cat c4.4 acert engine specification manual - tier 4 interim

Cat C4.4 ACERTENGINE SPECIFICATION MANUALC4.4 ACERT Four cylinder diesel engines for agricultural, industrial, construction applications

Developed to meet EEC off-road mobile machinery Stage IIIB and EPA off-road Tier 4 Interim legislation Note: Information in this manual is preliminary and is subject to change or withdrawal. TPD1752 Issue 7 Cat Confidential:YELLOW C4.4 ACERT Electronic FIE Engine Specification Manual, TPD1752 Issue 7, May 2012

Publication TPD1752 Issue 7. Proprietary information of Cat limited, all rights reserved. The information is correct at the time of print. Published in May 2012 by Marketing Support Services. i

Chapters 1 2 3 4 5 6 General information The engine range Engine specification Options Accessories Technical data

The following pages contain a detailed table of contents

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1 General informationIntroduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Electronic FIE . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. How to use the manual .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Creating an engine specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. The SPES method.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Abbreviations and codes Abbreviations.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4 Drawing standards . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5 1 1 2 3 3

2 The engine range 3 Engine specificationSub application codes Agricultural ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Construction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Material handling ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Option selection procedure Option and accessory selection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Main options ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Accessory options .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Machine load factor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Option selection template 12 12 12 12 10 10 10 10

General arrangement drawingsSide mounted turbocharger C4.4 ACERT TAD - Left view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Front view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Right view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Rear view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14 15 16 17 18

Engine Specification Manual, TPD1752 Issue 7, May 2012

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C4.4 ACERT Electronic FIE Top mounted turbocharger C4.4 ACERT TAD - Left view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Front view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Right view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Rear view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD - Plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Series turbocharger C4.4 ACERT TTAD - Left view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TTAD - Front view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TTAD - Right view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TTAD - Rear view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TTAD - Plan view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24 25 26 27 28 19 20 21 22 23

4 OptionsMechanical optionsIntroduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Ratings Maximum intermittent ratings Industrial A continuous rating.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial B rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial C intermittent rating . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial D rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial E rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C4.4 ACERT TAD Turbocharged air to air cooled - balanced and non balanced ... ... ... ... ... ... ... ... ... ... 32 C4.4 ACERT TTAD Turbocharged air to air cooled - balanced and non balanced ... ... ... ... ... ... ... ... ... ... 33 ECM AM001 - ECM fuel cooled .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 AM002 - ECM air cooled. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 AM003 - ECM fuel cooled .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Adaptor plate B0000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36 31 31 31 31 31

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C4.4 ACERT Electronic FIE Flywheel housings C1000 - Not required, starter spigot on LHS of block. ... ... ... ... ... ... ... ... ... ... ... ... ... C0001 - Cast iron SAE 3, 156,4 mm (6.16 in) deep with sealed inspection plate cover C0002 - Cast iron SAE 3, 135,0 mm (5.32 in) deep with high mounting pads .. ... ... ... C0006 - Adaptor plate for combine harvesters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C0010 - Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter .. ... ... ... ... ... ... ... ... C0011 - Similar to C0010 but with increased access aperture . ... ... ... ... ... ... ... ... ... C0021 - Cast iron SAE 2, 156,4 mm (6.16 in) deep, LHS or RHS starter . ... ... ... ... ... C0022 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter . ... ... ... ... ... ... ... ... C0023 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, LHS starter less torque converter access hole . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... C0030 - Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter ... ... ... ... ... ... ... ... ... C0031 - Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter ... ... ... ... ... ... ... ... ... Flywheels D0000 - Crankshaft palm .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0003 - For Centaflex couplings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0004 - For SAE, Borg and Beck, twin disc .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0005 - As D0004 but with pilot bearing housing . ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0008 - For Clark 18000 torque converters (non stressed) .. ... ... ... ... ... ... ... ... ... ... D0014 - For Borg Warner torque converters (non stressed) . ... ... ... ... ... ... ... ... ... ... D0030 - For Allison AT545 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0044 - For SAE transmissions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0045 - For Spicer transmissions . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0046 - For hydrostatic transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0053 - For various transmissions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0056 - For various transmissions stressed cylinder block .. ... ... ... ... ... ... ... ... ... ... D0063 - For customer transmission stressed cylinder block . ... ... ... ... ... ... ... ... ... ... D0064 - For customer transmission .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0067 - For customer transmission stressed cylinder block . ... ... ... ... ... ... ... ... ... ... D0068 - For customer transmission stressed cylinder block . ... ... ... ... ... ... ... ... ... ... D0070 - For ZF115 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0092 - For ZFWG9 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... D0114 - For Borg Warner torque converters (stressed cylinder block) . ... ... ... ... ... ... Starter motors E0012 - Studs only for LHS starter. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... E0013 - Studs only for RHS starter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... E0100 - 12V, 4.0 kW, RHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0121 - 12V, 4.0 kW, LHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0141 - 12V, 4.0 kW, Ag block only, suitable for dry back end only, for use with AM003 (high ECM) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... E0200 - 24V, 5.5 kW, RHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0205 - 24V, 4.5 kW, RHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0206 - 24V, 4.5 kW, LHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0207 - 24V, 5.5 kW, LHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0301 - 12V, 3.0 kW, LHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... E0311 - 12V, 3.0 kW, RHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... 55 55 56 56 57 57 58 58 59 59 60 45 45 46 46 47 47 48 48 49 49 50 50 51 51 52 52 53 53 54 37 38 39 39 40 40 41 41 42 42 43


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C4.4 ACERT Electronic FIE Fan drive Standard duty multi-vee belt .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... F0000 - Fan drive not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... F0133 - Fan centre 356 mm (14.02 in) pulley dia. 200 mm ... ... ... ... ... ... ... ... ... ... ... F0137 - Fan centre 310 mm (12.20 in) pulley dia. 200 mm ... ... ... ... ... ... ... ... ... ... ... F0141 - Fan centre 262 mm (10.31 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0142 - Fan centre 285 mm (11.22 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0143 - Fan centre 356 mm (14.02 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0147 - Fan centre 310 mm (12.20 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0151 - Fan centre 262 mm (10.31 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0152 - Fan centre 285 mm (11.22 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0153 - Fan centre 356 mm (14.02 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0157 - Fan centre 310 mm (12.20 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0161 - Fan centre 262 mm (10.31 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0162 - Fan centre 285 mm (11.22 in) pulley dia. 167 mm ... ... ... ... ... ... ... ... ... ... ... F0173 - Fan centre 356 mm (14.02 in) pulley dia. 200 mm ... ... ... ... ... ... ... ... ... ... ... F0177 - Fan centre 310 mm (12.20 in) pulley dia. 200 mm ... ... ... ... ... ... ... ... ... ... ... F0181 - Fan centre 262 mm (10.31 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0182 - Fan centre 285 mm (11.22 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0183 - Fan centre 356 mm (14.02 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0187 - Fan centre 310 mm (12.20 in) pulley dia. 150 mm ... ... ... ... ... ... ... ... ... ... ... F0191 - Fan centre 262 mm (10.31 in) pulley dia. 125 mm ... ... ... ... ... ... ... ... ... ... ... F0192 - Fan centre 285 mm (11.22 in) pulley dia. 125 mm ... ... ... ... ... ... ... ... ... ... ... F0197 - Fan centre 310 mm (12.20 in) pulley dia. 125 mm ... ... ... ... ... ... ... ... ... ... ... F0501 - Fan centre 262 mm (10.31 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... F0502 - Fan centre 285 mm (11.22 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... F0503 - Fan centre 356 mm (14.02 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... F0504 - Fan centre 395 mm (15.55 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... F0507 - Fan centre 310 mm (12.20 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... F1000 - No fan drive supplied. Additional pulley and bracket supplied to complete drive ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Belt tensioner FD000 - No belt auto - tensioner required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76 FD001 - Belt auto - tensioner required, for belt systems without a low RHS A/C compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76 FD002 - Belt auto - tensioner required, for belt systems with a low RHS A/C compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77 Lubricating oil sump Non stressed cylinder block .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G0100 - Steel, flat bottomed sump (LHS dipstick only) . ... ... ... ... ... ... ... ... ... ... ... ... G0200 - Steel, flat bottomed sump (RHS dipstick only) . ... ... ... ... ... ... ... ... ... ... ... ... G0300 - Cast iron, flat bottomed sump .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G0600 - Aluminium, shallow rear well sump .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G0800 - Aluminium, shallow rear well sump with oil filler pad RHS ... ... ... ... ... ... ... ... G1100 - Aluminium, high gradeability ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78 78 79 79 80 80 81 61 61 62 62 63 63 64 64 65 65 66 66 67 67 68 68 69 69 70 70 71 71 72 72 73 73 74 74 75

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C4.4 ACERT Electronic FIE Stressed sump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G2000 - Cast Iron, deep flat bottom sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G2100 - Cast Iron, shallow tunnel sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G2300 - Cast Iron, deep tunnel sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... G2500 - High oil capacity 11.5 litres plus .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Lubricating oil dipstick GD000 - No dipstick ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD001 - Short LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD002 - Long LHS, centre top... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD003 - Short RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD004 - Medium, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD006 - Long LHS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... GD007 - Medium, RHS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Oil capacities and gradability Gradient of operation and oil capacities . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86 Oil change period of low capacity sumps under review. ... ... ... ... ... ... ... ... ... ... ... ... 86 Breather H0300 - Open breather, filtered.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87 H0320 - Open breather, filtered, no hose... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88 Top cover oil filler HC000 - No filler ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89 HC002 - Top cover filler, rear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90 HC004 - Top cover filler, front ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90 Lubricating oil filler HD000 - Not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... HD001 - Timing case filler, LHS short filler forward facing ... ... ... ... ... ... ... ... ... ... ... HD002 - Timing case filler, LHS long ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... HD004 - Timing case filler, LHS rear facing, Q1100, Q30** only .. ... ... ... ... ... ... ... ... HD005 - Timing case filler, remote rear face, rearward facing, Q1100, Q30** only .. ... HD006 - Sump filler, RHS, G0800 only . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... HD007 - Timing case filler, remote side face, rearward facing .. ... ... ... ... ... ... ... ... ... HD011 - Timing case filler, LHS, mid mounted, extended ... ... ... ... ... ... ... ... ... ... ... Lubricating oil filter head J0050 - Vertically down, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... J0060 - Horizontal filter, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... J0070 - Vertically down filter head, RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... J0130 - Adaptor LHS for remote oil filter (customer to supply) . ... ... ... ... ... ... ... ... ... Front end drive K0020 - Primary drive, steel, 200 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98 K0030 - Primary drive, steel, 170 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99 K0120 - Primary drive, steel, 200 mm diameter, axial PTO .. ... ... ... ... ... ... ... ... ... ... 99 K0130 - Primary drive, steel, 170 mm diameter, axial PTO .. ... ... ... ... ... ... ... ... ... .. 100 95 96 96 97 91 91 92 92 93 93 94 94 85 85 85 85 85 85 85 82 82 83 83 84


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C4.4 ACERT Electronic FIE Secondary crankshaft pulley KD000 - No secondary pulley ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 101 KD001 - Single groove Vee belt 200 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... . 101 Coolant pump L0002 - Coolant pump - angled inwards inlet ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 102 L0004 - Coolant pump - vertical inlet . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 103 Coolant outlet connection LD152 - Horizontal outlet connection on LHS, with thermostat assembly . ... ... ... ... . 104 LD156 - Vertical outlet connection in centre .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 105 LD157 - 45 up outlet connection on RHS, with thermostat assembly .. ... ... ... ... ... . 105 Fan M0000 - Fan not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . M0005 - Diameter 660 mm (26 in) pusher, 7 blade at 26 pitch ... ... ... ... ... ... ... ... . M0007 - Diameter 660 mm (26 in) puller, 7 blade at 26 pitch .. ... ... ... ... ... ... ... ... . M0013 - Diameter 559 mm (22 in) pusher, 7 blade at 26 pitch ... ... ... ... ... ... ... ... . M0015 - Diameter 559 mm (22 in) puller, 7 blade at 26 pitch .. ... ... ... ... ... ... ... ... . Fan extension and fixings MD000 - Extension not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 109 MD003 38 mm (1.5 in), MD004 51 mm (2.0 in), MD005 63 mm (2.5 in), MD006 76 mm (3.0 in), MD008 103.4 mm (4.07 in) - Fan extension . ... ... ... ... ... ... ... ... ... . 109 MD010 - 127 mm (5.0 in) - Fan extension . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 110 Alternator N0000 - Alternator, bracket and tensioner not required.. ... ... ... ... ... ... ... ... ... ... ... . 111 N0101, N0102, N0200, N0201 - Alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 111 N0105, N0206 - Alternator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 112 Belt driven auxiliaries P0000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . P0001 - Auxiliary drive, single groove pulley, 200 mm diameter ... ... ... ... ... ... ... ... . P0003 - Auxiliary drive, single groove pulley, 140 mm diameter ... ... ... ... ... ... ... ... . P0100 - 12V, air conditioning compressor, pad mounted, RHS low .. ... ... ... ... ... ... . P0101 - 24V, air conditioning compressor, pad mounted, RHS low .. ... ... ... ... ... ... . Timing case Q1000, Q1030, Q1040, Q1050 - Timing case, LHS PTO .. ... ... ... ... ... ... ... ... ... ... . Q1100 - Timing case, no PTO capability ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Q3000, Q3030 - Timing case, single RHS PTO ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Q5000 - Heavy duty timing case, twin PTO capability 280 Nm Max. . ... ... ... ... ... ... . Q5010 - Heavy duty timing case, twin PTO, less RHS gear .. ... ... ... ... ... ... ... ... ... . 116 117 117 118 118 113 113 114 114 115 106 106 107 107 108

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C4.4 ACERT Electronic FIE Timing case auxiliaries QD000 - No auxiliaries ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. QD005 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange, 13 tooth spline, fitted LHS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. QD015 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange, 11 tooth spline, fitted LHS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. QD016 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange, 9 tooth spline, fitted LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. QD017 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE B flange, 13 tooth spline, fitted LHS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. QD024 - Adaptor 225cc compressor with SAE A flange, head unload . ... ... ... ... ... .. QD042 - 630cc compressor, SAE B flange, head unload for use with Q1030 .. ... ... .. QD042 - 630cc compressor, SAE B flange, head unload, for use with Q5000 . ... ... .. QD055 - Hydraulic pump drive adaptors, 2 bolt fixings, SAE B flange, 13 tooth spline fitted LHS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Balancer R0000 - Not required.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124 R0001 - Balancer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124 Turbocharger S6100 - Single side turbocharger, exhaust rearward, compressor up, inward offset .. S6101 - Single side turbocharger, exhaust rearward, compressor down, outward offset . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S6102 - Single side turbocharger, exhaust forward, compressor up, outward offset .. S6105 - Single side turbocharger, exhaust forward, compressor down, outward offset . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S6300 - Single top forward mounted turbocharger, exhaust rearward, compressor up ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S6301 - Single top forward mounted turbocharger, exhaust rearward, compressor up inward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S6302 - Single top forward mounted turbocharger, exhaust rearward, compressor horizontal across .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S7100 - Series side turbocharger, exhaust rearward, compressor up . ... ... ... ... ... .. S7101 - Series side turbocharger, exhaust rearward, compressor across, upward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. S7102 - Series side turbocharger, exhaust rearward, compressor horizontal out, downward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Soot sensor box and cable SA001/SA002 - Soot sensor box with 1.5/2.5 metre cable ... ... ... ... ... ... ... ... ... ... .. 131 SA003 - Soot sensor box engine mounted for use with IOPU/Genset/Electropak ... .. 131 125 126 126 127 127 128 128 129 129 130 119 119 120 120 121 121 122 122 123


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C4.4 ACERT Electronic FIE Turbo Exhaust outlet connection SD001 - Exhaust elbow rearward up (suits single side turbo) ... ... ... ... ... ... ... ... ... . SD002 - Exhaust elbow rearward down (suits single side turbo) ... ... ... ... ... ... ... ... . SD003 - Exhaust elbow rearward straight (suits single side turbo) ... ... ... ... ... ... ... . SD004 - Exhaust elbow forward up (suits single side turbo) . ... ... ... ... ... ... ... ... ... . SD005 - Exhaust elbow forward down (suits single side turbo) . ... ... ... ... ... ... ... ... . SD007 - Exhaust elbow rearward angled down (suits single side turbo) ... ... ... ... ... . SD008 - Exhaust elbow rearward down, long (suits single side turbo) .. ... ... ... ... ... . SD010 - Exhaust elbow rearward up for use with engine mounted aftertreatment (suits single top turbo) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SD011 - Exhaust elbow rearward up (suits series side turbo) ... ... ... ... ... ... ... ... ... . SD012 - Exhaust elbow rearward up, long (suits single side turbo) .. ... ... ... ... ... ... . SD014 - Exhaust elbow rearward down (suits series side turbo) .. ... ... ... ... ... ... ... . SD016 - Exhaust elbow rearward straight (suits single top turbo) . ... ... ... ... ... ... ... . SD017 - Exhaust elbow rearward straight (suits series side turbo) ... ... ... ... ... ... ... . Aftertreatment Non-modular .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF420 - Axial inlet, axial exit, installation angle 180 . ... ... ... ... ... ... ... ... ... ... ... ... . SF420 - Axial inlet, axial exit, installation angle 180 . ... ... ... ... ... ... ... ... ... ... ... ... . SF422 - Axial inlet, radial exit, exit angle 270, installation angle 180 . ... ... ... ... ... . SF422 - Axial inlet, radial exit, exit angle 270, installation angle 180 . ... ... ... ... ... . SF424 - Axial inlet, radial exit, exit angle 90, installation angle 180 ... ... ... ... ... ... . SF424 - Axial inlet, radial exit, exit angle 90, installation angle 180 ... ... ... ... ... ... . SF426 - Axial inlet, radial exit, exit angle 0, installation angle 180 . ... ... ... ... ... ... . SF426 - Axial inlet, radial exit, exit angle 0, installation angle 180 . ... ... ... ... ... ... . SF428 - Radial inlet, axial exit, inlet angle 270, installation angle 180 ... ... ... ... ... . SF428 - Radial inlet, axial exit, inlet angle 270, installation angle 180 ... ... ... ... ... . SF430 - Radial inlet, axial exit, inlet angle 90, installation angle 180 . ... ... ... ... ... . SF430 - Radial inlet, axial exit, inlet angle 90, installation angle 180 . ... ... ... ... ... . SF432 - Radial inlet, radial exit, inlet angle 90, exit angle 90, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF432 - Radial inlet, radial exit, inlet angle 90, exit angle 90, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF434 - Radial inlet, radial exit, inlet angle 270, exit angle 90, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF434 - Radial inlet, radial exit, inlet angle 270, exit angle 90, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF436 - Radial inlet, radial exit, inlet angle 180, exit angle 270, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF436 - Radial inlet, radial exit, inlet angle 180, exit angle 270, installation angle 180. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . SF438 - Radial inlet, radial exit, inlet angle 180, exit angle 90, installation angle 180 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Engine mounted aftertreatment SF450 - Radial exit, exit angle 250. engine mounted SF451 - Radial exit, exit angle 270. engine mounted SF452 - Radial exit, exit angle 270. engine mounted SF453 - Radial exit, exit angle 250. engine mountedx

132 133 133 134 134 135 135 136 136 137 137 138 138 139 139 140 140 141 141 142 142 143 143 144 144 145 145 146 146 147 147 148 148 149 149 149 149

... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... ... ... ... ... ... ... ... .


C4.4 ACERT Electronic FIE Engine to aftertreatment, flex pipe SU001 - Flex kit with straight adaptor (supplied loose in engine solution pack) ... ... .. SU002 - Flex kit with 45 adaptor (supplied loose in engine solution pack) .. ... ... ... .. SU003 - Flex kit with 90 adaptor (supplied loose in engine solution pack) .. ... ... ... .. SU004 - Flex kit to suit engine mounted aftertreatment only ... ... ... ... ... ... ... ... ... .. SU008 - Flexible exhaust installation kit with straight adaptor (SD) 90 elbow (SF) (supplied loose in engine solution pack) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. SU009 - Flexible exhaust installation kit with 45 adaptor (SD) 90 elbow (SF) (supplied loose in engine solution pack) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. SU010 - Flexible exhaust installation kit with 90 adaptor (SD) 90 elbow (SF) (supplied loose in engine solution pack) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Inlet manifold / connections T0001 - Forward facing swan neck inlet connection with low NRS mixer . ... ... ... ... .. 153 T0002 - Intake angled with low NRS mixer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154 T0003 - Rearward facing with low NRS mixer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154 Inlet air filter TD000 - Not required.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. TD001 - Standard duty air filter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. TD004 - Heavy duty air filter (supplied loose) low power .. ... ... ... ... ... ... ... ... ... ... .. TD004 - Heavy duty air filter (supplied loose) high power . ... ... ... ... ... ... ... ... ... ... .. Exhaust manifold U0000 - Not user selectable... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157 Exhaust manifold outlet connections UD000 - Not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158 Secondary fuel filter V0010 - Single LHS, centre ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V0010 - Single LHS, centre ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V0010 - Single LHS, centre ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V0030 - Twin LHS, centre . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V0030 - Twin LHS, centre . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V1301 - Remote filter arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. V1301 - Remote filter arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Cold starting aid W0011 - Glow plugs .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. W0016 - Glow plugs and ether .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. W0017 - Glow plugs, ether and lead . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. W0018 - Glow plugs and lead ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Engine lifting eyes X0011 - Fitted LHS at front and RHS at rear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 166 X0111 - Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted aftertreatment .. ... ... ... ... ... ... ... ... ... ... .. 167 X0113 - Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted aftertreatment (SF453 only) . ... ... ... ... ... .. 168Engine Specification Manual, TPD1752 Issue 7, May 2012

150 151 151 152 152 152 152

155 155 156 156

159 160 160 161 161 162 162 163 164 164 165

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C4.4 ACERT Electronic FIE Engine finish Y0000 - Lacquer . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 169 Y9012 - Cat gold with light preservatives ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 169 Y9027 - Cat gold with heavy preservative .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 169

Electronic optionsCat C4.4 ACERT electronic engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 170

5 AccessoriesIntroduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 171 Resistors and regulators ZA000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 172 Fuel cooler ZB000 - Fuel cooler not supplied ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 173 ZB001 - Fuel cooler factory fitted to the front of cooling pack frame .. ... ... ... ... ... ... . 173 ZB002 - fuel cooler supplied loose . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 174 Engine mounting brackets ZC000 - Not required, blanking plugs only.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC002 - Front pedestal brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC003 - Rear mounting brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC004 - Front pedestal brackets LHS and RHS, rear mounting brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC012 - Front mounting studs and nuts only . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC016 - Front mounting brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC019 - Front mounting brackets LHS and RHS .. ... ... ... ... ... ... ... ... ... ... ... ... ... . ZC025 - Front mounting brackets LHS (horizontal) and RHS (horizontal rearward facing) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Heater/starter switch ZE000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 180 ZE001 - Heater / starter switch and security lock supplied loose .. ... ... ... ... ... ... ... . 180 Oil drain valve ZG000 - Standard sump plug.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 181 ZG001/ZG004 - Sump oil drain valve fitted LHS/RHS ... ... ... ... ... ... ... ... ... ... ... ... . 181 Lubricating oil sampling/switch/gauge ZJ000 - Not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 182 ZJ005 - Lubricating oil sampling valve fitted in filter head . ... ... ... ... ... ... ... ... ... ... . 182 Coolant temperature sender and gauge ZL000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 183 175 176 176 177 177 178 178 179

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C4.4 ACERT Electronic FIE Radiator and mounting group ZM000 - Not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZM001 - Radiator and intercooler fitted, with fan guards (compatible with S7*** turbos) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZM002 - Radiator and intercooler fitted, with fan guards (compatible with S6*** turbos) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZM003 - Radiator and intercooler fitted, with fan guards (compatible with S7*** turbos) harsh environment protection ... ... ... ... ... ... ... ... ... .. ZM004 - Radiator and intercooler fitted, with fan guards (compatible with S6*** turbos) harsh environment protection ... ... ... ... ... ... ... ... ... .. Engine wiring harness ZN020 - Wiring harness, convoluted, with diagnostic connector ... ... ... ... ... ... ... ... .. 188 ZN031 - Wiring harness, convoluted with diagnostic connector to suit Ag block only .. 189 ZN032 - Wiring harness, convoluted, without diagnostic connector... ... ... ... ... ... ... .. 189 ZN033 - Wiring harness, convoluted, with diagnostic connector for compatibility with large LHS PTOs .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 190 Primary fuel filter Fuel pre filters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZV031 - Single filter, supplied loose with water separator and sensor, electric lift pump fitted ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZV032 - Single filter, supplied loose with water separator and sensor, electric lift pump off engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZV073 - Single filter, engine mounted with water separator and sensor, electric lift pump fitted ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZV074 - Single filter, engine mounted with water separator and sensor, electric lift pump off engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Label/badging ZY901 - Emission label fitted to front cover. Cat decal .. ... ... ... ... ... ... ... ... ... ... ... .. 194 Cab heater connections ZZ000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ZZ004 - Feed LHS cylinder head, straight return to rear of timing case ... ... ... ... ... .. ZZ014 - Feed LHS cylinder head, angled return to rear timing case ... ... ... ... ... ... .. ZZ017 - Feed LHS cylinder head, angled (45) return to rear timing case ... ... ... ... .. 195 195 196 196 191 191 192 192 193 184 184 185 186 187

6 Technical dataIntroduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 197 Basic technical data Models C4.4 TTAD. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 199


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C4.4 ACERT Electronic FIE Power curves T3584 - 110.1 kW, AD416 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3586 - 129.5 kW, AD503 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3624 - 105.1 kW, AD502 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3626 - 117.0 kW, AD504 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3632 - 97.9 kW, AD414 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3634 - 82 kW, AD404 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3636 - 102.1 kW, AD409 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3638 - 106 kW, AD406 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3640 - 92.5 kW, AD419 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3644 - 91 kW, AD408 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3648 - 85.9 kW, AD405 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3654 - 65.9 kW, AD424 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3656 - 74.5 kW, AD403 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3658 - 70.0 kW, AD402 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3660 - 61.5 kW, AD401 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . T3744 - 112.0 kW, AD510 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Cylinder block views non-stressed block Non-stressed block and head - left hand side view ... ... ... ... ... ... ... ... ... ... ... ... ... . Non-stressed block and head - front view... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Non-stressed block and head - right side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Non-stressed block and head - rear side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Non-stressed block and head - plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Cylinder block views stressed block Stressed block and head - left hand side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Stressed block and head - front view.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Stressed block and head - right side view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Stressed block and head - rear side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Stressed block and head - plan view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Cold start system Battery to starter lead resistance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 240 Cooling system Radiators. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Radiator coolant flow rates ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Cab heater coolant flow rates ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Tier IV under - bonnet temperatures... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Heat balance... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Exhaust system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 241 241 242 243 243 243 236 237 237 238 238 233 234 234 235 235 201 203 205 207 209 211 213 215 217 219 221 223 225 227 229 231

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C4.4 ACERT Electronic FIE Air flow T3584, 110.1 kW - AD416 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3586, 129.4 kW - AD503.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3624, 105.1 kW - AD502.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3626, 117.0 kW - AD504.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3632, 97.9 kW - AD414 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3634, 82.0 kW - AD404 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3636, 102.1 kW - AD409.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3638, 106.0 kW - AD406 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3640, 92.5 kW - AD419 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3644, 91.0 kW - AD408 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3648, 85.9 kW - AD405 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3654, 65.9 kW - AD424 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3656, 74.5 kW - AD403 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3658, 70.0 kW - AD402 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3660, 61.5 kW - AD401 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. T3744, 112.0 kW - AD510.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Induction system Air filters . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260 Inlet restriction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260 Restriction indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260 Fuel specifications For Tier 4 Interim engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261 Fuel system Low pressure fuel system - recommended layout.. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 262 Lubrication system Lubricating oil specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Maintenance intervals for engines that use biodiesel. ... ... ... ... ... ... ... ... ... ... ... ... .. Lubrication oil temperature. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Recommended viscosity grades ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Lubricating oil pressure .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Electrical system 4.4 litre factory installed wiring and components ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Engine mandatory wiring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Machine specific wiring .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. PV / PROD clean emissions module.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Starter motors Equipment required for cold temperatures . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Battery to starter lead resistance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Cold start oil specification... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Medium duty alternator data... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Engine mountings Standard methods .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269 Flexible mountings . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269Engine Specification Manual, TPD1752 Issue 7, May 2012 xv

244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259

263 263 263 263 263 264 264 264 264 265 266 267 268

C4.4 ACERT Electronic FIE Torsional vibration Flywheel/cylinder block bending moments . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 270 C4.4 Ag engine block fitted with a structural sump. ... ... ... ... ... ... ... ... ... ... ... ... ... . 271 Power take off Crankshaft thrust loading ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Crankshaft driven axial power take off ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Torsional vibration... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Crankshaft front over hung load (OHL) capability... ... ... ... ... ... ... ... ... ... ... ... ... ... . Crankshaft rear over hung load (OHL) capability ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Flywheel Inertia... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Alternative side mounted PTO Side mounted PTO position ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 276 Side mounted PTO operating data Application of PTO load: . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Typical uses (continuous duty) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Typical uses (intermittent duty) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Customer fitted pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Applications sign-off ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Duty cycles - assessment and sign-off criteria Continuous duty cycle. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 280 Intermittent duty cycle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 281 Mass elastic data 4.4 litre below 110 kW. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 282 4.4 litre above 110 kW ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 283 Centre of gravity.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 284 Ratings Allowances for engine driven auxiliary equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... . De-rating . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Inlet air temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Altitude ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Humidity .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Compressor performance curves Single cylinder 225cc - free air delivery .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Single cylinder 225cc - delivered air temperature... ... ... ... ... ... ... ... ... ... ... ... ... ... . Single cylinder 225cc - power consumption ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Single cylinder 225cc - air charging time to pressurise a 50 litre receiver .. ... ... ... ... . Twin cylinder, 630cc, ESS (Energy Saving System), free air delivery ... ... ... ... ... ... . Twin cylinder, 630cc, ESS (Energy Saving System), delivered air temperature ... ... . Twin cylinder, 630cc, ESS (Energy Saving System), power consumption . ... ... ... ... . Fan performance curve 26 inch diameter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 293 22 inch diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 294xvi Engine Specification Manual, TPD1752 Issue 7, May 2012

272 272 272 273 274 274

278 278 278 279 279

285 285 285 285 285 285 286 287 288 289 290 291 292

C4.4 ACERT Electronic FIE Important notes Company liability ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Installation .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Legislation .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Warranty. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 295 295 295 295


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C4.4 ACERT Electronic FIE

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1General informationIntroductionElectronic FIE The C4.4 ACERT range of four cylinder engines will be developed to meet EPA TIER 4 Interim and EEC Stage IIIB off highway emissions legislation. This Engine Sales Manual is a publication of ratings and options to enable sales and application personnel to select and specify C4.4 ACERT engines for a wide variety of industrial, construction, material handling and agricultural applications. This is the only manual that should be used for specifying C4.4 ACERT products. Included in the manual are: The range of ratings Information and drawings where available for the options. Technical information is provided for guidance only, to assist with option selection. Note: Information in this manual is subject to change. No commitment should be made to any customer, on any specification, until approval is obtained from the Four Cylinder Product Group.1


1

C4.4 ACERT Electronic FIE How to use the manualAll the information needed to specify an engine for an application can be found in chapters 2 to 6. Use the chapters as follows: The manual is designed to be user friendly and includes compatibility information and symbols in the options and accessories tables to assist the user to correctly specify an engine specification. Chapter 2: The engine range This chapter contains brief details of the power output of the C4.4 ACERT engine. Use the data in this chapter to determine which of the engines is required for the application. Chapter 3: Engine specification This chapter contains information that will guide the user in the process of specifying options and accessories necessary to complete a full engine specification. An option selection template can be found on page 10. To identify the Customers particular application, a table listing sub-application codes and descriptions is shown on page 8. General arrangement drawings for different specifications will be included in this chapter. Chapter 4: Options This chapter shows the range of options for selection (refer to option availability timing, before making a selection). Miniature drawings of the options are also shown where available. Chapter 5: Accessories This chapter shows the range of accessories for selection (refer to accessory availability timing, before making a selection). Miniature drawings of the accessories are also shown where available. To complete the specification of the engine, use the information shown in these chapters to select the options and accessories required for the application. Only one option or accessory can be selected from each group. Make a choice from each group even if it is not required. Chapter 6: Technical data This chapter contains preliminary technical information for the engines in the range and is intended to assist the user of the manual to select options.

2


C4.4 ACERT Electronic FIE Creating an engine specificationThe SPES method Project engine specifications should be completed using SPES (Sales Project Engine Specification). When completing the SPES refer to the Sales Project Engine Specification Guide. If it is established when specifying an engine that an option is required that is not listed in the Engine Specification Manual, a request should be made to the C4.4 product team using the NORF process complete with business case. A NORF request can be made using Team Centre Engineering which can be found on the intranet. The product team will assess the viability of introducing this requested option. Until this option has been approved, NO commitment should be made to the customer.


3

C4.4 ACERT Electronic FIE Abbreviations and codesAbbreviations A+I Engineering ACERT CAN dP DPF ECM ECR J1939 LHS MLIT NORF NRS PTO RHS SAE SPES TAC TAD TD TTAD ULS Application and Installation Engineering Advanced Combustion Emissions Reduction Technology Controller Area Network Delta Pressure Diesel Particulate Filter Engine Control Module Engineering Change Request SAE standard for CAN communications Left Hand Side, when viewed from the flywheel end of the engine Ministry of Land, Infrastructure and Transport New Option Request Form (part of revised DC process) Nox Reduction System Power Take Off Right Hand Side, when viewed from the flywheel end of the engine Society of Automotive Engineers Sales Project Engine Specification Turbocharged Aftercooled Turbocharged Aftercooled Diesel Turbocharged Diesel Twin Turbocharged Aftercooled Diesel Ultra Low Sulfur

4


C4.4 ACERT Electronic FIEDrawing standards XX X2X2 YY ZZ Diameter Rear face of cylinder block Rear face of cylinder block (engines with stressed cylinder block) Crankshaft centre line (horizontal) Crankshaft centre line (vertical) Third angle projection

Note: All dimensions are in mm unless otherwise stated. First angle projection

Engine type codes Engine type C4.4 ACERT TAD C4.4 ACERT TTAD Code MK ML


5


6



2The engine rangeThe C4.4 ACERT range of four cylinder engines are developed to meet EPA TIER 4 Interim and EEC Stage IIIB off highway emissions legislation. The engines have been developed to ISO TR 14396. This Engine Sales Manual covers four cylinder C4.4 ACERT Electronic FIE engines only. The full range of engines include air to air aftercooled four cylinder variants. The engines develop from 61.5 kW to 129.5 kW at 2200 rpm, and are suitable for most agricultural, industrial, construction, and Electric power generation. Some ratings will be developed to meet MLIT standards. The C4.4 engines are available as full authority electronic engines and use a common rail fuel system. Features essential to the operation of the engine will be included in the base engine specification, These include: Electronic Control Module Common rail fuel pump and injectors Wiring harness Sensors for: Engine speed Oil pressure Coolant temperature Intake manifold pressure and temperature Fuel rail pressure Fuel temperature EGR pressure and temperature Water in fuel switch.2


7


8



3Engine specificationMandatory specification requirements All engines must be specified using option codes A selection must be made for all options even if the option is not required Before selecting an option read carefully any notes relating to the option. These will indicate any restrictions if this option is chosen If it is established when specifying an engine that an option is required that is not listed in this Engine Sales Manual, then a NORF (part of the revised ECR (Engineering Change Request) process) must be raised, complete with justification to obtain A+I Engineering approval. Where the * symbol appears, this represents any series of characters. For example S6*** represents any turbo option starting with S6.3


9

C4.4 ACERT Electronic FIE Sub application codesAgriculturalApplication group/sub-application Tractors wheeled Tractors fast Special harvesters Combine harvesters Lawn and garden Sprayers Agricultural - other Wood chippers Forestry harvesters Code AGR20 AGR21 AGR22 AGR24 AGR25 AGR26 AGR28 AGR39 AGR85

IndustrialApplication group/sub-application Industrial - other Snow blowers Snow groomers Compressors Petroleum industry Mining equipment Locomotive/rail traction Pump sets Sweepers Code IND42 IND43 IND44 IND50 IND59 IND61 IND75 IND84 IND87

ConstructionApplication group/sub-application Self propelled drills Excavators Backhoe loaders Wheeled shovel loaders Bulldozer Scrapers Graders Dumpers Trenchers Skid steer loaders Mini excavators Pavers Road rollers Construction - other Code CON29 CON30 CON31 CON32 CON33 CON34 CON35 CON36 CON37 CON38 CON41 CON51 CON53 CON69

Material handlingApplication group/sub-application Aircraft baggage handlers Telescopic handlers Cranes Access platforms Forklift trucks Rough terrain, forklift trucks Towing tractors Side loaders Straddle carriers Code MAT14 MAT40 MAT54 MAT68 MAT70 MAT71 MAT72 MAT73 MAT76

10


C4.4 ACERT Electronic FIE Option selection procedureTo assist with the process of selecting options and accessories, an option selection template is included, see Option selection template on page 13. Copy this form, then follow the sequence of the option groups to prepare the engine specification. Once the specification has been drafted, it can be transferred to the engine order form, which is available from Cat. To enable the specification to be processed, additional information is required relating to the application into which the engine is to be installed. Listed below are the additional questions which need to be completed to enable the specification to proceed. Application formQuestion Range See page 10 EPA TIER 4 Interim EEC Stage IIIB 12 24 Up to 1676 metres Up to 3000 metres C C Up to 500 hours See page 12 Hours Years ULS Diesel PTO LHS PTO RHS Nm Nm kg m kg m For electronic options, see page 170 Nm Selection (one per question)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Sub application code Emission standard Voltage Maximum altitude Maximum ambient temperature Minimum start temperature Expected oil change period Average load factor Average usage (per year) Expected engine life (years) Special fuel requirements Front end drive - timing case

Front end inertia, including crankshaft pulley Rear end inertia, including flywheel EOS specification PTO torque from crankshaft pulley


11

C4.4 ACERT Electronic FIEOption and accessory selection Before selecting an option, read carefully any notes relating to the option as these will indicate any restrictions if the option is chosen. A selection must be made for all options and accessories, even if the option is not required. Main options A selection of one option code must be made from each of the option sections A through to Y. Put the correct codes onto the order form in the following manner:Lubricating oil fillers and breather Lubricating oil filters and coolers H J 0 0 1 1 0 3 0 0

Accessory options A selection of one option code must be made from each of the option sections ZA through to ZZ. Put the correct codes onto the order form in the following manner:Mountings Heater/starter switch Z Z C E 0 0 0 0 2 1

Machine load factor To enable the machine load factor to be calculated two methods are illustrated below to assist with the calculation. The first, to establish load factor, is based on fuel usage. The second, to estimate load factor, is based on operating conditions. Method 1 - To estimate machine load factor Fuel used over a one hour period of normal operation - A litres Fuel used over a one hour period at maximum rating Typical machine load factor is:A Litres ----------------------- 100 = C B Litres

- B litres

%

If it is not possible to calculate the load factor by this method, an alternative approach is to use method 2. Method 2 - To estimate machine load factor For a machine working in normal operating conditions use the following example to estimate the load factor based on estimated operating times. Note: These times will vary depending on machine type. Example using six cylinder power curve TBA Maximum available cycle power at 2200 rpm = 129,5 kW Worked example based on estimated operating times.Duration % Maximum Rated speed power Maximum torque speed power Idle speeds (high/low power) 20 40 40 100 x x x Power kW 129,5 95,0 0 = = = Weighted power 25,9 38,0 0,0 63,9

Estimated machine load factor is:63, 9-------------- 100 = 49 % 129, 5

If further assistance is required please contact Cat Applications department.

12


C4.4 ACERT Electronic FIE Option selection templateA AM F FD K KD M MD N NL P Q QD B C D E EL S SA SD SF SU T TD U UD G GD ZG H HC HL HD J JD R V VD ZV L LD ZM ZZ W ZA ZE ZJ ZL ZN X Y ZC ZY Option group Rating ECM Fan drive Belt tensioner Crank pulley Secondary crank pulley Fan Fan extension Alternator Alternator branding Belt driven auxiliaries Timing case Gear driven auxiliaries Adaptor plate Flywheel housing Flywheel and starter ring Starter motor Starter motor branding Turbocharger, manifold Soot sensor Turbo exhaust outlet connections Aftertreatment Engine to after treatment flexpipe kit Induction connections Inlet air filter Exhaust manifolds Exhaust manifold outlet connections Lubricating oil sump Dipstick Sump drain Breather Top cover oil filler Breather branding Timing case oil fillers Lubricating oil filter and cooler Lubricating oil filter branding Balancer Fuel filter secondary Fuel filter secondary branding Fuel filter primary Coolant pump inlet Thermostat housing, outlet connection Radiator Cab heater connections Cold start aid Resistor and regulators Heater switch Lubricating oil pressure switch Coolant temperature gauge and sender Engine wiring harness Lifting eyes Paint Engine mountings Emissions labels Option code Description


Dress

Controls

Coolant

Fuel

Oil

Aspiration

Back end

Front end

13


General arrangement drawingsSide mounted turbochargerC4.4 ACERT TAD - Left view51976_DPF_GA / 01

X X2

845.1 OVERALL 689 631.4 540 411 97.5 ECM CONNECTION 35 156.4 55.6 47.6

4-M 12 X 1.75 X 24.5 352.5

76.2

73.3

161

49.2

96.8

Y

451

281 ECM CONNECTION

481.2

250.9

17.5

88.9

Y247.7

94 4-M 12 X 1.75 X 20 321.3 365.4 431.8 479.5 553 569.7 630

61.6 233.5 304.5

28.6

X X2

14


C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Front view51976_DPF_GA / 01

Z

732 OVERALL 340.2 OUTLET INLET 237 15 THERMOSTAT

299.6

ALTERNATOR PULLEY 60 EFF.

50.8 O.D.

4-M8 X 1.25 EQUISPACED ON 63.5 P.C.D. 41

363.3 OUTLET

INLET

285

EARTH TERMINAL M6 X 1 54.8 13.9

316

246.5

Y66.9 29.5

100.5

885.2

OVERALL

57

Y20.9 210.6 20 REMOVAL 6-M12 X 1.75 EQUISPACED ON ON 110 P.C.D. 66.9 266.4

BATTERY TERMINAL M10 X 1.5 4-M16 X 2 X 25 128 130.3 CRANK PULLEY 200 EFF. 144.5 223.2 270.7 128 129.8 144.5 151.9 156 200 202.6 286 Z


15

C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Right view51976_DPF_GA / 01

X2 X

523 THERMOSTAT 50.9 31 57.1 THERMOSTAT 282.3

4-M12 X 1.75 X 24.5

88.9

76.2

Y

17.5

560.2

570

47.6

THERMOSTAT

Y247.7 49.2

28.6 MOUNTING HOLE 55.6

151 165 247.6 264 321.3 431.8 515 605 FIRST GROOVE 47.6

4-M12 X 1.75 X 20

X2 X

16


C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Rear view51976_DPF_GA / 01

Z

151 35

80 O.D.

Y20.5 MOUNTING HOLE-REAR BOTH SIDES

278.3

EXHAUST

483.7

561.6

Y

12-M 10 X 1.5 X 20 EQUISPACED ON 428.6 P.C.D. 238.1 MOUNTING HOLE 241.3 238.1 MOUNTING HOLE 241.3 296.8 EXHAUST

260.4 MOUNTING HOLE

Z


260.4 MOUNTING HOLE

17

C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Plan view51976_DPF_GA / 01

X X2

337.5 INLET 80 O.D. INLET 105

45

W 134.6 119.5

W

243.5

486.2

X X2

18


199.5 ECM CONNECTION

63.5

C4.4 ACERT Electronic FIE Top mounted turbochargerC4.4 ACERT TAD - Left view51980_DPF_GA / 01

X X2 845 OVERALL 673.5 468 449.1 411 BREATHER FILTER 97.5O.D. 50

156.4 31.2

57.1 THERMOSTAT

55.6 47.6

660.7

570

41

250.9

88.9

183.1

451

281

318.8

Y 162.4 76.2

Y

161 BREATHER VENT

94 115 233.4 237 283.2 305 365.4 452.2 567.2 574.7 630

23 23.8 28.6

X X2


223.2

19

C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Front view51980_DPF_GAZ

/ 01

661 OVERALL 163.3 243.5 202 135 THERMOSTAT 53.380

BREATHER FILTER

ALTERNATOR PULLEY 60 EFF.

O.D .

35 X 40

605.7

INLET

4 M8 X 1.25 ON 63.5 PCD

565 100.5 54.8 21.457

316

EARTH TERMINAL M6 X1

69.8

69.8

931 OVERALL

310

Y 20 REMOVAL 210.8

Y

29.5

8.1

BATTERY TERMINAL M10 X1.5 CRANK PULLEY 200 EFF. 223.2 156 BREATHER VENT 237 270.7 200 202.6 305 100 100 152

96.4

6 HOLES M12X1.75 ON 110 PCD

Z

20


240.2

C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Right view51980_DPF_GA / 01X2

X

598.5 523 THERMOSTAT 504.3 120.4 47.6 12 164.4 55.6

12

88.9

569.7

THERMOSTAT

223.2

76.2

Y

Y

115 165 185 247.6 264 367.7 515.4 605 FIRST GROOVE

X X2


21

C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Rear view51980_DPF_GA / 01Z

226.2 280 193.2 ECM 159.2 40

80

. O.D

501.4 EXHAUST 5.9 20 5.9

27 FILL ER

225.1

20

564.6

Y 815

Y

18 BOTH SIDES

126 232.1 238.1 250.9 272.5 305 312

126 238.1 263.3 12 HOLES M10X1.5 ON 428.6 PCD

Z

22


C4.4 ACERT Electronic FIEC4.4 ACERT TAD - Plan view51980_DPF_GA / 01

X

X2

W 134.6

W

63.5

486.2

X

X2


23

C4.4 ACERT Electronic FIE Series turbochargerC4.4 ACERT TTAD - Left viewOPTION CODE 51979_DPF_GA / 01

X X2

868 OVERALL 724.3 631.4 540 411 97.5 14.3 46.1

120.2

47.6 31.2

35

570

481.2

88.9

250.9

183.1

17.5

76.2

451

281

318.8

640 EXHAUST 49.2 23 24.3 145.1 220.5 237 305 431.8 479.5 533.3 571.5 630 X X2 28.6 84.1

24


137

390

Y

Y

C4.4 ACERT Electronic FIEC4.4 ACERT TTAD - Front view

OPTION CODE

51979_DPF_GA / 01

Z

749 OVERALL 377.2 309.8 225.457. 1

243.5 129.5 15

50 O.D.

ALTERNATOR PULLEY 60 EFF. EARTH TERMINAL M6 X 1 4 M8 X 1.25 ON 63.5 PCD 41 560.2 293 INLET 29 54.8 37.8 20.9 13.9 100.5 66.9 285 316 65 O.D. 894 OVERALL Y 161 223.6 20 REMOVAL 94 128 129.5 CRANK PULLEY 200 EFF. 144.5 152 186.7 201.7 222.9 237 270 7 286 202.6 128 129.5 144.5 156 6 HOLES M12X1.75 ON 110 PCD

66.9

Y 172.9 94.6

57

223.6

BATTERY TERMINAL M10 X 1.5


234.3

25

C4.4 ACERT Electronic FIEC4.4 ACERT TTAD - Right viewOPTION CODE 51979_DPF_GA / 01

X2 X

523 THERMOSTAT 338.1 287.4 14.3 47.6

88.9

76.2

69.7

17.5

35.5

457 EXHAUST

Y

Y

140 165 185 220.5 247.6 264 308.5 365.4 389.5 431.8 479.5 515 605 FIRST GROOVE X X2

26


49.2

C4.4 ACERT Electronic FIEC4.4 ACERT TTAD - Rear viewOPTION CODE 51979_DPF_GA / 01

Z

238.8 280 151 35

224.7

483.7

561.6

Y

Y

232.1 238.1 312 238.1

Z


27

C4.4 ACERT Electronic FIEC4.4 ACERT TTAD - Plan viewOPTION CODE 51979_DPF_GA / 01

X X2

105

31

45

80 O.D.

W 134.6 119.5

W

63.5

486.2

X X2

28



4Options Mechanical optionsIntroduction This chapter contains all information relating to the options for the C4.4 ACERT Electronic FIE engine range. Before specifying an option read carefully any notes relating to the option as these will indicate any restrictions if this option is chosen. Any notes relating to option selection and compatibility are only correct at the date of publication. Be aware that both product offerings and option compatibilities are subject to change or withdrawal at any time.4


29

C4.4 ACERT Electronic FIE RatingsThe selection of the A option code defines both the core of the engine specification (cylinder block, crankshaft, pistons and rings etc). As well as the electronic fuel injection hardware, air system and aftertreatment hardware specification. To accommodate this revised approach the selection process for the A option has been changed. For all electronic engines an AD option code must be selected. The AD option code defines the power curves available for selection. Initially each AD option code will include only one rating curve, however as new electronic software packages are introduced this will be expanded to include multiple curves. When making an engine specification decision, first select the AD code which includes the power curve that you require. All rating AD codes are listed , see Maximum intermittent ratings on page 31. To complete the engine specification including low idle and customer specific functionality selections must be made from the Electronic options on page 170.

30


C4.4 ACERT Electronic FIE Maximum intermittent ratingsIndustrial A continuous rating For heavy duty service when the engine is operated at the rated load and speed up to 100% of the time without interruption or load cycling. Time at full load up to 100% of the duty cycle. Industrial B rating For service where power and speed are cyclic. Time at full load not to exceed 80% of the duty cycle. Industrial C intermittent rating For service where power and speeds are cyclic. The horsepower and speed capability of the engine can be utilised for one interrupted hour followed by one hour of operation below the industrial A continuous power. Time at full rated power not to exceed 50% of the duty cycle. Industrial D rating For service where the rated power is required for periodic overloads. The maximum horsepower and speed capability of the engine can be utilised for a maximum of 15 minutes followed by one hour at industrial C intermittent rating or for the duration of the emergency. Time at full rated power not to exceed 10% of the duty cycle. Industrial E rating For service where rated power is required for a short time for industrial starting or sudden overload or for emergency where standard power is unavailable. The maximum horsepower and speed capability of the engine can be utilised for a maximum of 15 minutes followed by one hour at industrial C intermittent rating or for the duration of the emergency. Time at full rated power not to exceed 5% of the duty cycle.


31

C4.4 ACERT Electronic FIE C4.4 ACERT TADTurbocharged air to air cooled - balanced and non balancedMax. rating kW (bhp) @ rpm 61.5 kW @ 2200 65.9 kW @ 2200 70.0 kW @ 2200 74.5 kW @ 2200(1)

Torque Nm @ rpm 347.0 Nm @ 1400 372.0 Nm @ 1400 400.0 Nm @ 1400 450.0 Nm @ 1400 450.0 Nm @ 1400 500.0 Nm @ 1400 500.0 Nm @ 1400 530.0 Nm @ 1400 530.0 Nm @ 1400 560.0 Nm @ 1400 560.0 Nm @ 1400 560.0 Nm @ 1400

Max. TBU % 30 30 32 39 26 34 27 32 25 26 22 17

Rating C C C C C C C C C C C C

Power curve T3660 T3654 T3658 T3656 T3634 T3648 T3644 T3640 T3632 T3636 T3638 T3584

Option code AD401 AD424 AD402 AD403 AD404 AD405 AD408 AD419 AD414 AD409 AD406 AD416

82.0 kW @ 2200 85.9 kW @ 2200 91.0 kW @ 2200 92.6 kW @ 2200 (1) 97.9 kW @ 2200 102.1 kW @ 2200 106.0 kW @ 2200 110.1 kW @ 2200 (1). IOPU ratings.(1)

Notes: For all C4.4 ACERT TAD electronic engines an AD4** code must be selected A complete engine specification must include electronic software selections To complete the electronic specification refer to note Electronic options on page 170 All ratings to ISO 14396 gross All ratings to EPA TIER 4 Interim and EU Stage IIIB certification All electronic ratings to 3% For power curves, see page 200 Inlet restrictions 5 kPa clean All ratings approved to an altitude of 3000 metres Target 3000 rpm overspeed for all ratings of 2200 rpm or above Selected ratings with AD4** prefix will be MLIT certified and to be identified on individual T curves All AD4*** ratings single stage turbo after cooled DPF only All ratings only available with S6***.

32


C4.4 ACERT Electronic FIE C4.4 ACERT TTADTurbocharged air to air cooled - balanced and non balancedMax. rating kW (bhp) @ rpm 105.1 kW @ 2200 112.0 kW @ 2200 117.0 kW @ 2200 129.4 kW @ 2200 (1). IOPU ratings.(1)

Torque Nm @ rpm 630.0 Nm @ 1400 650.0 Nm @ 1400 683.0 Nm @ 1400 750.0 Nm @ 1400

Max. TBU % 38 34 35 33

Rating C C C C

Power curve T3624 T3744 T3626 T3586

Option code AD502 AD510 AD504 AD503

Notes: For all C4.4 ACERT TTAD electronic engines an AD5** code must be selected A complete engine specification must include electronic software selections To complete the electronic specification refer to Electronic options on page 170 All ratings to ISO 14396 gross All ratings to EPA TIER 4 Interim and EU Stage IIIB certification All electronic ratings to 3% For power curves, see page 200 Inlet restrictions 5 kPa clean All ratings approved to an altitude of 3000 metres Target 3000 rpm overspeed for all ratings of 2200 rpm or above Selected ratings with AD5** prefix will be MLIT certified and to be identified on individual T curves All ratings series stage turbo after cooled DPF only All ratings only available with S7***.


33

C4.4 ACERT Electronic FIE ECMDescription ECM fuel cooled ECM air cooled (1) ECM fuel cooled, high position Option AM001 AM002 AM003

(1). Can only be used if the under bonnet temperatures are acceptable. Please refer to the Applications and Installation guide for details.

Note: Incompatibilities TBC. AM001 - ECM fuel cooledOPTION AM001 AM002 DESCRIPTION FUEL COOLED ECM AIR COOLED ECM X X2 206 198 97.5 28.6 189

OPTION CODE MK_AM001 MK_AM002

/ 01 / 01

Z

A_C_OF_G

236

281

326

Y

Y

X

X2

Z

AM002 - ECM air cooled

34


C4.4 ACERT Electronic FIEAM003 - ECM fuel cooledOPTION CODE MK_AM003 / 00

Z

X

561.5

302.4 265.8 319.4 323.4 247 325

202

Y

365.5

250.5

69

Z

X

Y


35

C4.4 ACERT Electronic FIE Adaptor plateDescription Not required Option B0000

B0000 - Not required

36


C4.4 ACERT Electronic FIE Flywheel housingsOption only available upon approval by A+I Engineering and is subject to mandatory installation appraisal.

Stressed cylinder blockDescription Not required, starter spigot on LHS of blockC1000 - Not required, starter spigot on LHS of block

Option C1000

Non stressed cylinder blockDescription Not required, customer to supply housing with LHS starter(1) (2)

Option C0050 C0051(3)

Not required, customer to supply housing with RHS starter (1) (3) Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter with sealed inspection plate cover Cast iron SAE 3, 135,0 mm (5.32 in) deep, RHS starter with high mounting pads (3) Adaptor plate for combine harvesters, RHS starter(3)

C0001 C0002 C0006 C0010 C0011 C0021 as C0022 C0023 C0030(3)

Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter (2) (4) Similar to C0010 but with increased access aperture (2) (4) Cast iron SAE 2, 156,4 mm (6.16 in) deep, LHS or RHS starter (4) Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter (3) C0001 less torque convertor access hole Cast iron SAE 3, 156,4 mm (6.16 in) deep, LHS starter less torque converter access hole (2) (4) Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter (3) Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter as C0030 with different speed sensor tapping (1). Not compatible with E0012. (2). Incompatible with E0100/E0200/E0205/E0311. (3). Incompatible with E0121/E0206/E0207/E0301. (4). Incompatible with QD042.

C0031

Flywheel housing design11.25 22.5 22.5

45

16 HOLE SPACING 12 HOLE SPACING

8 HOLE SPACING

30 15

U1015

Note: If a bell housing or similar component is to fitted to a flywheel housing in this chapter, refer to the data


37

C4.4 ACERT Electronic FIEin the table below.SAE number 3 2 A diameter mm (in) Nominal size 409,6 (16.125) 447,7 (17.625) Tolerance -0.000 to +0,13 (+0.005) +0,13 (+0.005) B diameter mm (in) 450,9 (17.75) 489,0 (19.25) C diameter mm (in) 428,6 (16.875) 466,7 (18.375) Tapped holes Quantity 12 12 Size mm 10 10

C0001 - Cast iron SAE 3, 156,4 mm (6.16 in) deep with sealed inspection plate cover OPTION CODE: CONFIGURATIONS:Z 238.1 171.5 238.1 21841 .3

MK_C0001 / 01 339-5413 / 02 329-7880 / 02X 55.6

1-M16x1.5 PLUGGED BOTH SIDES

47.6

VIEW ON ARROW B45

76.2 Y A 156.4 X SEALED INSPECTION HOLE COVER

PL 38 UG .1 GE D

4-M12x1.75 BOTH SIDES

Y8.5 22

82

14

22 8.5

115

12-M10x1.5x20 DRILL PATTERN FLANGE PATTERN TO No.3 S.A.E.

145

6-M12x1.75 11 136 11 B 62.5 160 180 Z M10x1.5x2088.925 0.025

9 4.8 8.455 DEE P

62.5

2-M10x1.5

11

0.02 5

VIEW ON ARROW A

38


88.9

45

C4.4 ACERT Electronic FIEC0002 - Cast iron SAE 3, 135,0 mm (5.32 in) deep with high mounting pads OPTION CODE: Z CONFIGURATIONS: 238.1 238.1171.5 218 B41

MK_C0002 / 01 329-7881 / 02 339-5414 / 02X 55.6

1-M16x1.5 PLUGGED VIEW ON ARROW B

47.6

4-M12x1.75x24 BOTH SIDES233

Y 82 143.7 177.8 115

12-M10x1.5x20 DRILL PATTERN FLANGE PATTERN TO No. 3 S.A.E. 104.8 3-M10x1.5 62.5 11 M10x1.5x20

76.2 Y A 1350.025

145

6-M12x1.75

14

136 160 180 Z 2-M10x1.5 VIEW ON ARROW A 62.5 1188.925

X

62.5

5 D 98.45 EE 5 P

11

0.0 25

C0006 - Adaptor plate for combine harvestersZ OPTION CODE CONFIGURATIONS: MK_C0006 / 01 329-7882 / 01 X

210.9 154.5 50.8

218 2-M10 x 1.5 x 20 811.2

25

212.7

154.5

56.4

0.0635

88.9

1 38. D GE UG PL

30

Y 159.8 409.5115

Y

A

212.7

74.7

62.9

62.9

8.888.9255 D 98.45 EE 5 P

0.025

50.8 149 205.3 Z 362.9 8.8 VIEW ON ARROW A

8.8

28.50.0 2

X5

11.2


39

C4.4 ACERT Electronic FIEC0010 - Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter1-M16 x 1.5 PLUGGED X 19.1 47.6 VIEW ON ARROW B 12-M10 x 1.5 x 20 DRILL PATTERN FLANGE PATTERN TO No.3 S.A.E. 88.9 41

OPTION CODE CONFIGURATIONS:Z 238.1 214.4 B 238.1

MK_C0010 / 01 329-7883 / 02

30

39.7

233

2-M12 x 1.75 x 24 BOTH SIDES 2-M12 x 1.75 BOTH SIDES

1 D 38. GGE LU P

Y 41.3

Y

221

143.7 21.788.9 25 0.02 5

A 59.7 21.7

18 3-M10 x 1.5 PLUGGED 59.7 170.5 C 3-M10 x 1.5 INSPECTION HOLE COVER Z 135 X55 98.4 5 0.02 P DEE 5

21.7 VIEW ON ARROW A

59.7

VIEW ON ARROW C

C0011 - Similar to C0010 but with increased access apertureZ 238,1 X 19.1 214,4 starter motor mounting 47.641

238,1 1-M16x1.5 B

X OPTION CODE MK_C0011 / 00 CONFIGURATIONS:135 329-7884 / 00 47,6 Z 12-M10 X 1,5 X 20 drill pattern 238.1 FLANGE AND SPIGOT TO NO.3 S.A.E. 214.4 4-M12 X 1,75 X 24 BOTH SIDES 238.1 19,1

VIEW ON ARROW B

B

88,9

30 12-M10x1.5x20 DRILL PATTERN FLANGE PATTERN TO No.3 S.A.E.39,7

30

88.9

23 3

A233

39.7

Y Y 41.3

21,7 A88.92 5

59,721,7

21.7

59.7 21.7

M16 X 1,5 135 PLUGGED X

59,7

59.7

0.025

88,95 88,90 59.7

41

Z 025 0. P E 55 5 DE 98.4 21.7

98,48 98,43 X 5 3-M10x1.5 DEEP 21,7

3-M10x1.5 3-M10 X 1,5

VIEW ON ARROW B 3713K033 FLYWHEEL HOUSING

VIEW ON ARROW A

View on arrow A

40


59,7

Z

X INSPECTION HOLE COVER

143.7 222,6 177.8

221

2-M12x1.75 BOTH SIDES

cat c4.4 acert engine specification manual - tier 4 interim

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