change in the sound of the engine is not noted, the isolated cylinder is not operating under normal conditions. If the isolation of a cylinder results in a change in the sound that is less noticeable, the cylinder may be operating below normal performance.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221197

Alternator Problem - Charging Problem and/or Noisy Operation SMCS - 1405-035

Probable Causes • Alternator • Charging Circuit

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Condition of the Alternator Drive Belts

Values Drive belt

Results Result: The alternator drive belts are in good condition and the belt tension is correct.

A. Inspect the condition of the alternator drive belts.

Proceed to Test Step 2.

B. Check the belt tension. If the engine is equipped with an automatic belt tensioner, check the automatic belt tensioner.

Result: The alternator drive belts are not in good condition or the belt tension is incorrect.

Excessive belt tension can result in damage to the alternator.

Repair: If the alternator drive belts are worn or damaged, replace the belts. Refer to Disassembly and Assembly for the correct procedure.

If necessary, replace the automatic belt tensioner. Refer to Disassembly and Assembly for the correct procedure.

Result: There is excessive wear on the alternator drive pulley. 2. Condition of the Alternator Drive Pulley A. Check the condition of the alternator drive pulley. Look for deep grooves that have been worn into the pulley by the belt. Check that the nut for the pulley has not become loose.

Repair: Replace the pulley. Alternator Drive Pulley

Result: The alternator drive pulley nut was loose. Repair: Tighten the nut. Result: There is not excessive wear on the alternator drive pulley. Proceed to Test Step 3.

Result: The alternator bearings are OK. Proceed to Test Step 4. 3. Wear of the Alternator Bearings A. Check the alternator bearings for signs of wear.

4. Operation of the Alternator or Regulator A. Verify that the alternator or the regulator is operating correctly. Refer to Systems Operation, Testing and Adjusting, "Alternator - Test" for the proper testing procedures.

Alternator bearings

Result: The alternator bearings are not OK. Repair: Repair the alternator or replace the alternator, as needed. Refer to Disassembly and Assembly for the correct procedure.

Regulator and alternator

Result: The regulator and alternator are operating properly. Proceed to Test Step 5. Result: The regulator and alternator are not operating properly. Repair: Repair the alternator and regulator or replace the alternator and regulator, as needed. Refer to Disassembly and Assembly for the

correct procedure.

Result: The charging circuit is not working properly.

5. Inspection of the Charging Circuit A. Inspect the battery cables, wiring, and connections in the charging circuit.

Charging circuit

Repair: Clean all connections and tighten all connections. Replace any faulty parts.

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C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 50) - Documentation

Page 1 of 2

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221204

Battery Problem SMCS - 1401-035

Probable Causes • Charging circuit • Battery • Auxiliary device

Recommended Actions Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps

Values

Results Result: The charging circuit is not OK.

1. Charging Circuit A. Check that the battery charging Charging circuit is operating correctly. Refer to circuit Troubleshooting, "Alternator Problem".

Repair: Repair the charging circuit, as necessary. Result: The charging circuit is OK. Proceed to Test Step 2.

2. Battery A. Verify that the battery is no longer able to hold a charge. Refer to Systems Operation/Testing and

Battery

Result: The battery is not OK. Repair: Replace the battery. Refer to the Operation and Maintenance Manual, "Battery - Replace".

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C3.4B Industrial Engine CJG00001-UP(SEBP6150 - 50) - Documentation

Page 2 of 2

Adjusting, "Battery - Test". Result: The battery is OK. Proceed to Test Step 3.

Result: The battery has been drained by an auxiliary device being left in the ON position. 3. Auxiliary Device A. Check if an auxiliary device has drained the battery by being left in the ON position.

Auxiliary Device

Repair: Charge the battery. Verify that the battery is able to maintain a charge. Refer to Systems Operation/Testing and Adjusting for the correct procedure. Result: The battery has not been drained by an auxiliary device being left in the ON position. Contact the Dealer Solutions Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980345

Component Location SMCS - 1000; 1900

Electronic Control Circuit Diagram

g03746141

Illustration 1 Electronic control circuit diagram for the greater than 56 kW (75 hp) C3.4B engine

g03746149

Illustration 2

Electronic control circuit diagram for the less than 56 kW (75 hp) C3.4B engine equipped with a wall flow DPF

g03746150

Illustration 3

Electronic control circuit diagram for the less than 56 kW (75 hp) C3.4B engine equipped with a through-flow DPF

C3.4B Engine CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

g02737916

Illustration 4 Sensors and electrical connector locations on the left side of the C3.4B engine (typical example) (1) 10-pin engine interface connector (optional) (2) 62-pin engine interface connector (optional) (3) Fuel rail pressure sensor (4) Fuel temperature sensor (5) High-pressure fuel pump inlet metering valve (6) Oil pressure switch (7) Primary speed/timing sensor (crankshaft) (8) Water In Fuel (WIF) sensor

g02737996

Illustration 5 Close up views of the sensor locations on the left side of the C3.4B engine (typical example) (1) 10-pin engine interface connector (optional) (2) 62-pin engine interface connector (optional) (3) Fuel rail pressure sensor (4) Fuel temperature sensor (5) High-pressure fuel pump inlet metering valve (6) Oil pressure switch (7) Primary speed/timing sensor (crankshaft) (8) Water In Fuel (WIF) sensor

Illustration 6

g02737956

Sensors and electrical connector locations on the right side of the greater than 56 kW (75 hp) C3.4B engine (typical example) (9) Intake manifold air pressure and temperature sensor (10) Exhaust temperature sensor connector (11) Exhaust gas pressure sensor (12) NOx Reduction System (NRS) valve (13) Wastegate regulator (14) Oxygen sensor

Illustration 7

g03356014

Sensors and electrical connector locations on the right side of the less than 56 kW (75 hp) C3.4B engine (typical example) (15) Intake manifold temperature sensor (16) Intake manifold pressure sensor (17) Exhaust gas pressure sensor (18) NOx Reduction System (NRS) valve (19) Wastegate regulator (20) Oxygen sensor

Illustration 8 Sensors and electrical connection locations on the front of the C3.4B engine (typical example) (21) Intake throttle valve (22) Coolant temperature sensor (23) Secondary (camshaft) speed/timing sensor

Clean Emissions Module (CEM)

g03356021

g03356022

Illustration 9

Typical view of the sensor locations on the CEM on C3.4B engines equipped with a wall-flow DPF (typical example) (24) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (25) Diesel Particulate Filter (DPF) inlet temperature sensor (26) Inlet connection for the DPF differential pressure sensor (27) Outlet connection for the DPF differential pressure sensor

g03356028

Illustration 10

Typical view of the sensor locations on the CEM on C3.4B engines equipped with a through-flow DPF (typical example) (28) Diesel Oxidation Catalyst (DOC) inlet temperature sensor (29) Diesel Particulate Filter (DPF) inlet temperature sensor

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05982913

Configuration Parameters SMCS - 1900 The electronic service tool can be used to view certain parameters that can affect the operation of the engine. The electronic service tool can also be used to change certain parameters. Some parameters cannot be changed and some applications do not allow any changes to the programmable monitoring system. The parameters are stored in the Electronic Control Module (ECM). The parameters are divided into two different types: Customer Specified Parameters - Customer specified parameters can be changed using the electronic service tool. System Configuration Parameters - System configuration parameters affect the emissions of the engine or the power of the engine. Factory passwords may be required to change the values of system configuration parameters. 1. Connect to the electronic service tool. 2. Select the Service tab. 3. Select the Configuration tab to view the configuration parameters. If an ECM is replaced, the appropriate parameters must be copied from the old ECM. Refer to Troubleshooting, "ECM Software - Install" or Troubleshooting, "ECM - Replace".

NOTICE Changing the parameters during engine operation can cause the engine to operate erratically and can cause engine damage. Only change the settings of the parameters when the engine is STOPPED.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221207

Coolant Contains Oil SMCS - 1348-035; 1395-035

Probable Causes • Engine oil cooler • Cylinder head gasket • Cylinder head • Cylinder block

Recommended Actions Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps 1. Engine Oil Cooler A. Drain the coolant from the cooling system. Drain the lubricating oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more information. B. Check for leaks in the engine oil cooler. Refer to Systems Operation, Testing, and Adjusting, "Cooling System" for the proper procedure.

Values Oil Cooler

Results Result: A leak is found in the engine oil cooler. Repair: Install a new oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install" for the correct procedure. Flush the cooling system. Refer to the Operation and Maintenance Manual for the correct procedure. Refill the cooling system with the correct coolant. Refer to

the Operation and Maintenance Manual for the recommended coolant and capacities. Refill the engine with the proper oil after the leak has been repaired. Refer to the Operation and Maintenance Manual for the correct oil capacities and viscosity. Result: A leak was not found in the engine oil cooler. Proceed to Test Step 2.

Result: The cylinder head gasket does not show signs of damage or leakage.

2. Cylinder Head Gasket A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Cylinder Head - Remove". head gasket B. Inspect the cylinder head gasket for faults and any signs of leakage.

Repair: Install a new cylinder head gasket and install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install" . Result: The cylinder head gasket shows signs of damage or leakage. Proceed to Test Step 3.

Result: A fault is found in the cylinder head. 3. Cylinder Head A. Check for cracks in the cylinder head. Perform a leak test on the cylinder head. Refer to System Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.

Cylinder head

Repair: Repair the cylinder head or replace the cylinder head. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install". Result: A fault is not found in the cylinder head. Proceed to Test Step 4.

4. Cylinder Block A. Inspect the top face of the cylinder block for faults and signs of leakage. Refer to Systems Operation, Testing, and Adjusting, "Cylinder Block Inspect" for the correct procedure.

Cylinder block

Result: A fault is found in the cylinder block. Repair: Repair the cylinder block or replace the cylinder block. Inspect the top deck. Refer to the Reuse and Salvage Guidelines for the proper inspection procedure.

Result: No fault is found in the cylinder block. Repair: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install". .

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05989049

Coolant Level Is Low SMCS - 1395-035 Note: On engines equipped with a Diesel Exhaust Fluid (DEF) system, the DEF tank requires coolant flow around the tank. The coolant diverter valve will turn the flow to the DEF tank on or off. If the coolant system is filled when the coolant diverter valve is CLOSED , the coolant level will drop when the coolant diverter valve is opened. This situation does not necessarily indicate a fault. Inspect the cooling system for leaks. Refer to Systems Operation, Testing and Adjusting, "Cooling System - Test" for the correct procedure.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221217

Coolant Temperature Is High SMCS - 1395-035 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for High Coolant Temperature J1939 Code

110-15

Description

Engine Coolant Temperature : High least severe (1)

Notes The Electronic Control Module (ECM) detects that the coolant temperature is greater than 110° C (230° F) for at least 0.5 seconds. The code will be reset if the coolant temperature is less than 110° C (230° F) for at least 0.5 seconds. If equipped, the warning lamp will come on. The ECM will log the diagnostic code.

110-16

Engine Coolant Temperature : High moderate severity (2)

The Electronic Control Module (ECM detects that the coolant temperature is greater than 112° C (233.6° F) for at least 0.5 seconds. The code will be reset if the coolant temperature is less than 110° C (230° F) for at least 0.5 seconds. If equipped, the warning lamp will flash. The ECM will log the diagnostic code.

Probable Causes • Diagnostic codes • Coolant level

• Coolant temperature sensor • Radiator and hoses • Radiator cap and pressure relief valve • Thermostat - Water temperature regulator • Engine cooling fan • Quality of coolant • Coolant pump • Cylinder head gasket

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps

Values

Result: Diagnostic codes are not present.

1. Diagnostic Codes A. Use the electronic service tool to check for diagnostic codes that relate to the temperature in the cooling system.

Results

Diagnostic Codes

Return the unit to service. Result: Diagnostic codes are present. Proceed to Test Step 2.

Result: The engine coolant level is low.

2. Coolant Level A. Check the coolant level.

Engine coolant level

Repair: Check the cooling system for leaks. Refer to Systems Operation, Testing and Adjusting, "Cooling System Test" for additional information. Repair any leaks immediately. Result: The engine coolant level is OK. Proceed to Test Step 3.

3. Coolant Temperature Sensor

Coolant

Result: The temperature sensor is

A. Compare the reading for the coolant temperature on the electronic service tool to the reading for the coolant temperature on a calibrated test gauge.

temperature sensor

not accurate. Repair: Troubleshoot the circuit and the coolant temperature sensor. Refer to Troubleshooting, "Sensor Signal (Analog, Passive) - Test". Result: The temperature sensor is reading accurately. Proceed to Test Step 4.

4. Radiator and Hoses Result: The radiator fins are blocked or damaged.

A. Check the radiator fins for dirt, debris, and/or damage.

Repair: Remove any dirt and/or debris and straighten any bent fins.

B. Check for collapsed hoses and/or other restrictions. C. Check the radiator for internal blockage.

Radiator and hoses

D. Ensure that the radiator size is sufficient. An undersized radiator does not have enough area for the effective release of heat. An undersized radiator may cause the engine to run at a temperature that is higher than normal. The normal temperature is dependent on the ambient temperature.

Repair: Remove the blockage. Result: The radiator fins are not damaged and the radiator does not have an internal blockage. Proceed to Test Step 5.

5. Radiator Cap and Pressure Relief Valve

Result: The pressure relief valve and/or the water temperature regulator are not operating properly.

A. Pressure-test the cooling system. Refer to Systems Operation, Testing, and Adjusting, "Cooling System" for the correct procedure. Radiator cap B. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and undamaged. C. Check operation of the pressure relief valve and/or the water temperature regulator.

Result: The radiator has internal blockage.

Repair: Clean the components or replace the components. Result: The pressure relief valve and/or the water temperature regulator are operating properly. Proceed to Test Step 6.

6. Water Temperature Regulator A. Check the water temperature regulator for correct operation. Refer to Systems Operation, Testing, and Adjusting, "Cooling System" for the proper procedure.

Water Temperature Regulator

Result: The water temperature regulator is not operating correctly. Repair: Replace the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator Remove and Install". Result: The water temperature regulator is operating correctly. Proceed to Test Step 7.

Result: The drive belt is not tensioned correctly. Repair: Tension the fan belt. Refer to Operation and Maintenance Manual, "Alternator and Fan Belts - Replace".

7. Engine Cooling Fan A. Check for a loose drive belt. Note: A loose fan drive belt will cause a reduction in the air flow across the radiator.

Fan and drive belt

B. Check the engine cooling fan for damage.

Result: The fan is damaged. Repair: Repair the fan or replace the fan, as necessary. Refer to Disassembly and Assembly, "Fan - Remove and Install". Result: The fan is OK and the fan belt is tensioned correctly. Proceed to Test Step 8.

8. Quality of Coolant A. Check the quality of the coolant. Refer to the Operation and Maintenance Manual, "Refill Capacities and Recommendations Coolant".

Coolant

Result: The coolant is not of an acceptable quality. Repair: Drain and refill the coolant system with coolant of the correct quality. Refer to the Operation and Maintenance Manual, "Refill Capacities and Recommendations - Coolant". Result: The coolant is of an acceptable quality.

Proceed to Test Step 9.

Result The coolant pump is damaged or not operating correctly.

9. Inspection of the Coolant Pump A. Inspect the impeller of the coolant pump for damage and/or erosion.

Repair: If necessary, replace the coolant pump. Refer to Disassembly and Assembly, "Water Pump - Remove" and Coolant pump Disassembly and Assembly, "Water Pump - Install". Result The coolant pump is not damaged and the pump is operating correctly. Proceed to Test Step 10.

Result: Bubbles are present in the coolant or the coolant is discolored. Repair: Check the cylinder head gasket. Refer to the recommended action for the cylinder head gasket within Troubleshooting, "Oil Contains Coolant".

10. Cylinder Head Gasket A. Switch off the engine and allow the engine to cool to below normal working temperature. Remove the pressure cap for the coolant system. Start the engine and inspect the coolant for the presence of bubbles or discoloration of the coolant. Note: If bubbles are present in the coolant or the coolant is discolored, combustion gases may be entering the cooling system.

Cylinder Head gasket

Check the cylinder head for flatness. Refer to the recommended action for checking flatness of the cylinder head within Systems Operation, Testing, and Adjusting, "Cylinder Head - Inspect". Result: There is no evidence of gas leakage into the cooling system.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221244

Crankcase Breather Ejects Oil SMCS - 1000-035-BBY; 1317-035 The crankcase breather includes a pressure relief valve that prevents a build-up of excessive pressure in the breather system.

Illustration 1 (1) Crankcase pressure relief valve

g02919637

In normal operation of the engine, the pressure relief valve remains closed. If there is evidence of oil staining around pressure relief valve (1), perform the following procedure in order to diagnose the fault.

Probable Causes • Breather filter • Breather hoses • Breather heater • Excessive blow-by

Recommended Actions

Illustration 2

g02919737

Table 1 Troubleshooting Test Steps 1. Breather Filter

Values Breather filter

Results Result: The breather element is incorrectly installed or damaged.

A. Check that the breather element is correctly installed and that the element is not damaged.

Repair: Install a new filter element. Refer to Operation and Maintenance Manual, "Engine Crankcase Breather Element - Replace". Note: If a new filter element blocks before the service period is completed, the blockage can indicate a fault in the engine.

B. Check for restrictions or blockages in orifice (2).

Result: There is a restriction or blockage in orifice (2). Repair: If necessary, replace the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" and refer to Disassembly and Assembly, "Crankcase Breather - Install" Result: The breather filter is OK. Proceed to Test Step 2.

Result: There is a restriction or blockage in one of the breather hoses. 2. Breather Hoses A. Check the oil return hose and the breather outlet hose for restrictions or blockages.

Breather hoses

Repair: Replace the breather hoses, as necessary. Result: The breather hoses are OK. Proceed to Test Step 3.

3. Breather Heater A. Turn the keyswitch to the OFF position. B. Disconnect the breather heater connector.

10 V to 14 V for step D Less than 10 k Ohms for step F.

Result: The measured voltage is less than 10 V. There is a fault in the wiring to the breather heater. Repair: Repair the harness or repair the harness

C. Turn the keyswitch to the ON position.

Result: The measured resistance is greater than 10 k Ohms.

D. Use a suitable multimeter to measure the voltage at the harness connector for the heater.

Repair: Replace the breather heater. Result: All measurements are within the expected ranges.

E. Turn the keyswitch to the OFF position.

Proceed to Test Step 4.

F. Use a suitable multimeter to measure the resistance of the heater element.

4. Excessive Blow-by Excessive blow-by increases the flow of fumes through the breather system and can cause the breather element to block. The pressure relief valve may then open.

Result: The fault has been rectified. Return the engine to service.

A. If excessive blow-by is suspected, replace the breather element. Refer to the Operation and Maintenance Manual, "Engine Crankcase Breather Element - Replace".

Blow-by

B. Investigate the cause of the excessive blow-by. Refer to Troubleshooting, "Oil Consumption Is Excessive".

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06221272

Cylinder Is Noisy SMCS - 1223-035

Probable Causes • Diagnostic codes • Fuel quality • Valve train components • Injectors • Pistons

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Diagnostic Codes

Values Codes

Results Result: A diagnostic trouble code is active or logged.

A. Establish communication between the electronic service tool and the Electronic Control Module (ECM).

Repair: Troubleshoot the active or logged codes. Refer to Troubleshooting, "Diagnostic Trouble Codes".

B. Check for active diagnostic codes.

Result: A diagnostic trouble code is not active or logged. Proceed to Test Step 2.

Result: The fuel quality is not OK. Repair: Drain the fuel system and replace the fuel filters. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element Replace" and Operation and Maintenance Manual, "Fuel System Filter - Replace".

2. Fuel Quality A. Check the fuel quality. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test". Fuel B. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine.

Fill the fuel system with fuel that meets the standard in the Operation and Maintenance Manual, "Fluid Recommendations". Prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime". Verify that the procedure has eliminated the noise. Result: The fuel quality is OK. Proceed to Test Step 3.

3. Valve Train Components A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive". B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:

Result: Valve train components are damaged.

Valve train · Valve springs · Rocker shaft · Pushrods · Camshaft followers Refer to the Disassembly and Assembly for additional information.

Repair: Make the necessary repairs, Verify that the repair has eliminated the noise. Result: The valve train components are not damaged. Proceed to Test Step 4.

4. Electronic Unit Injectors

Diagnostic codes

A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Troubleshoot any active diagnostic codes before continuing with this procedure.

Result: There is an active diagnostic code for the injectors. Repair: Troubleshoot any active injector diagnostic codes. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no active diagnostic codes for the injectors. Proceed to Test Step 5.

Result: One or more pistons are worn or damaged. Repair : Replace any worn or damaged parts.

5. Pistons A. Inspect the pistons for damage and wear.

Pistons

Verify that the repair has eliminated the noise. Result: All pistons are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06008869

Data Link - Test SMCS - 1900-038 Use this procedure if a fault is suspected in the CAN data link. This procedure also covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for the CAN Data Link J1939 Code

Description

639-9

J1939 Network #1 : Abnormal Update Rate

639-14

J1939 Network #1 : Special Instruction

Notes Another controller has incorrectly stopped transmitting a J1939 speed request (TSC1) or another controller has incorrectly started transmitting a J1939 speed request. The ECM will log the diagnostic code. The engine will not start. Another controller has incorrectly stopped transmitting a signal on the CAN data link.

The following background information is related to this procedure: The CAN data link is also known as J1939 data link. The data link is an industry standard for sending data between different devices in the same application. High speed data is transferred via the data link. The data link cannot be accurately tested without complicated equipment. The data link requires a resistance of 60 Ohms between the two wires in order to transmit the data correctly. This resistance is made up of two 120 Ohm resistors. The two resistors are known as "Terminating Resistors". The terminating resistors should be at opposite ends of a data link circuit. If this resistance is not present, then the data will be intermittent or unreadable.

Note: The wiring for the J1939 data link is a shielded twisted pair cable. If the wiring is damaged, the replacement type must be shielded twisted pair cable.

Illustration 1

g03600780

Typical example of the schematic for the CAN data link

Illustration 2

g03600802

Typical view of the pin locations on the P1 connector (46) CAN + (47) CAN -

Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position.

Result: A damaged wire or damaged connector was found.

B. Inspect the connectors in the circuit for the CAN data link. Refer to Troubleshooting, "Electrical Damaged wire Connectors - Inspect" for details. or connector

Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: A damaged wire or damaged connector was not found.

C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the CAN data link.

Proceed to Test Step 2. D. Check all of the wiring associated with the CAN data link for abrasions and pinch points.

2. Check the Data Link Terminating Resistance A. Disconnect the P1 connector from the ECM. B. Measure the resistance between the P1:46 and P1:47.

Between 50 Ohms and 70 Ohms

Result: The resistance is less than 50 Ohms there is a short circuit in the harness. Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The resistance is between 110 and 130 Ohms - one of the terminating resistors may have failed. Locate the two terminating resistors and remove the two terminating resistors from the harness. The terminating resistors may be located in other ECMs on the data link. Refer to the Electrical Schematic. Measure the resistance of the two terminating

resistors. If one of the terminating resistors is incorrect, replace the faulty terminating resistor. If the two terminating resistors are between 50 and 70 Ohms each, proceed to Test Step 4. Result: The resistance is greater than 150 Ohms. Proceed to Test Step 3. Result: The resistance is between 50 and 70 Ohms This is the correct resistance. The fault may be in the connection to other devices on the data link. Proceed to Test Step 3.

3. Check the Data Link Wiring A. Disconnect each of the connectors that connect other devices on the data link.

Result: At least one of the resistance measurements is greater than 5 Ohms - there is an open circuit or high resistance in the wiring.

B. Use a multimeter to measure the resistance between P1:46 and each of the CAN+ pins for other devices on the CAN data link. C. Use a multimeter to measure the Less than 5 resistance between P1:46 and pin F on Ohms the diagnostic connector. D. Use a multimeter to measure the resistance between P1:47 and each of the CAN- pins for other devices on the CAN data link.

A. Use the appropriate service tools in

Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the fault. Result: All measured resistances are less than 2 Ohms.

E. Use a multimeter in order to measure the resistance between P1:47 and pin G on the diagnostic connector.

4. Check the Other Devices on the CAN Data Link

Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all seals are correctly in place and ensure that the connectors are correctly connected.

Proceed to Test Step 4

Other devices are OK

Result: At least one of the other devices is not operating correctly. Use the appropriate service tools in order to

order to diagnose other devices on the data link.

repair other devices on the data link. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The other devices are operating correctly. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05981906

Diagnostic Capabilities SMCS - 1900

Diagnostic Codes The Electronic Control Module (ECM) can monitor the circuitry between the ECM and the engines components. The ECM can also monitor the engines operating conditions. If the ECM detects a problem, a diagnostic code is generated. Codes can have two different states: • Active • Logged

Active Codes An active code indicates that a problem is present. Service the active code first. For the appropriate troubleshooting procedure for a particular code, refer to the following troubleshooting procedure: • Troubleshooting, "Diagnostic Trouble Codes"

Logged Codes The codes are logged and stored in the ECM memory. The problem may have been repaired and/or the problem may no longer exist. If the system is powered, an active diagnostic code may be generated whenever a component is disconnected. If the component is reconnected, the code is no longer active but the code may become logged. Logged diagnostic codes will be cleared from the "Logged Diagnostic Codes" screen on the electronic service tool when the code has not been active for 40 hours.

Logged codes may not indicate that a repair is needed. The problem may have been temporary. Logged codes may be useful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and of the electronic system.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06867595

Diagnostic Trouble Codes SMCS - 1900 The following table lists all the J1939 diagnostic trouble codes for the engine. The table includes a description for each code and the recommended troubleshooting procedure that must be performed. Portions of this material are reprinted with permission from SAE J1939DA_201607© 2016 SAE International. SAE International is not responsible for any use or translation of this material, in whole or in part. Please contact SAE International to obtain a complete copy of SAE J1939DA_201607, the official definitive source of this standard. Table 1 J1939 Code

Description

Refer to Procedure

27-3

Engine Exhaust Gas Recirculation Valve Position : Voltage Above Normal

Valve Position - Test

27-4

Engine Exhaust Gas Recirculation Valve Position : Voltage Below Normal

Valve Position - Test

29-3

Accelerator Pedal Position 2 : Voltage Above Normal

Speed Control - Test

29-4

Accelerator Pedal Position 2 : Voltage Below Normal

Speed Control - Test

51-3

Engine Throttle Valve 1 Position : Voltage Above Normal

Valve Position - Test

51-4

Engine Throttle Valve 1 Position : Voltage Below Normal

Valve Position - Test

91-3

Speed Control - Test

Accelerator Pedal Position 1 : Voltage Above Normal 91-4

Accelerator Pedal Position 1 : Voltage Below Normal

Speed Control - Test

97-15

Water in Fuel Indicator : High least severe (1)

Fuel Contains Water

100-2

Engine Oil Pressure : Erratic, Intermittent, or Incorrect

Switch Circuits - Test (Oil Pressure Switch)

100-17

Engine Oil Pressure : Low - least severe (1)

Oil Pressure Is Low

102-3

Engine Intake Manifold #1 Pressure : Voltage Above Normal

Sensor Signal (Analog, Active) - Test

102-4

Engine Intake Manifold #1 Pressure : Voltage Below Normal

Sensor Signal (Analog, Active) - Test

102-20

Engine Intake Manifold #1 Pressure : Data Drifted High

Sensor Signal (Analog, Active) - Test

102-21

Engine Intake Manifold #1 Pressure : Data Drifted Low

Sensor Signal (Analog, Active) - Test

105-3

Engine Intake Manifold #1 Temperature : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

105-4

Engine Intake Manifold #1 Temperature : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

107-2

Engine Air Filter 1 Differential Pressure : Erratic, Intermittent, or Incorrect

Switch Circuits - Test (Air Filter Restriction Switch)

107-15

Engine Air Filter 1 Differential Pressure : High - least severe (1)

Inlet Air Is Restricted

107-16

Engine Air Filter 1 Differential Pressure : High - moderate severity (2)

Inlet Air Is Restricted

108-3

Barometric Pressure : Voltage Above Normal

Sensor Signal (Analog, Active) - Test

108-4

Barometric Pressure : Voltage Below Normal

Sensor Signal (Analog, Active) - Test

110-3

Engine Coolant Temperature : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

110-4

Engine Coolant Temperature : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

110-15

Engine Coolant Temperature : High - least severe (1)

Coolant Temperature Is High

110-16

Engine Coolant Temperature : High - moderate severity (2)

Coolant Temperature Is High

152-2

Number Of ECU Resets : Erratic, Intermittent, or Incorrect

ECM Memory - Test

157-0

Engine Injector Metering Rail #1 Pressure : High - most severe (3)

Fuel Rail Pressure Problem

157-2

Engine Injector Metering Rail #1 Pressure : Erratic, Intermittent, or Incorrect

Fuel Rail Pressure Problem

157-3

Engine Injector Metering Rail #1 Pressure : Voltage Above Normal

Sensor Signal (Analog, Active) - Test

157-4

Engine Injector Metering Rail #1 Pressure : Voltage Below Normal

Sensor Signal (Analog, Active) - Test

157-10

Engine Injector Metering Rail #1 Pressure : Abnormal Update Rate

Sensor Signal (Analog, Active) - Test

157-16

Engine Injector Metering Rail #1 Pressure : High - moderate severity (2)

Fuel Rail Pressure Problem

157-17

Engine Injector Metering Rail #1 Pressure : Low - least severe (1)

Fuel Rail Pressure Problem

157-18

Engine Injector Metering Rail #1 Pressure : Low - moderate severity Fuel Rail Pressure Problem (2)

166-2

Engine Rated Power : Erratic, Intermittent, or Incorrect

ECM Memory - Test

166-14

Engine Rated Power : Special Instuction

ECM Memory - Test

168-3

Battery Potential / Power Input 1 : Voltage Above Normal

Electrical Power Supply - Test

168-4

Battery Potential / Power Input 1 : Voltage Above Normal

Electrical Power Supply - Test

172-3

Engine Air Inlet Temperature : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

172-4

Engine Air Inlet Temperature : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

173-3

Engine Exhaust Gas Temperature : Sensor Signal (Analog, Passive) - Test Voltage Above Normal

173-4

Sensor Signal (Analog, Passive) - Test

Engine Exhaust Gas Temperature : Voltage Below Normal 174-3

Engine Fuel Temperature 1 : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

174-4

Engine Fuel Temperature 1 : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

190-8

Engine Speed : Abnormal Frequency, Pulse Width, or Period

Speed/Timing - Test

190-15

Engine Speed : High - least severe (1)

Engine Overspeeds

558-2

Accelerator Pedal 1 Low Idle Switch : Erratic, Intermittent, or Incorrect

Idle Validation - Test

593-31

Engine Idle Shutdown has Shutdown Engine

This code indicates that an engine idle shutdown is about to occur. This code does not represent a fault. If equipped, the warning lamp will come on.

594-31

Engine Idle Shutdown Driver Alert Mode

This code indicates that an engine idle shutdown has occurred. This code does not represent a fault. If equipped, the warning lamp will flash and the shutdown lamp will come on.

623-5

Red Stop Lamp : Current Below Normal

Indicator Lamp - Test

623-6

Red Stop Lamp : Current Above Normal

Indicator Lamp - Test

624-5

Amber Warning Lamp : Current Below Normal

Indicator Lamp - Test

624-6

Amber Warning Lamp : Current Above Normal

Indicator Lamp - Test

630-2

Calibration Memory : Erratic, Intermittent, or Incorrect

Injector Data Incorrect - Test

637-11

Engine Timing Sensor : Other Failure Mode

Speed/Timing - Test

639-9

J1939 Network #1 : Abnormal Update Rate

Data Link - Test

639-14

J1939 Network #1 : Special Instruction

Data Link - Test

651-5

Engine Injector Cylinder #01 : Current Below Normal

Injector Solenoid - Test

651-6

Engine Injector Cylinder #01 : Current Above Normal

Injector Solenoid - Test

651-20

Engine Injector Cylinder #01 : Data Drifted High

Injector Data Incorrect - Test

651-21

Engine Injector Cylinder #01 : Data Drifted Low

Injector Data Incorrect - Test

652-5

Engine Injector Cylinder #02 : Current Below Normal

Injector Solenoid - Test

652-6

Engine Injector Cylinder #02 : Current Above Normal

Injector Solenoid - Test

652-20

Engine Injector Cylinder #02 : Data Drifted High

Injector Data Incorrect - Test

652-21

Engine Injector Cylinder #02 : Data Drifted Low

Injector Data Incorrect - Test

653-5

Engine Injector Cylinder #03 : Current Below Normal

Injector Solenoid - Test

653-6

Engine Injector Cylinder #03 : Current Above Normal

Injector Solenoid - Test

653-20

Engine Injector Cylinder #03 : Data Drifted High

Injector Data Incorrect - Test

653-21

Engine Injector Cylinder #03 : Data Drifted Low

Injector Data Incorrect - Test

654-5

Engine Injector Cylinder #04 : Current Below Normal

Injector Solenoid - Test

654-6

Engine Injector Cylinder #04 : Current Above Normal

Injector Solenoid - Test

654-20

Engine Injector Cylinder #04 : Data Drifted High

Injector Data Incorrect - Test

654-21

Engine Injector Cylinder #04 : Data Drifted Low

Injector Data Incorrect - Test

676-5

Engine Glow Plug Relay : Current Below Normal

Glow Plug Starting Aid - Test

676-6

Engine Glow Plug Relay : Current Above Normal

Glow Plug Starting Aid - Test

676-19

Engine Glow Plug Relay : Data Error

Glow Plug Starting Aid - Test

677-3

Engine Starter Motor Relay : Voltage Above Normal

Relay - Test (Start Relay)

677-5

Relay - Test (Start Relay)

Engine Starter Motor Relay : Current Below Normal 677-6

Engine Starter Motor Relay : Current Above Normal

Relay - Test (Start Relay)

723-8

Engine Speed Sensor #2 : Abnormal Frequency, Pulse Width, or Period

Speed/Timing - Test

970-31

Engine Auxiliary Shutdown Switch

This code indicates that the shutdown switch for the engine has been activated. The ECM will disable fuel injection until the switch has been deactivated. No troubleshooting is required.

976-2

PTO Governor State : Erratic, Intermittent, or Incorrect

Power Take-Off - Test

1041-2

Start Signal Indicator : Erratic, Intermittent, or Incorrect

Relay - Test (Start Relay)

1076-2

Engine Fuel Injection Pump Fuel Control Valve : Erratic, Intermittent, or Incorrect

Solenoid Valve - Test

1076-5

Engine Fuel Injection Pump Fuel Control Valve : Current Below Normal

Solenoid Valve - Test

1076-6

Engine Fuel Injection Pump Fuel Control Valve : Current Above Normal

Solenoid Valve - Test

1081-5

Engine Wait to Start Lamp : Current Below Normal

Indicator Lamp - Test

1081-6

Engine Wait to Start Lamp : Current Above Normal

Indicator Lamp - Test

111031

Engine Protection System has Shutdown Engine

The engine protection system has shutdown the engine. Troubleshoot all other diagnostic codes in order to clear this code.

112716

Engine Turbocharger 1 Boost Pressure : High - moderate severity (2)

Intake Manifold Air Pressure Is High

112718

Engine Turbocharger 1 Boost Pressure : Low - moderate severity Intake Manifold Air Pressure Is Low (2)

1188-5

Engine Turbocharger Wastegate Actuator 1 Position : Current Below Normal

Solenoid Valve - Test

1188-6

Engine Turbocharger Wastegate Actuator 1 Position : Current Above Normal

Solenoid Valve - Test

1209-3

Engine Exhaust Gas Pressure : Voltage Above Normal

Sensor Signal (Analog, Active) - Test (Exhaust Gas Pressure Sensor)

1209-4

Engine Exhaust Gas Pressure : Voltage Below Normal

Sensor Signal (Analog, Active) - Test (Exhaust Gas Pressure Sensor)

1221-2

Continuously Monitored Systems Support/Status ; Erratic, Intermittent, or Incorrect

ECM Memory - Test

122114

Continuously Monitored Systems Support/Status ; Special Instruction

Another diagnostic code has requested engine speed limitation. The warning lamp will flash. The engine speed is limited to 1200 rpm. Troubleshoot all other diagnostic codes. If this code is the only active diagnostic code, replace the ECM. Refer to Troubleshooting, "ECM Replace"

1239-0

Engine Fuel Leakage 1 : High most severe (3)

Fuel Rail Pressure Problem

1485-7

ECM Main Relay : Not Responding Properly

Relay - Test (ECM Main Relay)

148514

ECM Main relay : Special Instruction

Relay - Test (ECM Main Relay)

2791-5

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Below Normal

Motorized Valve - Test

2791-6

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Above Normal

Motorized Valve - Test

2791-7

Engine Exhaust Gas Recirculation (EGR) Valve Control : Not Responding Properly

Motorized Valve - Test

2797-6

Engine Injector Group 1 : Current Above Normal

Injector Solenoid - Test

2797-7

Engine Injector Group 1 : Not Responding Properly

Injector Solenoid - Test

2798-6

Engine Injector Group 2 : Current Above Normal

Injector Solenoid - Test

284012

ECU Instance : Failure

ECM Memory - Test Relay - Test (ECM Main Relay)

284014

ECU Instance : Special Instruction

2880-2

Engine Operator Primary Intermediate Speed Select : Erratic, Intermittent, or Incorrect

Mode Selection - Test/Switch Circuits - Test (Throttle Switch)

2880-3

Engine Operator Primary Intermediate Speed Select : Voltage Above Normal

Mode Selection - Test/Switch Circuits - Test (Throttle Switch)

2880-4

Engine Operator Primary Intermediate Speed Select : Voltage Below Normal

Mode Selection - Test/Switch Circuits - Test (Throttle Switch)

2970-2

Accelerator Pedal 2 Low Idle Switch : Erratic, Intermittent, or Incorrect

Idle Validation - Test

3217-3

Aftertreatment #1 Intake O2 : Voltage Above Normal

Oxygen Level - Test

3217-4

Aftertreatment #1 Intake O2 : Voltage Below Normal

Oxygen Level - Test

3217-5

Aftertreatment #1 Intake O2 : Current Below Normal

Oxygen Level - Test

3217-6

Aftertreatment #1 Intake O2 : Current Above Normal

Oxygen Level - Test

321712

Aftertreatment #1 Intake O2 : Failure

Oxygen Level - Test

321713

Aftertreatment #1 Intake O2 : Out of Calibration

Oxygen Level - Test

321715

Aftertreatment #1 Intake O2 : High - least severe (1)

Oxygen Level - Test

321915

Aftertreatment #1 Intake Gas Sensor at Temperature : High least severe (1)

Oxygen Level - Test

321917

Aftertreatment #1 Intake Gas Sensor at Temperature : Low least severe (1)

Oxygen Level - Test

3222-3

Aftertreatment #1 Intake Gas Sensor Heater : Voltage Above Normal

Oxygen Level - Test

3222-4

Aftertreatment #1 Intake Gas Sensor Heater : Voltage Below Normal

Oxygen Level - Test

3222-5

Oxygen Level - Test

Aftertreatment #1 Intake Gas Sensor Heater : Current Below Normal 3242-0

Particulate Trap Intake Gas Temperature : High - most severe (3)

Sensor Signal (Analog, Passive) - Test

3242-3

Particulate Trap Intake Gas Temperature : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

3242-4

Particulate Trap Intake Gas Temperature : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

3251-0

Particulate Trap Differential Pressure : High - most severe (3)

Diesel Particulate Filter Collects Excessive Soot

3251-3

Particulate Trap Differential Pressure : Voltage Above Normal

Sensor Signal (Analog, Active) - Test

3251-4

Particulate Trap Differential Pressure : Voltage Below Normal

Sensor Signal (Analog, Active) - Test

3251-7

Particulate Trap Differential Pressure : Not Responding Properly

Diesel Particulate Filter Has Differential Pressure Problem

325110

Particulate Trap Differential Pressure : Abnormal Rate of Change

Diesel Particulate Filter Has Differential Pressure Problem

325116

Particulate Trap Differential Pressure : High - moderate severity (2)

Diesel Particulate Filter Collects Excessive Soot

325117

Particulate Trap Differential Pressure : Low - least severe (1)

Diesel Particulate Filter Has Differential Pressure Problem

325118

Particulate Trap Differential Diesel Particulate Filter Has Differential Pressure : Low - moderate severity Pressure Problem (2)

335810

Engine Exhaust Gas Recirculation 1 Intake Pressure : Abnormal Rate of Change

NRS Mass Flow Rate Problem

3509-2

Sensor Supply Voltage 1 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

3510-2

Sensor Supply Voltage 2 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

3511-2

Sensor Supply Voltage 3 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

3697-5

Particulate Trap Lamp Command : Indicator Lamp - Test Current Below Normal

3697-6

Particulate Trap Lamp Command : Indicator Lamp - Test Current Above Normal

3698-5

Exhaust System High Temperature Lamp Command : Current Below Indicator Lamp - Test Normal

3698-6

Exhaust System High Temperature Lamp Command : Current Above Indicator Lamp - Test Normal

3702-5

Diesel Particulate Filter Active Regeneration Inhibited Status : Current Below Normal

Indicator Lamp - Test

3702-6

Diesel Particulate Filter Active Regeneration Inhibited Status : Current Above Normal

Indicator Lamp - Test

3719-0

Aftertreatment 1 Diesel Particulate Filter Soot Load Percent : High Diesel Particulate Filter Collects Excessive Soot most severe (3)

371916

Aftertreatment 1 Diesel Particulate Filter Soot Load Percent : High Diesel Particulate Filter Collects Excessive Soot moderate severity (2)

4765-3

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Above Normal

Sensor Signal (Analog, Passive) - Test

4765-4

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Below Normal

Sensor Signal (Analog, Passive) - Test

505517

Engine Oil Viscosity : Low - least severe (1)

Oil Contains Fuel

505518

Engine Oil Viscosity : Low moderate severity (2)

Oil Contains Fuel

5099-5

Engine Oil Pressure Low Lamp Data - Current Below Normal

Indicator Lamp - Test

5099-6

Engine Oil Pressure Low Lamp Data - Current Above Normal

Indicator Lamp - Test

524615

Aftertreatment SCR Operator Inducement Severity : High - least severe (1)

See "Operator Inducement Codes". See "Operator Inducement Codes".

524616

Aftertreatment SCR Operator Inducement Severity : High moderate severity (2)

531931

Aftertreatment 1 Diesel Particulate Diesel Particulate Filter Active Regeneration Filter Incomplete Regeneration Was Interrupted

5324-7

Engine Glow Plug 1 : Not Responding Properly

Glow Plug Starting Aid - Test

5325-7

Engine Glow Plug 2 : Not Responding Properly

Glow Plug Starting Aid - Test

5326-7

Engine Glow Plug 3 : Not Responding Properly

Glow Plug Starting Aid - Test

5327-7

Engine Glow Plug 4 : Not Responding Properly

Glow Plug Starting Aid - Test

535731

Engine Fuel Injection Quantity Error for Multiple Cylinders

ECM Memory - Test

5419-5

Engine Throttle Actuator #1 : Current Below Normal

Motorized Valve - Test

5419-6

Engine Throttle Actuator #1 : Current Above Normal

Motorized Valve - Test

5419-7

Engine Throttle Actuator #1 : Not Responding Properlyl

Motorized Valve - Test

5571-2

High Pressure Common Rail Fuel Pressure Relief Valve : Erratic, Intermittent, or Incorrect

Fuel Rail Pressure Problem

5571-7

High Pressure Common Rail Fuel Pressure Relief Valve : Not Responding Properly

Fuel Rail Pressure Problem

557110

High Pressure Common Rail Fuel Pressure Relief Valve : Abnormal Rate of Change

Fuel Rail Pressure Problem

557114

High Pressure Common Rail Fuel Pressure Relief Valve : Special Instruction

Fuel Rail Pressure Problem

557116

High Pressure Common Rail Fuel Pressure Relief Valve : High moderate severity (2)

Fuel Rail Pressure Problem

582615

Emission Control System Operator Inducement Severity : High - least See "Operator Inducement Codes". severe (1)

582616

See "Operator Inducement Codes".

Emission Control System Operator Inducement Severity : High moderate severity (2)

Operator Inducement Codes If any of the diagnostic codes listed in Table 2 are active, a 5246 or a 5826 diagnostic code will also be active. When a 5246 or a 5826 diagnostic code is active, the engine will be derated. In order to clear an active 5246 or a 5826 diagnostic code, first troubleshoot any active codes that are listed in Table 2. Once all other codes are cleared, cycle the keyswitch in order to clear the 5246 or 5826 diagnostic code. Table 2 J1939 Code

Description

Refer to Procedure

27-3

Engine Exhaust Gas Recirculation Valve Position : Voltage Above Normal

Valve Position Sensor - Test

27-4

Engine Exhaust Gas Recirculation Valve Position : Voltage Below Normal

Valve Position Sensor - Test

102-3

Engine Intake Manifold #1 Pressure : Voltage Above Normal

Engine Pressure Sensor Open or Short Circuit - Test

102-4

Engine Intake Manifold #1 Pressure : Voltage Below Normal

Engine Pressure Sensor Open or Short Circuit - Test

102-20

Engine Intake Manifold #1 Pressure : Data Drifted High

Engine Pressure Sensor Open or Short Circuit - Test

102-21

Engine Intake Manifold #1 Pressure : Data Drifted Low

Engine Pressure Sensor Open or Short Circuit - Test

105-3

Engine Intake Manifold #1 Temperature : Voltage Above Normal

Engine Temperature Sensor Open or Short Circuit - Test

105-4

Engine Intake Manifold #1 Temperature : Voltage Below Normal

Engine Temperature Sensor Open or Short Circuit - Test

108-3

Barometric Pressure : Voltage Above Normal

Engine Pressure Sensor Open or Short Circuit - Test

108-4

Barometric Pressure : Voltage Below Normal

Engine Pressure Sensor Open or Short Circuit - Test

157-0

Engine Injector Metering Rail #1 Pressure : High - most severe (3)

Fuel Rail Pressure Problem

157-2

Engine Injector Metering Rail #1 Pressure : Erratic, Intermittent, or Incorrect

Fuel Rail Pressure Problem

157-16

Engine Injector Metering Rail #1 Pressure : High - moderate severity (2)

Fuel Rail Pressure Problem

157-18

Engine Injector Metering Rail #1 Pressure : Low Fuel Rail Pressure Problem - moderate severity (2)

173-3

Engine Exhaust Gas Temperature : Voltage Above Normal

Engine Temperature Sensor Open or Short Circuit - Test

173-4

Engine Exhaust Gas Temperature : Voltage Below Normal

Engine Temperature Sensor Open or Short Circuit - Test

1076-5

Engine Fuel Injection Pump Fuel Control Valve : Current Below Normal

Solenoid Valve - Test

1076-6

Engine Fuel Injection Pump Fuel Control Valve : Current Above Normal

Solenoid Valve - Test

1188-5

Engine Turbocharger Wastegate Actuator 1 Position : Current Below Normal

Solenoid Valve - Test

1209-3

Engine Exhaust Gas Pressure : Voltage Above Normal

Engine Pressure Sensor Open or Short Circuit - Test

1209-4

Engine Exhaust Gas Pressure : Voltage Below Normal

Engine Pressure Sensor Open or Short Circuit - Test

1239-0

Engine Fuel Leakage 1 : High - most severe (3)

Fuel Rail Pressure Problem

2791-5

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Below Normal

Motorized Valve - Test

2791-6

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Above Normal

Motorized Valve - Test

2791-7

Engine Exhaust Gas Recirculation (EGR) Valve Control : Not Responding Properly

Motorized Valve - Test

3251-3

Particulate Trap Differential Pressure : Voltage Above Normal

Engine Pressure Sensor Open or Short Circuit - Test

3251-4

Particulate Trap Differential Pressure : Voltage Below Normal

Engine Pressure Sensor Open or Short Circuit - Test

3251-7

Particulate Trap Differential Pressure : Not Responding Properly

Diesel Particulate Filter Has Differential Pressure Problem

3251-10

Particulate Trap Differential Pressure : Abnormal Rate of Change

Diesel Particulate Filter Has Differential Pressure Problem

3251-18

Particulate Trap Differential Pressure : Low moderate severity (2)

Diesel Particulate Filter Has Differential Pressure Problem

3358-10

Engine Exhaust Gas Recirculation 1 Intake Pressure : Abnormal Rate of Change

NRS Mass Flow Rate Problem

3509-2

Sensor Supply Voltage 1 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

3510-2

Sensor Supply Voltage 2 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

3511-2

Sensor Supply Voltage 3 : Erratic, Intermittent, or Incorrect

Sensor Supply - Test

4765-3

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Above Normal

Engine Temperature Sensor Open or Short Circuit - Test

4765-4

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Below Normal

Engine Temperature Sensor Open or Short Circuit - Test

5319-31

Aftertreatment 1 Diesel Particulate Filter Incomplete Regeneration

Diesel Particulate Filter Active Regeneration Was Interrupted

5419-7

Engine Throttle Actuator #1 : Not Responding Properly

Motorized Valve - Test

5571-7

High Pressure Common Rail Fuel Pressure Relief Valve : Not Responding Properly

Fuel Rail Pressure Problem

5571-16

High Pressure Common Rail Fuel Pressure Relief Valve : High - moderate severity (2)

Fuel Rail Pressure Problem

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06091277

Diesel Particulate Filter Active Regeneration Occurrence Is Excessive SMCS - 108F-035 Note: This procedure is only applicable to engines equipped with a wall flow Diesel Particulate Filter (DPF) and a DPF differential pressure sensor. An active regeneration of the DPF will normally be initiated by the soot model that is calculated in the Electronic Control Module (ECM). If the differential pressure across the DPF is too high, the ECM will initiate an active regeneration based on the DPF differential pressure.

Probable Causes • Insulation on the exhaust duct (if equipped) • Diagnostic codes • Incorrect wiring for temperature sensors • Maintenance schedule • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinders

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps

Values

Results

1. Insulation on the Exhaust Duct (if equipped)

Codes

A. Check the insulation on the exhaust duct between the engine and the Clean Emissions Module (CEM). Make sure that insulation is not missing or damaged.

Result: The insulation is missing or damaged. Repair: Repair or replace the insulation. Result: The insulation is OK. Proceed to Test Step 2.

Result: There are active diagnostic codes.

2. Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. B. Check for active diagnostic codes.

Diagnostic codes

C. Use the electronic service tool to perform a service regeneration.

Result: There are no active diagnostic codes.

D. Check for active diagnostic codes on the electronic service tool.

Proceed to Test Step 3.

3. Incorrect Wiring for Temperature Sensors A. Check that the Diesel Oxidation Catalyst (DOC) inlet temperature sensor and DPF inlet temperature sensor wiring has not been switched. Note: The engine may run without indicating a fault for many hours with this condition.

Result: The wiring for the DOC inlet temperature sensor or the DPF inlet temperature sensor is incorrect.

Wiring

A. Check the maintenance schedule for the DPF. Refer to the Operation and Maintenance Manual, "Maintenance Interval

Repair: Repair the faulty wiring or replace the faulty wiring. Result: The wiring for the DOC inlet temperature sensor and the DPF inlet temperature sensor is OK.

B. Check that the wiring for the DOC inlet temperature and the DPF inlet temperature sensor is connected to the correct ECM pins. Refer to the Electrical Schematic for the application.

4. Maintenance Schedule

Repair: Investigate any active codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".

Proceed to Test Step 4.

Maintenance schedule

Result: The DPF is due for an ash service. Repair: Perform an ash service. Refer to the Operation and Maintenance Manual, "Diesel

Schedule".

Particulate Filter - Clean". Result: The DPF is not due for an ash service. Proceed to Test Step 5.

Result: Low compression is recorded on one or more cylinders. Repair: Possible causes of low compression are shown in the following list: 5. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

· Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Make any repairs, as necessary. Result: No faults found. Proceed to Test Step 6.

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. 6. Individual Malfunctioning Cylinders A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Cylinders

Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance. Result: There is a noticeable change in the sound of the engine for each cylinder. Contact the Dealer Solution Network (DSN).

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05992289

Diesel Particulate Filter Active Regeneration Was Interrupted SMCS - 108F-035 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Code for Diesel Particulate Filter (DPF) Active Regeneration Interrupted J1939 Code

531931

Description

Aftertreatment 1 Diesel Particulate Filter Incomplete Regeneration

Notes The Electronic Control Module (ECM) has interrupted an active regeneration. The maximum duration for an active regeneration has been exceeded three times. If equipped, the warning lamp will flash. The engine will be derated. The ECM will log the diagnostic code. The code will become inactive once a successful active regeneration has occurred.

Perform the following steps:

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps

Values

Results

1. Diagnostic Codes

Codes

A. Establish communication between the electronic service tool and the Electronic Control Module (ECM).

Result: A diagnostic trouble code is active or logged. Troubleshoot any diagnostic codes that could have caused an unsuccessful regeneration before continuing with this procedure.

B. Check for active diagnostic codes.

Result: A diagnostic trouble code is not active or logged. Proceed to Test Step 2.

Result: The insulation is missing or damaged.

2. Insulation on the Exhaust Duct (If Equipped) A. Check the insulation on the exhaust duct Insulation between the engine and the Clean Emissions Module (CEM). Make sure that insulation is not missing or damaged.

Repair or replace the insulation on the exhaust duct. Result: The insulation is OK. Proceed to Test Step 3.

Result: There are exhaust leaks. 3. Exhaust Leaks A. Thoroughly inspect the exhaust duct Exhaust leaks between the engine and the CEM for leaks. Ensure that all connections are secure and no leaks are present.

Make the necessary repairs, Verify that the repair has eliminated the fault. Result: The exhaust duct is OK. Proceed to Test Step 4.

4. Manual Regeneration A. Use one of the following methods to perform a manual regeneration:

Complete regeneration

Result: The regeneration completed successfully and there are no active diagnostic codes. Return the engine to service.

· The "Force Regeneration" switch on the application (if equipped) · The "Particulate Filter Forced Regeneration" on the electronic service tool B. Use the electronic service tool to clear all logged diagnostic codes.

Result: The regeneration did not complete successfully. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06091309

Diesel Particulate Filter Collects Excessive Soot SMCS - 108F-035 This procedure covers the following diagnostic code: Note: This procedure is applicable to engines equipped with a wall flow DPF only. Table 1 Diagnostic Trouble Codes for Diesel Particulate Filter (DPF) Collects Excessive Soot J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

325116

Particulate Trap Differential Pressure : High - moderate severity (2)

The differential pressure across the DPF is high for at least 100 seconds. The pressure at which this code becomes active is dependent on the level of soot indicated by the soot model that is calculated by the ECM. The battery voltage is at least 10 VDC. If equipped, the warning lamp will flash. The engine will be derated.

32510

Particulate Trap Differential Pressure : High - most severe (3)

The Electronic Control Module (ECM) detects the following conditions: The differential pressure across the DPF is very high for at least 100 seconds. The pressure at which this code becomes active is dependent on the level of soot indicated by the soot model that is calculated by the ECM.

The battery voltage is at least 10 VDC. If equipped, the warning lamp will flash and the shutdown lamp will come on. 37190

Aftertreatment 1 Diesel Particulate Filter Soot Load Percent : High - most severe (3)

The ECM detects that the soot level in the DPF is high. The warning lamp will come on.

371916

Aftertreatment 1 Diesel Particulate Filter Soot Load Percent : High - moderate severity (2)

The ECM detects that the soot load in the DPF is very high. The warning lamp will flash. The engine may be derated.

The Electronic Control Module (ECM) uses the Diesel Particulate Filter (DPF) differential pressure sensor to monitor the soot load in the DPF. An excessive accumulation of soot in the DPF can be caused by the following faults:

Probable Causes • Faulty injectors • Incorrect Wiring for Temperature Sensors • Individual malfunctioning cylinders • Low exhaust gas temperature • A faulty valve in the NOx Reduction System (NRS)

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Note: Engine operation must be kept to a minimum in order to minimize the amount of soot that is created. Follow the troubleshooting procedure in order to minimize the amount of engine operation. Table 2 Troubleshooting Test Steps 1. Diagnostic Codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). B. Check for active diagnostic codes. Check specifically for codes that relate to the

Values Diagnostic codes

Results Result: A diagnostic trouble code is active or logged. Repair: Troubleshoot any related diagnostic codes before continuing with this procedure. Result: A related diagnostic

"Probable Causes" in this procedure.

trouble code is not active or logged. Proceed to Test Step 2.

2. Incorrect Wiring for Temperature Sensors A. Check that the Diesel Oxidation Catalyst (DOC) inlet temperature sensor and DPF inlet temperature sensor wiring has not been switched. Note: The engine may run without indicating a fault for many hours with this condition.

Result: The wiring for the DOC inlet temperature sensor or the DPF inlet temperature sensor is incorrect.

Wiring

Repair: Repair the faulty wiring or replace the faulty wiring. Result: The wiring for the DOC inlet temperature sensor and the DPF inlet temperature sensor is OK.

B. Check that the wiring for the DOC inlet temperature and the DPF inlet temperature sensor is connected to the correct ECM pins. Refer to the Electrical Schematic for the application.

Proceed to Test Step 3.

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. 3. Individual Malfunctioning Cylinders If the engine will run, perform the following steps. A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Insulation

Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance. When all faults have been rectified, proceed to Test Step 4. Result: There is a noticeable change in the sound of the engine for each cylinder. Proceed to Test Step 4.

4. Exhaust Leaks A. Thoroughly inspect the exhaust duct between the engine and the CEM for leaks. Ensure that all connections are secure and no

Exhaust leaks

Result: There are exhaust leaks. The insulation is damaged. Repair: Make the necessary

leaks are present.

repairs. Proceed to Test Step 5.

B. Inspect the insulation on the exhaust duct (if equipped) for damage.

Result: The exhaust duct is OK. Proceed to Test Step 5.

5. Manual Regeneration A. If a 3251-16 or 3719-16 diagnostic code was active, use the electronic service tool to perform a "Particulate Filter Forced Regeneration". Make sure that the high soot loading diagnostic trouble code is no longer active. B. If a 3251-0 or 3719-0 diagnostic code was active, the DPF must be replaced. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and refer to Disassembly and Assembly, "Diesel Particulate Filter - Install". Use the electronic service tool to perform the "DPF Replacement Reset".

Result: The regeneration completed successfully and there are no active diagnostic codes. Complete regeneration

Return the engine to service. Result: The regeneration did not complete successfully. Contact the Dealer Solution Network (DSN).

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05995809

Diesel Particulate Filter Has Differential Pressure Problem SMCS - 108F-035 Note: This procedure is only applicable to engines equipped with a wall flow Diesel Particulate Filter (DPF) and a DPF differential pressure sensor. This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for the DPF Differential Pressure J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

3251-7

Particulate Trap Differential Pressure : Not Responding Properly

The measured differential pressure from the DPF differential pressure sensor is invalid. The battery voltage is at least 10 VDC. This fault can be caused by damaged or blocked pipes to the DPF differential pressure sensor. If equipped, the warning lamp will come on. The engine will be derated.

325110

Particulate Trap Differential Pressure : Abnormal Rate of Change

The ECM detects the following conditions: The differential pressure across the DPF does not drop below 2.5 kPa (0.36 psi) after the engine has stopped. This code will be active when the defect has been detected for at least 6 seconds.

The battery voltage is at least 10 VDC.

325117

Particulate Trap Differential Pressure : Low - least severe (1)

325118

Particulate Trap Differential Pressure : Low - moderate severity (2)

If equipped, the warning lamp will come on. The engine will be derated. The ECM detects the following conditions: There is no differential pressure across the DPF for at least 100 seconds. The battery voltage is at least 10 VDC. The engine will be derated. The fault will be cleared if the differential pressure is within the acceptable range for at least 10 seconds.

Probable Causes • Diagnostic codes • Exhaust leaks • Connections to the DPF differential pressure sensor • Incorrect installation of the DPF • Faulty DPF differential pressure sensor

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps

Values

Result: A 3251-3 or 3251-4 diagnostic code is active

1. Diagnostic Codes A. Establish communication between -the electronic service tool and the Electronic Control Module (ECM). B. Check for active diagnostic codes. Check specifically for an active 3251-3 or 3251-4 diagnostic code.

Results

Diagnostic codes

Refer to Troubleshooting, "Sensor Signal (Analog, Active) - Test" before returning to this procedure. Result: A related diagnostic trouble code is not active or logged. Proceed to Test Step 2.

2. Exhaust Leaks

Exhaust leaks

A. Thoroughly inspect the exhaust duct between the engine and the DPF for leaks. Ensure that all connections are secure and no leaks are present.

Result: There are leaks in the exhaust system. Make any necessary repairs. Result: The exhaust system is OK. Proceed to Test Step 3.

Illustration 1

g02726855

Typical view of the DPF differential pressure sensor (1) Connection to the DPF inlet (2) Connection to the DPF outlet

Table 3 Troubleshooting Test Steps 3. Connections to the DPF Differential Pressure Sensor A. Thoroughly inspect the following components for blockages and/or damage:

Values Damage and/or blockages

Results Result: One of the connections is damaged and/or blocked Replace any damaged or blocked components. Result: All connections are OK.

· Connection (1) on the DPF differential pressure sensor · Connection (2) on the DPF differential pressure sensor · The pipes between the DPF

Proceed to Test Step 4.

differential pressure sensor and the DPF · The pipe connections on the DPF for the differential pressure sensor

Result: The DPF is not installed correctly. Remove the DPF and install the DPF correctly. Refer to Disassembly and Assembly, "Diesel Particulate Filter Remove" andDisassembly and Assembly, "Diesel Particulate Filter Install".

4. Incorrect Installation of the DPF A. Check that the DPF is installed correctly. Refer to Disassembly and Assembly, "Diesel Particulate Filter Install" for the correct installation method for the DPF.

DPF

Result: The DPF is installed correctly. Install a replacement DPF differential pressure sensor. Run the engine and use the electronic service tool to check for active 3251 diagnostic codes. If the fault has not been eliminated, contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980520

Diesel Particulate Filter Regeneration SMCS - 108F

Regeneration The wall-flow Diesel Particulate Filter (DPF) traps both soot and ash. Regeneration is the removal of soot from the DPF. The engine aftertreatment system is designed to oxidize the soot in the DPF at the same rate as the soot is produced by the engine. The oxidization of the soot will occur when the engine is operating under normal conditions. The soot in the DPF is constantly monitored. If the engine is operated in a way that produces more soot than the oxidized soot, the engine management system will automatically activate systems to raise the exhaust temperature. The long-term buildup of ash is removed through a manual cleaning process. Refer to Operation and Maintenance Manual, "Diesel Particulate Filter - Clean" for more information on the service of the DPF. No service is required for the through-flow DPF. For additional information on the regeneration of the DPF, refer to Systems Operation/Testing and Adjusting. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06092634

Diesel Particulate Filter Temperature Is Low SMCS - 108F-035 The Electronic Control Module (ECM) monitors the temperature at the intake of the Diesel Particulate Filter (DPF).

Probable Causes • Diagnostic codes • Incorrect wiring for temperature sensors • Insulation on the exhaust duct (if equipped) • Exhaust leaks • Wastegate

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Diagnostic Codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM).

Values Codes

Results Result: A diagnostic trouble code is active or logged. Repair: Troubleshoot any diagnostic codes before continuing with this procedure.

B. Check for active diagnostic codes. Result: A diagnostic trouble code is not active or logged.

Proceed to Test Step 2.

Result: The wiring for the DOC inlet temperature sensor or the DPF inlet temperature sensor is incorrect.

Wiring

Result: The wiring for the DOC inlet temperature sensor and the DPF inlet temperature sensor is OK.

B. Check that the wiring for the DOC inlet temperature and the DPF inlet temperature sensor is connected to the correct ECM pins. Refer to the Electrical Schematic for the application.

Proceed to Test Step 3.

Result: The insulation is missing or damaged.

3. Insulation on the Exhaust Duct (If Equipped) A. Check the insulation on the exhaust duct between the engine and the Clean Emissions Module (CEM). Make sure that insulation is not missing or damaged.

Repair: Repair the faulty wiring or replace the faulty wiring.

Insulation

Repair: Repair or replace the insulation on the exhaust duct. Result: The insulation is OK. Proceed to Test Step 4.

Result: There are exhaust leaks. 4. Exhaust Leaks A. Thoroughly inspect the exhaust duct between the engine and the CEM for leaks. Ensure that all connections are secure and no leaks are present.

Exhaust leaks

Repair: Make the necessary repairs, Verify that the repair has eliminated the fault. Result: The exhaust duct is OK. Proceed to Test Step 5.

5. Wastegate A. Check for correct operation of the wastegate. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger -

Wastegate

Result: The wastegate or the wastegate actuator is faulty. Repair: Install a replacement turbocharger. Refer to Disassembly and

Inspect".

Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install". Result: The wastegate and the wastegate actuator are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06535538

ECM - Replace SMCS - 1901-510

NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

The engine is equipped with an Electronic Control Module (ECM). The ECM contains no moving parts. Follow the troubleshooting procedures in this manual to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem. Note: Ensure that the ECM is receiving power and that the ECM is properly grounded before replacement of the ECM is attempted. Refer to the schematic diagram. Use the electronic service tool to read the parameters in the suspect ECM. Record the parameters in the suspect ECM. Install the flash file into the new ECM. After the ECM is installed on the engine, the parameters must be programmed into the new ECM.

NOTICE If the flash file and engine application are not matched, engine damage may result.

Perform the following procedure to replace the ECM. 1. Connect the electronic service tool to the diagnostic connector. 2. From the menu bar go to the following menu options: Service Copy Configuration ECM Replacement 3. Click "Load From File" at the bottom of the screen. 4. Once the ECM data has been loaded, click "Save to File" at the bottom of the screen. Select a folder location and click "Save". 5. Remove the ECM. Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install". 6. Install the replacement ECM. Refer to Disassembly and Assembly, "Electronic Control Module Remove and Install". 7. Install the software on the new ECM. Refer to Troubleshooting , ECM Software - Install. 8. From the menu bar go to the following menu options: Service Copy Configuration ECM Replacement 9. Click "Load From File" at the bottom of the screen. 10. Select the correct ECM replacement file. Check that the date and time stamp matches that of the desired replacement file and click "OK". 11. Click "Program ECM" at the bottom of the screen. 12. Once the "Programming Complete" dialog box appears on-screen, click "OK". 13. Check for logged diagnostic codes. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06580077

ECM Memory - Test SMCS - 1901-038 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Code for the ECM Memory J1939 Code

Description

Notes The software in the Electronic Control Module (ECM) has reset when the engine was running.

152-2

Number Of ECU Resets : Erratic, Intermittent, or Incorrect

166-2

Engine Rated Power : Erratic, Intermittent, or Incorrect

There may be a brief loss of electrical power. The indicator lamps may come on for 2 seconds (lamp test). The ECM has detected an error during a software upgrade. If equipped, the warning lamp will come on. The ECM has detected a rating mismatch in the software.

166-14

1221-2

Engine Rated Power : Special Instruction

Continuously Monitored Systems Support/Status: Erratic, Intermittent, or Incorrect

If equipped, the warning lamp will flash and the shutdown lamp will come on. The engine will be shut down. The engine will not start. The ECM continuously monitors the operating conditions of the engine. If there is an irregularity that is not detected by the engine sensor diagnostics, this code will become active.

If equipped, the warning lamp will come on. 284012

ECU Instance : Failure

The ECM detects that the flash file that is installed is invalid. If equipped, the warning lamp will come on. Table 2

Troubleshooting Test Steps

Values

Results Result: A 1221-2 diagnostic code is active or recently logged. Repair: Make a note of all other active or recently logged diagnostic codes. Troubleshoot all other codes before continuing this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes". If 1221-2 is the only active or recently logged diagnostic code, proceed to Test Step 2.

1. Check for Active or Recently Logged Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools". B. Turn the keyswitch to the ON position. Diagnostic If the engine will start, then run the codes engine. C. Monitor the electronic service tool for active and/or recently logged diagnostic codes. D. Turn the keyswitch to the OFF position.

Result: A 152-2 diagnostic code is active or recently logged. Repair: Make a note of all other active or recently logged diagnostic codes. Troubleshoot all other codes before continuing this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes". If 152-2 is the only active or recently logged diagnostic code, proceed to Test Step 3. Result: A 166-X or 2840-12 diagnostic code is active or recently logged. Proceed to Test Step 4.

2. Clear the Diagnostic Code and Attempt to Start the Engine A. Use the electronic service tool to clear the 1221-2 diagnostic code. B. Turn the keyswitch to the ON position. If the engine will start, then run the

1221-2 diagnostic code

Result: The 1221-2 diagnostic code is no longer active. Return the engine to service. Result: The 1221-2 diagnostic code is still active.

engine for at least 10 minutes.

Proceed to Test Step 3.

C. Operate the engine over the full duty cycle to replicate the conditions in which the fault occurred. D. Stop the engine. Turn the keyswitch to the ON position. E. Use the electronic service tool to check for an active or recently logged 1221-2 diagnostic code.

Result: The ECM is receiving the correct voltage. 3. Check the Battery Supply Voltage to the ECM

Proceed to Test Step 4.

A. Check that the ECM is receiving the correct battery voltage. Refer to Troubleshooting, "Electrical Power Supply - Test".

Battery voltage

4. Re-Flash the ECM

Diagnostic codes

A. Ensure that the correct rating of flash file for the engine is installed. B. Ensure that the latest software is installed on the ECM. Refer to Troubleshooting, "ECM Software Install".

Result: Make any necessary repairs. Refer to Troubleshooting, "Electrical Power Supply Test". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. If the diagnostic code is still active, proceed to Test Step 4.

Result: The diagnostic code is no longer active. Use the electronic service tool to clear all logged diagnostic codes. Return the engine to service. Result:The diagnostic code is still active. Proceed to Test Step 5.

C. Turn the keyswitch to the ON position. D. Use the electronic service tool to check for active diagnostic codes. E. Turn the keyswitch to the OFF position.

5. Check if a Replacement ECM Eliminates the Fault

Result: There are no active diagnostic codes with the replacement ECM.

A. Contact the Dealer Solution Network (DSN).

Repair: Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

B. If the Dealer Solution Network (DSN) recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "ECM - Replace". C. Use the electronic service tool to recheck the system for active diagnostic codes.

Diagnostic codes

Result: The diagnostic code is still present with the replacement ECM. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06146657

ECM Software - Install SMCS - 1901-591; 7620-012 Flash Programming - A method of loading a flash file into the Electronic Control Module (ECM) The electronic service tool is utilized to flash program a flash file into the ECM. The flash programming transfers the flash file from the PC to the ECM. Use this process to program the engine flash file to the existing engine ECM. If the ECM is being replaced, refer to Troubleshooting, "ECM - Replace" to flash program a blank ECM.

Saving the Engine Configuration Data Note: Save the engine configuration data before beginning the ECM flashing process in order to avoid losing the engine configuration data. 1. Connect the electronic service tool to the diagnostic connector. 2. From the menu bar go to the following menu options: Service Copy Configuration ECM Replacement 3. Click on "Load From ECM" at the bottom of the screen. 4. Once the ECM data has been loaded, click on "Save to File" at the bottom of the screen. Select a folder location and click on "Save".

Flash Programming a Flash File Using "WinFlash"

1. Obtain the part number for the new flash file. Note: If you do not have the part number for the flash file, use the "Flash File Search" tool on the Service Technician Workbench (STW). Alternatively, use the "Flash Software Files" feature on SIS Web. Note: You must have the engine serial number in order to search for the part number of the flash file. 2. Connect the electronic service tool to the diagnostic connector. 3. Turn the keyswitch to the ON position. Do not start the engine. 4. Select "WinFlash" from the "Utilities" menu on the electronic service tool. 5. Flash program the flash file into the ECM. a. Select the engine ECM under the "Detected ECMs". Note: If "WinFlash" will not communicate with the engine ECM, proceed to "Loading the Engine Configuration Data". b. Press the "Browse" button in order to select the part number of the flash file that will be programmed into the ECM. c. When the correct flash file is selected, press the "Open" button. d. Verify that the "File Values" match the application. If the "File Values" do not match the application, search for the correct flash file. e. When the correct flash file is selected, press the "Begin Flash" button. f. The electronic service tool will indicate when flash programming has been successfully completed. 6. Proceed to "Loading the Engine Configuration Data"

"WinFlash" Error Messages If any error messages are displayed during flash programming, click on the "Cancel" button in order to stop the process. Access the information about the "ECM Summary" under the "Information" menu. Ensure that you are programming the correct flash file for your engine.

Flash Programming the ECM Using "ECM Flash" 1. Download the flash file that is to be installed. Note: When using version 2015A or earlier of the electronic service tool, contact the Dealer Solutions Network (DSN) in order to obtain the flash file in the correct format.

2. Connect the electronic service tool to the diagnostic connector. If necessary, refer to Troubleshooting, "Electronic Service Tools". 3. Navigate to the following menu options in the electronic service tool: Utilities ECM Flash 4. Click on "Select File" on the bottom left of the screen. Navigate to the location of the flash file to be installed. Once the flash file has been selected, the flash file information will be displayed. 5. Click on "Start Download" to begin the installation process. 6. Proceed to "Loading the Engine Configuration Data" Note: If "WinFlash" or "ECM Flash" will not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Does Not Communicate".

Loading the Engine Configuration Data 1. From the menu bar go to the following menu options: Service Copy Configuration ECM Replacement 2. Click on "Load From File" at the bottom of the screen. 3. Select the correct ECM replacement file. Check that the date and time stamp matches that of the desired replacement file and click on "OK". 4. Click on "Program ECM" at the bottom of the screen. 5. Once the "Programming Complete" dialog box appears on screen, click on "OK". 6. Access the "Configuration" screen under the "Service" menu in order to determine the parameters that require programming. 7. Start the engine and check for proper operation. Check that there are no active diagnostic codes.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06233954

Electrical Connectors - Inspect SMCS - 7553-040-WW Most electrical faults are caused by poor connections. The following procedure will assist in detecting faults with connectors and with wiring. If a fault is found, correct the condition and verify that the fault is resolved. Intermittent electrical faults are sometimes resolved by disconnecting and reconnecting connectors. It is very important to check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic codes after reconnecting the connector. If the status of a diagnostic code is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate mating of a connection. Follow these guidelines: • Never break the insulation of a wire in order to access a circuit for measurements. • If a wire is cut, always install a new terminal for the repair.

The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.

Illustration 1

g01131019

Seal for a three-pin connector (typical example)

Table 1 Troubleshooting Test Steps 1. Check Connectors for Moisture and Corrosion

Values

Harness, connectors, A. Inspect all the harnesses. Ensure that the routing of and seals are the wiring harness allows the wires to enter the face OK. of each connector at a perpendicular angle. Otherwise, the wire will deform the seal bore. This will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly. B. Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector. C. Disconnect the suspect connector and inspect the connector seal. Ensure that the seal is in good condition. If necessary, replace the connector. D. Thoroughly inspect the connectors for evidence of moisture entry. Note: It is normal to see some minor seal abrasion on connector seals. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If

Results Result: A fault has been found with the harness or the connectors. Repair: Repair the connectors or the wiring, as required. Ensure that all of the seals are correctly installed. Ensure that the connectors have been reattached. If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires. Use the electronic service tool in

the source of the moisture entry is not repaired, the fault will recur. Simply drying the connector will not rectify the fault. Check the following items for the possible moisture entry path: · Missing seals · Incorrectly installed seals · Nicks in exposed insulation · Improperly mated connectors Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector harness for damage. Also check other connectors that share the harness for moisture. Note: The ECM is a sealed unit. If moisture is found in an ECM connector, the ECM is not the source of the moisture. Do not replace the ECM.

order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The harness, connectors, and seals are in good condition. Proceed to Test Step 2.

2. Check the Wires for Damage to the Insulation Result: There is damage to the harness.

A. Carefully inspect each wire for signs of abrasion, nicks, and cuts. Inspect the wires for the following conditions: · Exposed insulation · Rubbing of a wire against the engine · Rubbing of a wire against a sharp edge The wiring is B. Check all of the fasteners for the harness and the OK strain relief components on the ECM in order to verify that the harness is correctly secured. Also check all of the fasteners in order to verify that the harness is not compressed. Pull back the harness sleeves in order to check for a flattened portion of wire. A fastener that has been overtightened flattens the harness. This damages the wires that are inside the harness.

3. Inspect the Connector Terminals A. Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are correctly aligned in the connector and verify that the terminals are correctly located in the connector.

Terminals are aligned and undamaged

Repair: Repair the wires or replace the wires, as required. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The wires are free of abrasion, nicks, and cuts and the harness is correctly clamped. Proceed to Test Step 3.

Result: The terminals of the connector are damaged. Repair: Repair the terminals and/or replace the terminals, as required. Use the electronic service tool in order to clear all logged diagnostic codes and then verify

that the repair eliminates the fault. Result: The terminals are OK. Proceed to Test Step 4.

Illustration 2

g01802454

A typical example of the lock wedge. (1) Lock wedge

Table 2 Troubleshooting Test Steps 4. Perform a Pull Test on Each Wire Terminal Connection A. Ensure that the locking wedge for the connector is installed correctly. Terminals cannot be retained inside the connector if the locking wedge is not installed correctly. B. Perform the 30 N (6.7 lb) pull test on each wire. Each terminal and each connector should easily withstand 30 N (6.7 lb) of tension and each wire should remain in the connector body. This test checks whether the wire was correctly crimped in the terminal and whether the terminal was correctly inserted into the

Values Pull test OK

Results Result: A wire has been pulled from a terminal or a terminal has been pulled from the connector in the 30 N (6.7 lb) pull test. Repair: Replace the terminal. Replace damaged connectors, as required. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: All terminals pass the

connector.

pull test. Proceed to Test Step 5. Result: Terminals are damaged.

5. Check Individual Pin Retention into the Socket A. Verify that the sockets provide good retention for the pins. Insert a new pin into each socket one at a time in order to check for a good grip on the pin by the socket.

The sockets provide good retention for the new pin.

Repair: Replace the damaged terminals. Verify that the repair eliminates the problem. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The terminals are OK. Proceed to Test Step 6.

Result: The locking mechanism for the connector is damaged or missing.

6. Check the Locking Mechanism of the Connectors A. Ensure that the connectors lock correctly. After locking the connectors, ensure that the two halves cannot be pulled apart. B. Verify that the latch tab of the connector is correctly latched. Also verify that the latch tab of the connector returns to the locked position.

The connectors are locked and are not damaged

Repair: Repair the connector or replace the connector, as required. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The connectors are in good condition. Reconnect all connectors. If there are still active diagnostic codes, refer to Troubleshooting, "Diagnostic Trouble Codes".

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05981997

Electrical Connectors SMCS - 7553-WW

Connectors for the Electronic Control Module (ECM)

Illustration 1 View of the engine ECM (1) J1 ECM connector (2) J2 ECM connector

g03747067

Illustration 2

g02277053

View of the J1 ECM connector (ECM side)

Illustration 3 View of the J2 ECM connector (ECM side)

g02266273

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06229707

Electrical Power Supply - Test SMCS - 1401-038 This procedure tests that the correct voltage is being supplied to the Electronic Control Module (ECM). This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Electrical Power Supply Circuit J1939 Code

Code Description

Notes This code indicates that the battery circuit to the ECM has excessive voltage while the engine is running. The ECM detects the following conditions:

168-3

Battery Potential / Power Input 1 : Voltage Above Normal

The battery voltage is high for at least 5 seconds. The keyswitch is in the ON position. The engine is not cranking. The warning lamp will come on.

168-4

Battery Potential / Power Input 1 : Voltage Below Normal

This code indicates that the battery circuit for the ECM has low voltage while the engine is running. The ECM detects the following conditions: The battery voltage is low for at least 5 seconds. The keyswitch is in the ON position.

The engine is not cranking. The ECM will normally log the diagnostic code. If battery voltage disappears without returning, the ECM will not log this diagnostic code and the engine will shut down. The engine may experience changes in the engine rpm, and intermittent engine shutdowns or complete engine shutdowns while the conditions that cause this diagnostic code are present. Battery+ voltage is supplied through P1: 1, 3, and 5. The battery- is supplied through P1: 2, 4, and 6. The ECM receives the keyswitch signal at P1:54 when the keyswitch is in the ON position or in the START position. When the ECM detects battery voltage at this input, the ECM will activate the main relay. When battery voltage is removed from this input, after a short time (up to 60 seconds) the ECM will deactivate the main relay. The cause of an intermittent power supply to the ECM can occur on either the positive side or on the negative side of the battery supply circuit. Usually, battery power to the diagnostic connector is available and the battery power to the data link connector is independent of the keyswitch. Therefore, although the electronic service tool can be powered up, there may be no communication with the engine ECM. The engine ECM requires the keyswitch to be in the ON position in order to maintain communications. The ECM may power down a short time after connecting the electronic service tool if the keyswitch is in the OFF position.

Illustration 1

g03722958

Schematic diagram for the electrical power supply circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 2

g03722982

View of the pin locations on the P1 connector for the electrical power supply circuit (1) Battery+ (2) Battery ground (3) Battery+ (4) Battery ground (5) Battery+ (6) Battery ground (8) Start Signal (28) ECM main relay (54) Ignition key switch

Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Check the fuses.

Values Damaged wire or connector

Results Result: A damaged wire or damaged connector was found. A fuse is blown.

B. Thoroughly inspect the battery connections and the connections to the relays. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.

Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

C. Perform a 30 N (6.7 lb) pull test on each

Result: All connectors, pins, and sockets

of the wires in the ECM connector that are associated with electrical power supply circuit.

are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

D. Check the harness for abrasion and for pinch points from the battery to the ECM.

Proceed to Test Step 2.

Result: There are no active 168 diagnostic codes at this time.

2. Check for Active Diagnostic Codes or Logged Diagnostic Codes

Repair: If the fault is intermittent, refer to Troubleshooting, "Electrical Connector Inspect". If the ECM is receiving no battery voltage, proceed to Test Step 3.

A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position and start the engine.

Diagnostic codes

C. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes or logged diagnostic codes. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

Result: There is an active 168-3 diagnostic code. Proceed to Test Step 3. Result: There is an active 168-4 diagnostic code. Proceed to Test Step 4.

Result: The alternator is faulty. 3. Check the Alternator A. Test the alternator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Alternator - Test".

Alternator

Repair: Replace the alternator. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The alternator is operating correctly. Proceed to Test Step 4.

4. Check the Battery A. Load-test the battery. Use a suitable battery load tester. Refer to Systems Operation, Testing and Adjusting, "Battery -

Battery load test passed

Result: The battery does not pass the load test. The measured voltage is less than 11 VDC. Repair: Recharge or replace the faulty battery.

Test" for the correct procedure.

Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The battery passes the load test. The measured voltage is at least 11 V. Repair: Check the wiring between the battery and the ECM. Refer to the Electrical Schematic for the application. Make any necessary repairs. If the fault is still present, contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06233880

Electronic Service Tool Does Not Communicate SMCS - 0785; 1900

Probable Causes • Configuration of the communications adapter • Electrical connectors • Communication adapter and/or cables • Electrical power supply to the diagnostic connector • Electronic service tool and related hardware • Electrical power supply to the Electronic Control Module (ECM)

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Configuration of the Communications Adapter A. Access "Preferences" under the "Utilities" menu on the electronic service tool.

Values

Results

Communications adapter configuration

Result: The correct "Communications Interface Device" is not selected. Repair: Select the correct "Communications Interface Device".

Result: The correct port is not selected for use by the communication adapter.

B. Check for hardware that uses the same ports as the communications adaptor.

Repair: Select the correct port for use by the communication adapter. Note: The most commonly used port is "COM 1". Result: Other hardware is sharing the same port with the communications adaptor. Repair: Exit or close the software programs for that device. Result: The communications adaptor is correctly configured. Proceed to Test Step 2.

Result: The connectors are not correctly installed.

2. Electrical Connectors A. Check for correct installation of the P1 and P2 ECM connectors and of the connector for the electronic service tool.

Electrical connectors

Repair: Repair or replace the connectors, as necessary. Result: The connectors are OK. Proceed to Test Step 3.

3. Communication Adapter and/or Cables A. Check that the firmware and driver files are the most current files for the type of communication adapter that is being used. Verify that the correct cable is being used between the communication adapter and the diagnostic connector. B. Disconnect and then reconnect the cable that attaches the communication adapter to the diagnostic connector.

Comms adaptor and cables

Result: The firmware or driver files are not the most current files. Repair: Update the firmware or driver files to the most current files. Result: The cable between the communication adapter and the diagnostic connector is not correct. Repair: Replace the cable between the communication adapter and the diagnostic connector with the correct type. Result: The laptop computer has a

C. Check the operating system on the laptop computer.

Windows operating system. Repair: Restart the laptop computer in order to eliminate the possibility of a conflict in the software. Result: The adaptor and cables are OK. Proceed to Test Step 4.

Result: Battery voltage is not present between terminals A and B of the diagnostic connector.

4. Electrical Power Supply to the Diagnostic Connector A. Use a multimeter to check that battery voltage is present between terminals A and B of the diagnostic connector.

Electrical power

Result: Battery voltage is present between terminals A and B of the diagnostic connector.

Note: If the communication adapter is not receiving power, the LED display on the communication adapter will be off.

Proceed to Test Step 5.

Result: The same fault occurs on a different engine.

5. Electronic Service Tool and Related Hardware A. Connect the electronic service tool to a different engine.

Repair: Investigate the cause and repair, as necessary.

Hardware

Note: This process eliminates the electronic service tool and the related hardware as the fault.

Repair: Check the electronic service tool and the related hardware for faults. Result: The fault does not occur on a different engine. Proceed to Test Step 6.

6. Electrical Power Supply to the Electronic Control Module (ECM) A. Check the power supply to the ECM. Refer to Troubleshooting, "Electrical Power Supply - Test". Note: If the ECM is not receiving battery

Power to ECM

Result: The power supply to the ECM is incorrect. Repair: Investigate the cause and repair, as necessary. Result: The power supply to the ECM is OK.

voltage, the ECM will not communicate. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05857076

Electronic Service Tools SMCS - 0785 Caterpillar electronic service tools are designed to help the service technician perform the following tasks: • Information access • System diagnostics • System calibrations • System configurations • Data link communications

Required Service Tools Table 1 Required Service Tools Part Number

Description

6V-2197

Transducer

7X-1171

Transducer Adapter

5P-7277

Voltage Tester

7X-1710

Multimeter Probe

6V-7070

Digital Multimeter (HEAVY-DUTY) or

9U-7330

Digital Multimeter or

146-4080

Digital Multimeter Gp (RS232) or

212-2160

Digital Multimeter Gp

Optional Service Tools Table 2 lists the optional service tools that can be used when the engine is serviced. Table 2 Part Number

Description

198-4240 or 1U-5470

Digital Pressure Indicator Engine Pressure Group

4C-4911(1)

Battery Load Tester

6V-9130(2)

Temperature Adapter (MULTIMETER)

215-9512(3)

Hose Connector (Quick Disconnect, Male)

215-9513

Hose Connector (Quick Disconnect, Female)

155-5176

AC/DC Current Probe

2P-8278

Tube As

217-0113

Harness As

(1)

Refer to Special Instructions, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12 V Lead Acid Batteries" and Special Instructions, SEHS7633, "Battery Test Procedure".

(2)

Refer to Special Instructions, SEHS8382, "Use of the 6V-9130 Temperature Adapter Group".

(3)

This item is used with a 2P-8278 Tube Assembly.

Caterpillar Electronic Technician (ET) Cat ET can display the following information: • Status of all pressure sensors and temperature sensors • Programmable parameter settings • Active diagnostic codes and logged diagnostic codes • Logged events • Histograms Cat ET can also be used to perform the following functions: • Diagnostic tests

• Calibrations • Programming of flash file • Parameter programming • Copy configuration function for Electronic Control Module (ECM) replacement • Data logging • Graphs (real time) Table 3 lists the service tools that are required in order to use Cat ET. Table 3 Standard Hardware for Connecting with Cat ET Part Number N/A 317-7484

Description Personal Computer (PC) Communication Adapter Gp

Components of the 317-7484 Communication Adapter Gp 317-7485

Communication Adapter (3)

370-4617

Cable As (USB)

457-6114

Cable As

Tool Operating Manual & Software CD ROM, NETG5057, "Communication Adapter 3" Note: More information on the use of Cat ET and the PC requirements is in the documentation that accompanies the Cat ET software.

Connecting Cat ET and the Communication Adapter Gp Use the following procedure in order to connect Cat ET and the CA3 Communication Adapter. 1. Turn the keyswitch to the OFF position.

Illustration 1

g02051513

(1) PC (2) 353-5083 Cable As (USB) (3) 317-7485 Communication Adapter (3) (4) 457-6114 Cable As

2. Connect cable (2) between the "COMPUTER" end of CA3 adapter (3) and a USB port of PC (1). 3. Connect cable (4) between the "DATA LINK" end of CA3 adapter (3) and the service tool connector. 4. Place the keyswitch in the ON position. If the Electronic Service Tool and the CA3 adapter do not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshooting, "Electronic Service Tool Does Not Communicate".

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06223543

Engine Cranks but Does Not Start SMCS - 1000-035; 1450-035

Probable Causes Note: Wait at least 30 seconds between attempts to start the engine. The engine will not start unless the keyswitch has been turned to the OFF position for at least 30 seconds. • Ground level shutdown switch • Diagnostic codes • Visible faults • Air intake and exhaust system • Fuel system • Fuel filters • Fuel rail Pressure Relief Valve (PRV) • Fuel pump timing • Low compression (cylinder pressure)

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Ground Level Shutdown Switch (If

Values

Results

Shutdown

Result: The ground level shutdown

Equipped)

switch

A. Ensure that the ground level shutdown switch has not been activated.

switch has been activated. Repair: Deactivate the ground level shutdown switch. Result: The ground level shutdown switch has not been activated. Proceed to Test Step 2.

Result: There are active diagnostic codes.

2. Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. B. Crank the engine for 30 seconds.

Diagnostic codes

Repair: Troubleshoot all active diagnostic codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".

C. Turn the keyswitch to the ON position. Result: There are no active diagnostic codes.

D. Use the electronic service tool to check for active diagnostic codes.

Proceed to Test Step 3.

3. Visible Faults A. Visually inspect the engine for the following faults: ·Missing components ·Damaged components ·Damaged electrical cables or loose electrical cables ·Oil leaks ·Fuel leaks

Visible faults

Result: Faults found during engine inspection. Repair: Make any repairs, as necessary. Attempt to start the engine. If the engine will not start, proceed to Test Step 4. Result: No faults found. Proceed to Test Step 4.

B. Check for the correct levels of fuel, oil, and coolant. C. If the ambient temperature is below 0 °C (32 °F), make sure that the correct specification of engine oil is used. D. Check that the battery voltage is correct. E. Use the electronic service tool to check the average cranking speed of the engine. If the cranking speed is less than 150 rpm,

investigate the cause of the low cranking speed. F. Make sure that all fuel filters are correctly installed. G. Drain any water from the primary fuel filter/water separator.

4. Air Intake and Exhaust System

Result: A defect was found in the air intake or exhaust system.

A. Check the air filter restriction indicator. B. Ensure that the air filter is clean and serviceable Defects C. Check the air intake and exhaust systems for the following defects:

Result: No defects found in the air intake or exhaust systems.

· Blockages · Restrictions · Damage to lines or hoses

5. Fuel System Inspection A. Check that the fuel shut-off valve is in the OPEN position. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). C. Check for fuel supply lines that are restricted. D. Check that the low-pressure fuel lines are correctly installed. E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test" F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test". G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".

Repair: Make any necessary repairs. Attempt to start the engine. If the engine will not start, proceed to Test Step 5.

Proceed to Test Step 5.

Fuel System

Result: A defect was found in the fuel system. Repair: Make any necessary repairs. Attempt to start the engine. If the engine will not start, proceed to Test Step 6. Result: No defects found. Proceed to Test Step 6.

H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Prime".

6. Fuel Filters A. Replace the primary fuel filter and the secondary fuel filter. Refer to the Engine Operation and Maintenance Manual, "Fuel start System Primary Filter (Water Separator) Element - Replace".

Result: The engine starts. Return the engine to service. Result: The engine does not start. Proceed to Test Step 7.

B. Attempt to start the engine. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

www.FPTIndustrialEngineParts.com

Illustration 1

g03705140

View of the fuel manifold (typical example)

Table 2 Troubleshooting Test Steps

Values

7. Fuel Rail Pressure Relief Valve Fuel in (PRV) container A. Turn the keyswitch to the OFF position. B. Disconnect plastic tube assembly (4) from fuel manifold (1). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) Remove and Install".

Results Result: Fuel is present in the container. Repair: Install a replacement fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) Remove and Install". When the fuel manifold has been replaced, use the electronic service tool to perform the "Rail Pressure Sensor Replacement Reset". Result: No fuel is present in the container.

C. Securely seal the end of plastic tube assembly (4). Note: Plastic tube assembly (4) must be sealed to prevent air ingress into the fuel system. D. Attach a length of hose to fuel

Proceed to Test Step 8.

manifold (1) and secure with a clip at position (3). E. Place the other end of the hose into a container that is suitable for fuel. Ensure that the hose is secure and will not come out of the container while the engine is running. F. Turn the keyswitch to the ON position. G. Crank the engine for a maximum of 30 seconds. H. After the engine has stopped, check the container for fuel.

Result: The fuel pump timing is incorrect. 8. Fuel Pump Timing A. Check the timing of the highpressure fuel pump. Refer to Systems Operation, Testing, and Adjusting, "Fuel Injection Timing Check".

Fuel pump timing

Repair: Make any necessary adjustments. Attempt to start the engine. If the engine will not start, proceed to Test Step 9. Result: The fuel pump timing is OK. Proceed to Test Step 9.

9. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

Result: Low compression is recorded on one or more cylinders. Possible causes of low compression are shown in the following list: ·Loose glow plugs ·Faulty piston ·Faulty piston rings ·Worn cylinder bores ·Worn valves ·Faulty cylinder head gasket ·Damaged cylinder head Repair: Make any repairs, as necessary. Attempt to start the engine. If the engine will not start, contact the Dealer Solution Network (DSN). Result: No faults found.

Contact the Dealer Solutions Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06223545

Engine Does Not Crank SMCS - 1000-035; 1450-035

Probable Causes • Battery cables and batteries • Switches and/or circuit breakers • Safety interlock on the application • Starting motor solenoid or starting circuit • Starting motor and/or flywheel ring gear • Engine accessories and transmission • Hydraulic lock

Recommended Repairs Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps 1. Battery Cables and Batteries A. Inspect the main power switch, battery posts, and battery cables for loose connections and for corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections.

Values Batteries and cables

Results Result: The batteries and cables are not OK. Repair: Make the necessary repairs. Result: The batteries and cables are OK.

B. Inspect the batteries. Proceed to Test Step 2. C. Charge the batteries. Test the batteries. Refer to Systems Operation, Testing and Adjusting, "Battery - Test ".

Result: The switches and/or circuit breakers are not OK. 2. Switches and/or Circuit Breakers A. Check any switches and/or circuit breakers that may interfere with the engine cranking. Refer to the applications electrical schematic for additional information.

Switches and/or circuit breakers

Repair: Make the necessary repairs. Result: The switches and/or circuit breakers are OK. Proceed to Test Step 3.

Result: A safety interlock is preventing the engine from starting. 3. Safety Interlock on the Application A. Check that any safety interlock features on Safety the application are in the safe position. Refer to interlocks the OEM documentation for details of any safety interlocks on the application.

Repair: Disengage the safety interlock if it is safe to do so. If necessary, repair the safety interlock. Result: There are no safety interlocks preventing the engine from starting. Proceed to Test Step 4.

4. Starting Motor Solenoid and Starting Circuit A. Test the operation of the starting motor circuit. Refer to Systems Operation/Testing and Adjusting, "Electric Starting System - Test".

Starting motor solenoid and circuit

Result: The starting motor solenoid and circuit are not OK. Repair: Make the necessary repairs. Result: The starting motor solenoid and circuit are OK.

Proceed to Test Step 5.

5. Starting Motor and/or Flywheel Ring Gear

Result: The starter pinion and flywheel ring gear are not OK.

A. Test the operation of the starting motor. B. Check the wiring for the starting motor. Refer to Systems Operation, Testing, and Adjusting, Starter pinion "Electric Starting System - Test". and flywheel ring gear are OK C. Check the pinion clearance. Inspect the pinion and the flywheel ring gear for damage. Refer to Systems Operation/Testing and Adjusting, "Electrical System" for additional information.

Repair: Make the necessary repairs. Result: The starting motor and flywheel ring gear are OK. Proceed to Test Step 6.

6. Engine Accessories and Transmission Result: The engine accessories and transmission are not OK.

A. Ensure free movement of the driveline. B. Remove and inspect any engine accessories that may lock up the engine. The following list contains examples of engine accessories that may lock up the engine:

Engine accessories and transmission

· Hydraulic pump that is driven from the rear gear group · Air compressor · Engine oil pump · Other components that are driven by the engine

7. Hydraulic Lock Note: If an injector has been replaced, evacuate any fluids from the cylinder and attempt to start the engine. Fuel will flow from the cylinder head into the cylinders when a unit injector is removed. A. Check for fluid in the cylinders by removing the individual unit injectors. Check for damaged seals. B. If there was excessive fuel in the cylinder, replace the seals and reinstall the injector. Drain any excess fuel from the cylinder head.

Repair: Make the necessary repairs. Result: The engine accessories and transmission are OK. Proceed to Test Step 7.

Hydraulic lock

Result: The engine has a hydraulic lock. Repair: Make the necessary repairs. Result: The engine rotates freely. Contact the Dealer Solution Network (DSN).

C. If a mechanical problem is suspected, disassemble the engine. Refer to the Disassembly and Assembly manual. Inspect the internal components for the following conditions: · Seizure · Broken components · Bent components

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06223552

Engine Has Early Wear SMCS - 1000-035; 1200-035

Probable Causes • Contaminated oil • Leaks in air intake system • Engine History • Low oil pressure • Dirt in engine oil • Incorrect oil • Dirt in fuel

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Contaminated Oil A. Check an oil sample for contamination with fuel. Refer to Troubleshooting, "Oil Contains Fuel".

Values Oil contains fuel

Results Result: The engine oil is contaminated with fuel. Repair: Investigate the cause. Refer to Troubleshooting, "Oil Contains Fuel". Result: The engine oil is not

contaminated with fuel. Proceed to Test Step 2.

2. Leaks in Air Intake System Result: Leaks found in air intake system.

A leak in the air intake system may allow unfiltered air into the engine. A. Inspect the air intake system for streaks which may indicate a leakage of unfiltered air. Inspect all of the gaskets and the connections. Refer to Systems Operation, Testing, and Adjusting, "Air Inlet and Exhaust System".

Leaks in Air Intake System

Repair: Repair any leaks. Result: The air intake system is OK. Proceed to Test Step 3.

3. Engine History A. Check that the engine has been serviced to the correct maintenance intervals. Refer to Operation and Maintenance Manual, "Maintenance Interval Schedule" B. Check the engine history for frequent starting and stopping in cold conditions.

Result: The engine is not correctly maintained.

Maintenance intervals

Repair: Make sure that the engine is maintained at the correct maintenance intervals. Refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule". Result: The engine is correctly maintained.

Note: Frequent starting and stopping of the engine can cause early wear. Also, operation of the engine for short periods of time in cold conditions can cause early wear.

Proceed to Test Step 4.

Result: The engine has a history of low oil pressure. 4. Low Oil Pressure A. Check for frequently logged diagnostic codes relating to low oil pressure.

Low oil pressure

Repair: Refer to Troubleshooting, "Oil Pressure Is Low". Result: There are no logged diagnostic codes for low oil pressure. Proceed to Test Step 5.

5. Dirt in Engine Oil

Dirt in engine oil

Result: The engine oil shows signs of dirt or debris

A. Check the engine oil for dirt or debris. Repair: Drain the oil from the crankcase and refill the crankcase with clean engine oil. Install new engine oil filters. Refer to the Operation and Maintenance Manual for more information. Result: The engine oil is clean. Proceed to Test Step 6.

Result: The oil specification is incorrect. 6. Incorrect Oil A. Check that the engine is filled with oil of the correct specification. Refer to the Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Oil specification

Repair: Drain the engine oil system and refill the engine oil system. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change". Result: The oil specification is correct. Proceed to Test Step 7.

Result: The fuel has contamination. 7. Dirt in Fuel

Repair: Determine the cause of any contamination and make the necessary repairs.

A. Remove the fuel filters. Inspect the fuel filters for contamination. Note: Contaminants in the fuel such as hydrogen sulfide and sulfur can lead to the formation of acids in the crankcase. B. Obtain a fuel analysis.

Fuel and fuel filters

Install new fuel filters. Refer to the Operation and Maintenance Manual. Result: The fuel is not contaminated. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06704802

Engine Has Mechanical Noise (Knock) SMCS - 1000-035

Probable Causes • Diagnostic codes • Electrical connections • Fuel quality • Correct lubrication • Engine accessories • Valve train components • Gear train and lower end components • Crankshaft

Values Diagnostic codes

Results Result: There are active codes. Repair: Troubleshoot any active codes before continuing with this procedure.

if necessary.

Result: There are no active codes. Proceed to Test Step 2.

Result: There are suspect connectors. Repair: Repair connectors that are suspect or replace connectors that are suspect.

2. Electrical Connections A. Check for the correct installation of the ECM P1 and P2 connectors. Check for correct installation of the fuel injector connectors.

Connectors

Perform the "Wiggle Test" on the electronic service tool Result: There are no suspect connectors. Proceed to Test Step 3.

Result: The fuel quality is not OK.

3. Fuel Quality A. Obtain a fuel analysis to confirm that the correct fuel is being used for the engine. Refer to Systems Operation/Testing and Adjusting, "Fuel System Quality Test" for the proper procedure.

Fuel

Note: Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, Repair: Replace the fuel. Verify that the repair eliminated the noise. Result: The fuel quality is OK. Proceed to Test Step 4.

4. Correct Lubrication A. Check for correct lubrication of the valve components. Check for sufficient lubrication between the injector tappets and the rocker arms. B. Check for blocked oil passages. Oil passages must be clean. Clean any oil passages that are questionable. Refer to the Disassembly and Assembly for additional

Lubrication

Result: The oil passages are blocked or the engine does not have correct lubrication. Repair: Make the necessary repairs, Verify that the repair eliminated the noise. Result: The oil passages are not blocked and the engine has proper lubrication.

information. Proceed to Test Step 5. C. Inspect the engine oil filters for ferrous material. D. Obtain an oil analysis. The analysis will contribute to a better understanding of oil contamination and the origin of the contamination.

Result An engine accessory is the source of the noise. 5. Engine Accessories A. Attempt to isolate the source of the noise.

Engine accessory

Repair: Repair the engine accessory and/or replace the engine accessory, as necessary. Result An engine accessory is not the source of the noise. Proceed to Test Step 6.

6. Valve Train Components A. Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Valve Lash - Inspect/Adjust".

Valve train

Result: The valve train components are damaged. Repair: Make the necessary repairs, Verify that the repair eliminated the noise.

B. Check for damage to valve train components. Remove the valve cover. Check the following items for damage:

Result: The valve train components are not damaged.

· Camshaft

Proceed to Test Step 7.

· Valve springs · Camshaft followers · Rocker shaft · Pushrods Refer to the Disassembly and Assembly for additional information. C. Check for valves that do not move freely. If necessary, remove the cylinder head and inspect the valves. Refer to the Disassembly and Assembly for

additional information.

Result: The gear train or lower end components are damaged. 7. Gear Train and Components of the Lower End

Repair: Replace any damaged parts. Gear train

A. Inspect the gear train and lower end components.

Result: The gear train or lower end components are not damaged. Proceed to Test Step 8.

8. Crankshaft

Result: The crankshaft or the related components are damaged or worn.

A. Inspect the crankshaft and the related components. Look for worn thrust plates and wear on the crankshaft.

Repair: Repair or replace any damaged parts. Verify that the repair eliminated the noise.

Crankshaft

B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.

Result: The crankshaft or the related components are not damaged or worn. Contact the Dealer Solution Network (DSN).

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06224976

Engine Misfires, Runs Rough or Is Unstable SMCS - 1000-035 Note: If the fault is intermittent and the fault cannot be duplicated, refer to Troubleshooting, "Power Is Intermittently Low or Power Cutout Is Intermittent". Note: If the fault only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.

Probable Causes • Diagnostic codes • Air Intake and Exhaust System • Fuel System Inspection • Throttle Position Sensor/Throttle Switches • High-pressure fuel pump • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinder

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps

Values

Results

1. Diagnostic Codes

Diagnostic codes

A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.

Result: There are active codes. Repair: Troubleshoot any active codes before continuing with this procedure. Result: There are no active codes. Proceed to Test Step 2.

2. Air Intake and Exhaust System Result: A defect was found in the air intake or exhaust system.

A. Check the air filter restriction indicator. B. Ensure that the air filter is clean and serviceable Fuel System C. Check the air intake and exhaust systems for the following defects:

Result: No defects found in the air intake or exhaust systems.

· Blockages · Restrictions · Damage to lines or hoses

3. Fuel System Inspection A. Check that the fuel shut-off valve is in the OPEN position. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). C. Check for fuel supply lines that are restricted. D. Check that the low-pressure fuel lines are correctly installed. E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test" F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test". G. Check for air in the fuel system. Refer to

Repair: Make any necessary repairs.

Proceed to Test Step 3.

Fuel supply

Result: A defect was found in the fuel system. Repair: Make any necessary repairs. Result: No defects found. Proceed to Test Step 4.

Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Prime".

Result: The throttle response is not as expected. 4. Throttle Position Sensor/Throttle Switches (if equipped) A. Turn the start switch to the ON position. B. Run the engine until the speed is equal to the maximum no-load speed.

Electrical connections

Repair: If the maximum no-load speed cannot be obtained refer to Troubleshooting, "Switch Circuits - Test (Throttle Switch)" and Troubleshooting, "Mode Selection - Test". If the engine speed is erratic refer to Troubleshooting, "Speed Control - Test".

C. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.

Result: All responses are normal. Proceed to Test Step 5.

Result: There are diagnostic codes associated with the highpressure fuel pump.

5. High-Pressure Fuel Pump Note: The fuel injection pump that is installed by the factory is a nonserviceable item. If any fault occurs within the fuel injection pump, the fuel injection pump must HP fuel be replaced. pump A. Use the electronic service tool to select the correct screen in order to display any diagnostic trouble codes that relate to the fuel injection pump.

Repair: Diagnose the codes. Refer to Troubleshooting, "Diagnostic Trouble Codes". If necessary, replace the highpressure fuel pump. Result: The high-pressure fuel pump is OK. Proceed to Test Step 6.

6. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting,

Cylinder compression

Result: The results of the compression test are outside the specifications. Repair: Investigate the cause

"Compression - Test ".

and rectify any faults. Note: Possible causes of low compression are shown in the following list: · Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 7.

Result: There are active diagnostic codes relating to the fuel injectors. 7. Electronic Unit Injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.

Diagnostic codes

Repair: Troubleshoot any active diagnostic codes associated with the fuel injectors. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: All injectors are OK. Proceed to Test Step 8.

8. Individual Malfunctioning Cylinders A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Cylinders

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance. Result: There is a noticeable change in the sound of the engine for each cylinder.

Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980574

Engine Monitoring System SMCS - 1900 The Electronic Control Module (ECM) provides a comprehensive engine monitoring system for this engine. The ECM monitors specific engine operating parameters in order to detect abnormal conditions that may develop. The ECM will generate a diagnostic code if a specific engine parameter exceeds an acceptable range that is defined by the engine monitoring system. The ECM will react with an action that is dependent on the severity of the condition. For information on diagnostic codes , refer to Troubleshooting, "Diagnostic Trouble Codes". The following actions may be initiated by the ECM. These actions are dependent on the severity of the condition. • Illumination of a warning lamp or warning alarm • Engine derate • Engine shutdown Use the electronic service tool to perform the following activities for the monitoring system: • Viewing parameters • Parameter programming • Set delay times The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, some of the parameters may be reprogrammed with the electronic service tool. Use the electronic service tool to modify the monitoring system parameters. Note: Some parameters cannot be changed. Some applications do not allow any changes to the programmable monitoring system.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06224985

Engine Overspeeds SMCS - 1915-035 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code

190-15

Description

Engine Speed : High least severe (1)

Notes The Electronic Control Module (ECM) detects that the engine speed has exceeded 3100 rpm for at least 5 seconds. If equipped, the warning lamp will flash.

The Electronic Control Module (ECM) limits the flow of fuel in order to prevent the engine speed from exceeding the maximum rpm. When the engine speed has dropped to less than the maximum rpm, the engine overspeed diagnostic code will be reset. The following operating conditions can cause the engine speed to exceed this value: • On a mobile machine, an incorrect transmission gear is selected. • Use of an incorrect fuel • Combustible gases in the air inlet for the engine If the engine speed exceeds the maximum rpm, the ECM illuminates the warning lamp and an engine overspeed diagnostic code is logged. No troubleshooting is required. The history of engine overspeeds can be viewed on the electronic service tool.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06224988

Engine Shutdown Occurs Intermittently SMCS - 1900-035 Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.

Probable Causes • Diagnostic codes • Air Intake • Electrical connectors • Fuel supply • Switches

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Diagnostic Codes Note: Certain diagnostic codes and/or event codes may cause an engine shutdown. A. Connect the electronic service tool and check for active codes and for

Values Codes

Results Result: There are active codes. Repair: Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: There are no active codes.

logged codes.

Proceed to Test Step 2.

2. Air Intake

Result: Blockages or restrictions found.

A. Check the air filter for blockages or restrictions.

Blockages or restrictions

B. Check the air intake duct for blockages or restrictions.

Repair: Make any repairs, as necessary. Result: The air intake system is OK. Proceed to Test Step 3.

Result: There are suspect connectors. 3. Electrical Connectors A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors.

Connectors

Repair: Repair connectors that are suspect or replace connectors that are suspect. Result: There are no suspect connectors. Proceed to Test Step 4.

4. Fuel System Inspection A. Check that the fuel shut-off valve is in the OPEN position. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).

Fuel System

Result: A defect was found in the fuel system. Repair: Make any necessary repairs. Result: No defects found. Proceed to Test Step 5.

Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Prime".

Result: The shutdown switches and wiring are not OK. 5. Switches A. Check the keyswitch input to the ECM. B. Check any engine shutdown switches and associated wiring.

Switches

Repair: Make the necessary repairs, Verify that the repair eliminated the fault. Result: The shutdown switches and wiring are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225009

Engine Stalls at Low RPM SMCS - 1000-035; 1900-035

Probable Causes • Diagnostic codes • Accessory equipment • Fuel system inspection • Low compression (cylinder pressure) • Electronic unit injectors

Values Diagnostic code

Results Result: A code is active or logged. Repair: Troubleshoot any codes before continuing with this procedure. Result: A code is not active or logged. Proceed to Test Step 2.

Result: An engine accessory is creating an excessive load. 2. Accessory Equipment A. Check all accessory equipment for faults that may create excessive load on the engine.

Accessories

Repair: Repair or replace the engine accessory. Result: An engine accessory is not creating an excessive load. Proceed to Test Step 3.

D. Check that the low-pressure fuel lines are correctly installed. E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test"

Fuel System

Repair: Make any necessary repairs. Result: No defects found.

F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Proceed to Test Step 4.

4. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

Result: Low compression is recorded on one or more cylinders. Repair: Possible causes of low compression are shown in the following list:

·Loose glow plugs ·Faulty piston ·Faulty piston rings ·Worn cylinder bores ·Worn valves ·Faulty cylinder head gasket ·Damaged cylinder head Make any repairs, as necessary. Result: No faults found. Proceed to Test Step 5.

Result: There are active diagnostic codes for the fuel injectors 5. Electronic Unit Injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the fuel injectors.

Diagnostic codes

Repair: Troubleshoot the active diagnostic codes. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: All injectors are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225011

Engine Top Speed Is Not Obtained SMCS - 1915-035 Note: If this fault occurs only under load, refer to Troubleshooting, "Acceleration Is Poor or Throttle Response Is Poor".

Probable Causes • Diagnostic codes • Engine accessories and transmission • ECM parameters • Throttle signal from the throttle position sensor • Air intake and exhaust system • Fuel system inspection • Fuel filters • Low compression (cylinder pressure) • Individual malfunctioning cylinders

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Diagnostic Codes

Values Diagnostic

Results Result: There are active or

codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.

logged codes. Repair: Troubleshoot any codes before continuing with this procedure. Result: There are no active or logged codes. Proceed to Test Step 2.

Result: The engine accessories and transmission are not OK.

2. Engine Accessories and Transmission A. Check that the engine accessories and transmission are operating correctly. B. Remove and inspect any engine accessories that may be adding unexpected load to the engine.

Engine accessories and transmission

Repair: Make the necessary repairs. Result: The engine accessories and transmission are OK. Proceed to Test Step 3.

Result: The parameters are not configured correctly. 3. ECM Parameters A. Use the electronic service tool to verify that the correct engine parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.

Repair: Correctly configure the parameters. Parameters

Verify that the configuration change eliminated the fault. Result: The parameters are configured correctly. Proceed to Test Step 4.

4. Throttle Signal From the Throttle Position Sensor (if equipped) A. If a fault is suspected in the throttle sensor, refer to Troubleshooting, "Speed Control Test".

Throttle Result: The throttle position position sensor sensor or the associated faults wiring is faulty. Repair: Repair or replace the throttle position sensor or the associated wiring. Result: The throttle position sensor and the associated

wiring are OK. Proceed to Test Step 5.

Result: The air filter is plugged. Repair: Clean or replace the air filter. Refer to the Operation and Maintenance Manual for further information.

5. Air Intake and Exhaust System A. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.

Restrictions

B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".

Result: There are restrictions in the air inlet or exhaust system. Repair: Make the necessary repairs, Verify that the repair eliminated the fault. Result: There are no restrictions in the air inlet or exhaust system. Proceed to Test Step 6.

6. Fuel System Inspection A. Check that the fuel shut-off valve is in the OPEN position. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). C. Check for fuel supply lines that are restricted. D. Check that the low-pressure fuel lines are correctly installed. E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test" F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Fuel System

Result: A defect was found in the fuel system. Repair: Make any necessary repairs. Result: No defects found. Proceed to Test Step 7.

7. Fuel Filters A. Replace the primary fuel filter and the secondary fuel filter. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element Replace".

Result: The engine reaches top speed. Return the engine to service. Top speed Result: The engine does not reach top speed.

B. Run the engine at top speed.

Proceed to Test Step 8.

Result: Low compression is recorded on one or more cylinders.

8. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

Repair: Possible causes of low compression are shown in the following list: ·Loose glow plugs ·Faulty piston ·Faulty piston rings ·Worn cylinder bores ·Worn valves ·Faulty cylinder head gasket ·Damaged cylinder head Make any repairs, as necessary. Result: No faults found. Proceed to Test Step 9.

9. Individual Malfunctioning Cylinders A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the

Cylinders

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. Repair: Investigate the cause of the fault on any cylinder that is not operating.

sound of the engine.

Investigate the cause of the fault on any cylinder that is operating below normal performance. Result: There is a noticeable change in the sound of the engine for each cylinder. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225015

Engine Vibration Is Excessive SMCS - 1000-035; 1152-035; 3252-035 Refer to Systems Operation, Testing, and Adjusting for additional information on determining the cause of this condition.

Probable Causes • Engine supports • Driven equipment • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinder

Recommended Actions Note: Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps 1. Engine Supports

Values Engine supports

Results Result: The mounts and brackets are loose and/or broken.

A. Inspect the mounts and the brackets while you run the engine through the speed range. Look for mounts and brackets that are loose and/or broken.

Repair: Replace the mounts and brackets that are loose and/or broken.

B. Check the alignment of the following before operating the engine under load for

Result: The mounts and brackets are not loose and/or broken.

any length of time: Proceed to Test Step 2. · Mounts · Coupling

Result The driven equipment and the alignment are not OK.

2. Driven Equipment A. Inspect the mounting bolts for the driven equipment. Inspect the alignment and the balance of the driven equipment.

Driven equipment

Repair: Repair or replace the driven equipment. Result: The driven equipment and the alignment are OK.

B. Inspect the coupling.

Proceed to Test Step 3.

Result: Low compression is recorded on one or more cylinders.

3. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

4. Electronic Unit Injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.

Diagnostic codes

Result: There are active diagnostic codes for the fuel injectors Repair: Troubleshoot the active diagnostic codes. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: There are no active diagnostic codes for the fuel

injectors. Proceed to Test Step 5.

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. 5. Individual Malfunctioning Cylinders A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test". As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Cylinders

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06004613

Exhaust Has Excessive Black Smoke SMCS - 1088-035; 1250-035 If excessive black smoke is caused by a fault in the engine, and the engine is equipped with a wallflow Diesel Particulate Filter (DPF), the smoke will only be visible when the DPF has also failed. Perform the following procedure to diagnose the cause of the black smoke and then investigate the failure of the DPF. A faulty DPF will allow some smoke to be visible. In this situation, there may not be a fault in the engine. If excessive black smoke is caused by a fault in the engine, and the engine is equipped with a through-flow DPF, the DPF will allow some smoke to be visible. This condition does not mean that the DPF has failed. Note: If the DPF is replaced as part of this procedure, use the electronic service tool to perform the "DPF Replacement Reset". Note: If the DPF is replaced as part of this procedure, use the electronic service tool to perform the "DPF Replacement Reset".

Probable Causes • Diagnostic codes • Parameters in the Electronic Control Module (ECM) • Air intake system or exhaust system • Valve lash • Turbocharger • Low compression (cylinder pressure) • Electronic unit injectors

• Individual malfunctioning cylinder

Recommended Actions Note: Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps

Values

Results Result: A diagnostic code is present.

1. Diagnostic Codes Note: Certain diagnostic codes and/or event Engine Derate codes may cause poor performance. Refer to or Diagnostic in the electronic service tool. Codes

Troubleshoot the code. Refer to Troubleshooting, "Diagnostic Trouble Codes"

A. Use the electronic service tool to check for active or logged codes.

Result: A diagnostic code is not present. Proceed to Test Step 2.

Parameters

Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information. Result: The parameters are correct. Proceed to Test Step 3.

3. Air Intake and Exhaust System A. Check the air filter restriction indicator, if equipped. Replace a plugged air filters. Refer to the Operation and Maintenance Manual. B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System - Inspect"

Restrictions

Result: There are restrictions in the air inlet or exhaust system. Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information. Result: There are no restrictions in the air inlet or exhaust system.

Proceed to Test Step 4.

Result: The valve lash is not set correctly. 4. Valve Lash A. Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect/Adjust".

Valve lash

Set the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect/Adjust" for the correct procedure. Result: The valve lash is correct. Proceed to Test Step 5.

5. Turbocharger Note: The turbocharger that is installed on the engine is a non-serviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced. A. Ensure that the mounting bolts for the turbocharger are tight. Result: There is a fault on the turbocharger.

B. Check that the oil drain for the turbocharger is not blocked or restricted. C. Check that the compressor housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged. D. Check that the turbine housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged. E. Check that the turbine blades rotate freely in the turbocharger. F. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".

Turbocharger

Repair the turbocharger or replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install". Result: The turbocharger is OK. Proceed to Test Step 6.

6. Low Compression (Cylinder Pressure)

Low compression

A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Result: Low compression is recorded on one or more cylinders. Possible causes of low compression are shown in the following list: ·Loose glow plugs ·Faulty piston ·Faulty piston rings ·Worn cylinder bores ·Worn valves ·Faulty cylinder head gasket ·Damaged cylinder head Make any repairs, as necessary. Result: No faults found. Proceed to Test Step 7.

Result: There are active diagnostic codes for the fuel injectors 7. Electronic Unit Injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.

Diagnostic codes

Troubleshoot the active diagnostic codes. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: There are no active diagnostic codes for the fuel injectors. Proceed to Test Step 8.

Cylinders

Result: There is not a noticeable change in the sound of the engine for at least one cylinder. Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance.

Result: There is a noticeable change in the sound of the engine for each cylinder. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06006429

Exhaust Has Excessive White Smoke SMCS - 1088-035; 1250-035 Note: Some white smoke may be present during cold start-up conditions and during acceleration after a prolonged period at low idle. If the white smoke persists, there may be a fault.

Probable Causes • Diagnostic codes • ECM Flash file • Starting aids • Coolant temperature • Cooling system • Fuel quality • Valve lash • Low compression (cylinder pressure) • Individual malfunctioning cylinder

Recommended Actions Diagnostic Codes Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps

Values

Results

1. Diagnostic Codes

Diagnostic codes

Result: There are active diagnostic codes.

A. Establish communication between the electronic service tool and the Electronic Control Module (ECM) . Refer to Troubleshooting, "Electronic Service Tools", if necessary.

Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".

B. Use the electronic service tool to check for active diagnostic

Result: There are no active diagnostic codes. Proceed to Test Step 2.

Result: The latest flash file is not installed.

2. ECM Flash File A. Verify that the latest flash file is installed in the ECM.

Flash file

Install the latest flash file. Refer to Troubleshooting, "ECM Software Install" for the correct procedure. Verify that the repair eliminates the fault. Result: The latest flash file is installed. Proceed to Test Step 3.

Result: The glow plugs are not operating correctly. 3. Glow Plugs A. Check the operation of the glow plug Glow plugs circuit. Refer to Troubleshooting, "Glow Plug Starting Aid - Test".

Make the necessary repairs. Verify that the repair corrected the fault. Result: The glow plugs are operating correctly. Proceed to Test Step 4.

4. Coolant Temperature A. Check that the water temperature regulator is operating correctly. Refer to Systems Operation, Testing, and Adjusting, "Water Temperature Regulator - Test".

Coolant temperature

Result: The water temperature regulator is not operating correctly. Replace the water temperature regulator. Verify that the repair corrected the fault. Result: The water temperature regulator is operating correctly.

Proceed to Test Step 5.

Result: There is an internal coolant leak. 5. Cooling System A. Check for an internal coolant leak Internal into the cylinder and/or the exhaust. coolant leak Refer to Systems Operation/Testing and Adjusting, "Cooling System".

Make the necessary repairs. Verify that the repair eliminated the fault. Result: There is not an internal coolant leak. Proceed to Test Step 6.

Result: The fuel quality is not OK. Drain the fuel system and replace the fuel filters. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" and Operation and Maintenance Manual, "Fuel System Filter - Replace".

6. Fuel Quality A. Check the fuel quality. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Fuel

B. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine.

7. Valve Lash Note: Excessive valve lash will cause a change in the timing of the opening and closing of the inlet and exhaust valves. Excessive valve lash can cause a reduction of the flow of combustion air into the engine. Reduced flow of

Valve lash

Result: The valve lash is excessive. The hydraulic lifter will compensate for all normal wear of the components of the valve train. Repair or replace any excessively worn or damaged components of the valve train.

combustion air will increase the fuel consumption rate.

Result: The valve lash is correct.

A. Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash Inspect/Adjust".

Proceed to Test Step 8.

Result: Low compression is recorded on one or more cylinders.

8. Low Compression (Cylinder Pressure) A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

Low compression

Possible causes of low compression are shown in the following list: ·Loose glow plugs ·Faulty piston ·Faulty piston rings ·Worn cylinder bores ·Worn valves ·Faulty cylinder head gasket ·Damaged cylinder head Make any repairs, as necessary. Attempt to start the engine. If the engine will not start, contact the Dealer Solution Network (DSN). Result: No faults found. Proceed to Test Step 9.

Result: There is not a noticeable change in the sound of the engine for at least one cylinder.

Cylinders

Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance. Result: There is a noticeable change in the sound of the engine for each cylinder. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225022

Exhaust System Contains Coolant SMCS - 1050-035; 1395-035 Use the following procedure to troubleshoot a problem with coolant in the exhaust system.

Probable Causes • Exhaust Gas Recirculation (EGR) cooler leak • Cylinder head gasket leak • Cylinder head leak

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. EGR cooler A. Check the EGR cooler for leaks for utilizing the "On Engine Test Procedure". Refer to Systems Operation, Testing and Adjusting, "Exhaust Cooler (NRS) - Test".

Values

Results

EGR Cooler

Result : The EGR cooler has a leak. Repair: Replace the EGR cooler. Refer to the Disassembly and Assembly manual for the correct procedure. Proceed to Step 5. Result : The EGR cooler does not have a leak.

Proceed to Test Step 2.

Result : The cylinder head gasket is leaking. 2. Cylinder head gasket leak A. Check the cylinder head gasket for leaks. Refer to the Systems Operation/Testing and Adjusting for the proper procedure for checking the cylinder head.

Cylinder Head Gasket

Repair: Replace the cylinder head gasket. Refer to the Disassembly and Assembly manual. Result : The cylinder head gasket is not leaking. Proceed to Test Step 3.

Result : A crack is found in the cylinder head. 3. Cylinder head A. Check for cracks in the cylinder head. Perform a leak test on the cylinder head. Refer to the Systems Operation/Testing and Adjusting for the proper procedure for checking the cylinder head.

Cylinder Head

Repair: Repair the cylinder head and/or replace the cylinder head. Refer to the Disassembly and Assembly manual. Result :There are no cracks in the cylinder head. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225084

Exhaust System Contains Oil SMCS - 1050-035; 1348-035

Probable Causes • Extended idle times • Failed turbocharger seals • Worn valve guide seals or faulty valve guide seals • Worn valve guides • Worn piston rings Complete the procedure in the order in which the steps are listed. Table 1 Troubleshooting Test Steps

Values

Results Result The idle times are extensive.

1. Extended Idle Times A. Extended idle times will allow oil to pass into the exhaust system.

Idle times

Repair: Reduce the idle times. Result The idle times are not extensive. Proceed to Test Step 2.

2. Failed Turbocharger Seals

Turbo

Result: Oil is present in the inlet or exhaust manifold.

A. Check the inlet manifold and the exhaust manifold for oil.

seals Repair: Replace the turbocharger. Verify the repair. Result: Oil is not present in the inlet or exhaust manifold. Proceed to Test Step 3.

Result: The valve guide seals are damaged. 3. Worn Valve Guide Seals or Faulty Valve Guide Seals A. Inspect the valve guide seals for wear and for damage.

Valve guide seals

Repair: Replace the valve guide seals. Verify the repair. Result: The valve guide seals are not damaged. Proceed to Test Step 4.

Result: The valve guides are worn. 4. Worn Valve Guides A. Inspect the valve guides for wear. Refer to the Specification manual for the maximum permissible wear of the valve guides.

Valve guides

If necessary, recondition the cylinder head. Verify the repair. Result: The valve guides are not worn. Proceed to Test Step 5.

5. Worn Piston Rings A. Remove the pistons. Refer to Disassembly and Assembly, "Pistons and Connecting Rods Remove". B. Remove the piston rings from the pistons. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Disassemble" C. Inspect the pistons and piston rings for wear or damage. Refer to the "Specifications" manual for

Piston rings

Result The piston rings are worn. Repair: Replace the piston rings. Verify the repair. Result The piston rings are not worn. Contact the Dealer Solution Network (DSN).

further information.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225091

Fuel Consumption Is Excessive SMCS - 1250-035

Probable Causes • Diagnostic codes • Misreading of fuel level • Fuel leakage • Fuel quality • Quality of oil • Engine accessories and transmission • Coolant temperature • Prolonged operation at idle speed • Engine operating speed • Air intake and exhaust system • Cooling fan • Reduced pressure of intake air • Valve lash

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1

Troubleshooting Test Steps

Values

Results Result: A diagnostic code is present.

1. Diagnostic Codes Note: Certain diagnostic codes and/or event codes indicate the cause of high fuel consumption.

Diagnostic codes

A. Use the electronic service tool to check for active or logged codes.

Result: A diagnostic code is not present. Proceed to Test Step 2.

Result: Fuel consumption is normal for the operating conditions.

2. Misreading of Fuel Level Note: Misreading of the fuel gauge can give a false indication of fuel consumption.

Repair: Troubleshoot the diagnostic code and then verify that the fuel consumption is normal. Refer to Troubleshooting, "Diagnostic Trouble Codes".

Fuel level

Return the unit to service. Result: Fuel consumption is high for the operating conditions.

A. Monitor the fuel consumption over a period of 50 engine hours.

Proceed to Test Step 3.

Result: Evidence of a fuel leak is found. 3. Fuel Leakage A. Check the engine for signs of fuel leakage.

Fuel leaks

Repair: Repair or replace the component that is leaking fuel. Result: No evidence of a fuel leak is found. Proceed to Test Step 4.

4. Fuel Quality Note: The grade of the fuel affects the rate of fuel consumption. Refer to the engines Operation and Maintenance Manual for additional information. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for

Fuel quality

Result: The fuel quality does not meet specifications. Repair: Drain the fuel system and replace the fuel filters. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element Replace" and Operation and Maintenance Manual, "Fuel

information on improving the characteristics of the fuel during coldweather operation.

System Filter - Replace". Fill the fuel system with fuel that meets the standard in the Operation and Maintenance Manual, "Fluid Recommendations".

A. Check the fuel quality. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime".

B. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine.

Result: The fuel quality meets specifications. Proceed to Test Step 5.

5. Quality of Oil Note: The nominal viscosity of the lubricating oil that is used in the engine will affect the rate of fuel consumption. The viscosity of lubricating oil is defined by the SAE grade of the lubricating oil. The grade of the lubricating oil must be Engine oil correct for the ambient conditions. quality Lubricating oil for high ambient temperatures will affect fuel consumption in cold ambient temperatures. A. Check that the engine oil meets the required specification. Refer to "Engine Oil" in the Operation and Maintenance Manual, "Refill Capacities".

B. Remove and inspect any engine accessories that may be adding unexpected load to the engine.

7. Coolant Temperature Note: The operating temperature of the

Repair: Refill the oil system with oil of an acceptable quality. Refer to the applicable sections in the Operation and Maintenance Manual. Result: The engine oil meets the required specification. Proceed to Test Step 6.

Result: The engine accessories and transmission are not OK.

6. Engine Accessories and Transmission A. Check that the engine accessories and transmission are operating correctly.

Result: The engine oil does not meet the required specification.

Engine accessories and transmission

Repair: Make the necessary repairs. Result: The engine accessories and transmission are OK. Proceed to Test Step 7.

Coolant temperature

Result: The water temperature regulator is not operating correctly.

engine will affect the rate of fuel consumption. Operation of the engine below the correct temperature will increase fuel consumption. Failure of the water temperature regulator can prevent the engine from operating at the correct temperature.

Repair: Replace the water temperature regulator. Verify that the repair corrected the fault. Result: The water temperature regulator is operating correctly. Proceed to Test Step 8.

A. Check that the water temperature regulator is operating correctly. Refer to Systems Operation, Testing, and Adjusting, "Water Temperature Regulator - Test".

Result: The engine is operating at idle speed for extended periods.

8. Prolonged Operation at Idle Speed Note: Prolonged operation of the engine at idle speed increases fuel consumption. A. Check for extended periods of engine operation at idle speed.

Repair: When possible, stop the Extended idle engine to conserve fuel. operation Result: The engine is not operating at idle speed for extended periods. Proceed to Test Step 9.

9. Engine Operating Speed The operating speed of the engine will affect the rate of fuel consumption. High engine speed will increase fuel consumption. At high engine speeds, internal power losses in the engine increase and more power is required to drive the alternator and the fan. These losses of power increase fuel consumption. Lugging down the engine to a low engine speed will increase fuel consumption. At low engine speeds, the combustion efficiency of the engine is reduced and more fuel is required. A. Check that the engine has been operated at a suitable engine speed.

10. Air Intake and Exhaust System A. Check the air filter restriction indicator, if equipped.

Result: The engine has been operated at an unsuitable speed. Engine speed

Operate the engine at a suitable speed. Result: The engine has been operated at a suitable speed. Proceed to Test Step 10.

Air and Exhaust System

Result: The air filter is restricted. Repair: Replace the air filter.

restrictions B. Check the air intake and exhaust systems for the following defects:

Repair: Repair any defects in the air inlet and exhaust systems.

· Blockages · Restrictions · Damage to lines or hoses Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".

Result: The air intake and exhaust system is OK. Proceed to Test Step 11.

Result: The cooling fan is operating excessively.

11. Cooling Fan Excessive operation of the cooling fan will increase fuel consumption.

Result: There are system restrictions.

Cooling fan

Repair: Repair or replace the faulty cooling fan components. Result: The cooling fan is not operating excessively.

A. Check the operation of the cooling fan.

Proceed to Test Step 12.

12. Reduced Pressure of Intake Air Result: There is a leak in the intake air system.

Note: If the air pressure is lower than normal, the same power can only be achieved by the following:

Repair: Repair the leak or replace the component that is causing the leak.

· Higher engine speed · Injection of more fuel Either of these conditions will increase the fuel consumption.

Intake air

A. Check all pipes from the outlets of the turbocharger compressor to the inlet manifold for leaks.

Repair: Replace the turbocharger. Result: The air intake system and the wastegate are OK.

B. Check for the correct operation of the wastegate in the turbocharger. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect".

13. Valve Lash Note: Excessive valve lash will cause a change in the timing of the opening and closing of the inlet and exhaust valves.

Result: The turbocharger wastegate is not operating correctly.

Proceed to Test Step 13.

Valve lash

Result: The valve lash is excessive. The hydraulic lifter will compensate for all normal wear of

Excessive valve lash can cause a reduction of the flow of combustion air into the engine. Reduced flow of combustion air will increase the fuel consumption rate.

the components of the valve train. Repair: Repair or replace any excessively worn or damaged components of the valve train. Result: The valve lash is correct.

A. Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash Inspect".

Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225799

Fuel Contains Water SMCS - 1250-035 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for Fuel Contains Water J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the presence of water in the fuel for at least 60 seconds.

97-15

Water In Fuel Indicator : High - least severe (1)

If equipped, the warning lamp will come on. The fault will be cleared when no fuel is detected for at least 0.6 seconds.

Note: Visual identification of water in the bowl may be impossible. Water may turn dark yellow in color in the fuel system. The similarity in color would prevent the ability to differentiate the water from the fuel.

Recommended Actions Note: Complete the procedure in the order in which the steps are listed. Table 2 Troubleshooting Test Steps

Values

1. Drain the Fuel/Water Separator Bowl

Fuel/water separator

A. Turn the ignition key to the OFF position.

Results Result: The "Water-In-Fuel" warning disappears within 1 minute.

Proceed to Test Step 2. B. Drain the fuel/water separator bowl. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter/Water Separator - Drain".

Result: The "Water-In-Fuel" warning remains on. Proceed to Test Step 3.

C. If necessary, prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime". D. Turn the ignition key to the ON position. Do not start the engine. Wait for 1 minute.

Result: The "Water-In-Fuel" warning does not reappear within the 5 minutes. Return the unit to service. 2. Confirm That There is No Water in the Fuel

Water in fuel

A. Run the engine for 5 minutes.

Result: The "Water-In-Fuel" warning reappears within the 5 minutes. Repair: The fuel supply is contaminated with water. Drain the fuel tank and then fill the fuel tank with clean fuel. Repeat the procedure from Test Step 1.

Result: The Water-In-Fuel switch required a repair. Repeat the procedure from Test Step 1. 3. Water-In-Fuel Switch A. Check the operation of the Water-InFuel switch. Refer to Troubleshooting, "Water In Fuel - Test".

Water in fuel switch

Result The Water-In-Fuel switch is OK. Repair: The fuel supply is contaminated with water. Drain the fuel tank and then fill the fuel tank with clean fuel. Repeat the procedure from Test Step 1.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06704045

Fuel Rail Pressure Problem SMCS - 1252-035; 127A-035 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for the Fuel Rail Pressure J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

157-0

Engine Injector Metering Rail #1 Pressure : High most severe (3)

The fuel rail pressure is greater than 179000 kPa (25962 psi) while the engine has been derated. If equipped, the warning lamp will flash and the shutdown lamp will come on. The engine will be shut down.

157-2

Engine Injector Metering Rail #1 Pressure : Erratic, Intermittent, or Incorrect

The ECM detects one of the following conditions: The amount of fuel delivered by the high-pressure fuel pump is greater than 480 mL/min (16.3 oz/min) for at least 2 seconds while the engine is at low idle. If equipped, the warning lamp will flash. The engine will be derated.

15716

Engine Injector Metering Rail #1 Pressure : High moderate severity (2)

The ECM detects one of the following conditions: The fuel rail pressure is greater than 170000 kPa (24657 psi) for at least 1 second. OR The measured fuel rail pressure is greater than the desired fuel rail pressure for at least 2 seconds.

OR The fuel pressure remains too high after the keyswitch has been turned to the OFF position. If equipped, the warning lamp will flash. The engine will be derated.

15717

The ECM detects that the pressure in the fuel rail is low for at least 0.5 seconds. The point at which this diagnostic code becomes active is a calculated Engine Injector Metering parameter based on engine speed and engine Rail #1 Pressure : Low - least temperature. severe (1) If equipped, the warning lamp will come on. The engine will shut down.

15718

12390

55712

Engine Injector Metering Rail #1 Pressure : Low moderate severity (2)

Engine Fuel Leakage 1 : High - most severe (3)

High Pressure Common Rail Fuel Pressure Relief Valve : Erratic, Intermittent, or Incorrect

The ECM detects that the measured fuel rail pressure is lower than the desired fuel rail pressure for the current engine speed for at least 2 seconds. If equipped, the warning lamp will flash. Active regeneration will be disabled. The engine will be derated. The engine may shut down. The ECM detects that the pressure in the fuel rail is too low compared to the volume of fuel that is being supplied by the fuel injection pump. If equipped, the warning lamp will flash and the shutdown lamp will come on. The engine will be derated. The ECM detects that the fuel rail pressure is out of the expected range after the fuel Pressure Relief Valve (PRV) has been opened. This can either be high pressure (relief valve not fully open) or low pressure (fuel leak). If equipped, the warning lamp will flash. The engine will be derated. The PRV has been activated.

55717

High Pressure Common Rail Fuel Pressure Relief Valve : Not Responding Properly

The PRV activation is caused by another active diagnostic code. Troubleshoot any other active diagnostic codes. This diagnostic code will clear when the other fault has been rectified. If equipped, the warning lamp will flash. The engine will shut down.

557110

High Pressure Common Rail Fuel Pressure Relief Valve : Abnormal Rate of Change

The ECM detects that the volume of fuel being delivered is too low to open the PRV during a PRV test.

If equipped, the warning lamp will flash. Troubleshoot any other diagnostic codes before attempting to test the PRV again.

557114

High Pressure Common Rail Fuel Pressure Relief Valve : Special Instruction

The ECM detects one of the following conditions: The PRV has been open for a total of at least 300 minutes. OR The PRV has been activated at least 50 times. Perform this procedure to identify the cause of the PRV activation before replacing the PRV. If equipped, the warning lamp will flash. The engine will be derated. The ECM detects that the PRV is open.

557116

High Pressure Common Rail Fuel Pressure Relief Valve : High - moderate severity (2)

If equipped, the warning lamp will flash. The engine will be derated. This code will be reset when the PRV is closed and the keyswitch has been cycled.

Use this procedure to troubleshoot abnormal fuel rail pressure.

Probable Causes • Diagnostic trouble codes • Electrical connectors • Fuel filters • Fuel rail pressure sensor • Fuel system inspection • Fuel rail Pressure Relief Valve (PRV) • High-pressure fuel pump

Recommended Actions Table 2 Troubleshooting Test Steps 1. Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. Refer to

Values

Results

Diagnostic codes

Result: One of the diagnostic codes listed in Table 1 is active. Proceed to Test Step 2.

Troubleshooting, "Electronic Service Tools", if necessary.

Result: A diagnostic code that is not listed in Table 1 is active.

B. Use the electronic service tool to check for active diagnostic codes.

Repair: Troubleshoot the code. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no active diagnostic codes. Return the engine to service.

Result: There are suspect connectors. 2. Electrical Connectors A. Check for the correct installation of the Connectors ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the connector on the fuel rail pressure sensor.

Repair: Repair or replace connectors that are suspect. Result: There are no suspect connectors. Proceed to Test Step 3.

Result: The filters have been replaced and the fault is eliminated.

3. Fuel Filters A. Replace the primary fuel filter and the secondary fuel filters. Refer to the Operation and Maintenance Manual for further information.

Return the unit to service. Fuel filters Result: The filters have been replaced and the fault is still present. Proceed to Test Step 4.

4. Fuel Rail Pressure Sensor A. Make sure that the engine has been shut down for at least 10 minutes. Use the electronic service tool to check the status of the "Fuel Rail Pressure"

Pressure sensor

Result: The "Fuel Rail Pressure (absolute)" is more than 5,000 kPa (725 psi). Repair: Replace the fuel rail pressure sensor. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". Confirm that the fault has been eliminated. Result: The "Fuel Rail Pressure

(absolute)" is less than 5,000 kPa (725 psi). Proceed to Test Step 5.

Result: A defect was found in the fuel system. Fuel System

Repair: Make any necessary repairs. Result: No defects found.

F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

Proceed to Test Step 6.

G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Prime". CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

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Illustration 1

g02859420

Table 3 Troubleshooting Test Steps

Values

6. Fuel Rail Pressure Relief Valve (PRV)

Fuel in container

Results Result: Fuel is present in the container.

A. Turn the keyswitch to the OFF position. B. Disconnect plastic tube assembly (4) from fuel manifold (1). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". C. Securely seal the end of plastic tube assembly (4). Note: Plastic tube assembly (4) must be sealed to prevent air ingress into the fuel system. D. Attach a length of hose to fuel manifold (1) and secure with a clip at position (3). E. Place the other end of the hose into a container that is suitable for fuel. Ensure

Repair: Install a replacement fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) Remove and Install". When the fuel manifold has been replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset". Result: No fuel is present in the container. Proceed to Test Step 7.

that the hose is secure and will not come out of the container while the engine is running. F. Turn the keyswitch to the ON position. G. If the engine will start, use the electronic service tool to perform the "High Rail Pressure Test". This service test will run the engine with an elevated fuel rail pressure for a limited time. At this pressure, a PRV that is functioning correctly will remain closed. If the engine will not start, crank the engine for a maximum of 30 seconds. H. After the engine has stopped, check the container for fuel. Result: There are no active diagnostic codes. 7. High-Pressure Fuel Pump A. If all previous Test Steps have not identified a fault, and a fuel rail pressure diagnostic code is still active, replace the high-pressure fuel pump. Refer to Disassembly and Assembly, "Fuel Diagnostic Injection Pump - Remove" and refer to codes Disassembly and Assembly, "Fuel Injection Pump - Remove". B. Run the engine and use the electronic service tool to check for active diagnostic codes.

Return the engine to service. Result: A diagnostic code that is not listed in Table 1 is active. Repair: Troubleshoot the code. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: One of the diagnostic codes listed in Table 1 is still active. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225850

Fuel Temperature Is High SMCS - 1250-035-TA

Probable causes • Fuel level in tank • Location of the fuel tank

Recommended Actions Fuel Level in Tank If the level in the fuel tank is low, the hot fuel from the high-pressure fuel system can raise the temperature in the fuel tank. Replenish the fuel tank at the earliest opportunity.

Location of the Fuel Tank Make sure that the fuel tank is not close to a heat source. If necessary, shield the fuel tank from the heat source.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

Date Updated -02/11/2017

i06704782

General Information SMCS - 1000

Important Safety Information Do not perform any procedures in this Troubleshooting Guide until you have read the Operation and Maintenance Manual and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed. Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this publication and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Overview These engines are equipped with an electronic control system. The system consists of a computer, sensors, and software. The system performs these functions: • Control of the engine • Control of particulate emissions via the Clean Emission Module (CEM) • Applications control system interface

• Fault detection and reporting

Electronic Control System The Electronic Control Module (ECM) is a computer that controls the operation of the engine. The ECM contains a flash file. The flash file is the software for the ECM. The flash file contains the operating maps. The operating maps define the following characteristics of the engine: • Horsepower • Torque curves • Engine speed (rpm) Refer to Troubleshooting, "System Overview" for additional information on the electronic control system.

Application Interface The ECM interfaces with the machine via software and an electrical connector on the ECM. The software can be configured. The application control system provides inputs to the electrical connector on the ECM to indicate the status of switches. Correctly configure the ECM to interpret the inputs. The ECM provides outputs for the application control system via the electrical connector to control lamps, solenoids, and other devices. Correctly configure the ECM in order for the outputs to match the configuration of the application control system.

Clean Emissions Module (CEM) The CEM contains these components: Diesel Particulate Filter (DPF) - A DPF is installed in the exhaust system. The DPF collects soot and ash from the engine exhaust. Software - Software in the ECM monitors the DPF.

Fault Detection and Reporting The ECM monitors inputs from the sensors and inputs from the applications control system. Software in the ECM interprets the inputs. The software determines if the inputs are operating correctly. A diagnostic trouble code is activated when the software detects a problem with an input. The ECM broadcasts the codes on the J1939 CAN data link. If a problem is suspected with the data link, refer to Troubleshooting, "Data Link - Test".

The codes can be displayed on the electronic service tool and optional operator interfaces. Refer to Troubleshooting, "Diagnostic Trouble Codes" for additional information on diagnostic trouble codes and a complete list of codes.

Troubleshooting As a reference, simplified schematics for each of the engine subsystems are included with each of the circuit tests that are in this manual. For an accurate representation of the entire electrical schematic that is for your application, refer to the Electrical System Schematic. During troubleshooting, inspect all harness connections before any component is replaced. If these connections are not clean and tight, continuous electrical problems or intermittent electrical problems can result. Check that the wires are pushed into the connectors completely. Make sure that the connections are tight before other tests are made. Failure of an electrical component may cause the failure of other components. Always attempt to correct the cause of an electrical failure before you replace a component. If wire insulation is punctured, repair the damage. Seal the damaged wires with 8T-0065 Silicone Sealant. Cover the sealant with two layers of 1P-0810 Electrical Tape.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06704120

Glow Plug Starting Aid - Test SMCS - 1412-038 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for the Glow Plug Start Aid Circuit J1939 Code

676-5

676-6

676-19

5324-7

Description

Notes

Engine Glow Plug Relay : Current Below Normal

The Electronic Control Module (ECM) detects a low current condition in the control circuit for the Glow plug Control Unit (GCU) for at least 0.7 seconds. The warning lamp will come on.

Engine Glow Plug Relay : Current Above Normal

The ECM detects a high current condition in the control circuit for the GCU for at least 0.2 seconds. The ECM will attempt to activate the glow plug control unit for a further five attempts after the diagnostic code becomes active. The warning lamp will come on.

Engine Glow Plug Relay : Data Error

The ECM detects one of the following conditions: The diagnostic signal from the GCU indicates that there is an error in the GCU. OR The diagnostic signal from the GCU is invalid. The warning lamp will come on.

Engine Glow Plug 1 : Not Responding Properly

The ECM detects the following conditions: The diagnostic signal from the GCU indicates that there is a short

in the circuit for the glow plug for cylinder number 1. The ECM detects the following conditions: 5325-7

Engine Glow Plug 2 : Not Responding Properly

The diagnostic signal from the GCU indicates that there is a short in the circuit for the glow plug for cylinder number 2. The ECM detects the following conditions:

5326-7

Engine Glow Plug 3 : Not Responding Properly

The diagnostic signal from the GCU indicates that there is a short in the circuit for the glow plug for cylinder number 3. The ECM detects the following conditions:

5327-7

Engine Glow Plug 4 : Not Responding Properly

The diagnostic signal from the GCU indicates that there is a short in the circuit for the glow plug for cylinder number 4.

The following background information is related to this procedure: The starting aid is used to improve the engine starting when the engine is cold. With the keyswitch in the ON position, the Electronic Control Module (ECM) will monitor the coolant temperature and the engine air inlet temperature to decide if the glow plugs need to be switched ON. If the glow plugs are required, then the ECM will activate the glow plug control unit for a controlled period. While the glow plug control unit is activated, the glow plug control unit will supply power to the glow plugs. Glow plugs are used for temperatures that are below 5° C (41° F). The GCU transmits a diagnostic signal back to the engine ECM. If the GCU detects a fault for one of the glow plugs, a diagnostic code will become active for that glow plug.

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Illustration 1

g03770598

Schematic diagram for the glow plug starting aid circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 2

g02671559

View of the pin locations on the P1 connector for the Glow Plug Control unit (GCU) (22) GCU diagnostic return (52) GCU control signal (41) GCU ground

Illustration 3

g02674096

View of the pin locations on the GCU (1) Glow plug cylinder 3 (2) Glow plug cylinder 1 (3) GCU diagnostic return (4) Battery + (5) GCU ground (6) Glow plug cylinder 4 (7) Glow plug cylinder 2 (8) Glow plug control

Glow Plug Starting Aid Override Activate this override using the electronic service tool. This override is used to check that the glow plugs are functioning correctly. The override will remain active until switched off using the electronic service tool. Navigate to the following menu options in the electronic service tool to access the "Glow Plug Starting Aid Override": • Diagnostics • Diagnostic Tests

• Override Parameters Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring A. Check the fuses. B. Inspect the terminals on the GCU. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.

Result: A damaged wire or damaged connector was found. A fuse is blown.

C. Inspect the connectors between the GCU and the glow plugs. D. Inspect the terminals on the P1/J1 ECM connector and all other connectors associated with the glow plug circuit.

Damaged wire or connector

E. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector that are associated with glow plug circuit.

Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 2.

F. Check the harness for abrasion and for pinch points from the glow plugs to the GCU, and from the GCU to the ECM.

2. Check for Active Diagnostic Codes Diagnostic or Logged Diagnostic Codes codes

Result: A 5324-7, 5325-7, 5326-7, or 5327-7 diagnostic code is active or recently logged.

A. Connect the electronic service tool to the diagnostic connector.

Proceed to Test Step 3.

B. Turn the keyswitch to the ON position. Do not start the engine.

Result: A 676 diagnostic code is active or recently logged Proceed to Test Step 6.

C. Use the electronic service tool to override the glow plug start aid. D. Check for active diagnostic codes or recently logged diagnostic codes.

Result: An active diagnostic code or a recently logged diagnostic code was not displayed. Repair: To identify intermittent faults, refer to

Troubleshooting, "Electrical Connector Inspect".

E. Use the electronic service tool to turn off the glow plug start aid. F. Turn the keyswitch to the OFF position.

Result: The measurement indicates an open circuit between the glow plug and the ground point. 3. Check the Glow Plug for the Suspect Cylinder

The glow plug is faulty.

A. Turn the keyswitch to the OFF position.

Repair: Replace the suspect glow plug. Refer to Disassembly and Assembly, "Glow Plugs Remove and Install".

B. Disconnect the connectors for the glow plugs in any suspect cylinders. Refer to Table 1 to identify which cylinders are suspect.

Resistance

C. Use a multimeter to measure the resistance between the suspect glow plug connector and a suitable engine ground.

Use the electronic service tool to override the glow plug start aid and verify that the repair eliminates the fault. Clear all logged diagnostic codes. Result: The measurement indicates that there is a resistance between the glow plug and the ground point. The glow plug is OK. Proceed to Test Step 4.

4. Check the Glow Plug Wiring for an Open Circuit

Less than 5 Ohms

Result: At least one of the resistance measurements is greater than 5 Ohms.

A. Turn the keyswitch to the OFF position.

The fault is in the wiring between the suspect glow plug and the GCU.

B. Disconnect the connectors for any suspect glow plugs. Disconnect the connector for the GCU.

Repair: Check all wiring between the suspect glow plug and the GCU. Refer to the Electrical Schematic for the application. Make any necessary repairs.

C. Use a multimeter to measure the resistance between the harness connector for the suspect glow plug and the appropriate terminal on the GCU connector.

Result: All resistance measurements are less than 5 Ohms. Reconnect all connectors. Proceed to Test Step 5.

Result: The measured resistance is less than 1 k Ohm. 5. Check the Glow Plug Wiring for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect glow plug.

Greater than 1 k Ohm

C. Use a multimeter to measure the resistance between the harness connector for the suspect glow plug and engine ground.

There is a short to ground in the wiring for the suspect glow plug. Repair: Check the wiring between the suspect glow plug and the GCU. Refer to the Electrical Schematic for the application. Make any necessary repairs. Result: The measured resistance is greater than 1 k Ohm. The wiring is OK. Repair: Install a replacement GCU. Use the electronic service tool to override the glow plug start aid and verify that the repair eliminates the fault.

Result: The measured voltage is not within the expected range. 6. Check that the GCU is Receiving the Correct Voltage A. Turn the keyswitch to the OFF position. B. Disconnect the GCU. 10 V to 14 V C. Turn the keyswitch to the ONposition. D. Measure the voltage between pin 4 on the harness connector for the GCU and a suitable ground.

Repair: Check the fuse for the GCU. If the fuse is blown, replace the fuse. If the fuse is replaced and the fault reoccurs, there is a short in the wiring between the battery supply and pin 4 on the GCU. If the fuse is not blown, there is an open circuit in the wiring between the battery supply and pin 4 on the GCU. Repair the faulty wiring or replace the faulty wiring. Reconnect the GCU. Use the electronic service tool to override the glow plug start aid and verify that the repair eliminates the fault. Clear all logged diagnostic codes. Result: The measured voltage is within the expected range. Proceed to Test Step 7.

7. Check That the GCU is Grounded Correctly

10 V to 14 V

Result: The measured voltage is not within the expected range.

A. Turn the keyswitch to the OFF position.

The fault is in the wiring between pin 5 on the harness connector for the GCU and P1:41. Repair: Inspect the 9-pin engine interface connector. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to override the glow plug start aid and verify that the repair eliminates the fault. Clear all logged diagnostic codes.

B. Disconnect the GCU. C. Turn the keyswitch to the ON position. D. Measure the voltage between pin 4 and pin 5 on the harness connector for the GCU.

Result: The measured voltage is within the expected range. Proceed to Test Step 8.

8. Check the Type of Active Diagnostic Code Result: A 676-5 diagnostic code is active

A. Turn the keyswitch to the ON position. B. Use the electronic service tool to override the glow plug starting aid.

Proceed to Test Step 9. Diagnostic Codes

C. Check for active diagnostic codes.

Result: A 676-6 diagnostic code is active Proceed to Test Step 11. Result: A 676-19 diagnostic code is active

D. Use the electronic service tool to turn off the glow plug starting aid.

Proceed to Test Step 12.

E. Turn the keyswitch to the OFF position.

9. Check the GCU Wiring for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the GCU. C. Disconnect the P1 connector from the ECM. D. Use a multimeter to measure the resistance between the following points:

Less than 5 Ohms

Result: The measured resistance is not within the expected range. There is an open circuit or high resistance in the wiring between the GCU and the P1 connector. Inspect the 9-pin engine interface connector (if equipped). Repair the faulty wiring or replace the faulty wiring. Result: The measured resistance is within the expected range. Proceed to Test Step 10.

• Terminal 8 on the GCU harness connector and P1:52 • Terminal 5 on the GCU harness connector and P1:41

10. Check the GCU Wiring for a Short to Ground

Result: The measured resistance is not within the expected range.

A. Turn the keyswitch to the OFF position.

There is a short to ground in the wiring between the GCU and the P1 connector. Inspect the 9-pin engine interface connector (if equipped). Repair the faulty wiring or replace the faulty wiring.

B. Disconnect the GCU. C. Disconnect the P1 connector from the ECM.

Greater than 1 k Ohm

D. Use a multimeter to measure the resistance between the following terminals and a suitable engine ground: • Terminal 8 on the GCU harness connector • Terminal 3 on the GCU harness connector • Terminal 5 on the GCU harness connector

11. Check the GCU Wiring for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the GCU. C. Disconnect the P1 connector from the ECM. D. Use a multimeter to measure the resistance between the following points: • P1:52 and all other terminals on the P1 connector • P1:22 and all other terminals on the P1 connector • P1:41 and all other terminals on the

Result: The measured resistance is within the expected range. Repair: Install a replacement GCU. Use the electronic service tool to override the glow plug starting aid and verify that the repair eliminates the fault. Clear all logged diagnostic codes. If the repair does not eliminate the fault, contact the Dealer Solutions Network (DSN).

Greater than 1 k Ohm

Result: At least one of the resistance measurements is not within the expected range. There is a short in the wiring between the GCU connector and the P1 ECM connector. Inspect the 9-pin engine interface connector (if equipped). Repair the faulty wiring or replace the faulty wiring. Result: All resistance measurements are within the expected range. Repair: Install a replacement GCU. Use the electronic service tool to override the glow plug starting aid and verify that the repair eliminates the fault. Clear all logged diagnostic codes. If the repair does not eliminate the fault, contact the Dealer Solutions Network (DSN).

P1 connector

12. Check the Diagnostic Return Wire From the GCU

Result: The measured resistance is greater than 5 Ohms.

A. Turn the keyswitch to the OFF position.

There is an open circuit or high resistance in the wiring. Repair: Repair the faulty wiring or replace the faulty wiring.

B. Disconnect the GCU. Disconnect the P1/J1 connector. C. Measure the resistance between pin 3 on the harness connector for the GCU and P1:22.

Less than 5 Ohms

Result: The measured resistance is less than 5 Ohms. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06012069

Idle Validation - Test SMCS - 7332-038 This procedure covers the following diagnostic codes. Table 1 Diagnostic Trouble Codes J1939 Code

Code Description

558-2

Accelerator Pedal 1 Low Idle Switch : Erratic, Intermittent, or Incorrect

2970-2

Accelerator Pedal 2 Low Idle Switch : Erratic, Intermittent, or Incorrect

Comments The Electronic Control Module (ECM) detects one of the following conditions: The signal voltage from the throttle pedal is less than 1.05 V for 0.3 seconds while the idle validation switch is not active. The signal voltage from the throttle pedal is greater than 1.25 V for 0.3 seconds while the idle validation switch is active. The warning lamp will flash. The engine will be derated.

Follow the troubleshooting procedure in order to identify the root cause of the problem. If the application is equipped with two throttles, the engine will use the second throttle until the fault is repaired. If a second throttle is not installed or if the second throttle has a fault, the following conditions will occur: • The engine will default to limp home mode. • If the engine speed is higher than the speed in limp home mode, the engine will decelerate to limp home mode.

• If the engine speed is lower than the speed in limp home mode, the engine speed will remain at the current speed. • The engine will remain at this speed while the diagnostic code remains active. • All inputs from the faulty throttle are ignored by the ECM until the fault is repaired. • All inputs from the repaired throttle will be ignored by the ECM until the keyswitch has been cycled. The IVS may be installed. The IVS is required for mobile applications. The IVS is part of the throttle position sensor. The IVS is CLOSED when the low idle is set. The configuration parameters for the throttle and for the IVS thresholds are programmed into the ECM. Use the electronic service tool in order to display the configuration parameters for the throttle and for the IVS. If the IVS operates outside of the programmed range, then the engine speed may not respond to changes in the throttle position. The electronic service tool may be used for the following: • If necessary, reset the IVS threshold for an existing IVS. • If necessary, view the IVS change point and reset the IVS thresholds when a new throttle assembly is installed.

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Illustration 1

g03771038

Schematic diagram for the Idle Validation Switch (IVS) switch circuit

Illustration 2

g03771057

View of the pin locations on the P1 connector for the IVS circuit (42) IVS 2 (76) IVS 1

Table 2 Troubleshooting Test Steps

Values

Results

1. Check for Active Diagnostic Codes A. Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, "Electronic Service Tools"

Diagnostic Trouble Codes

Result: There is an active or logged , 558-2 or 29702 diagnostic code. Proceed to Test Step 2.

B. Check for active or logged codes.

2. Check the Operation of the IVS A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. D. Use the electronic service tool in order to check the current "Throttle Configuration". E. Select the "SERVICE" option from the dropdown menu of the electronic service tool. F. Select the "Throttle Configuration" option on the electronic service tool. Select the appropriate "Throttle Configuration" summary from the menu on the left of the screen. The IVS window for the throttle will indicate "YES" if an IVS is installed. G. Select the "Throttle status" function on the electronic service tool. Select "Status" function and then select "Throttles" function. H. The throttle is set in the low idle position. I. Operate the throttle slowly. The IVS status should change from CLOSED (ON) to OPEN

Switch state

Result: The IVS state changes from CLOSED (ON) to OPEN (OFF). Proceed to Test Step 3. Result: The IVS does not operate Proceed to Test Step 4.

(OFF).

3. Check the IVS Threshold A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position. C. Use the electronic service tool in order to check the current "Throttle Configuration".

Result: The IVS switch operates within the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" parameters.

D. Select the "SERVICE" option from the dropdown menu of the electronic service tool. E. Select the "Throttle Configuration" option on the electronic service tool. Select the appropriate "Throttle Configuration" summary from the menu on the left of the screen. The IVS window for the throttle will indicate "YES" if an IVS is installed. Make a note of the "Idle Validation Min OFF Threshold" parameters that are displayed in the "Throttle Configuration" menu of the electronic service tool. Make a note of the "Idle Validation Max ON Threshold" parameters that are displayed in the "Throttle Configuration" menu of the electronic service tool.

Switch operation

The fault appears to be resolved. Return the engine to service. Result: The IVS switch cannot operate within the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" parameters

F. To select the "Throttle status" function on the electronic service tool, select "Status" function and then select "Throttles" function.

Proceed to Test Step 10.

G. The throttle is set in the low idle position. H. Operate the throttle slowly. The IVS status should change from CLOSED (ON) to OPEN (OFF).

4. Inspect Electrical Connectors and Wiring A. Inspect the P1/J1 ECM connector. B. Inspect the connectors for the throttle position sensors. C. Perform a 30 N (6.7 lb) pull test on each of the

Damaged wire or connector

Result: A damaged wire or damaged connector was not found. Proceed to Test Step 5. Result: A damaged wire or damaged connector was

wires in the ECM connector and the connector for the throttle position sensors.

found. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

D. Check all of the wiring associated with the throttle position sensors for abrasions and pinch points.

5. Check the Voltage at the IVS Switch A. Disconnect the IVS harness connector.

Result: The voltage is within the expected range.

B. Turn the keyswitch to the ON position.

Proceed to Test Step 6.

C. Use a suitable multimeter to measure the voltage between the IVS terminal on the harness connector and a suitable ground.

7.9 V to 12.2 V

Result: The voltage is not within the expected range. Proceed to Test Step 7.

D. Turn the keyswitch to the OFF position.

Result: The voltage is within the expected range. Proceed to Test Step 9.

6. Check that the IVS is Grounded

Result: The voltage is not within the expected range. The fault is in the ground wire for the suspect IVS.

A. Disconnect the IVS harness connector. B. Turn the keyswitch to the ON position. C. Use a suitable multimeter to measure the voltage between the IVS terminal on the harness connector the ground terminal on the harness connector.

7.9 V to 12.2 V

D. Turn the keyswitch to the OFF position.

7. Check the Application Harness for an Open Less than 5 Ohms Circuit

Replace the faulty wiring. Refer to the OEM for more information on the wiring for the IVS. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: The measured resistance is less than 5

Ohms. A. Turn the keyswitch to the OFF position. Proceed to Test Step 8. B. Disconnect the connector for the suspect IVS. Disconnect the P1 connector.

Result: The measured resistance is greater than 5 Ohms.

C. If the IVS 1 is suspect, use a suitable multimeter to measure the resistance between the IVS terminal on the harness connector to P1:76. If the IVS 2 is suspect, use a suitable multimeter to measure the resistance between the IVS terminal on the harness connector to P1:42.

There is an open circuit or high resistance in the wiring between the IVS and the ECM. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: All resistance measurements are greater than 1 k Ohm.

8. Check the Application Harness for a Short Circuit

Contact the Dealer Solution Network (DSN).

A. Turn the keyswitch to the OFF position. Result: At least one of the measured resistances is less than 1 k Ohm.

B. Disconnect the suspect IVS connector. Disconnect the P1 connector. C. If the IVS 1 is suspect, use a suitable multimeter to measure the resistance between P1:76 and all other terminals on the P1 connector. If the IVS 2 is suspect, use a suitable multimeter to measure the resistance between P1:42 and all other terminals on the P1 connector.

9. Check the IVS at the Sensor A. Turn the keyswitch to the OFF position. B. Disconnect the IVS.

Greater than 1 k Ohm

There is a short in the wiring between the connector for the suspect IVS and the P1 connector. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Less than 10 Ohms at low Result: The IVS indicates idle. the expected resistance. Greater than 2000 Ohms at high idle.

No fault is indicated at this time. Recheck the harness

for intermittent connections.

C. Set the throttle to low idle. D. Check the resistance of the IVS.

Result: At least one of the resistance measurements is outside of the expected range.

E. Set the throttle to high idle. F. Check the resistance of the IVS.

Replace the IVS or replace the throttle sensor. Refer to OEM documentation for information on the throttle sensor. Proceed to Test Step 10.

10. Check the IVS Calibration A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position. C. Select the "Throttle Configuration" option on the electronic service tool. Select the appropriate "Throttle Configuration" summary from the menu on the left of the screen. The IVS window for the throttle will indicate "YES" if an IVS is installed. Make a note of the "Idle Validation Min OFF Threshold" parameters that are displayed in the "Throttle Configuration" menu of the electronic service tool. Make a note of the "Idle Validation Max ON Threshold" parameters that are displayed in the "Throttle Configuration" menu of the electronic service tool. D. Select the "Throttle status" function on the electronic service tool. Select "Status" function and then select "Throttles" function. E. Set the throttle to low idle. F. Operate the throttle slowly toward high idle. The raw percentage values for the throttle that are shown on the electronic service tool should increase and the IVS status should change from CLOSED (ON) to OPEN (OFF) position. Make a note of the raw reading for the throttle when the

The IVS operates within the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" values that are shown on the "Configuration" menu of the electronic service tool.

Result: The IVS operates within the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" values that are shown on the "Configuration" menu of the electronic service tool. Return the engine to service. Result: The IVS does not operate within the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" values that are shown on the "Configuration" menu of the electronic service tool. Proceed to Test Step 11.

IVS reading changes from the CLOSED position to the OPEN position. Repeat this step in order to obtain accurate raw percentage values for the throttle. The noted value should be within the previously noted "Idle Validation Min OFF Threshold" and "Idle Validation Max ON Threshold" limits. G. The throttle is set to the full throttle position or the high idle position. H. Operate the throttle slowly toward low idle. The raw percentage values for the throttle that are shown on the electronic service tool should decrease and the IVS status should change from OPEN (OFF) to CLOSED (ON) position. Make a note of the raw reading for the throttle when the IVS reading changes from the OPEN position to the CLOSED position. Repeat this step in order to obtain accurate raw percentage values for the throttle. The noted value should be within the previously noted "Idle Validation Min OFF Threshold" and "Idle Validation Max ON Threshold" limits.

11. Use the Electronic Service Tool to Reset the IVS Threshold Limits The electronic service tool can be used to change the "Idle Validation Min OFF Threshold" and the "Idle Validation Max ON Threshold" in order to suit the type of throttle that is installed. The limits are shown in the "Throttle Configuration" screen which is located in the "Service" menu. A. Refer to Test Step 8 and record the raw value of the throttle signal when the idle validation switch changes from the CLOSED position to the OPEN position. Note: The default value for the "Idle Validation Min OFF Threshold" is 21%. The lowest value that should be set is 5%. The default value for the "Idle Validation Max ON Threshold" is 25%. The maximum value that is expected is 28%. B. Set the "Idle Validation Min OFF Threshold" to 3% below the raw value that was previously

Fault cleared

Result: The fault is cleared after programming the new calculated values. Return the engine to service. Result: The fault is not cleared. Contact the Dealer Solution Network (DSN).

recorded. C. Set the "Idle Validation Max ON Threshold" to 3% above the raw value. D. Enter the new threshold limits into the electronic service tool. Click "Submit" on the electronic service tool screen. E. Turn the keyswitch to the OFF position and wait at least 5 seconds. Turn the keyswitch to the ON position. F. Repeat Test Step 8. Check that the IVS operates within the newly set threshold limits.

Complete the procedure in the order in which the steps are listed. If the procedure did not correct the issue, Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06013882

Indicator Lamp - Test SMCS - 7431-038 Use this procedure under the following circumstances: • The lamps are not receiving battery voltage. • The lamps are not operating correctly. • One of the following diagnostic codes is active: Table 1 Diagnostic Trouble Codes for the Indicator Lamps J1939 Code

Description

Notes

623-5

Red Stop Lamp : Current Below Normal

The Electronic Control Module (ECM) detects a low current condition in the circuit for the shutdown lamp.

623-6

Red Stop Lamp : Current Above Normal

The ECM detects a high current condition in the circuit for the shutdown lamp.

624-5

Amber Warning Lamp : Current Below Normal

The ECM detects a low current condition in the circuit for the warning lamp.

624-6

Amber Warning Lamp : Current Above Normal

The ECM detects a high current condition in the circuit for the warning lamp.

1081-5

Engine Wait to Start Lamp : Current Below Normal

The ECM detects a low current condition in the circuit for the wait to start lamp.

1081-6

Engine Wait to Start Lamp : Current Above Normal

The ECM detects a high current condition in the circuit for the wait to start lamp.

3697-5

Particulate Trap Lamp Command : Current Below Normal

The ECM detects a low current condition in the circuit for the Diesel Particulate Filter (DPF) lamp.

3697-6

Particulate Trap Lamp Command : Current Above Normal

The ECM detects a high current condition in the circuit for the DPF lamp.

3698-5

Exhaust System High Temperature Lamp Command : Current Below Normal

The ECM detects a low current condition in the circuit for the High Exhaust System Temperature (HEST) lamp.

3698-6

Exhaust System High Temperature Lamp Command : Current Above Normal

The ECM detects a high current condition in the circuit for the HEST lamp.

3702-5

Diesel Particulate Filter Active Regeneration Inhibited Status : Current Below Normal

The ECM detects a low current condition in the circuit for the DPF disabled lamp.

3702-6

Diesel Particulate Filter Active Regeneration Inhibited Status : Current Above Normal

The ECM detects a high current condition in the circuit for the DPF disabled lamp.

5099-5

Engine Oil Pressure Low Lamp Data : Current Below Normal

The ECM detects a low current condition in the circuit for the low oil pressure lamp.

5099-6

Engine Oil Pressure Low Lamp Data : Current Above Normal

The ECM detects a high current condition in the circuit for the low oil pressure lamp.

The Engine Control Module (ECM) provides nine outputs that can be used to illuminate indicator lamps. If applicable, some of the outputs can be programmed to a J1939 device. Each J1/P1 output is a low side driver. Low Side Driver - The ECM provides a connection to ground in order to activate the lamp. J1939 Device - The ECM sends digital data on the J1939 data link in order to control the lamp. Table 2 provides information on the typical lamp outputs. Table 2 Lamp Outputs (Typical Application) Lamp

Default Output Terminal

Regeneration Active Lamp

J1/P1:74

Shutdown Lamp

J1/P1:51

Warning Lamp

J1/P1:92

Wait to Start Lamp

J1/P1:50

Low Oil Pressure Lamp

J1/P1:69

Diesel Particulate Filter (DPF) Lamp

J1/P1:94

DPF Disabled Lamp

J1/P1:48

Testing the Circuits The ECM briefly activates the lamps when the keyswitch is turned from OFF to ON. Table 3 Troubleshooting Test Steps

Values

Results Result: The lamp does not illuminate. Troubleshoot any active codes before continuing with this procedure.

1. Test the Circuit A. Turn the keyswitch from OFF to ON in order to test the circuit. Watch the lamp during the test.

Proceed to Test Step 2. Circuit test

Result: The lamp illuminates. There is a problem with the wiring if the problem is intermittent. Troubleshoot the wiring by referring to the electrical schematic for the application. STOP

Result: The lamp illuminates. The problem is resolved. STOP 2. Check the Bulb Replace the bulb with a bulb that is known Bulb to be good. Test the circuit again.

Result: The lamp does not illuminate. The bulb is OK. The +Battery or the ground is not present at the lamp. Refer to the electrical schematic. Troubleshoot the wiring by referring to the electrical schematic if the lamp output is programmed to a J1939 device. Proceed to Test Step 3 if the lamp output is programmed to a J1/P1 terminal..

3. Troubleshoot the Wiring for the Lamp Check the wiring for an open circuit. Pay particular attention to possible problems with electrical connectors.

Lamp wiring

Result: There is an open circuit in the wiring for the lamp. Make the necessary repairs. STOP Result: The wiring for the lamp is OK. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05867872

Injector Code - Calibrate SMCS - 1290-524 Injector codes are seven digit alphanumerical codes that are supplied with each injector. The code is printed on the injector . The code is used by the Electronic Control Module (ECM) to balance the performance of the injectors. The electronic service tool is used to load the injector codes into the ECM. The injector codes must be loaded into the ECM if any of the following conditions occur: • An electronic unit injector is replaced. • The ECM is replaced. • Electronic unit injectors are exchanged between cylinders. • A 630-2 diagnostic code is active. If the ECM is replaced, the injector codes are normally transferred to the new ECM as part of the "Copy Configuration" procedure. If the "Copy Configuration" procedure fails, the injector codes must be loaded manually. Installing Injector Codes

Illustration 1

g02738616

Typical example of an electronic unit injector (1) Location of the injector code

1. Record the injector code for each electronic unit injector. 2. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools". 3. Turn the keyswitch to the ON position. 4. Select the following menu options on the electronic service tool: Service Calibrations Injector Trim Calibration 5. Select the appropriate cylinder. 6. Click on the "Change" button. 7. Input the applicable injector code that was recorded in Test Step 1.

8. Click on the "OK" button. The injector code is loaded into the ECM. 9. Repeat the procedure for each cylinder, as required. Exchanging Electronic Unit Injectors Exchanging electronic unit injectors can help determine if a combustion problem is in the electronic unit injector or in the cylinder. If two electronic unit injectors that are currently installed in the engine are exchanged between cylinders, the injector codes must also be exchanged. Record the injector trim codes for the two injectors that are to be exchanged. Use the electronic service tool to enter the injector codes for the correct cylinders. CAT C3.4B Engine Parts Contact phone: 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Alternate email: engineparts2@gmail.com Website: www.CATC34B.com Related website: www.HeavyEquipmentRestorationParts.com

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06014480

Injector Data Incorrect - Test SMCS - 1290-038 This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for "Injector Data Incorrect" J1939 Code

Description

Notes The Electronic Control Module (ECM) detects one of the following conditions.

630-2

Calibration Memory : Erratic, Intermittent, or Incorrect

An injector code has not been programmed for one or more of the injectors. OR The injector code for one or more of the injectors is invalid. The engine may have rough running at low idle.

651-20

Engine Injector Cylinder #01 : Data Drifted High

651-21

Engine Injector Cylinder #01 : Data Drifted Low

652-20

Engine Injector Cylinder #02 : Data Drifted High

652-21

Engine Injector Cylinder #02 : Data Drifted Low

653-20

The ECM will calibrate the injector energizing times while the engine is at low idle based on the readings from the oxygen sensor. If the calculated energizing times exceed the limits set by the injector code, one of these diagnostic codes will become active for the applicable cylinder.

Engine Injector Cylinder #03 : Data Drifted High 653-21

Engine Injector Cylinder #03 : Data Drifted Low

654-20

Engine Injector Cylinder #04 : Data Drifted High

654-21

Engine Injector Cylinder #04 : Data Drifted Low

The following background information is related to this procedure: Injector codes are seven digit alphanumeric codes that are supplied with each injector. The code is printed on each injector. The code is used by the ECM to balance the performance of the injectors. Refer to Troubleshooting, "Injector Code - Calibrate" for further information.

Illustration 1 Typical example of an electronic unit injector (1) Location of the injector code

g02738616

Table 2 Troubleshooting Test Steps

Values

1. Check for Diagnostic Codes That Are Related to this Procedure

Result: A 630-2 diagnostic code is active.

A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position.

Results

Proceed to Test Step 2. Diagnostic codes

C. Check for any active diagnostic codes that are listed in Table 1.

Result: An XXX-20 or XXX-21 diagnostic code is active. Proceed to Test Step 4.

D. Make a note of the active diagnostic codes.

2. Enter the Injector Codes Using the Electronic Service Tool A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools". Result: The 630-2 diagnostic code is no longer active.

B. Turn the keyswitch to the ON position. C. Manually enter the injector codes using the electronic service tool. Refer to Troubleshooting, "Injector Code - Calibrate".

Return the engine to service. Diagnostic codes

D. Use the electronic service tool to clear all active diagnostic codes.

Result: The 630-2 diagnostic code is still active. Proceed to Test Step 3.

E. Start the engine. F. Use the electronic service tool to check for active diagnostic codes. G. Turn the keyswitch to the OFF position.

3. Re-Flash the ECM A. Reflash the ECM. Refer to Troubleshooting, "ECM Software - Install".

Diagnostic codes

Result:The 630-2 diagnostic code is no longer active. Return the engine to service.

B. Ensure that all of the injector codes are programmed. Refer to Troubleshooting, "Injector Code - Calibrate".

Result: The 630-2 diagnostic code is still active Proceed to Test Step 7.

C. Use the electronic service tool to clear all active diagnostic codes. D. Start the engine. E. Use the electronic service tool to check for active diagnostic codes.

Result: There are no diagnostic codes for the oxygen sensor.

4. Check the Oxygen Sensor for Faults

Proceed to Test Step 5.

A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position.

10 V to 14 V

Troubleshoot the oxygen sensor before returning to this procedure. Refer to Troubleshooting, "Oxygen Level - Test".

C. Check for active or recently logged diagnostic codes for the oxygen sensor.

5. Enter the Injector Code for the Suspect Cylinder A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools". B. Turn the keyswitch to the ON position. C. Manually enter the injector code for the suspect cylinder using the electronic service tool. Refer to Troubleshooting, "Injector Code - Calibrate". D. Use the electronic service tool to clear all active diagnostic codes. E. Start the engine. F. Use the electronic service tool to check for active diagnostic codes.

Result: There are diagnostic codes for the oxygen sensor

Diagnostic codes

Result: There are no active XXX20 or XXX-21 diagnostic codes for the injectors. Return the engine to service. Result: The XXX-20 or XXX-21 diagnostic code is still active. Proceed to Test Step 6.

G. Turn the keyswitch to the OFF position.

6. Replace the Suspect Injector A. Replace the injector for the cylinder with the XXX20 or XXX-21 diagnostic code. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and refer to Disassembly and Assembly, "Electronic Unit Injector - Install".

Result: There are no active XXX20 or XXX-21 diagnostic codes for the injectors. Diagnostic Codes

B. Use the electronic service tool to input the code for the new injector. Refer to Troubleshooting, "Injector Code - Calibrate".

Return the engine to service. Result: The XXX-20 or XXX-21 diagnostic code is still active. Proceed to Test Step 7.

C. Use the electronic service tool to check for active diagnostic codes.

Result: There are no active diagnostic codes with the replacement ECM.

7. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN). B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

Diagnostic codes

Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06229778

Injector Solenoid - Test SMCS - 1290-038-JV This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Circuit for the Injector Solenoids J1939 Code

Description

651-5

Engine Injector Cylinder #01 : Current Below Normal

652-5

Engine Injector Cylinder #02 : Current Below Normal

653-5

Engine Injector Cylinder #03 : Current Below Normal

654-5

Engine Injector Cylinder #04 : Current Below Normal

651-6

Engine Injector Cylinder #01 : Current Above Normal

652-6

Engine Injector Cylinder #02 : Current Above Normal

Notes These diagnostic codes are designed to indicate an open circuit (low current) in either the solenoid or the wiring for the electronic unit injector in the applicable cylinder. The Electronic Control Module (ECM) detects the following conditions: A low current condition (open circuit) for the applicable cylinder for at least three attempts to actuate the solenoid. The ECM will log the diagnostic code. The engine will have low power and/or rough running. An open circuit will prevent the operation of the electronic unit injector. These diagnostic codes are designed to indicate a short circuit (high current) in either the solenoid or the wiring for the electronic unit injector in the applicable cylinder. The ECM detects the following conditions: A high current condition (short circuit) for the applicable cylinder

653-6

654-6

Engine Injector Cylinder #03 : Current Above Normal Engine Injector Cylinder #04 : Current Above Normal

for at least five attempts to actuate the solenoid. The ECM will log the diagnostic code. The engine will have low power and/or rough running. A short circuit will prevent the operation of the electronic unit injector. The ECM detects the following conditions: A short circuit condition in the driver for injector 1 and injector 4. The fault is present for at least five attempts to actuate the driver.

2797-6

Engine Injector Group 1 : Current Above Normal

The ECM will log the diagnostic code. The engine will have low power and/or rough running. The engine may shut down. A short circuit will prevent the operation of the two electronic unit injectors. The ECM is unable to actuate any of the injectors.

2797-7

Engine Injector Group 1 : Not Responding Properly

The engine will be derated. The engine will shut down or the engine will be unable to start. The ECM detects the following conditions: A short circuit condition in the driver for injector 2 and injector 3. The fault is present for at least five attempts to actuate the driver.

2798-6

Engine Injector Group 2 : Current Above Normal

The ECM will log the diagnostic code. The engine will have low power and/or rough running. The engine may shut down. A short circuit will prevent the operation of the two electronic unit injectors.

An electrical fault can prevent the electronic unit injector from operating. An open circuit or a short circuit in the ECM that is unique to one electronic unit injector will prevent that electronic unit injector from operating. An open circuit or a short circuit in common wiring within the ECM can prevent the two electronic unit injectors that share that common wiring from operating. Injector 1 and injector 4 share common wiring within the ECM. Injector 2 and injector 3 share common wiring within the ECM. Perform this procedure under conditions that are identical to the conditions that exist when the fault occurs. Typically, faults with the injector solenoid occur when the engine is warmed up and/or when the engine is under vibration (heavy loads). These engines have Electronic Unit Injectors (EUI). The ECM sends a pulse to each injector solenoid. The pulse is sent at the correct time and at the correct duration for a given engine load and speed. The solenoid is mounted on top of the fuel injector body.

If an open circuit is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short circuit is detected, a diagnostic code is generated. The ECM will periodically try to fire the injector. If the short circuit remains, this sequence of events will be repeated until the fault is corrected.

Illustration 1

g03616577

Schematic of the circuit for the injector solenoids Not all connectors are shown. Refer to the electrical schematic for the engine.

Illustration 2 Typical example of the harness connector for the fuel injectors

g02373637

Illustration 3

g02373216

(1) Cylinder 3 injector supply (2) Cylinder 2 injector supply (16) Cylinder 1 injector supply (17) Cylinder 4 injector supply (31) Cylinder 3 injector return (32) Cylinder 1 injector return (46) Cylinder 2 injector return (48) Cylinder 4 injector return

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present

Values Damaged wire or connector

Results Result: A damaged wire or damaged connector was found. A fuse is blown. Repair: Repair the damaged wire or the damaged connector. Replace any blown

if the keyswitch is not turned OFF.

fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

B. Thoroughly inspect the connectors at the injectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

C. Inspect the terminals on the P1/J1 ECM connector and all other connectors associated with the injector solenoid circuits.

Proceed to Test Step 2.

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector that are associated with injector solenoids. E. Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM.

2. Check for Active Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector.

Result: An -5 diagnostic code is active or recently logged.

B. Start the engine.

Note the cylinders that the codes are applicable to. Proceed to Test Step 3.

C. Allow the engine to warm up to the normal operating temperature. D. Stop the engine.

Diagnostic codes

E. Turn the keyswitch to the ON position. Note: Wait at least 30 seconds for activation of the diagnostic codes.

A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present

Note the cylinders that the codes are applicable to. Proceed to Test Step 5. Result: A 2797-7 diagnostic code is active.

F. Use the electronic service tool in order to verify if any of the diagnostic codes that are listed in Table 1 are active or recently logged.

3. Create a Short at the Injector Connector

Result: An -6 diagnostic code is active or recently logged.

Proceed to Test Step 7.

Diagnostic codes

Result: A -6 diagnostic code was active with the jumper installed. Repair: Thoroughly inspect the electrical connector on the suspect injector and the

if the keyswitch is not turned OFF.

harness connector for the suspect injector. Ensure that the connectors are free from corrosion. Reconnect the connector for the suspect injector. Start the engine. If the fault is still present, replace the faulty injector. Refer to Disassembly and Assembly, "Electronic Unit Injector Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

B. Disconnect the connector from the suspect injector. C. Fabricate a jumper wire 100 mm (4 inch) long. D. Install the jumper wire between terminal 1 and terminal 2 on the harness connector for the suspect injector. E. Start the engine. Wait at least 30 seconds for activation of the diagnostic codes.

Result: A -5 diagnostic code is still present with the jumper installed.

F. Use the electronic service tool to check for active diagnostic codes.

Proceed to Test Step 4.

G. Turn the keyswitch to the OFF position. H. Remove the jumper wire.

4. Create a Short at the ECM Connector A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF. B. Disconnect the P2 connector. C. Fabricate a jumper wire 100 mm (4 inch) long. D. Install the jumper wire between the supply and return pins for the suspect cylinder on the J2 connector. Refer to Illustration 3 for the correct terminals. E. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes relating to the suspect injector.

Diagnostic codes

Result: A -6 diagnostic code is active with the jumper installed. The fault is in the wiring for the suspect injector. Repair: Check all wiring between the suspect injector and the ECM. Refer to the Electrical Schematic for the engine. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A -5 diagnostic code is still active with the jumper installed. Proceed to Test Step 7.

F. Use the electronic service tool to check for active diagnostic codes. G. Turn the keyswitch to the OFF position. H. Remove the jumper wire.

Result: A -5 diagnostic code is active with the injectors disconnected. 5. Create an Open Circuit at the Injector Connector or Connectors A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF. B. Disconnect the connector for any suspect injectors. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes.

Diagnostic codes

D. Use the electronic service tool to check for active diagnostic codes.

Repair: Thoroughly inspect the electrical connectors on the suspect injectors and the harness connector for the suspect injectors. Ensure that the connectors are free from corrosion. Reconnect the connector for the injectors. Start the engine. If the fault is still present, replace the faulty injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A -6 diagnostic code is still active with the injectors disconnected.

E. Turn the keyswitch to the OFF position.

Proceed to Test Step 6.

6. Create an Open Circuit at the ECM Connector A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.

Diagnostic Codes

Result: A -5 diagnostic code is active with the P2 connector disconnected. The fault is in the wiring for the suspect injector.

C. Thoroughly inspect the P2 connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Repair: Check all wiring between the suspect injector and the ECM. Refer to the Electrical Schematic for the engine. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

D. Turn the keyswitch to the ON position.

Result: A -6 diagnostic code is still active

B. Disconnect connector P2 from the ECM.

Wait for at least 30 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes and only look for codes relating to the suspect injectors.

with the P2 connector disconnected. Proceed to Test Step 7.

E. Use the electronic service tool to check for active diagnostic codes. F. Turn the keyswitch to the OFF position.

7. Check if a Replacement ECM Eliminates the Fault

Result: There are no active diagnostic codes with the replacement ECM.

A. Contact the Dealer Solution Network (DSN).

Repair: Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "ECM Replace".

Diagnostic codes

C. Use the electronic service tool to recheck the system for active diagnostic codes.

Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225853

Inlet Air Is Restricted SMCS - 1087-035 The Electronic Control Module (ECM) detects a fault with the air flow through the air filter. If the air flow has been restricted, the ECM will generate one of the following codes: Table 1 Code for Inlet Air Restriction J1939 Code

Description

Information The Electronic Control Module (ECM) detects the following conditions: The air filter restriction switch indicates that the air filter is blocked. The engine has been operating for at least 60 seconds. The engine speed is at least 1800 rpm. If equipped, the warning lamp will flash

107-15

Engine Air Filter 1 Differential Pressure : High - least severe (1)

107-16

Engine Air Filter 1 Differential Pressure: High - moderate severity (2)

The ECM detects that a 107-15 diagnostic code has been active for at least 30 minutes. If equipped, the warning lamp will flash. The engine will be derated.

Complete the procedure in the order in which the steps are listed. Table 2 Troubleshooting Test Steps 1. Check the Air Filter Element

Values Plugged Air

Results Result: The air filter is clogged.

A. Check the air intake system for plugged air filters or for damaged air filters. If the engine is equipped with an air intake precleaner, verify the proper operation of the air intake precleaner.

Filter Repair: Clean or replace the air filter. Verify that the problem is resolved. Result: The air filter is not clogged. Proceed to Test Step 2.

Result: The air inlet piping is damaged or has restrictions. 2. Check the Air Inlet Piping A. Check the air inlet piping for damage or restrictions.

Repair: Repair the piping or replace the piping. Damaged Air Verify that the problem is Inlet Piping resolved. Result: The air inlet piping does not have damage or restrictions. Proceed to Test Step 3.

Result: The engine does not have sufficient ventilation.

3. Check the Enclosure Ventilation A. Check that the engine has been installed in an enclosure that is sufficiently ventilated.

Enclosure Ventilation

Repair: Repair the ventilation for the enclosure. Verify that the problem is resolved.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225877

Intake Manifold Air Pressure Is High SMCS - 1058-035-PX This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for High Intake Manifold Air Pressure J1939 Code

Description

Notes The Electronic Control Module (ECM) detects that the actual intake manifold air pressure is greater than the desired intake manifold air pressure by 50 kPa (7.25 psi) for at least 10 seconds.

112716

Engine Turbocharger 1 Boost Pressure : High moderate severity (2)

If equipped, the warning lamp will flash. The engine will be derated. If the actual intake manifold pressure is within 25 kPa (3.6 psi) of the desired intake manifold air pressure for at least 11 minutes, the code will reset.

Probable Causes • Air inlet and exhaust restrictions • Turbocharger wastegate • Wastegate regulator

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order.

Table 2 Troubleshooting Test Steps

Values

Results

1. Air Inlet and Exhaust Restrictions

Result: Defects found in the air inlet or exhaust systems.

A. Check the air filter for damage.

Repair: Repair any defects. Replace damaged components.

B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation, Testing, and Adjusting, "Air Inlet and Exhaust System - Inspect".

Air inlet and exhaust system

Proceed to Test Step 2.

Result: There is a suspected fault in the wastegate or the wastegate actuator.

2. Turbocharger Wastegate A. Check the operation of the turbocharger wastegate. B. Check the operation of the wastegate actuator. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect".

Result: The air inlet and exhaust systems are OK.

Turbocharger wastegate

Repair: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install". Result: The wastegate and the wastegate actuator operate correctly. Proceed to Test Step 3.

Result: Diagnostic codes are present that relate to the wastegate regulator.

3. Wastegate Regulator Wastegate A. Use the electronic service tool to regulator check for diagnostic trouble codes that relate to the wastegate regulator.

Repair: Rectify the cause of any related codes. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no diagnostic codes that relate to the wastegate regulator. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225887

Intake Manifold Air Pressure Is Low SMCS - 1058-035-PX This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for Low Intake Manifold Air Pressure J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

112718

Engine Turbocharger 1 Boost Pressure : Low moderate severity (2)

The actual intake manifold air pressure is less than the desired intake manifold air pressure for at least 10 seconds. The difference between the two values is dependent on engine operating conditions. The engine speed is between 1000 rpm and 4000 rpm. The engine coolant temperature is greater than 45° C (113° F). There are no active 102 diagnostic codes for the intake manifold air pressure sensor. An active regeneration is not in progress. There are no other active engine derates. If equipped, the warning lamp will flash. The engine will be derated. The fault will be cleared when the intake manifold air pressure is within the acceptable range for at least 11 minutes.

Probable Causes • Intake air filter

• Air intake system • Wastegate regulator • Turbocharger

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps

Values

Results Result: The air filter is blocked.

1. Intake Air Filter A. Check the air filter restriction indicator, if equipped.

Air filter

B. Ensure that the air filter is clean and serviceable.

Repair: Replace the air filter element. Refer to the Operation and Maintenance Manual, "Engine Air Cleaner Element - Replace". Result: The air filter is OK. Proceed to Test Step 2.

2. Air Intake System

Result: The air intake system is blocked, restricted, damaged, or loose.

A. Check the air intake system for the following defects: · Blockages · Restrictions · Damage to the air intake ducts and hoses · Loose connections and air leaks

3. Wastegate Regulator A. Use the electronic service tool to check for diagnostic trouble codes that relate to the wastegate regulator.

Air intake

Repair: Make all necessary repairs to the air intake system. Result: The air intake system is OK. Proceed to Test Step 3.

Wastegate regulator

Result: Diagnostic codes are present that relate to the wastegate regulator. Repair: Rectify the cause of any related codes. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no diagnostic codes that relate to the wastegate regulator. Proceed to Test Step 4.

4. Turbocharger Note: The turbocharger that is installed on the engine is a nonserviceable item. If any mechanical fault exists, then the turbocharger must be replaced. A. Check that the compressor housings for the turbochargers are free of dirt and debris.

Result: There is a fault with the turbocharger.

Turbocharger

B. Check that the turbine housings for the turbochargers are free of dirt and debris.

Repair: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install". Result: The turbocharger is OK. Contact the Dealer Solution Network (DSN).

C. Check that the turbine blades rotate freely in the turbochargers.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06225888

Intake Manifold Air Temperature Is High SMCS - 1058-035-TA The Electronic Control Module (ECM) monitors the intake manifold air for excessive temperature. Use this procedure to determine the cause of high intake manifold air temperature.

Probable Causes • Coolant level • Air-to-air aftercooler (ATAAC) • Cooling fan • Air inlet and exhaust system • Ambient temperature • Altitude • Running condition

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Coolant Level A. Check that the coolant is filled to the correct

Values Coolant

Results Result: The coolant level is low.

level.

Repair: Fill the coolant system to the correct level. Refer to the Operation and Maintenance Manual, "Coolant Level - Check".

Note: If the coolant level is too low, air will get into the cooling system. Air in the cooling system will cause a reduction in coolant flow.

Result: The coolant level is OK. Proceed to Test Step 2.

Result: The ATAAC has excessive debris or is damaged. 2. Air-to-Air Aftercooler (ATAAC) A. Check the ATAAC for debris or damage.

ATAAC

Note: Debris between the fins of the ATAAC core restricts air flow through the core.

Repair: Clear the debris from the ATAAC or replace the ATAAC. Result: The ATAAC is OK. Proceed to Test Step 3.

Result: The cooling fan is not operating correctly. 3. Cooling Fan A. Check the operation of the cooling fan. Cooling fan Note: A fan that is not turning at the correct speed can result in insufficient airflow through the aftercooler core.

Repair: Investigate the cause of the incorrect fan operation Result: The cooling fan is operating correctly. Proceed to Test Step 4.

4. Air Intake and Exhaust System A. Check the air intake and exhaust system for the following defects: · Blockages · Restrictions · Damage to the air intake ducts and hoses · Loose connections and air leaks

Air intake and exhaust

Result: The air intake or exhaust system is blocked, restricted, damaged, or loose. Repair: Make all necessary repairs to the air intake system. Result: The air intake and exhaust system is OK.

Proceed to Test Step 5.

Result: The ambient air temperature is high. 5. Ambient Temperature A. Check for a high ambient temperature. Note: When outside temperatures are too high, there is insufficient temperature difference between the outside air and the intake air.

Ambient Temperature

Repair: Operate the engine at reduced speed or reduced power. Result: The ambient air temperature is OK. Proceed to Test Step 6.

Result: The engine is being operated at high altitude. 6. Altitude A. Check for operation at high altitude. Altitude Note: The cooling capacity of the ATAAC is reduced as the engine is operated at higher altitudes.

Repair: Operate the engine at reduced speed or reduced power. Result: The engine is not being operated at high altitude. Proceed to Test Step 7.

Result: The engine is operating in the lug condition.

7. Running Condition A. Check that the engine is not operating in the lug condition. Note: When the load that is applied to the engine is too large, the engine will run in the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes a reduction in coolant flow through the system.

Running condition

Repair: Reduce the load on the engine or, if possible, increase the power rating of the engine. Result: The engine is not operating in the lug condition. Contact the Dealer Solution Network (DSN).

Cat C3.4B Engine Parts

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06229833

Mode Selection - Test SMCS - 7332-038 Table 1 Diagnostic Trouble Codes for the Mode Selection Circuit J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

2880-2

Engine Operator Primary Intermediate Speed Select : Erratic, Intermittent, or Incorrect

The signal voltage from the mode selection switch is between 0.35 V and 4.8 V. The signal voltage from the mode selection switch is not valid for any of the available modes for at least 0.5 seconds. The battery voltage is at least 10 V. The warning lamp will come on. The ECM detects the following conditions:

2880-3

Engine Operator Primary Intermediate Speed Select : Voltage Above Normal

The signal voltage from the mode selection switch is above 4.8 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The warning lamp will come on.

2880-4

Engine Operator Primary Intermediate Speed Select : Voltage Below Normal

The ECM detects the following conditions: The signal voltage from the mode selection switch is less than 0.35 VDC for at least 0.5 seconds.

The battery voltage is at least 10 VDC. The warning lamp will come on. The mode selection switch uses resistors to modify the voltage signal from the ECM. The resistance of the switch changes dependent on which position the switch is in. The ECM uses the signal voltage to determine which mode has been selected.

Illustration 1

g03117957

View of the signal voltage range for the mode selection switch

Note: Position (4) is not available on the mode selection switch. If the signal voltage range is between 3.7 and 4.4 VDC, the mode that is selected will be the same as position (3).

Illustration 2 Typical example of the schematic for the mode selection switch Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03728025

Illustration 3

g02723018

Typical view of the pin locations on the P1 connector for the mode selection switch (55) Mode selection switch signal (77) Mode selection switch ground

Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring Result: A damaged wire or damaged connector was not found.

A. Thoroughly inspect the terminal connections on the P1/J1 connector.

Proceed to Test Step 2.

B. Thoroughly inspect the connector for the mode selection switch. C. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Damaged wire or connector

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the connectors that are associated with the mode selection switch. E. Check the harness for abrasions and for pinch points from the switch back to the ECM.

2. Check for Active or Recently Logged Diagnostic Codes

Diagnostic

Result: A damaged wire or damaged connector was found. Repair: Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

Result: A 2880-4 diagnostic code is active.

A. Turn the keyswitch to the OFF position.

Trouble Codes

B. Connect the electronic service tool to the diagnostic connector.

Result: A 2880-3 diagnostic code is active.

C. Turn the keyswitch to the ON position. Do not start the engine.

Proceed to Test Step 4.

D. Check for active diagnostic codes with the mode selection switch in each position. Wait at least 10 seconds with the switch in each position for activation of the diagnostic codes.

Result: A 2880-2 diagnostic code is active. Proceed to Test Step 5.

Result: A 2880-3 diagnostic code is active with the switch disconnected.

3. Create an Open Circuit at the Switch A. Turn the keyswitch to the OFF position. B. Disconnect the mode selection switch. C. Turn the keyswitch to the ON position.

Proceed to Test Step 3.

Diagnostic codes

D. Use the electronic service tool to check for an active 2880 diagnostic code. Wait at least 10 seconds for activation of the diagnostic codes.

Repair: Replace the mode selection switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 2880-4 diagnostic code is still active with the switch disconnected.

E. Turn the keyswitch to the OFF position. Reconnect the switch and proceed to Test Step 7.

4. Create a Short at the Switch Connector A. Turn the keyswitch to the OFF position. B. Disconnect the mode selection switch. C. Fabricate a jumper wire and install the jumper wire between the two harness connector terminals for the mode selection switch. D. Turn the keyswitch to the ON position. E. Use the electronic service tool to check for an active 2880 diagnostic code. Wait at least 10

Diagnostic codes

Result: A 2880-4 diagnostic code is active with the jumper installed. Repair: Replace the mode selection switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 2880-3 diagnostic code is still active with the jumper installed.

seconds for activation of the diagnostic codes.

Reconnect the mode selection switch and proceed to Test Step 7.

F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

Result: The voltage is within the expected range.

5. Check the Voltage at the Switch Connector A. Turn the keyswitch to the OFF position. B. Disconnect the mode selection switch. C. Turn the keyswitch to the ON position.

4.9 V to 5.1 V

D. Use a suitable multimeter to measure the voltage between the signal terminal and the ground terminal at the switch connector.

Result: The voltage is not within the expected range.

E. Turn the keyswitch to the OFF position.

Proceed to Test Step 6.

Result: At least one of the resistance measurements is greater than 5 Ohms. The fault is in the wiring between the switch connector and the P1 connector.

6. Check the Wiring for High Resistance A. Turn the keyswitch to the OFF position. B. Disconnect the mode selection switch. Disconnect the P1 connector. C. Use a suitable multimeter to measure the resistance between the following points:

Repair: Replace the mode selection switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Less than 5 Ohms

· P1:55 to the signal terminal at the switch connector · P1:77 to the ground terminal at the switch connector

Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: Both resistance measurements are less than 5 Ohms. Proceed to Test Step 7.

7. Check the Wiring for a Short Circuit A. Turn the keyswitch to the OFF position.

Greater than 1 k Ohm

Result: At least one of the resistance measurements is less than 1 k Ohm. There is a short in the wiring

B. Disconnect the P1 connector from the ECM.

between the mode selection switch and the P1 connector.

C. Disconnect the mode selection switch. D. Use a suitable multimeter to measure the resistance between the following points: · P1:55 and all other terminals on the P1 connector · P1:77 and all terminals on the P1 connector

Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: All resistance measurements are greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06015840

Motorized Valve - Test SMCS - 5479-038; 5927-038-VL This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Motorized Valves J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

2791-5

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Below Normal

A low current condition in the output for the NOx Reduction System (NRS) valve for at least 0.3 seconds. The battery voltage is at least 10 VDC. The engine will be derated. The ECM will log the diagnostic code. The ECM detects the following conditions:

2791-6

Engine Exhaust Gas Recirculation (EGR) Valve Control : Current Above Normal

A high current condition in the output for the NRS valve for at least 0.3 seconds. The battery voltage is at least 10 VDC. The engine will be derated. The ECM will log the diagnostic code.

2791-7

Engine Exhaust Gas Recirculation (EGR) Valve Control : Not Responding Properly

The ECM detects the following conditions: The signal from the NRS valve position sensor indicates that the valve is not in the desired position. The difference between the desired position and the actual position is greater than 12 percent. This diagnostic code can be caused by a loss of the 5 VDC supply to the NRS valve position sensor. The engine will be derated. The ECM will log the diagnostic code. The ECM detects the following conditions:

5419-5

Engine Throttle Actuator #1 : Current Below Normal

A low current condition in the output for the engine intake throttle valve for at least 0.5 seconds. The ECM will log the diagnostic code. The ECM detects the following conditions:

5419-6

Engine Throttle Actuator #1 : Current Above Normal

A high current condition in the output for the engine intake throttle valve for at least 0.5 seconds. The ECM will log the diagnostic code. The ECM detects the following conditions: The signal from the intake throttle valve position sensor indicates that the valve is not in the desired position for at least 0.05 seconds.

5419-7

Engine Throttle Actuator #1 : Not Responding Properly

The difference between the desired position and the actual position is greater than 12 percent. This diagnostic code can be caused by a loss of the 5 VDC supply to the intake throttle valve position sensor. The engine will be derated. The ECM will log the diagnostic code.

The following background information is related to this procedure: NRS Valve The NRS valve is used to control the amount of exhaust gas which is recirculated into the intake manifold.

The amount of exhaust gas that is required is calculated by the software that is contained in the ECM. The NRS valve is controlled by a PWM signal from the ECM. Intake Throttle Valve The intake throttle valve is used to increase the exhaust gas temperature to aid the Diesel Particulate Filter (DPF) regeneration process.

Illustration 1

g03616796

Schematic diagram for the motorized valves Not all connectors are shown. Refer to the electrical schematic for the machine.

Illustration 2 Typical view of the pin locations on the J2 connector for the motorized valves. (8) Intake throttle valve position sensor 5 VDC supply (9) NRS valve position sensor 5 VDC supply (24) NRS valve position sensor ground (34) Intake throttle valve return

g03616849

(35) NRS valve return (37) Intake throttle valve position sensor ground (39) NRS valve position sensor signal (49) Intake throttle valve PWM signal (50) NRS valve PWM signal (53) Engine intake throttle valve position sensor signal

Table 2 Troubleshooting Test Steps

Values

Result: A damaged wire or damaged connector was found.

1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect connectors for the motorized valves. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details. B. Thoroughly inspect the P2/J2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

Results

Damaged wire or connector

C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the motorized valves.

Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 2.

Result: An XXXX-7 diagnostic code is active or recently logged for one or more of the motorized valves

2. Check for Diagnostic Codes

Proceed to Test Step 3. A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector.

Diagnostic codes

Result: An XXXX-5 diagnostic code is active or recently logged for one or more of the motorized valves.

C. Turn the keyswitch to the ON position.

Proceed to Test Step 4.

D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.

Result: An XXXX-6 diagnostic code is active or recently logged for one or more of the motorized valves. Proceed to Test Step 6.

3. Measure the Sensor Supply Voltage at the Valve Connector

4.9 v to 5.1 V

A. Turn the keyswitch to the OFF position.

Result: The measured voltage is within the expected range. Install a replacement for the suspect valve. Refer to Disassembly and Assembly for more information. Note: If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset". Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

B. Disconnect the suspect valve from the engine harness. C. Turn the keyswitch to the ON position. D. Measure the voltage at the harness connector for the valve from the 5 VDC supply terminal of the position sensor to the sensor ground terminal.

Result: The measured voltage is not within the expected range. The fault is in the wiring between the suspect valve and the ECM P2 connector. Check all of the wiring between the suspect valve and the P2 connector. Refer to the Electrical Schematic for the engine. Replace the suspect wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

4. Create a Short Circuit at the Valve Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect valve. C. Fabricate a jumper wire that is 150 mm (6 inch) long. D. Install the jumper between the PWM signal and return pins on the connector for the suspect valve in order to create a short circuit.

Diagnostic codes

Result: An XXXX-6 is active with the jumper installed. Reconnect the valve. Start the engine. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed. If the XXXX-5 diagnostic code returns, then replace the valve. Refer to Disassembly and Assembly for the correct procedure. Note: If the NRS valve is replaced, use the electronic service tool to

perform the "EGR Valve Learn Reset". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

E. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. F. Remove the jumper wire.

Result: An XXXX-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 5.

5. Create a Short Circuit at the ECM Connector Result: An XXXX-6 diagnostic code was active with the jumper installed.

A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between the PWM supply wire and the return wire for the suspect valve on the J2 connector. Diagnostic D. Turn the keyswitch to the ON position. Wait at codes least 30 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve. E. Look for an active XXXX-6 diagnostic code for the suspect valve.

The fault is in the wiring between the suspect valve and the ECM P2 connector. Check all of the wiring between the suspect valve and the P2 connector. Refer to the Electrical Schematic for the engine. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: An XXXX-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 8.

F. Turn the keyswitch to the OFF position.

6. Create an Open Circuit at the Valve Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect valve in order to create an open circuit. C. Turn the keyswitch to the ON position. Check

Diagnostic Codes

Result: An XXXX-5 diagnostic code is active with the valve disconnected. Reconnect the valve. Start the engine. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed. If the XXXX-5 diagnostic code

for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed.

returns, then replace the valve. Refer to Disassembly and Assembly for the correct procedure. Note: If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: An XXXX-6 diagnostic code is still active with the valve disconnected. Proceed to Test Step 7.

Result: An XXXX-5 diagnostic code is active with the P2 connector disconnected.

7. Create an Open Circuit at the ECM Connector A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic Diagnostic codes. codes Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes and only look for codes that relate to the suspect valve.

The fault is in the wiring between the suspect valve and the ECM P2 connector. Check all of the wiring between the suspect valve and the P2 connector. Refer to the Electrical Schematic for the engine. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: An XXXX-6 diagnostic code is still active with the P2 connector disconnected.

D. Check for an active XXXX-5 diagnostic code for the suspect valve.

Proceed to Test Step 8. 8. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN). B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM".

Diagnostic codes

Result: There are no active diagnostic codes with the replacement ECM. Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair

C. Use the electronic service tool to recheck the system for active diagnostic codes.

eliminates the fault. Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06042298

NRS Mass Flow Rate Problem SMCS - 1088-035 This procedure covers the following diagnostic trouble code: Table 1 Diagnostic Trouble Codes J1939 Code

3358-10

Code Description

Comments The ECM detects an air leak in the Exhaust Gas Recirculation (EGR) system. The warning lamp will flash. The engine may be derated.

Engine Exhaust Gas Recirculation 1 Intake Pressure : Abnormal Rate of Change

Probable Causes • Diagnostic codes • Electrical connectors and harness • Air inlet and exhaust system

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps 1. Diagnostic Codes

Values Diagnostic

Results Result: A diagnostic code for

codes A. Connect the electronic service tool to the diagnostic connector. If necessary, refer to Troubleshooting, "Electronic Service Tools".

the EGR valve is active or logged. Rectify the EGR valve code. Refer to Troubleshooting, "Diagnostic Trouble Codes".

B. Turn the keyswitch to the ON position. Result: A 3358-10 diagnostic code is active.

C. Use the electronic service tool to check for active or logged codes.

Proceed to Test Step 2.

2. Inspect the Electrical Connectors and the Harness A. Turn the keyswitch to the OFF position. B. Inspect the connectors for the components in the EGR system. Refer to Troubleshooting, "Electrical Connector Inspect".

Result: An electrical connector or a cable is not correctly installed.

C. Perform a 30 N (6.7 lb) pull test on each of the wires in any suspect connector and the connections at the ECM. D. Check that the ground connection on the ECM and the negative terminal on the battery are correctly installed. E. Check the ground connection on the ECM for abrasions and pinch points.

Install the connector or cable correctly. Connectors and harness

Result: The harness is faulty. Install a replacement harness. Result: The harness and connectors are OK. Proceed to Test Step 3.

F. Check the harness for abrasion and pinch points from the EGR components to the ECM. H. Check that any suspect connector is installed correctly.

3. Check the Air Inlet and Exhaust System

Air inlet and Result: The air inlet system has exhaust system a leak or is restricted.

A. Check the air inlet system for leaks and for restrictions.

Clear any restrictions in the air inlet system.

B. Check the exhaust system for leaks and

Repair any air leaks in the air inlet system.

for restrictions. Result: The exhaust system has a leak or is restricted. Clear any restrictions in the exhaust system. Repair any air leaks in the exhaust system. If the fault is still present, contact the Dealer Solution Network (DSN).

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06226001

Oil Consumption Is Excessive SMCS - 1348-035

Probable Causes • Misreading oil level • Oil leaks • Engine crankcase breather • Oil level • Air intake and exhaust system • Turbocharger • Low compression (cylinder pressure)

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Misreading Oil Level A. Accurately measure the consumption of oil and fuel over a period of 50 engine hours.

Values Oil level

Results Result: The oil consumption is less than 0.1% of the fuel consumption. Oil consumption is within specification. Return the unit to service Result: The oil consumption is greater than 0.1% of the fuel consumption.

Proceed to Test Step 2.

Result: An oil leak is identified. Repair: Rectify the cause of the oil leak.

2. Oil Leaks A. Check for evidence of oil leaks on the engine.

Result: Oil is present in the coolant. Oil leaks

B. Check for evidence of oil in the coolant.

Repair:Refer to Troubleshooting, "Coolant Contains Oil". Result: No oil leaks are identified Proceed to Test Step 3.

Result: The engine crankcase breather is blocked or restricted. Repair: Clear the blockage or restriction. Result: Excessive oil is ejected from the outlet of the breather.

3. Engine Crankcase Breather A. Check the engine crankcase breather for blockage or restrictions. B. Check for excessive oil from the outlet of the breather.

Breather

C. Check the centrifugal breather for a mechanical failure.

Repair: Investigate the cause of the excessive oil content in the breather flow. If necessary, replace the element in the breather. Refer to Operation and Maintenance Manual, "Engine Crankcase Breather Element - Replace". Result: There is oil around the crankcase breather pressure relief valve.

D. Check for oil around the crankcase breather pressure relief valve.

Repair: Refer to Troubleshooting, "Crankcase Breather Ejects Oil". Result: No oil is ejected through the breather. Proceed to Test Step 4.

4. Oil Level A. Check for a high oil level in the engine.

Oil level

Result: The oil level in the engine is high. Repair: Make sure that the oil is not contaminated with fuel. Refer to Troubleshooting, "Oil Contains Fuel".

Make sure that the oil is not contaminated with coolant. Refer to Troubleshooting, "Oil Contains Coolant". Remove the excess oil. Result: The oil level is OK. Proceed to Test Step 5.

Result: The air filter restriction indicator has operated or the air filter is blocked. 5. Air Intake and Exhaust System

Repair: Make sure that the air filter is clean and serviceable. If necessary, replace the air filter.

A. Check the air filter restriction indicator, if equipped. B. Check the air intake and the exhaust system for the following defects:

Air intake and exhaust system

Result: The air intake or the exhaust system is blocked, restricted, or damaged. Repair: Repair the air intake or the exhaust system, as required.

· Blockages · Restrictions · Damage to the air intake and exhaust lines and hose

Result: The air intake or the exhaust system is OK. Proceed to Test Step 6.

Result: The oil drain for the turbocharger is blocked or restricted.

6. Turbocharger Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical fault exists, then the turbocharger must be replaced.

Repair: Remove the blockage or restriction. If necessary, replace the oil drain line. Turbocharger

A. Check that the oil drain for the turbocharger is not blocked or restricted.

Repair: Replace the turbocharger. Result: The turbocharger is OK.

B. Check the turbocharger for evidence of an internal oil leak.

7. Low Compression (Cylinder Pressure) A. Perform a compression test.

Result: The turbocharger has an internal oil leak.

Proceed to Test Step 7.

Cylinder compression

Result: The results of the compression test are outside the specifications. Repair: Investigate the cause and rectify

Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".

any faults. Note: Possible causes of low compression are shown in the following list: · Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06226024

Oil Contains Coolant SMCS - 1348-035; 1395-035

Probable Causes • Engine oil cooler • Cylinder head gasket • Cylinder head • Cylinder block

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Engine Oil Cooler A. Drain the engine lubricating oil and coolant from the engine. Check for leaks in the oil cooler assembly. Refer to Systems Operation, Testing, and Adjusting, "Cooling System" for the correct procedure.

Values

Results

Oil level

Result: Evidence of coolant in the oil system is identified. Repair: Install a new oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler Remove" and Disassembly and Assembly, "Engine Oil Cooler Install" for the correct procedure. Result: No evidence of coolant in the oil system is found.

Proceed to Test Step 2.

Result: The cylinder head gasket is faulty or shows signs of leakage.

2. Cylinder Head Gasket A. Remove the cylinder head. Refer to Cylinder Disassembly and Assembly, "Cylinder Head - head Remove" for the correct procedure. Inspect gasket the cylinder head gasket for faults and any signs of leakage.

Repair: Install a new cylinder head gasket. Result: The cylinder head gasket is OK. Proceed to Test Step 3.

Result: The cylinder head is not within specification for flatness. Repair: Install a new cylinder head. Refer to Disassembly and Assembly, "Cylinder Head Install" for the correct procedure.

3. Cylinder Head A. Check the cylinder head for flatness. Refer to Systems Operation, Testing, and Adjusting, "Cylinder Head - Inspect" for the correct procedure. B. Check the mating face of the cylinder head for faults and signs of leakage. If a fault is found, replace the cylinder head. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation, Testing, and Adjusting, "Cylinder Head - Inspect" for the correct procedure.

Result: The cylinder head shows signs of a fault or leakage. Cylinder head

Repair: Install a new cylinder head. Refer to Disassembly and Assembly, "Cylinder Head Install" for the correct procedure. Result: An internal core plug in the cylinder head shows signs of leakage.

C. Check the internal core plugs in the cylinder head for signs of leakage.

Repair: Replace the faulty core plug. Result: The cylinder head is OK. Proceed to Test Step 4.

4. Cylinder Block A. Inspect the top face of the cylinder block for faults and signs of leakage.

Cylinder block

Result: The top face of the cylinder block has a fault. Repair: Replace the cylinder block. Result: The top face of the cylinder block shows signs of

leakage. Repair: Determine the cause of the leakage. Refer to Systems Operation, Testing, and Adjusting, "Cylinder Block - Inspect" for the correct procedure. Result: The cylinder block is OK. Repair: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head Install". Remove the oil filter element. Install a new engine oil filter element. Fill the engine with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Change" for more information. Fill the cooling system. Refer to the Operation and Maintenance Manual for more information. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06008534

Oil Contains Fuel SMCS - 1250-035; 1348-035 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for Oil Contains Fuel J1939 Code

5055-17

Description

Engine Oil Viscosity : Low least severe (1)

Notes The Electronic Control Module (ECM) calculates that the amount of fuel in the engine oil is high. If equipped, the warning lamp will come on.

5055-18

Engine Oil Viscosity : Low moderate severity (2)

The ECM detects that the amount of fuel in the engine oil is very high. If equipped, the warning lamp will flash. The engine will be derated.

The engine ECM calculates the amount of fuel in the engine oil based on the engine operating conditions and the number of Diesel Particulate Filter (DPF) active regenerations since the last time the "Engine Oil Life Reset" was performed. Note: Before continuing with this procedure, ensure that the engine oil has been changed according to the maintenance schedule. Refer to Operation and Maintenance Manual, "Maintenance Interval Schedule". If the engine oil has been changed, ensure that the "Engine Oil Life Reset" is performed. Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change".

Measuring Fuel Dilution

Diesel fuel is chemically similar to the lubricants that are used in diesel engines. A slow fuel leak will blend the fuel into the oil. Normal operating temperatures may cause volatile parts of the fuel to vaporize. The fuel that remains in the oil is less volatile. A closed cup flash test can be performed in order to detect fuel dilution. The flash test is designed to measure the volatile parts of the fuel that are remaining in the oil. Detecting less volatile fuel is difficult. The less volatile fuel reduces the accuracy of the flash test. Since the flash test does not accurately detect fuel dilution, do not use the flash test as the only measure of fuel dilution. Instead, verify the dilution by the following methods: • Gas chromatograph fuel dilution test • Oil viscosity The test that uses a gas chromatograph is designed to measure fuel dilution in crankcase oils. The gas chromatograph can identify the small chemical differences between diesel fuel and lubricating oil. A gas chromatograph is used to measure fuel dilution at all Caterpillar regional SOS laboratories. Some Cat dealers also use a gas chromatograph. Even though the gas chromatograph provides a more accurate measure of fuel dilution, always verify the results with the viscosity test. A significant level of fuel dilution reduces oil viscosity. If an unacceptable level of fuel dilution is suspected, the kinematic viscosity of the oil must be measured. Fuel dilution that is greater than 10 percent will usually cause viscosity that is less than the specified viscosity grade. If the oil is still within the specified viscosity grade, fuel dilution has not reached an unacceptable level.

Verifying Fuel Dilution Verify fuel dilution by the combination of low oil viscosity and a gas chromatograph that gives a result in excess of 10 percent before investigating or servicing the engine. Ask the Cat dealer to submit an oil sample to a Caterpillar regional SOS laboratory for analysis if a fuel dilution test cannot be performed locally.

Probable Causes • Diagnostic codes • Maintenance interval schedule • Excessive use of active regeneration (wall flow DPF only) • Fuel injector seals • Fuel injector tip

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2

Troubleshooting Test Steps

Values

Results

1. Diagnostic Codes

Result: A 5055 diagnostic code is active.

A. Connect the electronic service tool to the diagnostic connector.

Proceed to Test Step 2.

B. Use the electronic service tool to check for an active 5055 diagnostic code.

Diagnostic codes

Proceed to Test Step 3.

Result: The number of hours since the last "Engine Oil Life Reset" is greater than the maintenance interval for an oil change.

2. Maintenance Interval Schedule A. Use the electronic service tool to check the number of hours since the last "Engine Oil Life Reset" was performed. B. Compare the number of hours since the last "Engine Oil Life Reset" to the maintenance interval for an oil change. Refer to Operation and Maintenance Manual, "Maintenance Interval Schedule".

Result: A 5055 diagnostic code is not active.

Greater than oil change interval

Change the engine oil and perform the "Engine Oil Life Reset". Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change". Result: The number of hours since the last "Engine Oil Life Reset" is less than the maintenance interval for an oil change. Proceed to Test Step 3.

3. Excessive Use of Active Excessive Regeneration regeneration Note: This step is only applicable to engines equipped with a wall flow DPF. A. Excessive use of active regeneration may cause excessive fuel in the engine oil. Refer to Troubleshooting, "Diesel Particulate Filter Active Regeneration Occurrence Is Excessive".

Result: There is excessive use of active regeneration. Make any necessary repairs. Refer to Troubleshooting, "Diesel Particulate Filter Active Regeneration Occurrence Is Excessive". Change the engine oil and perform the "Engine Oil Life Reset". Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change". Result: There is no excessive use of active regeneration. Proceed to Test Step 4.

Result: Injector seals are damaged.

4. Fuel Injector Seals A. Check for signs of damage to the seals for the fuel injectors.

Fuel injector seals

Replace any damaged injector seals. Change the engine oil and perform the "Engine Oil Life Reset". Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change". Result: All injector seals are OK. Proceed to Test Step 5.

Result: A fuel injector is damaged.

5. Fuel Injector Tip A. Check for signs of damage to the fuel injectors. Check the fuel injector tip for cracks or breakage.

Fuel injector tip

Replace the fuel injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install". Change the engine oil and perform the "Engine Oil Life Reset". Refer to Operation and Maintenance Manual, "Engine Oil and Filter Change". Result: All fuel injectors are OK. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06226085

Oil Pressure Is Low SMCS - 1348-035-PX This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for Low Engine Oil Pressure J1939 Code

Description

Notes The Electronic Control Module (ECM) detects that the engine oil pressure is low.

100-17

Engine Oil Pressure : Low least severe (1)

The engine speed is greater than 500 RPM. If equipped, the warning lamp will come on and the oil pressure lamp will come on.

NOTICE Do not operate the engine with low oil pressure. Engine damage will result. If measured oil pressure is low, discontinue engine operation until the fault is corrected.

The Electronic Control Module (ECM) monitors the engine oil pressure.

Probable Causes • Visible Leaks

• Engine oil level • Oil specification • Engine oil filter • Engine oil pressure switch • Engine oil relief valve • Engine oil cooler • Fuel in the engine oil • Piston cooling jets • Engine oil suction tube • Engine oil pump • Bearing clearance

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 2 Troubleshooting Test Steps

Values

Results Result: There are visible oil leaks.

1. Visible Leaks

Repair: Repair any leaks.

A. Thoroughly inspect the engine for Visible leaks oil leaks.

Result: There are no visible oil leaks Proceed to Test Step 2.

Result: The engine oil level is low. 2. Engine Oil Level Oil level A. Check the engine oil level.

Repair: Fill the oil system to the full mark on the dipstick. Result: The engine oil level is OK. Proceed to Test Step 3.

3. Oil Specification A. Check that engine oil of the

Oil specification

Result: An incorrect specification of engine oil is being used.

correct specification is being used. Refer to the Operation and Maintenance Manual, "Refill Capacities and Recommendations".

Repair: Drain the oil system and refill the oil system with engine oil of the correct specification. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change". Result: The engine contains oil of the correct specification. Proceed to Test Step 4.

Result: The oil filter is blocked. Repair: Install a new oil filter. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter Change" for further information.

4. Engine Oil Filter A. Remove the engine oil filter. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Change".

Oil filter

Result: The oil filter is OK. Repair: Install a new oil filter. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter Change" for further information.

B. Inspect the engine oil filter for evidence of blockage.

Proceed to Test Step 5.

Result: There is a fault with the oil pressure switch circuit. 5. Engine Oil Pressure Switch A. Ensure that the engine oil pressure switch is operating correctly. Refer to Troubleshooting, "Switch Circuits - Test (Engine Oil Pressure Switch)".

Engine Oil Pressure Switch

Repair: Make any necessary repairs. Refer to Troubleshooting, "Switch Circuits - Test (Engine Oil Pressure Switch)". Result: The oil pressure switch circuit is OK. Proceed to Test Step 6.

6. Engine Oil Relief Valve A. Inspect the engine oil relief valve for damage.

Damage

Result: The engine oil relief valve is damaged. Repair: Replace the oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief Valve - Remove and Install".

Result: The engine oil relief valve is OK. Proceed to Test Step 7.

Result: The oil cooler has signs of damage or restriction. 7. Engine Oil Cooler A. Check the oil cooler for signs of damage or restrictions.

Oil cooler

Repair: Install a new oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install". Result: The oil cooler is OK. Proceed to Test Step 8.

Result: The oil contains fuel. 8. Fuel in the Engine Oil Oil A. Check fuel contamination of the contamination engine oil. Refer to Troubleshooting, "Oil Contains Fuel".

Repair: Refer to Troubleshooting, "Oil Contains Fuel". Result: The oil is not contaminated. Proceed to Test Step 9.

Result: A piston cooling jet is cracked, damaged, or missing. 9. Piston Cooling Jets A. Inspect the piston cooling jets for cracks, damage, or missing jets.

Piston cooling jets

Result: Install a new piston cooling jet. Refer to Disassembly and Assembly, "Piston Cooling Jets Remove and Install". Result: The piston cooling jets are OK. Proceed to Test Step 10.

10. Engine Oil Suction Tube A. Check the inlet screen on the oil suction tube and remove any material that may be restricting oil flow.

Oil suction tube Result: The inlet screen on the oil suction tube is blocked with debris. Repair: Remove the debris from the inlet screen.

Result: The oil suction tube is cracked.

B. Check the joints of the oil suction tube for cracks or a damaged joint.

Repair: Install a new oil suction tube. Note: Cracks or damage may allow air leakage into the supply to the oil pump.

Result: The oil suction tube is OK. Proceed to Test Step 11.

Result: A component in the oil pump is not within specification.

11. Engine Oil Pump A. Inspect the components of the engine oil pump for excessive wear.

Oil pump

Repair: Repair the oil pump or replace the oil pump, if necessary. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove" and Disassembly and Assembly, "Engine Oil Pump - Install". Result: The oil pump is OK. Proceed to Test Step 12.

Result: An engine bearing is not within specification.

12. Bearing Clearance A. Inspect the engine components for excessive bearing clearance or damaged bearings. Inspect the following components for excessive bearing clearance: · Crankshaft main bearings · Connecting rod bearings · Camshaft front bearing · Idler gear bearing

Repair: Install a new bearing. Refer to Disassembly and Assembly. Bearing clearance

Result: All engine bearings are within specification. Repair: If the fault is still present there may be an open circuit condition in the oil pressure switch circuit. Refer to Troubleshooting, "Switch Circuits Test (Engine Oil Pressure Switch)".

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06015862

Oxygen Level - Test SMCS - 1096-038 This procedure covers the following diagnostic codes: Table 1 Diagnostic Trouble Codes for the Oxygen Sensor Circuit J1939 Code

Description

Notes

3217-3

Aftertreatment #1 Intake O2 : Voltage Above Normal

The Electronic Control Module (ECM) detects a fault in the circuit for the oxygen sensor.

3217-4

Aftertreatment #1 Intake O2 : Voltage Below Normal

The fault detected is either an open circuit or short circuit in the current pump, the ground, the current adjust or the voltage signal.

321915

Aftertreatment #1 Intake Gas The Electronic Control Module (ECM) detects a fault in Sensor at Temperature : High - least the circuit for the oxygen sensor. severe (1)

321917

The fault detected is either an open circuit or short circuit Aftertreatment #1 Intake Gas Sensor at Temperature : Low - least in the current pump, the ground, the current adjust or the voltage signal. severe (1)

3217-5

Aftertreatment #1 Intake O2 : Current Below Normal

The Electronic Control Module (ECM) detects a fault in the circuit for the oxygen sensor.

3217-6

Aftertreatment #1 Intake O2 : Current Above Normal

The fault detected is either an open circuit or short circuit in the current pump, the ground, the current adjust, the voltage signal or the heater circuit.

321713

Aftertreatment #1 Intake O2 : Out of Calibration

The Electronic Control Module (ECM) detects a fault in the circuit for the oxygen sensor.

321715

Aftertreatment #1 Intake O2 : High - least severe (1)

The fault detected is either an open circuit or short circuit in the current pump, the ground, the current adjust, the voltage signal or the heater circuit.

321712

Aftertreatment #1 Intake O2 : Failure

The ECM is unable to read any valid data from the oxygen sensor.

3222-3

Aftertreatment #1 Intake Gas Sensor Heater : Voltage Above Normal

The ECM detects a short to battery voltage in the heater circuit for the oxygen sensor.

3222-4

Aftertreatment #1 Intake Gas Sensor Heater : Voltage Below Normal

The ECM detects a short to ground in heater circuit for the oxygen sensor.

3222-5

Aftertreatment #1 Intake Gas Sensor Heater : Current Below Normal

The ECM detects an open circuit in the heater circuit for the oxygen sensor.

The oxygen sensor is used to monitor the oxygen in the engine exhaust. The ECM utilizes the signal from the oxygen sensor to ensure that the engine burns the fuel efficiently and reduces excessive build-up of soot in the Diesel Particulate Filter (DPF). The oxygen sensor generates a voltage signal that is directly proportional to the concentration of oxygen. This voltage signal cannot be measured accurately with a multimeter. The signal can only be interpreted correctly by the software that is contained in the ECM. A heater circuit within the oxygen sensor ensures that a build-up of condensation does not damage the sensor.

Illustration 1 Schematic diagram for the oxygen sensor Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03617457

Illustration 2 View of the pin locations on the P1 connector for the oxygen sensor (7) Sensor heating ground (63) Voltage signal (64) Current pump (85) Virtual ground (86) Current adjust

g02724356

Illustration 3

g03114187

View of the pin locations on the harness connector for the oxygen sensor (view from the front) (1) Current pump (2) Virtual ground (3) Sensor heating ground (4) Sensor heating power supply (switched battery +) (5) Current adjust (6) Voltage signal

Table 2 Troubleshooting Test Steps 1. Check for Active or Recently Logged Diagnostic Codes

Values Diagnostic codes

Results Result: There are other active or recently logged diagnostic codes that are not listed in this procedure.

A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. If the engine will start, run the engine for 15

Troubleshoot all other diagnostic codes before returning to this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes" Result: Only diagnostic codes that are listed

minutes or until one of the diagnostic codes listed in Table 1 is active.

in this procedure are active or recently logged.

D. Use the electronic service tool to check for active or recently logged diagnostic codes.

Proceed to Test Step 2.

E. Turn the keyswitch to the OFF position.

2. Inspect Electrical Connectors And Wiring Result: A damaged wire or damaged connector was found. A fuse is blown.

A. Check the fuses. B. Thoroughly inspect the connector for the oxygen sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect". C. Thoroughly inspect the P1/J1 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Damaged wire or connector

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the connectors that are associated with the oxygen sensor.

Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

E. Check the harness for abrasions and for pinch points from the oxygen sensor back to the ECM and from the oxygen sensor to the battery supply.

3. Check for Active or Recently Logged Diagnostic Codes A. Turn the keyswitch to the ON position. If the engine will start, run the engine for 15 minutes. B. Use the electronic service tool to check for active diagnostic codes.

Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool in order to clear all logged diagnostic codes. Run the engine for at least 15 minutes and check for active diagnostic codes to ensure that the repair eliminates the fault.

Proceed to Test Step 3.

Diagnostic codes

Result: One of the following diagnostic codes is active or recently logged: · 3217-5 · 3217-6 · 3217-13 · 3217-15 · 3222-3 · 3222-4 · 3222-5

C. Turn the keyswitch to the OFF position. Proceed to Test Step 4. Result: One of the following diagnostic codes is active or recently logged:

· 3217-3 · 3217-4 · 3219-15 · 3219-17 Proceed to Test Step 7. Result: A 3217-12 diagnostic code is active or recently logged. Proceed to Test Step 10.

Result: The measured voltage is not within the expected range. 4. Check the Voltage to the Oxygen Sensor Heater A. Turn the keyswitch to the OFF position. B. Disconnect the oxygen sensor. C. Turn the keyswitch to the ON position.

10 V to 14 V

D. Use a suitable multimeter to measure the voltage between pin 4 on the harness connector for the oxygen sensor and a suitable ground.

The fault is in the 12 V power supply wiring to the oxygen sensor. Check all the wiring between the oxygen sensor and the battery. Refer to the Electrical Schematic for the application. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes. Run the engine for 15 minutes and use the electronic service tool to verify that the repair eliminates the fault. Result: The measured voltage is within the expected range.

E. Turn the keyswitch to the OFF position.

Proceed to Test Step 5.

5. Check the Resistance of the Oxygen Sensor Heater A. Turn the keyswitch to the OFF position. B. Disconnect the oxygen sensor. C. Measure the resistance between pin 3 and pin 4 on the oxygen sensor. Note: Allow the oxygen sensor to cool before performing this measurement.

2.4 to 4 Ohms

Result: The measured resistance is not within the expected range. Replace the oxygen sensor. Refer to Disassembly and Assembly, "Oxygen Sensor - Remove and Install". Use the electronic service tool to perform the following resets: · "Lambda Sensor Replacement Reset" · "Lambda Sensor Learn Reset" · "Lambda Sensor Temperature Learn Reset"

Use the electronic service tool to clear all logged diagnostic codes. Run the engine for 15 minutes and use the electronic service tool to verify that the repair eliminates the fault. Result: The measured resistance is within the expected range. Proceed to Test Step 6.

Result: The measured resistance is greater than 5 Ohms.

6. Check the Sensor Heater Ground Wire A. Turn the keyswitch to the OFF. B. Disconnect the oxygen sensor. Less than 5 Disconnect the P1 connector from the ECM. Ohms C. Use a suitable multimeter to measure the resistance between terminal 3 on the harness connector for the oxygen sensor and P1:7.

The fault is in the wiring between the oxygen sensor and the ECM. Check all of the wiring between the oxygen sensor and the ECM. Refer to the Electrical Schematic for the application. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes. Run the engine for 15 minutes and use the electronic service tool to verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. If a 3222 diagnostic code is active, proceed to Test Step 10. If a 3217 diagnostic code is active, return all wires to the original configuration and proceed to Test Step 7.

7. Check the Wiring for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the oxygen sensor. Disconnect the P1 connector. C. Use a suitable multi meter to measure the

Less than 5 Ohms

Result: At least one of the resistance measurements is greater than 5 Ohms. There is an open circuit or high resistance in the wiring between the oxygen sensor connector and the P1 connector. Check all wiring between the oxygen sensor and the ECM. Refer to the Electrical Schematic for the application.

resistance between the following points: · Terminal 1 on the connector to P1:64 · Terminal 2 on the connector to P1:85 · Terminal 5 on the connector to P1:86 · Terminal 6 on the connector to P1:63

Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

oxygen sensor oxygen sensor oxygen sensor

Result: All resistance measurements are less than 5 Ohms.

oxygen sensor

Proceed to Test Step 8. Result: At least one of the resistance measurements is less than 1 k Ohm. There is a short circuit in the wiring between the oxygen sensor connector and the ECM.

8. Check the Wiring for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the oxygen sensor connector. Disconnect the P1 connector from the ECM. Greater than 1 k Ohm C. Use a suitable multimeter to measure the resistance from each terminal on the harness connector for the oxygen sensor to every other terminal on the harness connector for the oxygen sensor.

Check all wiring between the oxygen sensor and the ECM. Refer to the Electrical Schematic for the application. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: All resistance measurements are greater than 1 k Ohm. Proceed to Test Step 9.

9. Check if a Replacement Sensor Eliminates the Fault A. Replace the oxygen sensor. Refer to Disassembly and Assembly, "Oxygen Sensor - Remove and Install" for the correct procedure. B. Use the electronic service tool to perform the following resets: · "Lambda Sensor Replacement Reset" · "Lambda Sensor Learn Reset" · "Lambda Sensor Temperature Learn

Diagnostic codes

Result: The fault is cleared with the replacement sensor installed. Use the electronic service tool to clear all logged diagnostic codes. Result: The fault is still present with the replacement sensor. Install the original sensor and proceed to Test Step 10.

Reset" C. Turn the keyswitch to the ON position. If the engine will start, run the engine for 15 minutes. D. Use the electronic service tool to check for active diagnostic codes that relate to the oxygen sensor. E. Check for active diagnostic codes.

10. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN). Diagnostic B. If the DSN recommends the use of a codes replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06226122

Power Is Intermittently Low or Power Cutout Is Intermittent SMCS - 1000-035-PWR Note: Use this procedure only if the engine does not shut down completely.

Probable Causes • Diagnostic codes • Electrical connectors • ECM connection • Fuel system inspection • Air inlet and exhaust system

Recommended Actions NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1

Troubleshooting Test Steps

Values

Result: There are active or logged codes.

1. Diagnostic Codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.

Results

Diagnostic codes

Repair: Troubleshoot any codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no active or logged codes.

B. Use the electronic service tool to check for active diagnostic codes.

Proceed to Test Step 2.

Result: An electrical connector is damaged. 2. Electrical Connectors

Repair: Repair the electrical connector or replace the electrical connector.

A. Check all electrical connectors for damage. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Result: A connector seal is displaced or missing or an electrical connector is not correctly installed.

Electrical connectors

B. Make sure that all the connector seals are in place and that the connectors have been correctly installed.

Repair: Repair the electrical connector or replace the electrical connector. Result: All electrical connectors are OK. Proceed to Test Step 3.

Result: An ECM connector is not correctly installed.

3. ECM Connection A. Check that the P2/J2 and P1/J1 connectors are correctly installed. Note: If a fault is suspected with the ECM power or ground connections, refer to Troubleshooting, "Electrical Power Supply - Test".

ECM connection

Repair: Repair the electrical connector or replace the electrical connector. Result: Both ECM connectors are correctly installed. Proceed to Test Step 4.

4. Fuel System Inspection

Fuel System

A. Check that the fuel shut-off valve is in the OPEN position.

Result: A defect was found in the fuel system. Repair: Make any necessary repairs.

B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).

Result: No defects found. Proceed to Test Step 5.

C. Check for fuel supply lines that are restricted. D. Check that the low-pressure fuel lines are correctly installed. E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test" F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test". G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".

5. Fuel Filters A. Replace the primary fuel filter and the secondary fuel filter. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".

Result: The fault has been rectified. Return the engine to service. Fault cleared Result: The fault is still present.

B. Run the engine in the conditions that the fault occurred.

6. Air Inlet and Exhaust System

Proceed to Test Step 6.

Defects

Result: A defect was found in the air intake or exhaust system.

A. Check the air filter restriction indicator. B. Ensure that the air filter is clean and serviceable

Repair: Make any necessary repairs. Result: No defects found in the air

intake or exhaust systems. C. Check the air intake and exhaust systems for the following defects: · Blockages · Restrictions · Damage to lines or hoses

Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06230595

Power Take-Off - Test SMCS - 1165-038-ZS; 7332-038 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes J1939 Code

Code Description

Comments The Electronic Control Module (ECM) detects one of the following conditions:

976-2

PTO Governor State : Erratic, Intermittent, or Incorrect

One of the PTO switches was pressed within 2.5 seconds of the keyswitch being turned on. OR One of the PTO switches was pressed for more than 10 seconds. OR Two PTO switches were pressed at the same time for at least 0.5 seconds. The battery voltage is at least 10 VDC. The warning lamp will come on.

Follow the troubleshooting procedure in order to identify the root cause of the problem.

Illustration 1

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Schematic diagram for the PTO switches Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 2

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View of the pin locations on the P1 connector for the PTO switches (9) PTO mode - OFF (10) PTO mode - resume (31) PTO mode - raise (32) PTO mode - lower

Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position.

Damaged wire or connector

Result: A damaged wire or damaged connector was not found. The fuses are OK. Proceed to Test Step 2. Result: A damaged wire or damaged connector was found. A fuse is blown.

B. Check the fuses. C. Perform a 30 N (6.7 lb) pull test on each wire in the PTO switch connectors and on each wire in the ECM connector that is associated with the PTO switches.

Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

D. Check the harness for corrosion, abrasion, and pinch points from the PTO switches to the ECM and the battery supply.

Result: A 976-2 diagnostic code is active. Proceed to Test Step 3. 2. Check for Active Diagnostic Codes

Result: A 976-2 diagnostic code is recently logged.

A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position.

Diagnostic Trouble Codes

D. Check the "Active Diagnostic Codes" screen. Look for an active or recently logged 976-2 diagnostic code.

Repair: The logged code may be caused by operating the PTO switches in one of the conditions that are listed in Table 1 or an intermittent fault may exist. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults. Result: There is no active or recently logged 976-2 diagnostic code. If the switches are not operating correctly, an open circuit may exist. Proceed to Test Step 3.

3. Check the PTO Mode Switches on the Electronic Service Tool A. Turn the keyswitch to the OFF position.

Switch status

Result: The status of each switch changes when the switch is operated. The fault appears to be resolved. Return the engine to service.

B. Connect the electronic service tool to the diagnostic connector.

Result: One of the switches indicates "OPEN" even when the switch is pressed.

C. Turn the keyswitch to the ON position.

Proceed to Test Step 4.

D. Observe the status of the PTO switch on the electronic service tool while the PTO on/off switch is cycled.

Result: One of the switches indicates "CLOSED" even when the switch is not pressed.

E. Use the electronic service tool in order to observe the status of the PTO mode switch while the PTO lower/raise switch is cycled.

Proceed to Test Step 6.

F. Use the electronic service tool in order to observe the status of the PTO switch while the PTO Resume switch is cycled.

4. Check the Power Supply to the Suspect Switch Result: The measured voltage is within the expected range.

A. Turn the keyswitch to the OFF position. B. Disconnect the battery supply wire from the suspect switch.

Proceed to Test Step 6. 10 V to 14 V

C. Turn the keyswitch to the ON position.

Proceed to Test Step 5.

D. Check the voltage between the battery supply wire to the suspect switch and a suitable ground.

5. Check the Wiring Between the Suspect switch and the ECM Main Power Relay A. Turn the keyswitch to the OFF position. B. Disconnect the battery supply wire from the suspect switch. C. Disconnect the ECM main relay.

Result: The measured voltage is not within the expected range.

Less than 5 Ohms

Result: The measured resistance is greater than 5 Ohms. The fault is in the wiring between the suspect switch and the ECM main relay Repair: Check all wiring between the suspect switch and the ECM main relay. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

D. Use a multimeter to measure the resistance between the disconnected wire and terminal 87 on the harness connector for the ECM main relay.

Result: The measured resistance is less than 5 Ohms. Repair: Refer to Troubleshooting, "Relay Test (ECM Main Relay)" in order to test the circuit for the ECM main relay.

Result: When the jumper wire is connected, the status of the suspect PTO switch is "CLOSED". When the jumper wire is disconnected, the status of the suspect PTO switch is "OPEN".

6. Create at Short Circuit at the Switch A. Turn the keyswitch to the OFF position.

Repair: Replace the switch. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the problem.

B. Disconnect the connector for the suspect switch. C. Fabricate a jumper wire and install the Switch jumper wire between the two terminals for status the switch.

Result: When the jumper wire is disconnected, the status of the suspect PTO switch is "CLOSED".

D. Turn the keyswitch to the ON position. Reconnect the switch and proceed to Test Step 7.

E. Monitor the status screen on the electronic service tool while the jumper wire is being disconnected and reconnected.

Result: When the jumper wire is connected, the status of the suspect PTO switch is "OPEN". Proceed to Test Step 8.

7. Check the Switch Return Wire for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect switch. Disconnect the P1 connector from the ECM. C. Use a suitable multimeter to measure the resistance between the terminal for the suspect switch on the P1 connector and all

Greater than 1 k Ohm

Result: At least one of the resistance measurements is less than 1 k Ohm. There is a short in the wiring between the suspect switch and the P1 ECM connector. Repair: Check all wiring between the suspect switch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

other terminals on the P1 connector.

Result: All resistance measurements are greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

Result: The measured resistance is greater than 5 Ohms. The fault is in the wiring between the suspect switch and the P1 connector.

8. Measure the Resistance of the Switch Return Wire to the ECM A. Disconnect the P1 connector from the ECM. B. Thoroughly inspect the J1/P1 connectors on the ECM. Refer to Troubleshooting, "Electrical Connectors Inspect" for details.

Less than 5 Ohms

C. Measure the resistance between the appropriate pin on the P1 connector for the suspect switch and the wire to the suspect switch. Refer to Illustration 1.

Repair: Check all wiring between the suspect switch and the P1 connector. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the fault. Result: The measured resistance is less than 5 Ohms. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06230637

Relay - Test - ECM Main Relay SMCS - 4493-038 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes J1939 Code

1485-7

148514

Code Description

ECM Main Relay : Not Responding Properly

ECM Main relay : Special Instruction

Comments The Electronic Control Module (ECM) detects that the battery supply voltage is still present 0.5 seconds after the shut-off request from the ECM. The warning lamp will come on. The ECM is receiving battery voltage after the keyswitch has been turned OFF, which will drain battery power. The ECM requires battery voltage for up to 60 seconds after the keyswitch has been turned OFF. A fault is caused when the ECM has lost battery voltage before this period has elapsed. The fault is detected the next time the keyswitch is turned ON. The diagnostic code becomes active when the fault is detected for three consecutive starts. The warning lamp will come on. This condition is most likely caused by shutting the engine down using the battery disconnect switch instead of the keyswitch for three consecutive shutdowns or using the battery disconnect switch immediately after the keyswitch has been turned OFF.

284014

ECU Instance : Special Instruction

The ECM was unable to write data to the internal memory. This condition is most likely caused by removing battery power from the ECM while the ECM was attempting to write data to the internal memory.

Follow the troubleshooting procedure in order to identify the root cause of the problem.

Illustration 1 Schematic diagram for the ECM main relay Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03729651

Illustration 2

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View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit (1) Battery+ (2) Battery ground (3) Battery+ (4) Battery ground (5) Battery+ (6) Battery ground (28) ECM main relay (54) Ignition key switch

Table 2 Troubleshooting Test Steps

Values

1. Inspect Electrical Connectors and Wiring A. Check the fuses. B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly inspect the Damaged connector for the ECM main relay. Refer wire or to Troubleshooting, "Electrical connector Connectors - Inspect" for details. C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the main relay.

Results

Result: A damaged wire or damaged connector was not found. The fuses are OK. Proceed to Test Step 2. Result: A damaged wire or damaged connector was found. A fuse is blown. Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

2. Check for Diagnostic Codes A. Turn the keyswitch to the OFF position.

Diagnostic Trouble Codes

Result: A 1485-7 diagnostic code is active or recently logged. Proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic connector.

Result: A 1485-14 or 2840-14 diagnostic code is active or recently logged.

C. Turn the keyswitch to the ON position.

Repair: Ensure that the correct procedure is used to shut down the engine. Refer to Operation and Maintenance Manual, "Stopping the Engine". If the engine is being shut down correctly, an intermittent fault may be causing the ECM to lose battery power. Refer to Troubleshooting, "Electrical Power Supply - Test" and refer to Troubleshooting, "Electrical Connectors Inspect".

D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.

Result: The resistance measurement indicates "Open Circuit"

3. Check the ECM Main Relay

Proceed to Test Step 4.

A. Turn the keyswitch to the OFF position. B. Disconnect the ECM main relay.

Open circuit

C. Measure the resistance between Test Point C (terminal 30) and Test Point D (terminal 87) on the relay.

4. Check the Wiring Between the Relay and the ECM

Result: The resistance measurement indicates continuity between Test Point C and Test Point D on the relay. Repair: Replace the ECM main relay. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: The voltage measurement is 0 VDC. Contact the Dealer Solution Network (DSN).

A. Turn the keyswitch to the OFF position. B. Disconnect the ECM main relay. Disconnect the P1 connector. C. Measure the voltage between Test Point A (terminal 86) and Test Point B (terminal 85) on the harness connector

Result: The voltage measurement indicates battery voltage. The wiring between Test Point B on the harness connector for the relay and P1:28 is shorted to ground. Repair: Check all wiring between the ECM main relay and the P1 connector. Refer to the

for the ECM main relay.

Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

If the procedure did not correct the issue, contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06230630

Relay - Test - Start Relay SMCS - 4493-038 This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for the Starting Motor Relay J1939 Code

677-3

Description

Engine Starter Motor Relay : Voltage Above Normal

Notes The Electronic Control Module (ECM) detects the following conditions: A short circuit to battery in the circuit for the starting motor relay while no start request is detected. The battery voltage is between 9.5 and 16 VDC. The warning lamp will come on. The start relay circuit will be disabled.

677-5

Engine Starter Motor Relay : Current Below Normal

The ECM detects the following conditions: A low current condition on the circuit for the starting motor relay while no start request is detected. The battery voltage is between 9.5 and 16 VDC. The warning lamp will come on. The start relay circuit will be disabled.

677-6

Engine Starter Motor Relay : Current Above Normal

The ECM detects the following conditions: A high current condition (short circuit) in the circuit for the starting motor relay. The battery voltage is between 9.5 and 16 VDC. If equipped, the warning lamp will come on. The engine

may be derated. The start relay circuit will be disabled.

1041-2

Start Signal Indicator : Erratic, Intermittent, or Incorrect

This diagnostic code indicates that the start signal has remained active for too long. This condition may be caused by the keyswitch being held in the START position for too long. The warning lamp will come on.

Illustration 1 Schematic diagram for the start relay circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03730757

Illustration 2

g02731945

View of the pin locations on the P1 connector for the starting motor relay (8) Start signal (27) Starting motor relay return (53) Starting motor relay control

The following background information is related to this procedure: When the keyswitch is turned to the START position, a signal is sent to pin P1:8 on the engine ECM. Power is supplied from P1:53 to the starting motor relay. The starting motor relay supplies battery power to the relay solenoids in the starting motor. This internal relay provides high current battery voltage to the starting motor. Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Check the fuses. B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly inspect the connector for the start relay. Refer to Troubleshooting, "Electrical Connector Inspect" for details.

Values Damaged wire or connector

Results Result: A damaged wire or damaged connector was not found. The fuses are OK. Proceed to Test Step 2. Result: A damaged wire or damaged connector was found. A fuse is blown.

C. Inspect the connections on the starting motor. D. Perform a 30 N (6.7 lb) pull test on each of the

Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses.

wires that are associated with the start relay.

Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

Result: Diagnostic code 677-5 is active. Proceed to Test Step 3. Result: Diagnostic code 677-6 or 677-3 is active. Proceed to Test Step 5. Result: A 1041-2 diagnostic code is active or recently logged.

2. Check for Active or Recently Logged Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. B. If the engine will start, then start the engine.

Diagnostic Trouble Codes

C. Make a note of any active diagnostic codes.

If a 1041-2 diagnostic code is recently logged, this may be caused by the keyswitch being held in the START position for too long. If a 1041-2 diagnostic code is active without the keyswitch being held in the START position, proceed to Test Step 9. Result: An active diagnostic code was not displayed. There may be a fault with the start signal from the keyswitch or the power circuit for the starting motor. The ECM does not monitor the status of these conditions. Proceed to Test Step 7.

3. Create a Short Circuit at the Starting Motor Relay

Diagnostic codes

Result: A 677-6 diagnostic code was active with the jumper installed.

A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the starting motor relay.

Repair: Install a replacement starting motor. Refer to Disassembly and Assembly,

"Electric Starting Motor Remove and Install". Use the electronic service tool to check for an active 677-5 diagnostic code. Confirm that the fault has been eliminated.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. D. Use the jumper wire to connect pin 1 to pin 2 on the harness connector for the starting motor relay. E. Turn the keyswitch to the ON position.

Result: A 677-5 diagnostic code is still active with the jumper installed.

F. Use the electronic service tool to check for an active 677-6 diagnostic code. G. Turn the keyswitch to the OFF position.

Reconnect the starting motor relay and proceed to Test Step 4.

H. Remove the jumper.

Result: Each resistance measurement is less than 5 Ohms. Contact the Dealer Solution Network (DSN).

4. Check the Wiring Between the Start Relay and the ECM for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the starting motor relay connector. Disconnect the P1 connector. C. Use a suitable multimeter to measure the resistance between the following points:

Less than 5 Ohms

Repair: Check all wiring between the start relay connector and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

· P1:53 to terminal 1 on the harness connector for the start relay · P1:27 to terminal 2 on the harness connector for the start relay

5. Create an Open Circuit at the Relay

Result: At least one of the resistance measurements is greater than 5 Ohms. There is open circuit or high resistance in the wiring between the start relay connector and the P1 connector.

Diagnostic codes

A. Turn the keyswitch to the OFF position.

Result: A 677-5 diagnostic code became active with the starting motor relay disconnected.

B. Disconnect the starting motor relay connector.

Repair: Install a replacement

starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor Remove and Install". Use the electronic service tool to check for an active 677-5 diagnostic code. Confirm that the fault has been eliminated.

C. Turn the keyswitch to the ON position. D. Use the electronic service tool to check for an active 677-5 diagnostic code. E. Turn the keyswitch to the OFF position. F. Reconnect the starting motor relay connector.

Result: A 677-6 diagnostic code is still active with the starting motor relay disconnected. Proceed to Test Step 6.

Result: Each resistance measurement is greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

6. Check the Wiring Between the Start Relay and the ECM for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the start relay connector. Disconnect the P1 connector from the ECM.

Greater than 1 k Ohm

C. Use a multimeter to measure the resistance between the following points:

Repair: Check all wiring between the start relay connector and the P1 connector. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

· P1:53 and all other terminals on the P1 connector · P1:27 and all other terminals on the P1 connector

7. Check the Start Signal Wire A. Turn the keyswitch to the OFF position. B. Disconnect the P1 connector from the engine ECM.

Result: At least one of the resistance measurements is less than 1 k Ohm. There is a short in the wiring between the start relay connector and the P1 connector.

10 V to 14 V

Result: The measured voltage is less than 10 V. The fault is in the start signal wiring. Repair: Check all of the start

C. Use a suitable voltmeter to measure between P1:8 and ground.

signal wiring between the ignition keyswitch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

D. With the keyswitch held in the START position, note the voltage on the voltmeter. E. Turn the keyswitch to the OFF position. F. Reconnect the P1 connector to the engine ECM.

Result: The measured voltage is within the expected range. Proceed to Test Step 8.

Result: All voltage readings are OK Repair: Replace the starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".

8. Check the Wiring Between the Batteries and the Starting Motor A. Use a voltmeter to check the voltage between the battery+ terminal on the starting motor and a suitable ground on the engine. The voltmeter must read battery voltage. If the reading is less than battery voltage, there is a fault in the wiring between the battery positive 10 V to 14 terminal and the starting motor. V B. Use a voltmeter to check the voltage between the battery+ terminal and the ground terminal on the starting motor. The voltmeter must read battery voltage. If the reading is less than battery voltage, there is a fault in the wiring between the battery negative terminal and the starting motor.

9. Check the Start Signal Voltage at the ECM Connector A. Turn the keyswitch to the OFF position.

Result: At least one of the measured voltages is not within the expected range. The fault is in the wiring between the batteries and the starting motor. Repair: Check all wiring between the batteries and the starting motor. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

10 V to 14 V

Result: The voltage is within the expected range. Proceed to Test Step 10.

B. Disconnect the P1 connector from the ECM.

Result: There is no voltage present.

C. Turn the keyswitch to the ON position. Do not attempt to start the engine.

Contact the Dealer Solution Network (DSN).

D. Use a suitable multimeter to measure the voltage between P1:8 and a suitable ground. E. Turn the keyswitch to the OFF position.

Result: The measured voltage is within the expected range. Repair: Install a replacement ignition keyswitch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

10. Check the Start Signal Voltage at the Keyswitch Connector A. Turn the keyswitch to the OFF position. B. Disconnect the electrical connector for the ignition keyswitch. C. Disconnect the wire from the start signal "S" terminal on the connector for the ignition keyswitch. D. Reconnect the electrical connector for the ignition keyswitch.

10 V to 14 V

E. Turn the keyswitch to the ON position. Do not attempt to start the engine. F. Use a suitable multimeter to measure the voltage between the start signal "S" terminal on the connector for the ignition keyswitch and a suitable ground.

Result: The measured voltage is not within the expected range. The fault is in the start signal wiring between the ignition keyswitch and the ECM. Repair: Check all wiring between the ignition keyswitch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

If the procedure did not correct the issue, Contact the Dealer Solution Network (DSN). Cat C3.4B Engine Parts www.CATC34B.COM

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06017538

Sensor Signal (Analog, Active) - Test - Exhaust Gas Pressure Sensor SMCS - 1439-038 This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code

Description

Notes The ECM detects the following conditions:

1209-3

Engine Exhaust Gas Pressure : Voltage Above Normal

The signal voltage from the exhaust gas pressure sensor is greater than 4.74 VDC for at least 1.8 seconds. The battery voltage is at least 10 VDC. The ECM will use the default value for exhaust gas pressure while this code is active. The default value is 50 kPa (7.25 psi). The engine will be derated.

1209-4

Engine Exhaust Gas Pressure : Voltage Below Normal

The ECM detects the following conditions: The signal voltage from the exhaust gas pressure sensor is less than 0.4 VDC for at least 1.8 seconds. The battery voltage is at least 10 VDC. The ECM will use the default value for exhaust gas pressure while this code is active. The default value is 50 kPa (7.25 psi).

The engine will be derated. The following conditions must exist before any of the above codes will become active: • There are no active 3509 codes. • There are no active 168 codes. The following background information is related to this procedure: The 5 VDC sensor supply provides power to all 5 VDC sensors. The ECM supplies 5.0 ± 0.1 VDC to each of the pressure sensor connectors. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM.

Illustration 1 Schematic diagram for the exhaust gas pressure sensor Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03622560

Illustration 2

g03118316

Typical view of the pin locations on the P2 connector for the pressure sensors (12) Exhaust gas pressure sensor 5 VDC supply (27) Exhaust gas pressure sensor ground (43) Exhaust gas pressure sensor signal

Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the terminal connections on the P2/J2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Result: A damaged wire or damaged connector was found. A fuse is blown.

B. Thoroughly inspect the connector for the exhaust gas pressure sensor. Refer to Troubleshooting, "Electrical Damaged Connectors - Inspect". wire or connector C. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the exhaust gas pressure sensor.

Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 2.

D. Check the harness for abrasions and for pinch points from the exhaust gas pressure sensor back to the ECM.

Result: None of the preceding diagnostic codes are active.

2. Check For Active Diagnostic Codes A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. B. Verify if any of the diagnostic codes that are listed in Table 1 are active.

Diagnostic codes

If the codes in Table 1 are logged, an intermittent condition may be causing the logged codes. Refer to Troubleshooting, "Electrical Connectors - Inspect". Result: A 1209-3 or a 1209-4 diagnostic code is active. Proceed to Test Step 3.

3. Check the Supply Voltage at the Sensor Connector

4.9 V to 5.1 V

A. Turn the keyswitch to the OFF position.

Result: The voltage measurement is not within the expected range. The fault is in the wiring between the exhaust gas pressure sensor and the P2 ECM connector. Check all wiring between the sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

B. Disconnect the connector for the exhaust gas pressure sensor. C. Turn the keyswitch to the ON position. Do not start the engine. D. Measure the voltage between terminal 1 and terminal 2 on the harness connector for the exhaust gas pressure sensor. The voltage measurement should be 5.0 ± 0.1 VDC.

Result: The voltage measurement is within the expected range. Proceed to Test Step 4.

E. Turn the keyswitch to the OFF position. F. Reconnect the sensor. 4. Verify the Type of Active Diagnostic Code

Result: A 1209-3 diagnostic code is active. Proceed to Test Step 5.

A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.

Result: A 1209-4 diagnostic code is active. Diagnostic codes

C. Determine if the fault is related to an open circuit diagnostic code or a short circuit diagnostic code.

5. Create An Open Circuit at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the exhaust gas pressure sensor.

Proceed to Test Step 7. Result: Neither of the preceding diagnostic codes are active. An intermittent fault may exist. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.

Diagnostic codes

Result: A 1209-4 diagnostic code became active after disconnecting the sensor. Temporarily connect a new exhaust gas pressure sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently install the new

sensor. Use the electronic service tool in order to clear all logged diagnostic codes. Clear all logged diagnostic codes.

C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes. D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for an active 1209-4 diagnostic code.

Result: The 1209-3 diagnostic code is still active with the exhaust gas pressure sensor disconnected. Proceed to Test Step 6.

6. Create an Open Circuit at the ECM Connector A. Turn the keyswitch to the OFF position.

Result: A 1209-4 diagnostic code became active after the P2 connector was disconnected.

B. Disconnect the P2 connector from the ECM. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes and only look for a 1209 diagnostic code.

Diagnostic Codes

The fault is in the wiring between the exhaust gas pressure sensor and the P2 ECM connector. Check all wiring between the sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The 1209-3 diagnostic code is still active with the P2 connector disconnected.

D. Access the "Active Diagnostic Codes" screen on the electronic service tool and check for an active 1209-4 diagnostic code for the suspect sensor.

Proceed to Test Step 9.

E. Turn the keyswitch to the OFF position.

7. Create a Short at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the exhaust gas pressure sensor.

Diagnostic codes

Result: A 1209-3 diagnostic code was active with the jumper installed. Temporarily connect a new exhaust gas pressure sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently install the new sensor.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between terminal 1 and terminal 3 on the harness connector for the exhaust gas pressure sensor.

Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 1209-4 diagnostic code is still active with the jumper installed.

D. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.

Proceed to Test Step 8.

E. Use the electronic service tool to check for an active 1209-3 diagnostic code for the suspect sensor. F. Turn the keyswitch to the OFF position. Remove the jumper wire.

8. Create a Short Circuit at the ECM A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM.

Result: A 1209-3 diagnostic code was active with the jumper installed.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between J2:43 and J2:12 .

D. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes. Only look for a 1209 diagnostic code.

Diagnostic codes

Result: A 1209-4 diagnostic code is still active with the jumper installed.

E. Use the electronic service tool to check for an active 1209-3 diagnostic code for the suspect sensor.

Proceed to Test Step 9.

F. Turn the keyswitch to the OFF position. Remove the jumper wire.

9. Check if a Replacement ECM

Diagnostic

Result: There are no active diagnostic codes

Eliminates the Fault

codes

A. Contact the Dealer Solution Network (DSN). B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

with the replacement ECM. Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06017448

Sensor Signal (Analog, Active) - Test SMCS - 1439-038 Note: This procedure is applicable to all engine pressure sensors except the exhaust gas pressure sensor. This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

102-3

Engine Intake Manifold #1 Pressure : Voltage Above Normal

The signal voltage from the intake manifold air pressure sensor is greater than 4.92 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The ECM will use the default value for the intake manifold air pressure while this code is active. The default value is 50 kPa (7.25 psi). The engine will be derated.

102-4

Engine Intake Manifold #1 Pressure : Voltage Below Normal

The ECM detects the following conditions: The signal voltage from the intake manifold air pressure sensor is less than 0.2 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC.

The ECM will use the default value for the intake manifold air pressure while this code is active. The default value is 50 kPa (7.25 psi). The engine will be derated.

108-3

The ECM detects that the signal voltage from the barometric pressure sensor is greater than 4.9 VDC for at least 0.8 seconds. Barometric Pressure : Voltage The barometric pressure sensor is contained within the ECM. Above Normal The ECM will use the default value for the barometric pressure while this code is active. The default value is 97 kPa (14 psi).

108-4

The ECM detects that the signal voltage from the barometric pressure sensor is less than 0.2 VDC for at least 0.8 seconds. Barometric Pressure : Voltage The barometric pressure sensor is contained within the ECM. Below Normal The ECM will use the default value for the barometric pressure while this code is active. The default value is 97 kPa (14 psi).

157-3

The ECM detects that the signal voltage from the fuel rail Engine Injector Metering Rail pressure sensor is greater than 4.9 VDC for at least 0.2 seconds. #1 Pressure : Voltage Above Normal The engine will be derated. The engine may shut down.

157-4

The ECM detects that the signal voltage from the intake Engine Injector Metering Rail manifold air pressure sensor is less than 0.34 VDC for at least #1 Pressure : Voltage Below 0.2 seconds. Normal The engine will be derated. The engine may shut down. The ECM detects the following conditions:

157-10

An implausible rate of change in the signal from the fuel rail Engine Injector Metering Rail pressure sensor. The condition has been detected five times within 3 seconds. #1 Pressure : Abnormal Rate There are no other active diagnostic codes for the fuel rail of Change pressure sensor. This diagnostic code indicates an intermittent connection in the circuit for the fuel rail pressure sensor.

3251-3

Particulate Trap Differential Pressure : Voltage Above Normal

The ECM detects that the signal voltage from the Diesel Particulate Filter (DPF) differential pressure sensor is greater than 4.87 VDC for at least 1.8 seconds. The ECM will use the default value for the DPF differential

If equipped, the warning lamp will flash. The engine will be derated. The ECM detects that the signal voltage from the DPF differential pressure sensor is less than 0.2 VDC for 1.8 seconds. 3251-4

Particulate Trap Differential Pressure : Voltage Below Normal

The ECM will use the default value for the DPF differential

If equipped, the warning lamp will flash. The engine will be derated. The ECM detects the following conditions: The intake manifold pressure is greater than 7 kPa (1 psi) above the barometric pressure for at least 5 seconds. 102-20

Engine Intake Manifold #1 Pressure : Data Drifted High

The engine is not cranking. The battery voltage is greater than 10 VDC. The engine will be derated. The ECM detects the following conditions:

102-21

Engine Intake Manifold #1 Pressure : Data Drifted Low

The intake manifold pressure is greater than 7 kPa (1 psi) below the barometric pressure for at least 5 seconds. The engine is not cranking. The battery voltage is greater than 10 VDC. The engine will be derated.

The following conditions must exist before any of the above codes will become active: • There are no active 3509 codes. • There are no active 168 codes. The following background information is related to this procedure: The 5 VDC sensor supply provides power to all 5 VDC sensors. The ECM supplies 5.0 ± 0.1 VDC to each of the pressure sensor connectors. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM. Pull-up Voltage

The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. This pull-up voltage is required for correct sensor operation and diagnostics. When the sensor is disconnected, this pull-up voltage can be measured at the harness connector for the sensor.

Illustration 1

g03774823

Schematic diagram for the engine pressure sensors Not all connectors are shown. Refer to the Electrical Schematic for the application.

Note: The DPF differential pressure sensor is installed on engines equipped with a wall flow DPF only.

Illustration 2

g03623078

Typical view of the pin locations on the P2 connector for the pressure sensors (10) Intake manifold air pressure sensor 5 VDC supply (11) Fuel rail pressure sensor 5 VDC supply (25) Intake manifold air pressure sensor ground (26) Fuel rail pressure sensor ground (40) Intake manifold air pressure sensor signal (41) Fuel rail pressure sensor signal

Illustration 3

g02293895

Typical view of the pin locations on the P1 connector for the DPF differential pressure sensor (14) DPF differential sensor 5 VDC supply (36) DPF differential pressure sensor ground (58) DPF differential pressure sensor signal

Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the terminal connections on the P2/J2 and P1/J1 ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect". B. Thoroughly inspect the connectors for the engine pressure sensors. Refer to Troubleshooting, "Electrical Connectors -

Values Damaged wire or connector

Results Result: A damaged wire or damaged connector was found. Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the

Inspect".

harness is free of corrosion, of abrasion or of pinch points.

C. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the exhaust gas pressure sensor.

Proceed to Test Step 2.

D. Check the harness for abrasions and for pinch points from the exhaust gas pressure sensor back to the ECM.

Result: A 108-3 or 108-4 diagnostic code is active. Proceed to Test Step 9. 2. Check For Active Diagnostic Codes A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of Diagnostic the diagnostic codes. codes B. Verify if any of the diagnostic codes that are listed in Table 1 are active.

Result: An XXXX-3 or an XXXX-4 diagnostic code is active for one or more of the other pressure sensors. A 102-20 or 102-21 diagnostic code is active. Proceed to Test Step 3. Result: A 157-10 diagnostic code is active or recently logged. An intermittent connection exists in the circuit for the fuel rail pressure sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent connections.

3. Check the Supply Voltage at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect sensor. C. Turn the keyswitch to the ON position. Do not start the engine. D. Measure the voltage between the 5

4.9 V to 5.1 V

Result: The voltage measurement is not within the expected range. The fault is in the wiring between the suspect sensor and the P2 ECM connector. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The voltage measurement is within the expected range.

VDC supply terminal and the ground terminal on the harness connector for the suspect sensor. The voltage measurement should be 5.0 ± 0.1 VDC.

Proceed to Test Step 4.

E. Turn the keyswitch to the OFF position. F. Reconnect the sensor.

Result: An XXXX-4 diagnostic code is active for one or more of the pressure sensors at this time.

4. Verify the Type of Active Diagnostic Code

Proceed to Test Step 5.

A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.

Result: An XXXX-3 diagnostic code is active for one or more of the pressure sensors at this time.

Diagnostic B. Use the electronic service tool to check codes for active diagnostic codes. Record all active diagnostic codes. C. Determine if the fault is related to an open circuit diagnostic code or a short circuit diagnostic code.

5. Create An Open Circuit at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the sensor with the XXXX-4 diagnostic code. C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes. D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for an XXXX-3 diagnostic

Proceed to Test Step 7. Result: None of the preceding diagnostic codes are active. An intermittent fault may exist. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.

Diagnostic codes

Result: An XXXX-3 diagnostic code became active after disconnecting the sensor. Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently install the new sensor. If the fuel rail is replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset". Use the electronic service tool in order to clear all logged diagnostic codes. Result: The XXXX-4 diagnostic code is still

code for the suspect sensor.

active with the sensor disconnected. Proceed to Test Step 6.

6. Create an Open Circuit at the ECM Connector A. Turn the keyswitch to the OFF position.

Result: An XXXX-3 diagnostic code for the suspect sensor became active after the P2 connector was disconnected.

B. Disconnect the P2 connector from the ECM. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes. Diagnostic Note: Diagnostic codes for all of the Codes engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes and only look for codes relating to the suspect sensor.

The fault is in the wiring between the suspect sensor and the P2 ECM connector. Check all wiring between the suspect sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The XXXX-4 diagnostic code for the suspect sensor is still active with the P2 connector disconnected.

D. Access the "Active Diagnostic Codes" screen on the electronic service tool and check for an active XXXX-3 diagnostic code for the suspect sensor.

Proceed to Test Step 9.

E. Turn the keyswitch to the OFF position.

7. Create a Short at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect sensor. C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between the sensor signal terminal and the sensor ground terminal on the harness connector for the suspect sensor. D. Turn the keyswitch to the ON position.

Diagnostic codes

Result: An XXXX-4 diagnostic code was active with the jumper installed. Temporarily connect a new pressure sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently install the new sensor. If the fuel rail is replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Wait at least 10 seconds for activation of the diagnostic codes.

Result: An XXXX-3 diagnostic code is still active with the jumper installed.

E. Use the electronic service tool to check for an active XXXX-4 diagnostic code for the suspect sensor.

Proceed to Test Step 8.

F. Turn the keyswitch to the OFF position. Remove the jumper wire.

8. Create a Short Circuit at the ECM A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM.

Result: An XXXX-3 diagnostic code was active with the jumper installed.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between the suspect sensor signal pin and the sensor ground pin on the J2 connector. Diagnostic D. Turn the keyswitch to the ON position. codes Wait at least 10 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other diagnostic codes. Only look for codes that relate to the suspect sensor.

The fault is in the wiring between the suspect sensor and the P2 ECM connector. Check all wiring between the suspect sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: An XXXX-3 diagnostic code is still active with the jumper installed. Proceed to Test Step 9.

E. Use the electronic service tool to check for an active XXXX-4 diagnostic code for the suspect sensor. F. Turn the keyswitch to the OFF position. Remove the jumper wire.

9. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN).

Diagnostic codes

Result: There are no active diagnostic codes with the replacement ECM. Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM.

B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06019084

Sensor Signal (Analog, Passive) - Test SMCS - 1439-038 This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Engine Temperature Sensors J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

105-3

Engine Intake Manifold #1 Temperature : Voltage Above Normal

The signal voltage for the intake manifold temperature sensor is greater than 4.94 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The ECM will use a default value for the intake manifold temperature while this diagnostic code is active. The engine will be derated. The ECM detects the following conditions:

105-4

Engine Intake Manifold #1 Temperature : Voltage Below Normal

The signal voltage for the intake manifold temperature sensor is less than 0.26 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The ECM will use a default value for the intake manifold temperature while this diagnostic code is active. The engine will be derated.

110-3

Engine Coolant Temperature : Voltage Above Normal

The ECM detects that the signal voltage for the coolant temperature sensor is greater than 4.93 VDC for at least 0.5 seconds. The ECM will use the default value for the coolant temperature while this diagnostic code is active. The default value is (194° F) as the engine is running. The engine will be derated. The ECM detects that the signal voltage for the coolant temperature sensor is less than 0.2 VDC for at least 0.5 seconds.

110-4

Engine Coolant Temperature : Voltage Below Normal

The ECM will use the default value for the coolant temperature while this diagnostic code is active. The default value is (194° F) as the engine is running. The engine will be derated. The ECM detects that the signal voltage for the air inlet temperature sensor is greater than 4.9 VDC for at least 0.5 seconds.

172-3

172-4

173-3

Engine Air Inlet Temperature : Voltage Above Normal

Engine Air Inlet Temperature : Voltage Below Normal

Engine Exhaust Gas Temperature : Voltage Above Normal

While this code is active, the ECM will gradually increase or decrease the air inlet temperature from the last valid reading until the default value is reached. The default value is 30° C (86° F). The ECM detects that the signal voltage for the air inlet temperature sensor is less than 0.2 VDC for at least 0.5 seconds. While this code is active, the ECM will gradually increase or decrease the air inlet temperature from the last valid reading until the default value is reached. The default value is 30° C (86° F). The ECM detects the following conditions: The signal from the exhaust gas temperature sensor is greater than 3.6 VDC for at least 1 second. The battery voltage is at least 10 VDC. While this code is active, the ECM will use the default value for the exhaust gas temperature. The default value is 350° C (662° F).

The engine will be derated. The ECM detects that the signal from the exhaust gas temperature sensor is less than 0.46 VDC for at least 1 second. 173-4

Engine Exhaust Gas Temperature : Voltage Below Normal

While this code is active, the ECM will use the default value for the exhaust gas temperature. The default value is 350° C (662° F). The engine will be derated. The ECM detects that the signal voltage for the fuel temperature sensor is greater than 4.9 VDC for at least 0.5 seconds.

174-3

Engine Fuel Temperature 1 : Voltage Above Normal

174-4

32420

Engine Fuel Temperature 1 : Voltage Below Normal

Particulate Trap Intake Gas Temperature : High - most severe (3)

The ECM will use a default value for the fuel temperature while this code is active. The default value will be based on the coolant temperature. If the coolant temperature sensor has an active fault, the default value for the fuel temperature is 40° C (104° F). The ECM detects that the temperature signal from the Diesel Particulate Filter (DPF) inlet temperature sensor is implausibly high. The warning lamp will flash. The shutdown lamp will come on. The engine will be shut down. The ECM detects that the signal voltage for the Diesel Particulate Filter (DPF) inlet temperature sensor is greater than 3.6 VDC for at least 1 second.

32423

Particulate Trap Intake Gas Temperature : Voltage Above Normal

The ECM will use the default value for the DPF inlet temperature while this code is active. The default temperature is 100° C (212° F). The engine will be derated.

32424

The ECM detects that the signal voltage for the DPF inlet temperature sensor is less than 0.46 VDC for at least 1 second.

Particulate Trap Intake Gas Temperature : Voltage Below Normal

The ECM will use the default value for the DPF inlet temperature while this code is active. The default temperature is 100° C (212° F). The engine will be derated.

47653

47654

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Above Normal

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temperature : Voltage Below Normal

The ECM detects that the signal voltage for the Diesel Oxidation Catalyst (DOC) inlet temperature sensor is greater than 3.6 VDC for at least 1 second. The ECM will use the default value for the DOC inlet temperature sensor while this code is active. The default value is 80° C (176° F). The ECM detects that the signal voltage for the DOC inlet temperature sensor is less than 0.46 VDC for at least 1 second. The ECM will use the default value for the DOC inlet temperature sensor while this code is active. The default value is 80° C (176° F).

This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that are associated with the following sensors: • Intake manifold temperature sensor • Coolant temperature sensor • Exhaust gas temperature sensor • Fuel temperature sensor • Air inlet temperature sensor • DOC inlet temperature sensor • DPF inlet temperature sensor The following background information is related to this procedure: The troubleshooting procedures for the diagnostic codes of each temperature sensor are identical. The temperature sensors have two terminals. The signal voltage from each sensor is supplied to the appropriate terminal in the P2/J2 connector or the P1/J1 connector. Pull-up Voltage The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. This pull-up voltage is required for correct sensor operation and diagnostics.

When the sensor is disconnected, this pull-up voltage can be measured at the harness connector for the sensor.

Illustration 1

g03775307

Schematic diagram for the engine temperature sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Note: The engine may be equipped with a combined intake manifold pressure/temperature sensor or an individual intake manifold temperature sensor. Refer to the appropriate Electrical Schematic

Illustration 2

g03625277

Typical view of the P2 pin locations for the temperature sensors (23) Engine fuel temperature sensor ground (38) Engine fuel temperature sensor signal (55) Intake manifold temperature sensor signal (57) Coolant temperature/intake manifold sensor signal (58) Intake manifold temperature sensor ground

Illustration 3 Typical view of the P1 pin locations for the temperature sensors (19) Air inlet temperature sensor signal (20) Air inlet temperature sensor ground

g02868180

(79) DOC inlet temperature sensor ground (80) DOC inlet temperature sensor signal (81) Exhaust gas temperature sensor ground (82) Exhaust gas temperature sensor signal (83) DPF inlet temperature sensor ground (84) DPF inlet temperature sensor signal

Table 2 Troubleshooting Test Steps

Values

Results Result: A -3 diagnostic code is active. Proceed to Test Step 2.

1. Check for Diagnostic Trouble Codes

Result: A -4 diagnostic code is active. Proceed to Test Step 3.

A. Connect to the electronic service tool.

Result: A 3242-0 diagnostic code is active. Check that the DPF inlet and DOC inlet temperature sensors are installed in the correct location.

B. Turn the keyswitch to the ON position. C. Access the "Active Diagnostic Code" screen on the electronic service tool.

Codes

Wait at least 30 seconds in order for the diagnostic codes to become active. D. Check if any of the diagnostic codes listed in Table 1 are active or recently logged.

Check all electrical connectors related to the DPF inlet temperature sensor circuit. Refer to Troubleshooting, "Electrical Connectors Inspect" If the connectors are OK, replace the DPF inlet temperature sensor. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) Remove and Install". Result: If a diagnostic code is logged but not currently active, the fault may be intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.

2. Create a Short at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the suspect sensor.

Short Circuit Recognized

Result: The -3 diagnostic code remains active for the suspect sensor. Repair: The fault is in the wiring for the suspect sensor. Check all wiring between the suspect sensor and the ECM. Refer to the appropriate Electrical Schematic.

C. Install the jumper wire between terminal 1 (sensor signal) and terminal 2 (sensor return) at the sensor connector.

Replace the faulty wiring. Verify that the problem is resolved. Result: A -4 diagnostic code became active after creating the short at the sensor connector.

D. Turn the keyswitch to the ON position.

Repair: The wiring is OK. Replace the suspect sensor.

E. Monitor the diagnostic codes on the electronic service tool. Check for an active -4 diagnostic code for the suspect sensor.

Verify that the problem is resolved.

Wait at least 30 seconds in order for the diagnostic codes to become active. F. Turn the keyswitch to the OFF position.

3. Create an Open Circuit at the Suspect Sensor Connector Result: The -4 diagnostic code remains active for the suspect sensor.

A. Turn the keyswitch to the OFF position.

Repair: The fault is in the wiring for the suspect sensor.

B. Disconnect the sensor connector of the suspect sensor with the active -4 diagnostic code. C. Turn the keyswitch to the ON position. D. Monitor the diagnostic codes on the electronic service tool. Check for an active -3 diagnostic code for the suspect sensor. Wait at least 30 seconds in order for the diagnostic codes to become active.

Check all wiring between the suspect sensor and the ECM. Refer to the appropriate Electrical Schematic. Open Circuit Recognized

Replace the faulty wiring. Verify that the problem is resolved. Result: A -3 diagnostic code became active after disconnecting the sensor. Repair: The wiring is OK. Replace the sensor. Verify that the problem is resolved.

E. Turn the keyswitch to the OFF position. If the procedure did not correct the fault, contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06019176

Sensor Supply - Test SMCS - 1439-038 This procedure covers the following codes: Table 1 Diagnostic trouble Codes for the Sensor Supply Circuit J1939 Code

3509-2

Description

Sensor Supply Voltage 1 : Erratic, Intermittent, or Incorrect

Notes The Electronic Control Module (ECM) detects a fault in the 5 VDC sensor supply circuit supplied on the following pins: J2:8 J2:9 J2:10 J2:11 J2:12 J2:13 The engine will be derated.

3510-2

Sensor Supply Voltage 2 : Erratic, Intermittent, or Incorrect

The Electronic Control Module (ECM) detects a fault in the 5 VDC sensor supply circuit supplied on the following pins: J1:14 J1:16 If equipped, the warning lamp will come on. The engine will be derated.

3511-2

Sensor Supply Voltage 3 : Erratic, Intermittent, or Incorrect

The Electronic Control Module (ECM) detects a fault in the 5 VDC sensor supply circuit supplied on the following pin: J1:17 If equipped, the warning lamp will come on.

The following background information is related to this procedure: The ECM supplies regulated +5 VDC to the following sensors on the J2 connector (a 3509-2 diagnostic code applies to the 5 VDC supply for these sensors) : • The position sensor for the intake throttle valve • The position sensor for the NOx Reduction System (NRS) valve • The intake manifold air pressure sensor • The fuel rail pressure sensor • The exhaust gas pressure sensor • The secondary (camshaft) speed/timing sensor The ECM supplies regulated +5 VDC to the following sensors on the J1connector (a 3510-2 diagnostic code applies to the 5 VDC supply for these sensors) : • The Diesel Particulate Filter (DPF) differential pressure sensor • Analog throttle position sensor 1 The ECM supplies regulated +5 VDC to analog throttle position sensor 2 on the J1 connector. A 3511-2 diagnostic code applies to the 5 VDC supply for this sensor.

Illustration 1

g03620418

Schematic diagram of the 5 VDC supply circuit supplied by the J2 connector. Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Illustration 2

g03775432

Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3510-2 diagnostic code applies to the 5 VDC supply in this illustration. Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 3

g03775446

Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3511-2 diagnostic code applies to the 5 VDC supply in this illustration. Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 4 Typical view of the pin locations on the J2 connector for the 5 VDC supply. (8) Intake throttle valve position sensor 5 VDC supply (9) NRS valve position sensor 5 VDC supply (10) Intake manifold air pressure sensor 5 VDC supply (11) Fuel rail pressure sensor 5 VDC supply (12) Exhaust gas pressure sensor 5 VDC supply (13) Secondary (camshaft) speed/timing sensor 5 VDC supply (24) NRS valve position sensor ground (25) Intake manifold air pressure sensor (26) Fuel rail pressure sensor ground (27) Exhaust gas pressure sensor ground

g02727977

(28) Secondary (camshaft) speed/timing sensor ground (37) Intake throttle valve position sensor ground

Illustration 5

g02728012

Typical view of the pin locations on the P1 connector for the 5 VDC supply (14) DPF differential pressure sensor 5 VDC supply (16) Analog throttle position sensor (1) 5 VDC supply (17) Analog throttle position sensor (2) 5 VDC supply (36) DPF differential pressure sensor ground (38) Analog throttle position sensor (1) ground (39) Analog throttle position sensor (2) ground

Table 2 Troubleshooting Test Steps

Values

Result: A -2 diagnostic code is active.

1. Determine the Code A. Connect the electronic service tool to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary. B. Turn the keyswitch to the ON position. C. Check if one of the diagnostic codes listed in Table 1 is active or logged.

Results

Note which 5 V supply is reporting the active sensor supply code. Diagnostic Codes

Proceed to Test Step 2. Result: A -2 diagnostic code is logged. An intermittent fault may be present. Refer to Troubleshooting, "Electrical Connectors Inspect" in order to identify intermittent faults.

2. Check for a Failed Sensor A. Connect to the electronic service tool.

Failed Sensor

B. Turn the keyswitch to the ON position.

Result: The suspect sensor supply active code changes to logged when a sensor is unplugged. Repair: Replace the failed sensor.

C. Disconnect a sensor on the suspect sensor supply circuit.

Verify that the repair resolved the problem.

D. Monitor the electronic service tool while the sensor is disconnected to see if the active code changes to logged.

Result: The suspect sensor supply active code remains active after all sensors on the sensor supply circuit have been checked.

E. Connect the suspect sensor to the wiring harness

Repair: The fault is in the wiring harness. Check all wiring on the suspect sensor supply. Refer to the appropriate Electrical Schematic. Replace the faulty wiring.

F. Repeat steps C through E for each sensor on the suspect sensor supply.

If the procedure did not correct the fault, contact the Dealer Solution Network (DSN).

www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980293

Service Information Report SMCS - 0336 After verifying that the correct repair has been performed on the engine, provide brief, detailed information. This information is crucial and helps Caterpillar better serve you and the customer.

Recommendations Customer Complaint Obtain as much information from the customer as possible. Investigate any written information that is available and document any information that is gathered from the customer. The following information is of particular importance: • Indicate if an event code was logged. • Indicate if a diagnostic code was logged. Also, record the codes that are logged. • Indicate the symptoms of engine operation that are present. • Indicate the engine software part number. Be as specific as possible.

Cause of Failure Comments on the cause of failure include the number of diagnostic codes that were logged. Comments also indicate if the code was an active code. Indicate the source of the problem. Also indicate the method that was used to discover the problem. Examples of the methods that were used to discover the problem could be one of the following methods: • A specific procedure in the manual was followed. • A visual inspection indicated wire abrasion on the engine harness.

• An engine dynamometer test indicated that the power was below the specification at 1700 rpm. The power loss was due to the loss of the no. 4 injector. The engine dynamometer test indicated that the power was below the specification at all engine speeds above 1700 rpm. Be as specific as possible.

Repair Procedure Comments on the repair procedure include the following types of information: • The wiring harness was repaired. • The Full Load Setting (FLS) was changed per the factory instructions. Be as specific as possible.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06599992

Service Tool Features SMCS - 0785; 1900

Override Parameters The override parameters screen has multiple overrides. The parameters control various functions on the engine and the aftertreatment. These functions and features allow the technician to troubleshoot different engine systems. Navigate to the following menu options in the electronic service tool to access the "Override Parameters": • Diagnostics • Diagnostic Tests • Override Parameters

Glow Plug Starting Aid Override This override is used to check that the glow plugs are functioning correctly. The override will remain active until switched off using the electronic service tool.

Active Diagnostic Codes The purpose of this screen is to show all the active diagnostic codes. In the electronic service tool, select the engine ECM. Select the "Diagnostics" tab. Select the "Active Diagnostic Codes" tab.

Logged Diagnostic Codes The purpose of this screen is to show all the logged diagnostic codes. Logged diagnostic codes will be cleared from the "Logged Diagnostic Codes" screen when the code has not been active for 40 hours. In the electronic service tool, select the engine ECM. Select the "Diagnostics" tab. Select the "Logged Diagnostic Codes" tab.

Diagnostic Tests Electronic service tool diagnostic tests are listed below. Select the "Diagnostics" tab. Select the "Diagnostic Tests" tab.

Cylinder Cutout This test can disable individual cylinders when the engine is running to help identify cylinders that are performing below the required level. Click "Change" for an individual cylinder to switch off that cylinder manually. This test can be used to identify faults by listening to the sound of the engine as a cylinder is disabled. If there is no change in the sound of the engine as a cylinder is disabled, a fault in that cylinder may be indicated.

Fuel Rail Pressure Test This test raises the fuel pressure in the high-pressure fuel rail to 180000 kPa (26107 psi) for 1 minute at 1300 rpm. After this test has completed and the fuel pressure has dropped to a safe level, the fuel system can be inspected for signs of leakage.

Calibrations In the electronic service tool, go to the following menu options: Select the "Service" tab. Select the "Calibrations" tab.

Calibrations Listed in the Engine ECM Menu Injector Codes Calibration

Whenever an injector is replaced, the injector must be trimmed. Trimming the injector calibrates all the injectors to deliver the same amount of fuel. The Injector Codes Calibration allows the injector trim code information to be programmed into the ECM. After the injector is calibrated, the calibration data is checked for validity. When new injectors are installed, record the serial numbers of each injector and input using the electronic service tool. Refer to Troubleshooting, "Injector Code - Calibrate" for more information.

Component Replacement Resets In the electronic service tool, go to the "Configurations" screen.

Oxidation Catalyst Replacement Reset Use this reset when the Diesel Oxidation Catalyst (DOC) is replaced.

Lambda Sensor Replacement Reset Use this reset when the oxygen sensor is replaced.

EGR Valve Learn Reset Use this reset when the Exhaust Gas Recirculation (EGR) valve is replaced.

Rail Pressure Valve Learn Reset Use this reset when the fuel rail pressure valve is replaced. This reset will reset the counter in the ECM for the number of times that the pressure relief valve has opened.

DPF Ash Cleaning Use this reset when the Diesel Particulate Filter (DPF) has been cleaned and reinstalled. Refer to Systems Operation, Testing and Adjusting, "Diesel Particulate Filter - Clean" for details.

Lambda Sensor Learn Reset Use this reset when the oxygen sensor is replaced.

Lambda Sensor Temperature Learn Reset Use this reset when the oxygen sensor is replaced.

DPF Differential Pressure Sensor Replacement Use this reset when the DPF differential pressure sensor is replaced.

DPF Replacement Reset

Use this reset when a new DPF is installed. Refer to Systems Operation, Testing and Adjusting, "Diesel Particulate Filter - Clean" for details.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06019299

Solenoid Valve - Test SMCS - 5479-038 This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Solenoid Valves J1939 Code

1076-2

Description

Engine Fuel Injection Pump Fuel Control Valve : Erratic, Intermittent, or Incorrect

Notes The Electronic Control Module (ECM) detects an intermittent open or short circuit error in the control circuit for the fuel metering valve on the high-pressure fuel pump. This diagnostic code will not be active if a continuous fault in the circuit is detected. The ECM detects the following conditions:

1076-5

Engine Fuel Injection Pump Fuel Control Valve : Current Below Normal

A low current condition in the output from the ECM to the solenoid for the fuel metering valve on the high-pressure fuel pump for at least 0.3 seconds. The battery voltage is at least 9.5 VDC. The engine will be derated.

1076-6

Engine Fuel Injection Pump Fuel Control Valve : Current Above Normal

The ECM detects the following conditions: A high current condition in the output from the ECM to the solenoid for the fuel metering valve on the high-pressure

fuel pump for at least 0.2 seconds. The battery voltage is at least 9.5 VDC. The engine will be derated. The ECM detects the following conditions:

1188-5

Engine Turbocharger Wastegate Actuator 1 Position : Current Below Normal

A low current condition in the output from the ECM to the solenoid for the wastegate regulator for at least 0.2 seconds. The battery voltage is at least 10 VDC. The engine will be derated. The diagnostic code will be logged. The ECM detects the following conditions:

1188-6

Engine Turbocharger Wastegate Actuator 1 Position : Current Above Normal

A high current condition in the output from the ECM to the solenoid in the wastegate regulator for at least 0.2 seconds. The battery voltage is at least 10 VDC. The diagnostic code will be logged.

The following background information is related to this procedure: Electronically controlled wastegate The engine has a turbocharger with an electronically controlled wastegate. Typically, the wastegate is a mechanical valve that is used in the turbocharger in order to regulate the intake manifold pressure to a set value. The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate. The required intake manifold pressure is calculated by the software that is contained in the ECM. The ECM uses the wastegate regulator to control the wastegate in order to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal. Fuel metering valve for the high-pressure fuel pump: The high-pressure fuel pump is equipped with a fuel metering valve. The fuel metering valve precisely controls the amount of fuel that enters the high-pressure fuel pump. The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the suction control valve is controlled by a PWM signal from the ECM.

Illustration 1

g03626007

Schematic diagram for the solenoid valves Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Illustration 2 View of the pin locations on the P2 connector for the solenoid valves (4) Wastegate regulator return

g02351359

(15) Fuel metering valve supply (60) Fuel metering valve return

Illustration 3

g03086696

View of the pin locations on the P1 connector

Table 2 Troubleshooting Test Steps

Values

1. Inspect Electrical Connectors and Wiring

Result: A damaged wire or damaged connector was found. A fuse is blown.

A. Check the fuses. B. Thoroughly inspect the P2/J2 and P1/J1 ECM connectors and thoroughly inspect the connectors for the solenoid valves. Refer to Troubleshooting, "Electrical Connectors Inspect" for details. C. Inspect the terminals on the P1/J1 ECM connector and all other connectors associated with the glow plug circuit. D. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the solenoid valves.

Results

Damaged wire or connector

2. Check for Diagnostic Codes

Diagnostic codes

A. Turn the keyswitch to the OFF position.

Result: A 1076-5 diagnostic code is active or recently logged. Proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic connector.

Result: A 1188-5 diagnostic code is active or recently logged.

C. Turn the keyswitch to the ON position.

Proceed to Test Step 4.

D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.

Result: A 1076-6 or 1188-6 diagnostic code is active or recently logged. Proceed to Test Step 8. Result: A 1076-2 diagnostic code is active or recently logged An intermittent fault exists in the circuit for the fuel metering valve. For intermittent faults, refer to Troubleshooting, "Electrical Connectors Inspect".

3. Check the Power Supply to the ECM

Result: The power supply to P1:1 is faulty.

A. Check that pin P1:1 is receiving the correct voltage. Refer to Troubleshooting, "Electrical Power Supply - Test".

Perform any necessary repairs. Refer to Troubleshooting, "Electrical Power Supply - Test".

Power supply

Note: The power supply for the fuel pump metering valve is supplied through P1:1.

Result: The power supply to P1:1 is OK. Proceed to Test Step 4.

4. Create a Short Circuit in the Harness at the Solenoid A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect solenoid. C. Fabricate a jumper wire that is 150 mm

Diagnostic codes

Result: An XXXX-6 diagnostic code is active when the jumper is installed. Temporarily connect a replacement for the suspect valve to the harness. Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to

(6 inch) long.

be displayed. If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.

D. Install the wire between the two pins on the harness connector for the suspect solenoid in order to create a short circuit. E. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool.

Result: A 1076-5 diagnostic code is still active with the jumper installed.

F. Remove the jumper wire from the connector for the solenoid valve.

Proceed to Test Step 5. Result: A 1188-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 6.

5. Create a Short Circuit at the ECM Connector A. Turn the keyswitch to the OFF position. Result: A 1076-6 diagnostic code is active with the jumper installed.

B. Disconnect the P2 connector from the ECM. C. Fabricate a jumper wire and install the jumper wire between J2:15 and J2:60. D. Turn the keyswitch to the ON position.

Diagnostic codes

E. Use the electronic service tool to check for an active 1076 diagnostic code. Wait at least 30 seconds for activation of the diagnostic codes.

The fault is in the harness between the fuel pump metering valve connector and the P2 ECM connector. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The 1076-5 diagnostic code is still active with the jumper installed.

F. Turn the keyswitch to the OFF position.

Proceed to Test Step 10.

G. Remove the jumper wire. H. Reconnect the connectors.

6. Measure the Voltage at the Wastegate Regulator Connector A. Turn the keyswitch to the OFF position.

10 V to 14 V

Result: The measured voltage is not within the expected range. Check the fuse. If the fuse is blown, there is a short circuit in the switched battery

B. Disconnect the wastegate regulator.

supply to the wastegate regulator connector. If the fuse is not blown, there is an open circuit in the switched battery supply to the wastegate regulator connector. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

C. Turn the keyswitch to the ON position. D. Use a multimeter to measure the voltage between terminal 1 on the harness connector for the wastegate regulator and a suitable ground.

Result: The measured voltage is within the expected range. Proceed to Test Step 8.

Result: The measured resistance is greater than 5 Ohms. 7. Check the Wastegate Regulator Return Wire for an Open Circuit A. Turn the keyswitch to the OFF position. Diagnostic B. Disconnect the wastegate regulator and the codes P2 connector. C. Use a suitable multimeter to measure the resistance between P2:4 and terminal 2 on the harness connector for the wastegate regulator.

The fault is in the wiring between the wastegate regulator and the P2 ECM connector. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. Proceed to Test Step 10.

8. Create an Open Circuit at the Solenoid A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect solenoid valve. C. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes.

Diagnostic codes

Result: An XXXX-5 diagnostic code is active with the valve disconnected. Temporarily connect a replacement for the suspect valve to the harness. Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed. If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for

D. Turn the keyswitch to the OFF position.

the correct procedure. Result: An XXXX-6 diagnostic code is still active with the valve disconnected. Proceed to Test Step 9.

9. Create an Open Circuit at the ECM Result: An XXXX-5 diagnostic code is active with the P2 connector disconnected.

A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes.

Diagnostic codes

D. Use the electronic service tool to check for active diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve.

The fault is in the wiring between the suspect valve connector and the P2 ECM connector. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The XXXX-6 diagnostic code is still active with the P2 connector disconnected. Proceed to Test Step 10.

E. Turn the keyswitch to the OFF position.

Result: There are no active diagnostic codes with the replacement ECM.

10. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN). B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

Diagnostic codes

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06231642

Speed Control - Test SMCS - 7332-038-VF This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Analog Throttle Position Sensors J1939 Code

Description

91-3

Accelerator Pedal Position 1 : Voltage Above Normal

29-3

Accelerator Pedal Position 2: Voltage Above Normal

91-4

Accelerator Pedal Position 1 : Voltage Below Normal

The ECM detects that the signal from the throttle position sensor is less than the lower diagnostic limit for at least 0.2 seconds.

29-4

Accelerator Pedal Position 2: Voltage Below Normal

The warning lamp will flash. The engine will be derated.

Notes The Electronic Control Module (ECM) detects that the signal from the throttle position sensor is greater than the upper diagnostic limit for at least 0.2 seconds. The warning lamp will flash. The engine will be derated.

If a fault occurs with the primary throttle and a secondary throttle is installed, the engine will use the secondary throttle until the fault is repaired. If a fault occurs with the secondary throttle, the engine will use the primary throttle until the fault is repaired. If a functional throttle is not available, the following conditions will occur: • The engine will default to the limp home speed.

• If the engine speed is higher than the limp home speed, the engine will decelerate to the limp home speed. • If the engine speed is lower than the limp home speed, the engine speed will remain at the current speed. • The engine will remain at this speed while the diagnostic code remains active. • All inputs from the faulty throttle are ignored by the ECM until the fault is repaired. • All inputs from the repaired throttle will be ignored by the ECM until the keyswitch has been cycled. The diagnostic codes above relate to an analog sensor. Use this procedure only if the analog sensor uses an output from a variable resistor. The sensor is most likely to be mounted on a throttle pedal. The sensor is attached directly to the throttle assembly. The sensor provides an output voltage to the ECM. The sensor output voltage will vary with the position of the throttle. Foot operated or hand operated throttle assemblies are available. The sensor receives +5 V power from the ECM. The sensor will produce a raw signal voltage that will alter between low idle and high idle. The sensor senses the speed requirement from the throttle position. A second sensor may override this speed requirement from the first sensor. This override will be subject to an input from a secondary throttle or from the SAE J1939 (CAN) data link or from a PTO control. Use the electronic service tool in order to check the input status.

Illustration 1 Schematic diagram for the throttle position sensors Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03733275

Illustration 2

g02292314

View of the P1 pin locations for the analog throttle position sensors (16) 5 V supply (throttle 1) (17) 5 V supply (throttle 2) (38) Throttle 1 ground (39) Throttle 2 ground (60) Throttle 1 position (61) Throttle 2 position

Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring A. Turn the keyswitch to the OFF position. B. Check the connectors and the harness for the following faults: · Abrasion · Corrosion · Incorrect attachment Refer to Troubleshooting, "Electrical Connectors - Inspect". C. Perform a 30 N (6.7 lb) pull test on each of the wires in the harness that are associated with the throttle position sensor. Check the wire connectors at the ECM and at the throttle sensor.

Values Damaged wire or connector

Results Result: A damaged wire or damaged connector was found. Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 2.

D. Check the harness for abrasions and for pinch points from the sensors back to the ECM.

Result: One or more of the diagnostic codes that are listed in Table 1 is active or recently logged.

2. Check For Active Diagnostic Codes A. Turn the keyswitch to the ON position. B. Use the electronic service tool to check for diagnostic codes.

Proceed to Test Step 5. Diagnostic codes

Result: There are no active or recently logged diagnostic codes for the analog throttle position sensors. Proceed to Test Step 3.

Result: The throttle output is 0 percent at low idle and 100 percent at high idle.

3. Check the Throttle Position with the Electronic Service Tool

Proceed to Test Step 4.

A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position. Do not start the engine. C. Observe the throttle position reading on the throttle status screens in the electronic service tool.

Result: The throttle output is not correct. 0 percent at low idle 100 percent at high idle

D. Operate the throttle over the full range of movement.

4. Check the Throttle Selection Status with the Electronic Service Tool A. Check the status of the throttle selection switch (if equipped). Use the electronic service tool in order to check the status of the throttle selection switch. Note: The control of the engine speed may

Switch status

Repair: Use the electronic service tool to verify that the throttle has been configured correctly before continuing with this procedure. For information on the parameters that can be configured, refer to Troubleshooting, "Configuration Parameters". If the fault is still present after the throttle has been configured correctly, replace the analog throttle position sensor.

Result: If the status of the throttle selection switch is shown in the OFF position, then the throttle 1 has control of the engine speed. If the throttle selection switch status is shown in the ON position, then the throttle 2 has control of the engine speed. The throttle selection switch is operating correctly.

not switch between throttles unless both throttles are in the low idle position. The throttle may be overridden by using the SAE J1939 (CAN) data link or a PTO control.

Repair: There may be an intermittent fault. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults. Result: The incorrect throttle is selected. Repair: Change to the other throttle. There may be a fault with the selector switch input. Check the connections between the throttle selection switch and P1:62 and battery -. Refer to Troubleshooting, "Electrical Connectors - Inspect". Refer to the Electrical Schematic for the application.

Result: The measured voltage is not within the expected range. The fault is in the 5 V supply wire or the ground wire between the throttle position sensor and the ECM.

5. Check the Voltage at the Sensor A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect throttle position sensor. C. Turn the keyswitch to the ON position.

4.9 V to 5.1 V

D. Measure the voltage between the 5 V terminal and the sensor ground terminal on the harness connector for the sensor.

Repair: Check all wiring between the suspect sensor and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured voltage is within the expected range. Proceed to Test Step 8.

6. Verify the Type of Active Diagnostic Code A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.

Diagnostic codes

Result: A -3 diagnostic code is active at this time. Proceed to Test Step 7. Result: A -4 diagnostic code is active at this time. Proceed to Test Step 9. Result: There are no active diagnostic codes for the throttle position sensors.

Repair: The fault may be intermittent. Refer to Troubleshooting, "Electrical Connectors Inspect".

7. Create an Open Circuit at the Sensor Connector Result: A -4 diagnostic code became active after disconnecting the sensor.

A. Turn the keyswitch to the OFF position. B. Disconnect the throttle position sensor with the -3 diagnostic code. C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes.

Diagnostic Codes

Install a replacement sensor. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: There is still an active -3 diagnostic code with the sensor disconnected.

D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for an -4 diagnostic code.

Proceed to Test Step 8.

E. Turn the keyswitch to the OFF position.

Result: At least one of the resistance measurements is greater than 1 k Ohm. There is a short in the wiring for the sensor.

8. Check for a Short Circuit in the Wiring for the Sensor A. Turn the keyswitch to the OFF position. B. Disconnect the suspect throttle position sensor. Disconnect the P1 connector from the ECM.

Greater than 1 k Ohm

C. Use a suitable multimeter to measure the resistance between the sensor signal terminal on the P1 connector and all other terminals on the P1 connector.

Repair: Check all wiring between the suspect sensor and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: All resistance measurements are greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

9. Create a Short Circuit at the Sensor Connector A. Turn the keyswitch to the OFF position.

Diagnostic codes

Result: A -3 diagnostic code is active when the jumper is installed. Install a replacement sensor.

Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

B. Disconnect the connector for the throttle position sensor with the XX-4 diagnostic code.

Result: A -4 diagnostic code remains active when the jumper is installed.

C. Fabricate a jumper wire that is 150 mm (6 inch) long.

Proceed to Test Step 10. D. Insert one end of the jumper wire into the terminal for the 5 V supply on the harness connector for the suspect sensor. Insert the other end of the jumper wire into the signal terminal on the harness connector for the suspect sensor. E. Turn the keyswitch to the ON position F. Access the "Active Diagnostic Codes" screen on the electronic service tool and check for an active -3 diagnostic code for the suspect sensor. G. Remove the jumper.

Result: The measured resistance is greater than 5 Ohms. There is an open circuit or high resistance in the sensor signal wire between the sensor connector and the P1 connector.

10. Check the Sensor Signal Wire for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the suspect throttle position sensor connector. Disconnect the P1 connector from the ECM. C. Use a suitable multimeter to measure the resistance between the sensor signal terminal on the harness connector for the sensor and the sensor signal terminal on the P1 connector.

Less than 5 Ohms

Repair: Check all wiring between the suspect sensor and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. Contact the DSN.

If the procedure did not correct the fault, contact the DSN. Cat C3.4B Engine Parts www.CATC34B.COM www.FPTIndustrialEngineParts.com

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06019830

Speed/Timing - Test SMCS - 1912-038 This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Engine Speed/Timing Sensors J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions: A loss of signal from the primary speed/timing sensor for four camshaft revolutions. OR An invalid signal from the primary speed/timing sensor.

190-8

Engine Speed : Abnormal Frequency, Pulse Width, or Period

The engine speed is at least 450 rpm. There is a valid signal from the secondary speed/timing sensor. The diagnostic code will be logged. The ECM will use the signal from the secondary speed/timing sensor. The engine will be derated. If the signal from the secondary speed/timing sensor is also lost, the engine will shut down.

723-8

The Electronic Control Module (ECM) detects the following conditions:

Engine Speed Sensor #2 : Abnormal Frequency, Pulse Width or Period

A loss of signal from the secondary speed/timing sensor for four crankshaft revolutions. OR An invalid signal from the secondary speed/timing sensor for one engine revolution. The engine is running. The diagnostic code will be logged. The loss of signal from the secondary speed/timing sensor will prevent the engine from starting. The Electronic Control Module (ECM) detects the following conditions:

637-11

Engine Timing Sensor : Other Failure Mode

The outputs from the primary speed/timing sensor and the secondary speed/timing sensor differ by more than 10 crankshaft degrees for at least four engine revolutions. The engine is running. There is a valid signal from the secondary speed/timing sensor.

The engine uses two engine speed/timing sensors. The primary speed/timing sensor is located on the front left-hand side of the cylinder block. The primary speed/timing sensor generates a signal by detecting the movement of the teeth that are located on the crankshaft timing ring. The signal that is generated by the speed/timing sensor is transmitted to the ECM. The ECM uses the signal from the speed/timing sensor to calculate the position of the crankshaft. The signal is also used to determine the engine speed. The secondary speed/timing sensor is located in the front cover. The secondary speed/timing sensor generates a signal that is related to the camshaft position. The secondary speed/timing sensor detects the movement of the position wheel on the front of the camshaft. The signal that is generated by the speed/timing sensor is transmitted to the ECM. The ECM calculates the speed and the rotational position of the engine by using the signal. The secondary speed/timing sensor is required for starting purposes. During normal operation, the secondary speed/timing sensor is used to determine the cycle that the engine is on. When the timing has been established, the primary speed/timing sensor is then used to determine the engine speed and the angular position. The loss of signal to the primary sensor and/or the secondary sensor will result in one of the following faults: • The engine will continue to run when only one sensor signal is present from either the primary sensor or the secondary sensor. • Loss of signal from the primary sensor and the secondary sensor during operation of the engine will cause fuel injection to be terminated and the engine will stop. Pull-up Voltage

The ECM continuously outputs a pull-up voltage on the circuit for the secondary speed/timing sensor signal wire. This pull-up voltage is required for correct sensor operation and diagnostics. When the sensor is disconnected, this pull-up voltage can be measured at the harness connector for the sensor.

Illustration 1

g03628020

Schematic diagram for the engine speed/timing sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Illustration 2 View of the pin locations for the speed/timing sensors on the P2 connector (13) Secondary speed/timing sensor 5 V supply (14) Secondary speed/timing sensor signal (28) Secondary speed/timing sensor ground (44) Primary speed/timing sensor return

g02648462

(58) Shield (59) Primary speed/timing sensor supply

Illustration 3

g02648476

View of the sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor

Illustration 4

g02648517

Typical example of the secondary speed/timing sensor (1) Secondary speed/timing sensor ground (2) Secondary speed/timing sensor signal (3) Secondary speed timing sensor 5 V supply

Table 2 Troubleshooting Test Steps 1. Inspect Electrical Connectors and Wiring

Values Damaged

Results Result: A damaged wire or

A. Turn the keyswitch to the OFF position.

wire or connector

damaged connector was found. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

B. Inspect the connectors for the speed/timing sensors. Refer to Troubleshooting, "Electrical Connectors Inspect". C. Perform a 30 N (6.7 lb) pull test on each of the wires in the suspect sensor connector and the sensor connections at the ECM.

Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

D. Check that the ground connection on the ECM and the negative terminal on the battery are correctly installed. E. Check the ground connection on the ECM for abrasions and pinch points.

Proceed to Test Step 2.

F. Check the harness for abrasion and pinch points from the suspect sensor to the ECM. G. Check that the suspect sensor is installed correctly. Check that the suspect sensor is fully seated into the engine. Check that the sensor is securely latched.

2. Check for Active Diagnostic Codes and Recently Logged Diagnostic Codes

Result: Diagnostic code 190-8 is active or recently logged.

A. Turn the keyswitch to the OFF position.

Proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic connector.

Result: Diagnostic code 723-8 is active or recently logged.

C. Turn the keyswitch to the ON position. If the engine will start, then run the engine.

Diagnostic codes

Result: Diagnostic code 637-11 is active or recently logged.

D. Use the electronic service tool in order to monitor active diagnostic codes or recently logged diagnostic codes.

3. Measure the Signal Frequency at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the primary speed/timing sensor.

Proceed to Test Step 5.

Proceed to Test Step 8.

At least 100 Hz.

Result: The measured frequency is less than 100 Hz. Remove the primary speed/timing sensor. Refer to Disassembly and Assembly,

Note: A multimeter that can measure frequency (Hz) is required for this procedure.

"Crankshaft Position Sensor Remove and Install". Inspect the primary speed/timing sensor for damage and/or debris. If the primary speed/timing sensor is free from damage and/or debris, install a new primary speed/timing sensor. Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install". Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. If the primary speed/timing sensor is damaged and/or contaminated with debris, proceed to Test Step 9.

C. Connect the multimeter to pin 1 and pin 2 on the sensor connector. D. Turn the keyswitch to the START position. E. Record the frequency while the engine is cranking.

Result:The measured frequency is greater than 100 Hz. Proceed to Test Step 4.

4. Check the Engine Wiring Harness A. Turn the keyswitch to the OFF position. B. Disconnect the primary speed/timing sensor. Disconnect the P2 ECM connector. C. Measure the resistance between pin 1 on the harness connector for the primary speed/timing sensor and P2:59. D. Measure the resistance between pin 2 on the harness connector for the primary speed/timing sensor and P2:44.

Less than 5 Ohms

Result: At least one of the resistance measurements is greater than 5 Ohms. The fault is in the wiring between the primary speed/timing sensor and the P2 connector. Check all wiring between the primary speed/timing sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: Both resistance measurements are less than 5 Ohms.

Proceed to Test Step 10.

5. Check the Sensor Supply Voltage at the Sensor Connector

Result: The measured voltage is not within the expected range.

A. Turn the keyswitch to the OFF position.

The fault is in the wiring between the secondary speed/timing sensor and the P2 connector.

B. Disconnect the connector for the secondary speed/timing sensor. C. Turn the keyswitch to the ON position. Do not start the engine.

4.9 V to 5.1 V

D. Measure the voltage between pin 1 and pin 3 on the harness connector for the secondary speed/timing sensor.

Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

E. Turn the keyswitch to the OFF position.

Result: The measured voltage is within the expected range.

F. Reconnect the connector for the secondary speed/timing sensor.

Proceed to Test Step 6.

Result: The measured voltage is within the expected range.

6. Check for Signal Voltage at the Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the secondary speed/timing sensor. C. Turn the keyswitch to the ON position. Do not attempt to start the engine.

4.52 to 4.72 V

D. Measure the voltage between pin 1 and pin 2 on the harness connector for the secondary speed/timing sensor. E. Turn the keyswitch to the OFF position.

Replace the secondary speed/timing sensor. Refer to Disassembly and Assembly, "Camshaft Position Sensor Remove and Install" for the correct procedure. Start the engine. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured voltage is not within the expected range.

F. Reconnect the secondary speed timing sensor.

Proceed to Test Step 7.

7. Check the Sensor Signal Voltage at the ECM

4.52 to 4.72

Result: The measured voltage is

within the expected range.

A. Turn the keyswitch to the OFF position. The fault is in the sensor signal wire between the secondary speed/timing sensor and the P2 ECM connector. Check all wiring between the secondary speed/timing sensor and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

B. Disconnect the P2 connector. C. Turn the keyswitch to the ON position. Do not attempt to start the engine. D. Measure the voltage between J2:14 and J2:28 on the ECM. E. Turn the keyswitch to the OFF position. F. Reconnect the P2 connector.

Result: The measured voltage is not within the expected range. Proceed to Test Step 10. 8. Inspect the Sensors A. Ensure that the speed/timing sensors are correctly seated in the cylinder block and the front cover and that the retaining bolts are tightened to the correct torque. Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install" or refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install". Ensure that the speed/timing sensors are not damaged.

Result: A 637-11 diagnostic code is not active at this time.

Diagnostic code

B. Replace any damaged sensors. Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install" or refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install".

Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 637-11 diagnostic code is still active at this time. Proceed to Test Step 9.

C. Use the electronic service tool to check if the 637-11 diagnostic code is still active.

9. Check the Crankshaft Timing Ring and the Camshaft Position Wheel A. Inspect the crankshaft timing ring. Refer to Disassembly and Assembly, "Crankshaft Timing Ring Remove and Install".

Defects

Result: Found fault with the crankshaft timing ring or the camshaft position wheel If necessary, replace the camshaft position wheel. Refer to Disassembly and Assembly,

B. Inspect the camshaft position wheel. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

"Camshaft Gear - Remove and Install". If necessary, replace the crankshaft timing ring. Refer to Disassembly and Assembly, "Crankshaft Timing Ring Remove and Install". Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the fault. Result: No faults found. Contact the Dealer Solution Network (DSN).

Result: There are no active diagnostic codes with the replacement ECM. 10. Check if a Replacement ECM Eliminates the Fault A. Contact the DSN. B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.

Diagnostic codes

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06577530

Switch Circuits - Test - Air Filter Restriction Switch SMCS - 1435-038; 7332-038 Use this procedure to diagnose electronic faults in the air filter restriction switch circuit. This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for the Air Filter Restriction Switch J1939 Code

Description

Notes This code indicates a fault in the circuit for the air filter restriction switch.

107-2

Engine Air Filter 1 Differential Pressure : Erratic, Intermittent, or Incorrect

The Electronic Control Module (ECM) detects the following conditions: The signal from the air filter restriction switch indicates a restriction. The engine is not running. The ECM has been powered for at least 6 seconds. The warning lamp will come on. Monitoring of air filter restriction when the engine is running will be disabled whilst this code is active.

If the engine is equipped with an air filter restriction switch, the type of switch that is installed can be either "Normally Open" or "Normally Closed". The parameter for the type of switch that is installed can be set using the electronic service tool.

Use the electronic service tool to check which type of switch is installed in the application before continuing with this procedure. Ensure that the parameter is set correctly for the type of switch that is installed in the application. Refer to the OEM for more information. Table 2 Diagnostic Summary for a "Normally Open" Air Filter Restriction Switch Engine Condition

Switch State

Active Diagnostic Code

Not running (key on)

Open

Normal condition

Running

Open

Normal Condition (no air filter restriction detected)

Not running

Closed

107-2

Running

Closed

107-15 or 107-16 Table 3

Diagnostic Summary for a "Normally Closed" Air Filter Restriction Switch Engine Condition

Switch State

Active Diagnostic Code

Not running (key on)

Open

107-2

Running

Open

107-15 or 107-16

Not running

Closed

Normal condition

Running

Closed

Normal Condition (no air filter restriction detected)

Note: An active 107–15 or 107–16 diagnostic code indicates that the air inlet is restricted. Refer to Troubleshooting, "Inlet Air Is Restricted".

Illustration 1

g03636737

Schematic diagram for an air filter restriction switch Not all connectors are shown. Refer to the Electrical Schematic for the application.

Illustration 2

g02716382

View of the pin location on the P1 connector for the air filter restriction switch (87) Air filter restriction switch

Table 4 Troubleshooting Test Steps 1. Check the Type of Switch that is Installed and Configured A. Connect the electronic service tool to the diagnostic connector. B. Turn the keyswitch to the ON position. Do not start the engine. C. Use the electronic service tool to check that the "Air Filter Restriction Switch Installation Status" and the "Air Filter Restriction Switch Configuration" matches the type of switch that is installed.

Values Switch configuration

Results Result: An air filter restriction switch is installed and the "Air Filter Restriction Switch Installation Status" is "Not Installed". Use the electronic service tool to change the "Air Filter Restriction Switch Installation Status" to "Installed". Ensure that the "Air Filter Restriction Switch Configuration" matches the type of switch that is installed. Use the electronic service to check that the repair eliminates the fault. Result: An air filter restriction switch is not installed and the "Air Filter Restriction Switch Installation Status" is "Not Installed". The "Air Filter Restriction Switch Configuration" is "Normally Closed".

Repair: Change the "Air Filter Restriction Switch Configuration" to "Normally Open." Use the electronic service to check that the repair eliminates the fault. Result: An air filter is installed and the "Air Filter Restriction Switch Installation Status" is installed. The "Air Filter Restriction Switch Configuration" does not match the type of switch that is installed. Repair: Change the "Air Filter Restriction Switch Configuration" to match the type of switch that is installed. Use the electronic service to check that the repair eliminates the fault. Result: An air filter restriction switch is installed. The "Air Filter Restriction Switch Installation Status" is "Installed". The "Air Filter Restriction Switch Configuration" matches the type of switch that is installed. Proceed to Test Step 2.

2. Inspect Electrical Connectors and Wiring Result: A damaged wire or damaged connector was found.

A. Thoroughly inspect the terminal connections on the P1/J1 connector. B. Thoroughly inspect the connector for the air filter restriction switch. C. Refer to Troubleshooting, "Electrical Connectors - Inspect". D. Perform a 30 N (6.7 lb) pull test on each of the wires in the connectors that are associated with the air filter restriction switch. E. Check the harness for abrasions and for pinch points from the switch back to the ECM.

Damaged wire or connector

Repair: Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 3.

3. Check for Active or Recently Logged Diagnostic Codes

Diagnostic codes

A. Turn the keyswitch to the OFF position.

Result: A 107-2 diagnostic code is not active. If the diagnostic code is recently logged, an intermittent fault may exist. Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" to identify intermittent faults.

B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. Do not start the engine.

Result: A "Normally Open" switch is installed. A 107-2 diagnostic code is active. A short circuit condition exists in the air filter restriction switch circuit.

D. Use the electronic service tool to check whether a "Normally Open" or "Normally Closed" air filter restriction switch is installed in the application.

Proceed to Test Step 4. Result: A "Normally Closed" switch is installed. A 107-2 diagnostic code is active. An open circuit condition exists in the air filter restriction switch circuit.

E. Check for any active or recently logged diagnostic codes. Wait at least 10 seconds for activation of the diagnostic codes.

Proceed to Test Step 6.

4. Create an Open Circuit at the Switch Connector

Result: The fault is cleared with the switch disconnected.

A. Turn the keyswitch to the OFF position. B. Disconnect the connector from the air filter restriction switch. C. Turn the keyswitch to the ON position. Do not start the engine.

Diagnostic codes

D. Use the electronic service tool to check for an active 107-2 diagnostic code. Wait at least 10 seconds for activation of the diagnostic code.

Result: The 107-2 diagnostic code is still active with the air filter restriction switch disconnected. Reconnect the connector to the air filter restriction switch and proceed to Test Step 5.

E. Turn the keyswitch to the OFF position.

5. Check the Wiring for a Short Circuit

Repair: Replace the air filter restriction switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Greater than 1 k Ohm

Result: At least one of the resistance measurements is less than 1 k Ohm

A. Turn the keyswitch to the OFF position.

The fault is in the wiring between the air filter restriction switch and the P1 ECM connector.

B. Disconnect the connector for the switch. Disconnect the P1 connector from the ECM.

Repair: Check all wiring between the switch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

C. Use a suitable multimeter to measure the resistance between P1:87 and all other terminals on the P1 connector.

Result: All resistance measurements are greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

6. Create a Short at the Switch Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector from the air filter restriction switch.

Result: The fault is cleared with the jumper installed.

C. Fabricate a jumper wire and install the jumper wire across the two terminals on the harness connector for the switch.

Repair: Replace the air filter restriction switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

D. Turn the keyswitch to the ON position.

Diagnostic code

E. Use the electronic service tool to check for an active 107-2 diagnostic code. Wait at least 10 seconds for activation of the diagnostic code.

Result: A 107-2 diagnostic code is still active with the jumper installed. Proceed to Test Step 7.

F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

7. Check the Ground Wire for the Switch

Diagnostic code

Result: The fault is cleared with the jumper installed. The fault is in the ground wire between the

A. Turn the keyswitch to the OFF position.

air filter restriction switch and battery negative.

B. Disconnect the connector from the air filter restriction switch.

C. Fabricate a jumper wire. Install the jumper wire between the signal terminal on the harness connector for the switch and a suitable ground. D. Turn the keyswitch to the ON position.

Result: A 107-2 diagnostic code is active with the jumper installed.

E. Use the electronic service tool to check for an active 107-2 diagnostic code. Wait at least 10 seconds for activation of the diagnostic code.

Proceed to Test Step 8.

F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

Result: The measured resistance is greater than 5 Ohms. There is an open circuit or high resistance in the wiring between the air filter restriction switch and the ECM.

8. Check the Wiring for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the switch. Disconnect the P1 connector from the ECM. C. Use a suitable multimeter to measure the resistance between P1:87 and the signal terminal on the harness connector for the switch.

Less than 5 Ohms

Repair:Check all wiring between the switch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. Contact the Dealer Solution Network (DSN).

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06019874

Switch Circuits - Test - Engine Oil Pressure Switch SMCS - 1435-038; 7332-038 Use this procedure to diagnose electronic faults in the oil pressure switch circuit. This procedure covers the following diagnostic code: Table 1 Diagnostic Trouble Codes for the Oil Pressure Switch J1939 Code

Description

Notes When the keyswitch is in the ON position (engine not running), the oil pressure switch circuit should be closed.

100-2

Engine Oil Pressure : Erratic, Intermittent, or Incorrect

This diagnostic code will be active when the Electronic Control Module (ECM) detects the following conditions: The engine is not running. The circuit for the oil pressure switch is open for at least 3 seconds. The keyswitch has been switched on for at least 6 seconds. The battery voltage is at least 10 VDC.

The engine is equipped with an oil pressure switch. While the engine is running and oil pressure is detected, the switch will be open. When no oil pressure is detected, the switch will be closed. Table 2 Oil Pressure Switch States and Diagnostics Summary Engine Condition

Oil Pressure Switch State

Active Diagnostic Code

Not running

Closed

Normal condition (no oil pressure detected)

Running

Open

Normal condition (oil pressure detected)

Not running

Open

100-2

Running

Closed

100-17

Note: If a 100-17 diagnostic code is active, refer to Troubleshooting, "Oil Pressure Is Low" before returning to this procedure.

Illustration 1

g03636596

Schematic diagram for the oil pressure switch Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Illustration 2

g02710319

View of the pin location on the P2 connector for the oil pressure switch (6) Engine oil pressure switch

Table 3 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the terminal connections on the P2/J2 connector.

Damaged wire or connector

B. Thoroughly inspect the connector for the oil pressure switch. C. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Result: A damaged wire or damaged connector was found. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the connectors that are associated with the oil pressure switch.

Proceed to Test Step 2.

E. Check the harness for abrasions and for pinch points from the oil pressure switch back to the ECM.

2. Check for Active or Recently Logged Diagnostic Codes A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. Do not start the engine. D. Check for any active or recently logged diagnostic codes. Wait at least 10 seconds for activation of the diagnostic codes.

Diagnostic codes

Result: A 100-17 diagnostic code is recently logged. This diagnostic code indicates that the oil pressure is low, but can also be caused by a short circuit condition in the oil pressure switch circuit. Check for engine oil pressure problems before returning to this procedure. refer to Troubleshooting, "Oil Pressure Is Low". If the fault is still present, proceed to Test Step 3. Result: A 100-2 diagnostic code is not active. A 100-17 diagnostic code is not recently logged. An intermittent 100-2 diagnostic code can be caused by turning the keyswitch to the ON position after the engine has recently been stopped or an intermittent fault may exist. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults. Result: A 100-2 diagnostic code is active.

Proceed to Test Step 5.

Result: A 100-2 diagnostic code is active with the switch disconnected.

3. Create an Open Circuit at the Switch Connector A. Turn the keyswitch to the OFF position. B. Disconnect the harness connector for the oil pressure switch. C. Turn the keyswitch to the ON position. Do not start the engine.

Diagnostic codes

Result: A 100-2 diagnostic code is not active with the oil pressure switch disconnected.

D. Use the electronic service tool to check for an active 100-2 diagnostic code. Wait at least 10 seconds for activation of the diagnostic code.

Reconnect the harness connector for the oil pressure switch and proceed to Test Step 4.

4. Create an Open Circuit at the ECM Connector

Result: A 100-2 diagnostic code is active with the P2 connector disconnected.

A. Disconnect the P2 connector from the ECM. B. Turn the keyswitch to the ON position. Do not attempt to start the engine. Wait at least 30 seconds for activation of the diagnostic codes.

Replace the oil pressure switch. Refer to Disassembly and Assembly, "Engine Oil Pressure Switch - Remove and Install". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Diagnostic codes

C. Use the electronic service tool to check for an active 100-2 diagnostic code. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for a 100-2 diagnostic code.

The fault is in the wiring between the oil pressure switch and the P2 ECM connector. Check all wiring between the oil pressure switch and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 100-2 diagnostic code is not active with the wire disconnected. Proceed to Test Step 7.

D. Turn the keyswitch to the OFF position.

5. Create a Short at the Switch Connector A. Turn the keyswitch to the OFF position.

Diagnostic codes

Result: A 100-2 diagnostic code is not active with the jumper installed. Replace the oil pressure switch. Refer to

Disassembly and Assembly, "Engine Oil Pressure Switch - Remove and Install". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

B. Disconnect the harness connector for the oil pressure switch. C. Fabricate a jumper wire and install the jumper wire between the harness connector for the oil pressure switch and a suitable ground.

Result: A 100-2 diagnostic code is active with the jumper installed.

D. Turn the keyswitch to the ON position. Do not start the engine.

Proceed to Test Step 6.

E. Use the electronic service tool to check for an active 100-2 diagnostic code. Wait at least 10 seconds for activation of the diagnostic code. F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

6. Create a Short at the ECM Connector A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM.

Result: A 100-2 diagnostic code is not active with the jumper installed.

C. Fabricate a jumper wire and install the jumper wire between J2:6 and a suitable ground.

D. Turn the keyswitch to the ON position. Do not attempt to start the engine. Wait at least 30 seconds for activation of the diagnostic codes. E. Use the electronic service tool to check for an active 100-2 diagnostic code. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for a 100-2 diagnostic code. F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

Diagnostic Codes

Result: A 100-2 diagnostic code is active with the jumper installed. Proceed to Test Step 7.

7. Check if a Replacement ECM Eliminates the Fault

Diagnostic codes

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06233842

Switch Circuits - Test - Throttle Switch SMCS - 1435-038; 7332-038 Table 1 Diagnostic Trouble Codes for the Throttle Switch Circuit J1939 Code

Description

Notes The Electronic Control Module (ECM) detects the following conditions:

2880-2

Engine Operator Primary Intermediate Speed Select : Erratic, Intermittent, or Incorrect

The signal voltage from the throttle switch is between 0.35 V and 4.8 V. The signal voltage from the throttle switch is not valid for any of the available modes for at least 0.5 seconds. The battery voltage is at least 10 V. The warning lamp will come on. The ECM detects the following conditions:

2880-3

Engine Operator Primary Intermediate Speed Select : Voltage Above Normal

The signal voltage from the throttle switch is above 4.8 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The warning lamp will come on.

2880-4

Engine Operator Primary Intermediate Speed Select : Voltage Below Normal

The ECM detects the following conditions: The signal voltage from the throttle switch is less than 0.35 VDC for at least 0.5 seconds.

The battery voltage is at least 10 VDC. The warning lamp will come on. The throttle switch uses resistors to modify the voltage signal from the ECM. The resistance of the switch changes dependent on which position the switch is in. The ECM uses the signal voltage to determine which mode has been selected.

Illustration 1

g03117957

View of the signal voltage range for the throttle switch

Illustration 2 Typical example of the schematic for the throttle switch Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03734117

Illustration 3

g02723018

Typical view of the pin locations on the P1 connector for the throttle switch (55) Throttle switch signal (77) Throttle switch ground

Table 2 Troubleshooting Test Steps

Values

Results

1. Inspect Electrical Connectors and Wiring Result: A damaged wire or damaged connector was not found.

A. Thoroughly inspect the terminal connections on the P1/J1 connector.

Proceed to Test Step 2.

B. Thoroughly inspect the connector for the throttle switch. C. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Damaged wire or connector

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the connectors that are associated with the throttle switch. E. Check the harness for abrasions and for pinch points from the switch back to the ECM.

2. Check for Active or Recently Logged Diagnostic Codes

Diagnostic

Result: A 2880-4 diagnostic code is active.

A. Turn the keyswitch to the OFF position.

Trouble Codes

B. Connect the electronic service tool to the diagnostic connector.

Result: A 2880-3 diagnostic code is active.

C. Turn the keyswitch to the ON position. Do not start the engine.

Proceed to Test Step 4.

D. Check for active diagnostic codes with the throttle switch in each position. Wait at least 10 seconds with the switch in each position for activation of the diagnostic codes.

Result: A 2880-2 diagnostic code is active. Proceed to Test Step 5.

Result: A 2880-3 diagnostic code is active with the switch disconnected.

3. Create an Open Circuit at the Switch A. Turn the keyswitch to the OFF position. B. Disconnect the throttle switch. C. Turn the keyswitch to the ON position.

Proceed to Test Step 3.

Diagnostic codes

Repair: Replace the throttle switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

D. Use the electronic service tool to check for an active 2880 diagnostic code. Wait at least 10 seconds for activation of the diagnostic codes.

Result: A 2880-4 diagnostic code is still active with the switch disconnected.

E. Turn the keyswitch to the OFF position.

Reconnect the switch and proceed to Test Step 7.

4. Create a Short at the Switch Connector

Diagnostic codes

Result: A 2880-4 diagnostic code is active with the jumper installed.

A. Turn the keyswitch to the OFF position. B. Disconnect the throttle switch. C. Fabricate a jumper wire and install the jumper wire between the two harness connector terminals for the throttle switch. D. Turn the keyswitch to the ON position. E. Use the electronic service tool to check for an active 2880 diagnostic code. Wait at least 10 seconds for activation of the diagnostic codes.

Repair: Replace the throttle switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 2880-3 diagnostic code is still active with the jumper installed. Reconnect the throttle switch and proceed to Test Step 7.

F. Turn the keyswitch to the OFF position. G. Remove the jumper wire.

5. Check the Voltage at the Switch Connector

Result: The voltage is within the expected range.

A. Turn the keyswitch to the OFF position. B. Disconnect the throttle switch. C. Turn the keyswitch to the ON position. D. Use a suitable multimeter to measure the voltage between the signal terminal and the ground terminal at the switch connector.

4.9 V to 5.1 V

Result: The voltage is not within the expected range.

E. Turn the keyswitch to the OFF position.

Proceed to Test Step 6.

Result: At least one of the resistance measurements is greater than 5 Ohms. The fault is in the wiring between the switch connector and the P1 connector.

6. Check the Wiring for High Resistance A. Turn the keyswitch to the OFF position. B. Disconnect the throttle switch. Disconnect the P1 connector. C. Use a suitable multimeter to measure the resistance between the following points: · P1:55 to the signal terminal at the switch connector · P1:77 to the ground terminal at the switch connector

Repair: Replace the throttle switch. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Less than 5 Ohms

Repair: Check all wiring between the throttle switch and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: Both resistance measurements are less than 5 Ohms. Proceed to Test Step 7.

7. Check the Wiring for a Short Circuit A. Turn the keyswitch to the OFF position.

Greater than 1 Result: At least one of the resistance k Ohm measurements is less than 1 k Ohm. There is a short in the wiring between the throttle switch and the

B. Disconnect the P1 connector from the ECM.

P1 connector.

C. Disconnect the throttle switch.

D. Use a suitable multimeter to measure the resistance between the following points: · P1:55 and all other terminals on the P1 connector · P1:77 and all terminals on the P1 connector

Result: All resistance measurements are greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980308

System Overview SMCS - 1000; 1900 The engine is designed for electronic control of most engine operating functions. The electronic system consists of an Electronic Control Module (ECM), the wiring harness, switches, sensors, and fuel injectors. The engine ECM receives information from the sensors and the switches on the engine. The engine ECM processes the information that is collected in order to control the engine. By altering the fuel delivery with the fuel injectors, the engine ECM controls the speed and the power that is produced by the engine. The following information provides a general description of the control system. Refer to the Systems Operation manual for detailed information about the control system.

System Operation Engine Governor The ECM governs the engine. The ECM determines the timing, the injection pressure, and the amount of fuel that is delivered to each cylinder. These factors are based on the actual conditions and on the desired conditions at any given time during starting and operation. The ECM uses the throttle position sensor to determine the desired engine speed. The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is determined through interpretation of the signals that are received by the ECM from the engine speed/timing sensors. If the desired engine speed is greater than the actual engine speed, the ECM requests that more fuel is injected in order to increase engine speed.

Timing Considerations Once the ECM has determined the amount of fuel that is required, the ECM must determine the timing of the fuel injection. The ECM adjusts timing for optimum engine performance and for the fuel economy. Actual timing and desired timing cannot be viewed with the electronic service tool. The ECM determines the location of top center of the number one cylinder from the signals that are provided by the

engine speed/timing sensors. The ECM determines when injection should occur relative to the top center. The ECM then provides the signal to the injector at the desired time.

Fuel Injection The ECM sends a high voltage signal to the injector solenoids in order to energize the solenoids. By controlling the timing and the duration of the high voltage signal, the ECM can control the following aspects of injection: • Injection timing • Fuel delivery

Other ECM Functions for Performance Refer to Troubleshooting, "Configuration Parameters" for supplemental information about the systems that can be monitored by the ECM.

Programmable Parameters Certain parameters that affect engine operation may be changed with the electronic service tool. The parameters are stored in the ECM. These parameters are either system configuration parameters or customer parameters. System configuration parameters are set at the factory. System configuration parameters affect emissions or power ratings within an engine family. Some of the parameters may affect engine operation in an unusual way. An operator might not expect this type of effect. Without adequate training, these parameters may lead to power complaints or performance complaints even though the engines performance is to the specification. Customer parameters are variable. Customer parameters can be used to affect the characteristics of the engine. Limits are set by the factory and by the monitoring system. Refer to Troubleshooting, "Configuration Parameters" for additional information on this subject.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06228923

Valve Lash Is Excessive SMCS - 1105-035

Probable Causes • Lubrication • Valve train components

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 1 Troubleshooting Test Steps 1. Lubrication A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install" for the correct procedure. B. Crank the engine and check the lubrication in the valve compartment. Ensure that there is adequate engine oil flow in the valve compartment. The passages for the engine oil must be clean. Note: Do not run the engine with the valve mechanism cover removed.

Values Lubrication

Results Result: The oil flow to the valve mechanism is insufficient. Repair: Make sure that the passages for the engine oil are clear. Result: The oil flow to the valve mechanism is OK. Proceed to Test Step 2.

Result: A valve train component is worn, bent, or not clean.

2. Valve Train Components

Repair: Repair or replace the component. Refer to Disassembly and Assembly.

A. Inspect the following components of the valve train for abnormal or excessive wear, straightness, and cleanliness: · Rocker arms · Pushrods · Hydraulic lifters · Camshaft · Valve stems · Rocker shafts

Valve train components

Note: If the camshaft is replaced, new valve lifters must also be installed. Result: All the valve train components are OK. Contact the Dealer Solution Network (DSN).

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Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06020913

Valve Position - Test SMCS - 108A-038-PSN; 1130-038-PSN; 1439-038-PSN This procedure covers the following codes: Table 1 Diagnostic Trouble Codes for the Valve Position Sensors J1939 Code

27-3

Description

Engine Exhaust Gas Recirculation Valve Position : Voltage Above Normal

Notes The Electronic Control Module (ECM) detects that the signal voltage from the position sensor on the NOx Reduction System (NRS) valve is greater than 4.8 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The ECM will set the valve to the default position while this code is active. The default position is 0 percent. The engine will be derated.

27-4

Engine Exhaust Gas Recirculation Valve Position : Voltage Below Normal

The ECM detects that the signal voltage from the position sensor on the NRS valve is less than 0.2 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The ECM will set the valve to the default position while this code is active. The default position is 0 percent.

The engine will be derated. The ECM detects the following conditions:

51-3

Engine Throttle Valve 1 Position : Voltage Above Normal

The signal voltage from the position sensor on the intake throttle valve is greater than 4.75 VDC for at least 0.5 seconds. The battery voltage is at least 10 VDC. The intake throttle valve will move to the default position while the diagnostic code is active. The default position is 0 percent. The ECM detects the following conditions:

51-4

Engine Throttle Valve 1 Position : Voltage Below Normal

The signal voltage from the position sensor on the intake throttle valve is less than 0.25 VDC for at least 0.5 seconds. The intake throttle valve will move to the default position while the diagnostic code is active. The default position is 0 percent.

Use this procedure in order to troubleshoot the position sensors for the following valves: • NRS valve • Engine intake throttle valve Each position sensor is an integral part of the associated valve. If the following procedure indicates a fault with the position sensor, then the entire valve must be replaced. The following background information is related to this procedure: The troubleshooting procedures for the diagnostic codes of each position sensor are identical. The ECM supplies 5 VDC to terminal "1" of the engine intake throttle valve connector and to terminal "6" of the NRS valve connector. The sensor common from the ECM connector goes to terminal "3" of the engine intake throttle valve connector and to terminal "4" of the NRS valve connector. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM. The signal voltage from terminal "5" of the engine intake throttle valve and from terminal "2" of the NRS valve is supplied to the appropriate terminal at the P2/J2 ECM connector.

Illustration 1

g03636782

Schematic diagram for the valve position sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Illustration 2

g03616849

Typical view of the pin locations on the J2 connector for the valve position sensors. (8) Intake throttle valve position sensor 5 VDC supply (9) NRS valve position sensor 5 VDC supply (24) NRS valve position sensor ground (34) Intake throttle valve return (35) NRS valve return (37) Intake throttle valve position sensor ground (39) NRS valve position sensor signal (49) Intake throttle valve PWM signal (50) NRS valve PWM signal (53) Engine intake throttle valve position sensor signal

Table 2

Troubleshooting Test Steps

Values

Result: None of the preceding diagnostic codes are active or recently logged.

1. Verify All Active and Recently Logged Diagnostic Codes A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.

Results

Diagnostic codes

The fault may be intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults. Result: One or more of the preceding diagnostic codes are active or recently logged.

B. Verify if any of the diagnostic codes that are listed in Table 1 are active or recently logged.

Proceed to Test Step 2.

2. Inspect Electrical Connectors And Wiring

Result: A damaged wire or damaged connector was found.

A. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors. B. Thoroughly inspect the connectors for the valves. C. Refer to Troubleshooting, "Electrical Connectors - Inspect". D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the valve connectors that are associated with the active diagnostic code.

Damaged wire or connector

E. Check the harness for abrasions and for pinch points from the valves back to the ECM.

3. Measure the Sensor Supply Voltage at the Valve Connector A. Turn the keyswitch to the OFF position. B. Disconnect the suspect valve from the engine harness. C. Turn the keyswitch to the ON position.

4.9 v to 5.1 V

Result: The measured voltage is not within the expected range. The fault is in the wiring between the suspect valve and the ECM P2 connector. Check all wiring between the suspect valve and the ECM. Refer to the appropriate Electrical Schematic.

D. Measure the voltage at the harness connector for the valve from the 5 VDC supply terminal of the position sensor to the sensor ground terminal.

Replace the suspect wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured voltage is within the expected range. Proceed to Test Step 4.

Result: An XX-4 diagnostic code is active at this time.

4. Verify the Type of Active Diagnostic Code A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.

Proceed to Test Step 5. Diagnostic codes

B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.

5. Create an Open Circuit at the Valve Connector Diagnostic codes A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the valve with the XX-4 diagnostic code. C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes. D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for an XX3 diagnostic code. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve. E. Turn the keyswitch to the OFF position.

Result: An XX-3 diagnostic code is active at this time. Proceed to Test Step 7.

Result: An XX-3 diagnostic code is active with the valve disconnected. Reconnect the connector for the valve. If the XX-4 diagnostic code returns, there is a short in the valve. Install a replacement valve. Refer to Disassembly and Assembly for the correct procedure. If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: There is still an XX-4 diagnostic code active with the valve disconnected. Proceed to Test Step 6.

Result: An XX-3 diagnostic code is active with the P2 connector disconnected.

6. Create an Open Circuit at the ECM Connector A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.

Diagnostic Codes

D. Use the electronic service tool in order to monitor the "Active Diagnostic Code" screen. Check for an XX-3 diagnostic code for the suspect sensor. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect sensor.

The fault is in the wiring for the suspect sensor between the suspect valve connector and the P2 connector. Check all wiring between the suspect valve and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: An XX-4 diagnostic code is still active with the P2 connector disconnected. Proceed to Test Step 9.

7. Create a Short Circuit at the Valve Connector A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the valve with the XX-3 diagnostic code. C. Fabricate a jumper wire that is 150 mm (6 inch) long. D. Insert one end of the jumper wire into the terminal for the valve position sensor signal on the harness connector for the suspect valve. Insert the other end of the jumper into the terminal for the sensor ground on the harness connector for the suspect valve. E. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes. F. Access the "Active Diagnostic Codes" screen on the electronic service tool and check for an active

Diagnostic codes

Result: An XX-4 diagnostic code is active when the jumper is installed. Reconnect the connector for the suspect valve. Turn the keyswitch to the ON position. Use the electronic service tool to check for active diagnostic codes. If the XX-3 diagnostic code returns, there is an open circuit in the valve. Install a replacement valve. Refer to Disassembly and Assembly for the correct procedure. If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset". Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

XX-4 diagnostic code for the suspect sensor.

Result: An XX-3 diagnostic code remains active when the jumper is installed.

G. Remove the jumper.

Proceed to Test Step 8. 8. Create a Short Circuit at the ECM Connector

Result: An XX-4 diagnostic code is active with the jumper wire installed.

A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper between the suspect sensor signal pin and the sensor ground pin on the J2 connector. D. Turn the keyswitch to the ON position. Do not attempt to start the engine. Wait at least 10 seconds for activation of the diagnostic codes.

Diagnostic codes

E. Use the electronic service tool to check for an active XX-4 diagnostic code for the suspect sensor. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect sensor.

Result: The XX-3 diagnostic code is still active with the jumper wire installed.

F. Turn the keyswitch to the OFF position. Remove the jumper wire.

9. Check if a Replacement ECM Eliminates the Fault

The fault is in the wiring for the suspect sensor between the suspect valve connector and the P2 connector. Check all wiring between the suspect valve and the ECM. Refer to the appropriate Electrical Schematic. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Proceed to Test Step 9.

Diagnostic codes

Result: There are no active diagnostic codes with the replacement ECM.

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Contact the DSN.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i06233870

Water in Fuel - Test SMCS - 1263-038-NS; 1439-038 For a 97-15 diagnostic code, refer to Troubleshooting, "Fuel Contains Water" before returning to this procedure. Water-in-Fuel Sensor Operation The Water In Fuel (WIF) sensor is a normally open sensor. During normal operation, there will be no signal sent from the WIF sensor to the ECM. If water is detected in the fuel, the sensor will send a signal to the ECM. If the signal remains constant for 60 seconds, a 97-15 diagnostic code will become active. This diagnostic code can also be caused by a short in the WIF sensor circuit.

Illustration 1 Schematic diagram for the WIF sensor circuit Not all connectors are shown. Refer to the Electrical Schematic for the application.

g03636920

Illustration 2

g02734203

Typical view of the pin location on the P1 connector for the WIF sensor (30) WIF sensor signal

Table 1 Troubleshooting Test Steps

Values

1. Inspect Electrical Connectors and Wiring

Result: A damaged wire or damaged connector was found.

A. Turn the keyswitch to the OFF position. B. Thoroughly inspect the connector for the WIF sensor and the P1/J1 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Results

Damaged wire or connector

Repair: Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.

C. Perform a 30 N (10 lb) pull test on each of the wires that are associated with the WIF sensor.

Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.

D. Check the harness for abrasions, for pinch points, and for corrosion.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector.

Diagnostic codes

Result: A 97-15 diagnostic code is active. Repair: Ensure that there is no water present in the fuel before continuing with

this procedure. Refer to Troubleshooting, "Fuel Contains Water". Proceed to Test Step 3.

B. Turn the keyswitch to the ON position. C. Wait for at least 1 minute.

Result: A 97-15 diagnostic code is not active at this time. If the WIF sensor is not operating correctly, proceed to Test Step 5.

D. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.

Result: The code disappears with the sensor disconnected.

3. Disconnect the WIF Sensor A. Turn the keyswitch to the OFF position. B. Disconnect the WIF sensor from the harness. C. Turn the keyswitch to the ON position. Wait for at least 1 minute.

Diagnostic codes

D. Use the electronic service tool to check for an active 97-15 diagnostic code.

B. Disconnect the WIF sensor connector. Disconnect the P1 connector from the ECM. C. Use a suitable multimeter to check the resistance between P1:30 and all other terminals on the P1 connector.

Result: A 97-15 diagnostic code is still active with the sensor disconnected. Reconnect the sensor and proceed to Test Step 4.

Result: At least one of the resistance measurements is less than 1 k Ohm. The fault is in the wiring between the WIF sensor and the P1 ECM connector.

4. Check the Sensor Signal Wire for a Short Circuit A. Turn the keyswitch to the OFF position.

Repair: Replace the WIF sensor. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Repair: Check all wiring between the WIF sensor and the ECM. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Greater than 1 Use the electronic service tool to clear all k Ohm logged diagnostic codes and verify that the repair eliminates the fault. Result: Each resistance measurement is greater than 1 k Ohm. Contact the Dealer Solution Network (DSN).

5. Check that the Sensor is Receiving the Correct Voltage

Greater than 11 V

Result: The measured voltage is less than 11 V.

The fault is in the switched battery supply wiring to pin 3 on the WIF sensor connector.

A. Turn the keyswitch to the OFF position. B. Disconnect the WIF sensor from the harness.

Repair: Check all battery supply wiring to the WIF sensor. Refer to the Electrical Schematic for the application. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

C. Turn the keyswitch to the ON position. D. Measure the voltage between terminal 3 on the harness connector for the WIF sensor and a suitable ground. E. Turn the keyswitch to the OFF position.

Result: The measured voltage is at least 11 V. Proceed to Test Step 6.

Result: The measured voltage is less than 11 V. The fault is the wiring between terminal 2 on the WIF sensor connector and battery negative.

6. Check the WIF sensor Ground Wire A. Turn the keyswitch to the OFF position. B. Disconnect the WIF sensor from the harness. C. Turn the keyswitch to the ON position.

Greater than 11 V

D. Measure the voltage between terminal 2 and terminal 3 on the harness connector for the WIF sensor.

Repair: Check all wiring between the WIF sensor and battery negative. Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured voltage is at least 11 V. Proceed to Test Step 7.

7. Create a Short Circuit at the WIF Sensor Connector A. Turn the keyswitch to the OFF position. B. Disconnect the WIF sensor from the harness. C. Fabricate a jumper and install the jumper wire between terminal 1 and terminal 2 on the harness connector for the WIF sensor.

Diagnostic codes

Result: A 97-15 diagnostic code is active with the jumper installed. Repair: Replace the WIF sensor. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 97-15 diagnostic code is not active with the jumper installed.

Proceed to Test Step 8. D. Turn the keyswitch to the ON position. Wait for at least 1 minute. E. Use the electronic service tool to check for an active 97-15 diagnostic code. F. Turn the keyswitch to the OFF position. G. Remove the jumper.

Result: The measured resistance is greater than 5 Ohms. The fault is in the wiring between the WIF sensor and the P1 connector.

8. Check the Sensor Signal Wire for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the WIF sensor. Disconnect the P1 connector from the ECM. C. Use a suitable multimeter to measure the resistance between terminal 1 on the harness connector for the WIF sensor and P1:30.

Less than 5 Ohms

Repair: Check all wiring between the WIF sensor and the ECM. Refer to the Electrical Schematic for the application. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. Contact the DSN.

Troubleshooting C3.4B Engines Media Number -UENR0611-10

Publication Date -01/02/2015

i05980253

Welding Precaution SMCS - 1000 Correct welding procedures are necessary in order to avoid damage to the Electronic Control Module (ECM) , to sensors, and to associated components. Components for the driven equipment should also be considered. When possible, remove the component that requires welding. When welding on an application that is equipped with an electronically controlled engine and removal of the component is not possible, the following procedure must be followed. This procedure minimizes the risk to the electronic components. 1. Stop the engine. Remove the electrical power from the ECM. 2. Ensure that the fuel supply to the engine is turned off. 3. Disconnect the negative battery cable from the battery. If a battery disconnect switch is installed, open the switch. 4. Disconnect all electronic components from the wiring harnesses. Include the following components: Electronic components for the driven equipment ECM Sensors Electronically controlled valves Relays Electronic control units

NOTICE

Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.

Illustration 1

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Service welding guide (typical diagram)

5. When possible, connect the ground clamp for the welding equipment directly to the engine component that will be welded. Place the clamp as close as possible to the weld. Close positioning reduces the risk of welding current damage to the engine bearings, to the electrical components, and to other components. 6. Protect the wiring harnesses from welding debris and/or from welding spatter. 7. Use standard welding procedures to weld the materials together.