Service manual Caterpillar C4.4 Industrial Engine | KENR9120-03

This manual is applicable to the following models:

C4.4 Industrial Engine 44800001-UP
TH514C, TH417C, TH407C, TH414C, TH406C, TH337C, TH336C, Telehandler Transmission RCH00001-00149 (MACHINE)
TH406C Telehandler RCH00150-UP (MACHINE) POWERED BY C4.4 Engine

Manual contents:

Flow Control Valve – Remove and Install
Exhaust Cooler (NRS) – Remove and Install – Side mounted
Refrigerant Compressor – Remove and Install
Atmospheric Pressure Sensor – Remove and Install
Camshaft Position Sensor – Remove and Install
Crankshaft Position Sensor – Remove and Install
Coolant Temperature Sensor – Remove and Install
Engine Oil Pressure Sensor – Remove and Install
Fuel Pressure Sensor – Remove and Install
Fuel Temperature Sensor – Remove and Install
Soot Antenna – Remove and Install
Temperature Sensor (DPF) – Remove and Install
Exhaust Cooler (NRS) – Remove and Install – Top mounted
Temperature Sensor (Cooled Exhaust Gas) – Remove and
Pressure Sensor (Cooled Exhaust Gas) – Remove and Install –
Boost Pressure Sensor – Remove and Install
Inlet Manifold Temperature Sensor – Remove and Install
Glow Plugs – Remove and Install
Alternator Belt – Remove and Install
Idler Pulley – Remove and Install – Flat Idler Pulley
Idler Pulley – Remove and Install – Grooved Idler Pulley
Belt Tensioner – Remove and Install
Fan – Remove and Install
Inlet Air Control – Remove – NRS Induction Mixer
Fan Drive – Remove and Install
Electronic Control Module – Remove
Electronic Control Module – Install
Alternator – Remove
Alternator – Install
Electric Starting Motor – Remove and Install
Air Compressor – Remove and Install – Single Cylinder
Air Compressor – Remove and Install – Twin Cylinder
Inlet Air Control – Install – NRS Induction Mixer
Fuel Injection Pump – Remove
Fuel Injection Pump – Install
Fuel Injection Pump Gear – Remove
Fuel Injection Pump Gear – Install
Electronic Unit Injector – Remove
Electronic Unit Injector – Install
Fuel Filter Base – Remove and Install – Single Secondary Fuel
Turbocharger – Remove – First Stage Turbocharger
Turbocharger – Remove – Second Stage Turbocharger
Turbocharger – Remove – Top Mounted Turbocharger
Turbocharger – Remove – Side Mounted Turbochargers
Turbocharger – Install – First Stage Turbocharger
Turbocharger – Install – Second Stage Turbocharger
Turbocharger – Install – Top Mounted Turbocharger
Turbocharger – Install – Side Mounted Turbochargers
Wastegate Solenoid – Remove and Install
Exhaust Back Pressure Valve – Remove and Install
Fuel Filter Base – Remove and Install – Twin Secondary Fuel
Flexible Exhaust Pipe – Remove and Install
Exhaust Manifold – Remove and Install – Twin Turbocharger
Exhaust Manifold – Remove and Install – Single Turbocharger
Exhaust Elbow – Remove and Install
Exhaust Elbow – Remove and Install – Top Mounted and Side
Diesel Particulate Filter – Remove
Diesel Particulate Filter – Install
Inlet and Exhaust Valve Springs – Remove and Install
Inlet and Exhaust Valves – Remove and Install
Engine Oil Filter Base – Remove and Install
Water Separator and Fuel Filter (Primary) – Remove and
Engine Oil Cooler – Remove
Engine Oil Cooler – Install
Engine Oil Pump – Remove
Engine Oil Pump – Install
Water Pump – Remove
Water Pump – Install
Water Temperature Regulator – Remove and Install
Flywheel – Remove
Flywheel – Install
Crankshaft Rear Seal – Remove
Fuel Manifold (Rail) – Remove and Install
Crankshaft Rear Seal – Install
Flywheel Housing – Remove and Install – Wet Back End
Flywheel Housing – Remove and Install – Standard Housing
Crankshaft Pulley – Remove and Install
Crankshaft Front Seal – Remove and Install – Crankshaft Front
Crankshaft Front Seal – Remove and Install
Front Cover – Remove and Install – Heavy Duty Front Cover
Front Cover – Remove and Install
Gear Group (Front) – Remove and Install – Heavy Duty Gear
Gear Group (Front) – Remove and Install – Heavy Duty Gear
Relief Valve (Fuel) – Remove and Install
Gear Group (Front) – Remove and Install
Idler Gear – Remove
Idler Gear – Install
Housing (Front) – Remove – Heavy Duty Housing (Front)
Housing (Front) – Remove
Housing (Front) – Install – Heavy Duty Housing (Front)
Housing (Front) – Install
Accessory Drive – Remove and Install – Accessory Drive SAE
Accessory Drive – Remove and Install – Accessory Drive SAE
Crankcase Breather – Remove
Fuel Injection Lines – Remove
Crankcase Breather – Install
Valve Mechanism Cover – Remove and Install
Rocker Shaft and Pushrod – Remove
Rocker Shaft – Disassemble
Rocker Shaft – Assemble
Rocker Shaft and Pushrod – Install
Cylinder Head – Remove
Cylinder Head – Install
Lifter Group – Remove and Install – Hydraulic Lifter Group
Camshaft – Remove and Install
Fuel Injection Lines – Install
Camshaft Gear – Remove and Install
Camshaft Bearings – Remove and Install
Engine Oil Pan – Remove and Install – Aluminum and Pressed
Engine Oil Pan – Remove and Install – Cast Iron Oil Pan
Balancer – Remove
Balancer – Install
Piston Cooling Jets – Remove and Install
Pistons and Connecting Rods – Remove
Pistons and Connecting Rods – Disassemble
Pistons and Connecting Rods – Assemble
Exhaust Cooler (NRS) – Remove and Install – Twin
Pistons and Connecting Rods – Install
Connecting Rod Bearings – Remove – Connecting Rods in
Connecting Rod Bearings – Install – Connecting Rods in
Crankshaft Main Bearings – Remove and Install – Crankshaft
Crankshaft – Remove
Crankshaft – Install
Crankshaft Timing Ring – Remove and Install
Crankshaft Gear – Remove and Install
Crankshaft Gear (Balancer Drive) – Remove and Install
Bearing Clearance – Check
Fuel Priming Pump – Remove and Install – Electric Fuel Lift