Cat C4.4 ACERT

Cat™ C4.
4 ACERT™
ENGINE SPECIFICATION MANUAL
C4.4 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, February 2012
Publication TPD1752 Issue 7.

© Proprietary information of Cat limited, all rights reserved.
The information is correct at the time of print.
Published in February 2012 by Marketing Support Services.
i
Chapters
1 General information
2 The engine range
3 Engine specification
4 Options
5 Accessories
6 Technical data
The following pages contain a detailed table of contents
ii
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
Electronic FIE . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
How to use the manual .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2
Creating an engine specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 3
The SPES method.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 3
Abbreviations and codes
Abbreviations.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Drawing standards . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
2 The engine range
3 Engine specification
Sub application codes
Agricultural ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Construction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Industrial ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Material handling ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Option selection procedure
Option and accessory selection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Main options ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Accessory options .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Machine load factor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Option selection template
General arrangement drawings

Side mounted turbocharger
C4.4 ACERT TAD - Left view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14
C4.4 ACERT TAD - Front view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
C4.4 ACERT TAD - Right view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
C4.4 ACERT TAD - Rear view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
C4.4 ACERT TAD - Plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
Engine Specification Manual, TPD1752 Issue 7, February 2012 iii

Top mounted turbocharger
C4.4 ACERT TAD - Left view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
C4.4 ACERT TAD - Front view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
C4.4 ACERT TAD - Right view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21
C4.4 ACERT TAD - Rear view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
C4.4 ACERT TAD - Plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23
Series turbocharger
C4.4 ACERT TTAD - Left view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
C4.4 ACERT TTAD - Front view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
C4.4 ACERT TTAD - Right view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
C4.4 ACERT TTAD - Rear view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
C4.4 ACERT TTAD - Plan view . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
4 Options
Mechanical options
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Ratings
Maximum intermittent ratings
Industrial A continuous rating.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Industrial B rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Industrial C intermittent rating . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Industrial D rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Industrial E rating ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
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 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Adaptor plate
B0000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
iv Engine Specification Manual, TPD1752 Issue 7, February 2012

Flywheel housings
C1000 - Not required, starter spigot on LHS of block. ... ... ... ... ... ... ... ... ... ... ... ... ... 36
C0001 - Cast iron SAE 3, 156,4 mm (6.16 in) deep with sealed inspection plate cover 37
C0002 - Cast iron SAE 3, 135,0 mm (5.32 in) deep with high mounting pads .. ... ... ... 38
C0006 - Adaptor plate for combine harvesters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
C0010 - Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter .. ... ... ... ... ... ... ... ... 39
C0011 - Similar to C0010 but with increased access aperture . ... ... ... ... ... ... ... ... ... 39
C0021 - Cast iron SAE 2, 156,4 mm (6.16 in) deep, LHS or RHS starter . ... ... ... ... ... 40
C0022 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter . ... ... ... ... ... ... ... ... 40
C0023 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, LHS starter
less torque converter access hole . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
C0030 - Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter ... ... ... ... ... ... ... ... ... 41
C0031 - Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter ... ... ... ... ... ... ... ... ... 42
Flywheels
D0000 - Crankshaft palm .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
D0003 - For Centaflex couplings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
D0004 - For SAE, Borg and Beck, twin disc .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
D0005 - As D0004 but with pilot bearing housing . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
D0008 - For Clark 18000 torque converters (non stressed) .. ... ... ... ... ... ... ... ... ... ... 46
D0014 - For Borg Warner torque converters (non stressed) . ... ... ... ... ... ... ... ... ... ... 46
D0030 - For Allison AT545 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
D0044 - For SAE transmissions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
D0045 - For Spicer transmissions . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
D0046 - For hydrostatic transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
D0053 - For various transmissions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
D0056 - For various transmissions stressed cylinder block .. ... ... ... ... ... ... ... ... ... ... 49
D0063 - For customer transmission stressed cylinder block . ... ... ... ... ... ... ... ... ... ... 50
D0064 - For customer transmission .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
D0070 - For ZF115 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
D0092 - For ZFWG9 transmission ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
D0114 - For Borg Warner torque converters (stressed cylinder block) . ... ... ... ... ... ... 53
Starter motors
E0012 - Studs only for LHS starter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54
E0013 - Studs only for RHS starter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55
E0100 - 12V, 4.0 kW, RHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... 55
E0121 - 12V, 4.0 kW, LHS, suitable for dry back end only ... ... ... ... ... ... ... ... ... ... ... 56
E0141 - 12V, 4.0 kW, Ag block only, suitable for dry back end only,
for use with AM003 (high ECM) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Engine Specification Manual, TPD1752 Issue 7, February 2012 v

Fan drive
Standard duty multi-vee belt .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60
F0000 - Fan drive not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60
F0133 - Fan centre 356 mm (14.02 in) pulley dia. 200 mm ... ... ... ... ... ... ... ... ... ... ... 61
F0501 - Fan centre 262 mm (10.31 in) no pulley or belts .. ... ... ... ... ... ... ... ... ... ... ... 71
F1000 - No fan drive supplied. Additional pulley and
bracket supplied to complete drive ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 74
Belt tensioner
FD000 - No belt auto - tensioner required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75
FD001 - Belt auto - tensioner required, for belt systems
without a low RHS A/C compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75
FD002 - Belt auto - tensioner required, for belt systems
with a low RHS A/C compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76
Lubricating oil sump
Non stressed cylinder block .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
G0100 - Steel, flat bottomed sump (LHS dipstick only) . ... ... ... ... ... ... ... ... ... ... ... ... 77
G0200 - Steel, flat bottomed sump (RHS dipstick only) . ... ... ... ... ... ... ... ... ... ... ... ... 78
G0300 - Cast iron, flat bottomed sump .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78
G0600 - Aluminium, shallow rear well sump .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
G0800 - Aluminium, shallow rear well sump with oil filler pad RHS ... ... ... ... ... ... ... ... 79
G1100 - Aluminium, high gradeability ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
vi Engine Specification Manual, TPD1752 Issue 7, February 2012

Stressed sump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
G2000 - Cast Iron, deep flat bottom sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
G2100 - Cast Iron, shallow tunnel sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
G2300 - Cast Iron, deep tunnel sump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
G2500 - High oil capacity 11.5 litres plus .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Lubricating oil dipstick
GD000 - No dipstick ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD001 - Short LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD002 - Long LHS, centre top... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD003 - Short RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD004 - Medium, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD006 - Long LHS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
GD007 - Medium, RHS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
Oil capacities and gradability
Gradient of operation and oil capacities . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
Oil change period of low capacity sumps under review. ... ... ... ... ... ... ... ... ... ... ... ... 85
Breather
H0300 - Open breather, filtered 86
H0320 - Open breather, filtered, no hose 87
Top cover oil filler
HC000 - No filler ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88
HC002 - Top cover filler, rear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89
HC004 - Top cover filler, front ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89
Lubricating oil filler
HD000 - Not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90
HD001 - Timing case filler, LHS short filler forward facing ... ... ... ... ... ... ... ... ... ... ... 90
HD002 - Timing case filler, LHS long ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
HD004 - Timing case filler, LHS rear facing, Q1100, Q30** only .. ... ... ... ... ... ... ... ... 91
HD005 - Timing case filler, remote rear face, rearward facing, Q1100, Q30** only .. ... 92
HD006 - Sump filler, RHS, G0800 only . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92
HD007 - Timing case filler, remote side face, rearward facing .. ... ... ... ... ... ... ... ... ... 93
HD011 - Timing case filler, LHS, mid mounted, extended ... ... ... ... ... ... ... ... ... ... ... 93
Lubricating oil filter head
Oil filters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94
J0050 - Vertically down, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94
J0060 - Horizontal filter, LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
J0070 - Vertically down filter head, RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
J0130 - Adaptor LHS for remote oil filter (customer to supply) . ... ... ... ... ... ... ... ... ... 96
Front end drive
K0020 - Primary drive, steel, 200 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97
K0030 - Primary drive, steel, 170 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98
K0120 - Primary drive, steel, 200 mm diameter, axial PTO .. ... ... ... ... ... ... ... ... ... ... 98
K0130 - Primary drive, steel, 170 mm diameter, axial PTO .. ... ... ... ... ... ... ... ... ... ... 99
Engine Specification Manual, TPD1752 Issue 7, February 2012 vii

Secondary crankshaft pulley
KD000 - No secondary pulley ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 100
KD001 - Single groove Vee belt 200 mm diameter ... ... ... ... ... ... ... ... ... ... ... ... ... . 100
Coolant pump
L0002 - Coolant pump - angled inwards inlet ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 101
L0004 - Coolant pump - vertical inlet . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 102
Coolant outlet connection
LD152 - Horizontal outlet connection on LHS, with thermostat assembly . ... ... ... ... . 103
LD156 - Vertical outlet connection in centre .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 104
LD157 - 45° up outlet connection on RHS, with thermostat assembly .. ... ... ... ... ... . 104
Fan
M0000 - Fan not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 105
M0005 - Diameter 660 mm (26 in) pusher, 7 blade at 26° pitch ... ... ... ... ... ... ... ... . 105
M0007 - Diameter 660 mm (26 in) puller, 7 blade at 26° pitch .. ... ... ... ... ... ... ... ... . 106
M0013 - Diameter 559 mm (22 in) pusher, 7 blade at 26° pitch ... ... ... ... ... ... ... ... . 106
M0015 - Diameter 559 mm (22 in) puller, 7 blade at 26° pitch .. ... ... ... ... ... ... ... ... . 107
Fan extension and fixings
MD000 - Extension not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 108
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 . ... ... ... ... ... ... ... ... ... . 108
MD010 - 127 mm (5.0 in) - Fan extension . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 109
Alternator
N0000 - Alternator, bracket and tensioner not required .. ... ... ... ... ... ... ... ... ... ... ... . 110
N0101, N0102, N0200, N0201 - Alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 110
N0105, N0206 - Alternator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 111
Belt driven auxiliaries
P0000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 112
P0001 - Auxiliary drive, single groove pulley, 200 mm diameter ... ... ... ... ... ... ... ... . 112
P0003 - Auxiliary drive, single groove pulley, 140 mm diameter ... ... ... ... ... ... ... ... . 113
P0100 - 12V, air conditioning compressor, pad mounted, RHS low .. ... ... ... ... ... ... . 113
P0101 - 24V, air conditioning compressor, pad mounted, RHS low .. ... ... ... ... ... ... . 114
Timing case
Q1000, Q1030, Q1040, Q1050 - Timing case, LHS PTO .. ... ... ... ... ... ... ... ... ... ... . 115
Q1100 - Timing case, no PTO capability ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 116
Q3000, Q3030 - Timing case, single RHS PTO ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 116
Q5000 - Heavy duty timing case, twin PTO capability 280 Nm Max. . ... ... ... ... ... ... . 117
Q5010 - Heavy duty timing case, twin PTO, less RHS gear .. ... ... ... ... ... ... ... ... ... . 117
viii Engine Specification Manual, TPD1752 Issue 7, February 2012

Timing case auxiliaries
QD000 - No auxiliaries ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
QD005 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange,
13 tooth spline, fitted LHS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
9 tooth spline, fitted LHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119
QD017 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE B flange,
QD024 - Adaptor 225cc compressor with SAE A flange, head unload . ... ... ... ... ... .. 120
QD042 - 630cc compressor, SAE B flange, head unload for use with Q1030 .. ... ... .. 121
QD042 - 630cc compressor, SAE B flange, head unload, for use with Q5000 . ... ... .. 121
QD055 - Hydraulic pump drive adaptors, 2 bolt fixings, SAE B flange,
13 tooth spline fitted LHS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 122
Balancer
R0000 - Not required.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123
R0001 - Balancer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123
Turbocharger
S6100 - Single side turbocharger, exhaust rearward, compressor up, inward offset .. 124
S6101 - Single side turbocharger, exhaust rearward,
compressor down, outward offset . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125
S6102 - Single side turbocharger, exhaust forward, compressor up, outward offset .. 125
S6105 - Single side turbocharger, exhaust forward,
compressor down, outward offset . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126
S6300 - Single top forward mounted turbocharger, exhaust rearward, compressor up 126
S6301 - Single top forward mounted turbocharger, exhaust rearward,
compressor up inward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
S6302 - Single top forward mounted turbocharger, exhaust rearward,
compressor horizontal across .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
S7100 - Series side turbocharger, exhaust rearward, compressor up . ... ... ... ... ... .. 128
S7101 - Series side turbocharger, exhaust rearward,
compressor across, upward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
S7102 - Series side turbocharger, exhaust rearward,
compressor horizontal out, downward offset ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129
Soot sensor box and cable
SA001/SA002 - Soot sensor box with 1.5/2.5 metre cable ... ... ... ... ... ... ... ... ... ... .. 130
SA003 - Soot sensor box engine mounted for use with IOPU/Genset/Electropak ... .. 130
Engine Specification Manual, TPD1752 Issue 7, February 2012 ix

Turbo Exhaust outlet connection
SD001 - Exhaust elbow rearward up (suits single side turbo) ... ... ... ... ... ... ... ... ... . 131
SD002 - Exhaust elbow rearward down (suits single side turbo) ... ... ... ... ... ... ... ... . 132
SD003 - Exhaust elbow rearward straight (suits single side turbo) ... ... ... ... ... ... ... . 132
SD004 - Exhaust elbow forward up (suits single side turbo) . ... ... ... ... ... ... ... ... ... . 133
SD005 - Exhaust elbow forward down (suits single side turbo) . ... ... ... ... ... ... ... ... . 133
SD007 - Exhaust elbow rearward angled down (suits single side turbo) ... ... ... ... ... . 134
SD008 - Exhaust elbow rearward down, long (suits single side turbo) .. ... ... ... ... ... . 134
SD010 - Exhaust elbow rearward up for use with engine mounted aftertreatment
(suits single top turbo) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 135
SD011 - Exhaust elbow rearward up (suits series side turbo) ... ... ... ... ... ... ... ... ... . 135
SD012 - Exhaust elbow rearward up, long (suits single side turbo) .. ... ... ... ... ... ... . 136
SD014 - Exhaust elbow rearward down (suits series side turbo) .. ... ... ... ... ... ... ... . 136
SD016 - Exhaust elbow rearward straight (suits single top turbo) . ... ... ... ... ... ... ... . 137
SD017 - Exhaust elbow rearward straight (suits series side turbo) ... ... ... ... ... ... ... . 137
Aftertreatment
Non-modular .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 138
SF420 - Axial inlet, axial exit, installation angle 180° . ... ... ... ... ... ... ... ... ... ... ... ... . 138
SF420 - Axial inlet, axial exit, installation angle 180° . ... ... ... ... ... ... ... ... ... ... ... ... . 139
SF422 - Axial inlet, radial exit, exit angle 270°, installation angle 180° . ... ... ... ... ... . 139
SF422 - Axial inlet, radial exit, exit angle 270°, installation angle 180° . ... ... ... ... ... . 140
SF424 - Axial inlet, radial exit, exit angle 90°, installation angle 180° ... ... ... ... ... ... . 140
SF424 - Axial inlet, radial exit, exit angle 90°, installation angle 180° ... ... ... ... ... ... . 141
SF426 - Axial inlet, radial exit, exit angle 0°, installation angle 180° . ... ... ... ... ... ... . 141
SF426 - Axial inlet, radial exit, exit angle 0°, installation angle 180° . ... ... ... ... ... ... . 142
SF428 - Radial inlet, axial exit, inlet angle 270°, installation angle 180° ... ... ... ... ... . 142
SF428 - Radial inlet, axial exit, inlet angle 270°, installation angle 180° ... ... ... ... ... . 143
SF430 - Radial inlet, axial exit, inlet angle 90°, installation angle 180° . ... ... ... ... ... . 143
SF430 - Radial inlet, axial exit, inlet angle 90°, installation angle 180° . ... ... ... ... ... . 144
SF432 - Radial inlet, radial exit, inlet angle 90°, exit angle 90°,
installation angle 180° ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 144
installation angle 180°. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 147
Engine mounted aftertreatment
SF450 - Radial exit, exit angle 250°. engine mounted ... ... ... ... ... ... ... ... ... ... ... ... . 148
x Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine to aftertreatment, flex pipe
SU001 - Flex kit with straight adaptor (supplied loose in engine solution pack) ... ... .. 149
SU002 - Flex kit with 45° adaptor (supplied loose in engine solution pack) .. ... ... ... .. 150
SU003 - Flex kit with 90° adaptor (supplied loose in engine solution pack) .. ... ... ... .. 150
SU004 - Flex kit to suit engine mounted aftertreatment only ... ... ... ... ... ... ... ... ... .. 151
SU008 - Flexible exhaust installation kit with straight adaptor (SD) 90° elbow
(SF) (supplied loose in engine solution pack) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 151
SU009 - Flexible exhaust installation kit with 45° adaptor (SD) 90° elbow
SU010 - Flexible exhaust installation kit with 90° adaptor (SD) 90° elbow
Inlet manifold / connections
T0001 - Forward facing swan neck inlet connection with low NRS mixer . ... ... ... ... .. 152
T0002 - Intake angled with low NRS mixer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 153
T0003 - Rearward facing with low NRS mixer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 153
Inlet air filter
TD000 - Not required.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154
TD001 - Standard duty air filter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154
TD004 - Heavy duty air filter (supplied loose) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 155
Exhaust manifold
U0000 - Not user selectable... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
Exhaust manifold outlet connections
UD000 - Not required . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
Secondary fuel filter
V0010 - Single LHS, centre ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158
V0030 - Twin LHS, centre . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159
V1301 - Remote filter arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159
Cold starting aid
W0011 - Glow plugs .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160
W0016 - Glow plugs and ether .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 161
W0017 - Glow plugs, ether and lead . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 161
W0018 - Glow plugs and lead ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 162
Engine lifting eyes
X0011 - Fitted LHS at front and RHS at rear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 163
X0111 - Fitted LHS at front and RHS at rear compatible
with IOPU / Genset and engine mounted aftertreatment ... ... ... ... ... ... ... ... ... ... ... .. 163
X0113 - Fitted LHS at front and RHS at rear compatible
with IOPU / Genset and engine mounted aftertreatment (SF453 only).. ... ... ... ... ... .. 163
Engine finish
Y0000 - Lacquer. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 164
Y9012 - Cat gold with light preservatives ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 164
Y9027 - Cat gold with heavy preservative.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 164
Engine Specification Manual, TPD1752 Issue 7, February 2012 xi

Electronic options
Cat C4.4 ACERT electronic engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 165
5 Accessories
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 167
Resistors and regulators
ZA000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 168
Fuel cooler
ZB000 - Fuel cooler not supplied ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 169
ZB001 - Fuel cooler factory fitted to the front of cooling pack frame .. ... ... ... ... ... ... . 169
ZB002 - fuel cooler supplied loose.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 169
Engine mounting brackets
ZC000 - Not required, blanking plugs only.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 170
ZC002 - Front pedestal brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 171
ZC003 - Rear mounting brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 171
ZC004 - Front pedestal brackets LHS and RHS, rear mounting brackets
LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 172
ZC012 - Front mounting studs and nuts only . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 172
ZC016 - Front mounting brackets LHS and RHS ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 173
ZC019 - Front mounting brackets LHS and RHS .. ... ... ... ... ... ... ... ... ... ... ... ... ... . 173
ZC025 - Front mounting brackets LHS (horizontal) and RHS
(horizontal rearward facing) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 174
Heater/starter switch
ZE000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 175
ZE001 - Heater / starter switch and security lock supplied loose .. ... ... ... ... ... ... ... . 175
Oil drain valve
ZG000 - Standard sump plug.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 176
ZG001/ZG004 - Sump oil drain valve fitted LHS/RHS ... ... ... ... ... ... ... ... ... ... ... ... . 176
Lubricating oil sampling/switch/gauge
ZJ000 - Not required ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 177
ZJ005 - Lubricating oil sampling valve fitted in filter head . ... ... ... ... ... ... ... ... ... ... . 177
Coolant temperature sender and gauge
ZL000 - Not required... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 178
Radiator and mounting group
ZM000 - Not required.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 179
ZM001 - Radiator and intercooler fitted, with fan guards
(compatible with S7*** turbos) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 179
(compatible with S6*** turbos) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 180
(compatible with S7*** turbos) harsh environment protection. ... ... ... ... ... ... ... ... ... . 180
(compatible with S6*** turbos) harsh environment protection. ... ... ... ... ... ... ... ... ... . 180
xii Engine Specification Manual, TPD1752 Issue 7, February 2012
Engine wiring harness
ZN020 - Wiring harness, convoluted, with diagnostic connector ... ... ... ... ... ... ... ... .. 181
ZN031 - Wiring harness, convoluted with diagnostic connector to suit Ag block only .. 182
ZN032 - Wiring harness, convoluted, without diagnostic connector... ... ... ... ... ... ... .. 182
ZN033 - Wiring harness, convoluted, with diagnostic connector for compatibility with large
LHS PTOs . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183
Primary fuel filter
Fuel pre filters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
ZV031 - Single filter, supplied loose with water separator and sensor,
electric lift pump fitted. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
ZV032 - Single filter, supplied loose with water separator and sensor,
electric lift pump off engine. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
ZV073 - Single filter, engine mounted with water separator and sensor,
electric lift pump fitted. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
ZV074 - Single filter, engine mounted with water separator and sensor,
electric lift pump off engine. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
Label/badging
ZY901 - Emission label fitted to front cover. Cat decal .. ... ... ... ... ... ... ... ... ... ... ... .. 185
Cab heater connections
ZZ000 - Not required .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 186
ZZ004 - Feed LHS cylinder head, straight return to rear of timing case ... ... ... ... ... .. 186
ZZ014 - Feed LHS cylinder head, angled return to rear timing case ... ... ... ... ... ... .. 187
ZZ017 - Feed LHS cylinder head, angled (45°) return to rear timing case ... ... ... ... .. 187
6 Technical data
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 189
Basic technical data
Models C4.4 TTAD. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191
Power curves
T3584 - 110.1 kW, AD416 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 193
T3586 - 129.5 kW, AD503 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 195
T3624 - 105.1 kW, AD502 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 197
T3626 - 117.0 kW, AD504 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 199
T3632 - 97.9 kW, AD414 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 201
T3634 - 82 kW, AD404 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 203
T3636 - 102.1 kW, AD409 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 205
T3638 - 106 kW, AD406 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207
T3640 - 92.5 kW, AD419 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 209
T3644 - 91 kW, AD408 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211
T3648 - 85.9 kW, AD405 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 213
T3654 - 65.9 kW, AD424 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215
T3656 - 74.5 kW, AD403 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 217
T3658 - 70.0 kW, AD402 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 219
T3660 - 61.5 kW, AD401 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221
T3744 - 112.0 kW, AD510 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
Engine Specification Manual, TPD1752 Issue 7, February 2012 xiii
Cylinder block views non-stressed block
Non-stressed block and head - left hand side view ... ... ... ... ... ... ... ... ... ... ... ... ... . 225
Non-stressed block and head - front view... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 226
Non-stressed block and head - right side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 226
Non-stressed block and head - rear side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 227
Non-stressed block and head - plan view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 227
Cylinder block views stressed block
Stressed block and head - left hand side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 228
Stressed block and head - front view.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 229
Stressed block and head - right side view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 229
Stressed block and head - rear side view ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 230
Stressed block and head - plan view .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 230
Cold start system
Battery to starter lead resistance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 232
Cooling system
Radiators. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 233
Radiator coolant flow rates ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 233
Cab heater coolant flow rates ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 234
Tier IV under - bonnet temperatures... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 235
Heat balance... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 235
Exhaust system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 235
Air flow
T3584, 110.1 kW - AD416 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 236
T3586, 129.4 kW - AD503 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 237
T3624, 105.1 kW - AD502 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 238
T3626, 117.0 kW - AD504 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 239
T3632, 97.9 kW - AD414 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 240
T3634, 82.0 kW - AD404 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 241
T3636, 102.1 kW - AD409 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 242
T3638, 106.0 kW - AD406 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 243
T3640, 92.5 kW - AD419 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 244
T3644, 91.0 kW - AD408 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 245
T3648, 85.9 kW - AD405 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 246
T3654, 65.9 kW - AD424 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 247
T3656, 74.5 kW - AD403 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 248
T3658, 70.0 kW - AD402 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 249
T3660, 61.5 kW - AD401 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 250
T3744, 112.0 kW - AD510 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 251
Induction system
Air filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 252
Inlet restriction. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 252
Restriction indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 252
Fuel specifications
For Tier 4 Interim engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 253
xiv Engine Specification Manual, TPD1752 Issue 7, February 2012

Fuel system
Low pressure fuel system - recommended layout.. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 254
Lubrication system
Lubricating oil specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Maintenance intervals for engines that use biodiesel. ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Lubrication oil temperature. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Recommended viscosity grades ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Lubricating oil pressure .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Electrical system
4.4 litre factory installed wiring and components ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 256
Engine mandatory wiring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 256
Machine specific wiring .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 256
PV / PROD clean emissions module.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 256
Starter motors
Equipment required for cold temperatures . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 257
Battery to starter lead resistance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 258
Cold start oil specification... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 259
Medium duty alternator data... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260
Engine mountings
Standard methods .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261
Flexible mountings . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261
Torsional vibration
Flywheel/cylinder block bending moments. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 262
C4.4 Ag engine block fitted with a structural sump. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 263
Power take off
Crankshaft thrust loading ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 264
Crankshaft driven axial power take off ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 264
Torsional vibration .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 264
Crankshaft front over hung load (OHL) capability .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 265
Crankshaft rear over hung load (OHL) capability ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 266
Flywheel Inertia .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 266
Alternative side mounted PTO
Side mounted PTO position ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 268
Side mounted PTO operating data
Application of PTO load:. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270
Typical uses (continuous duty)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270
Typical uses (intermittent duty) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270
Customer fitted pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 271
Applications sign-off ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 271
Duty cycles - assessment and sign-off criteria
Continuous duty cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 272
Intermittent duty cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 273
Engine Specification Manual, TPD1752 Issue 7, February 2012 xv

Mass elastic data
4.4 litre below 110 kW. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 274
4.4 litre above 110 kW ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 275
Centre of gravity.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 276
De-ratings
Allowances for engine driven auxiliary equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
De-rating . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
Inlet air temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
Altitude ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
Humidity .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
Temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 277
Compressor performance curves
Single cylinder 225cc - free air delivery .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 278
Single cylinder 225cc - delivered air temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 279
Single cylinder 225cc - power consumption ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 280
Single cylinder 225cc - air charging time to pressurise a 50 litre receiver .. ... ... ... ... . 281
Twin cylinder, 630cc, ESS (Energy Saving System), free air delivery ... ... ... ... ... ... . 282
Twin cylinder, 630cc, ESS (Energy Saving System), delivered air temperature ... ... . 283
Twin cylinder, 630cc, ESS (Energy Saving System), power consumption . ... ... ... ... . 284
Fan performance curve
26 inch diameter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 285
22 inch diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 286
Important notes
Company liability. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 288
Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 288
Legislation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 288
Warranty . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 288
xvi Engine Specification Manual, TPD1752 Issue 7, February 2012

1
General information 1
Introduction
Electronic 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”.
Engine Specification Manual, TPD1752 Issue 7, February 2012 1

How to use the manual
All 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 Engine Specification Manual, TPD1752 Issue 7, February 2012

Creating an engine specification
The 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.

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

Drawing standards
Ø Diameter
XX Rear face of cylinder block
X2X2 Rear face of cylinder block (engines with stressed cylinder block)
YY Crankshaft centre line (horizontal)
ZZ Crankshaft centre line (vertical)
Note: All dimensions are in mm unless otherwise stated.
First angle projection Third angle projection
Engine type codes

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


2
The engine range 2
The 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.


3
Engine specification 3
Mandatory 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 approval.
Where the * symbol appears, this represents any series of characters. For example S6*** represents any
turbo option starting with S6.

Sub application codes
Agricultural Industrial
Application group/sub-application Code Application group/sub-application Code
Tractors wheeled AGR20 Industrial - other IND42
Tractors fast AGR21 Snow blowers IND43
Special harvesters AGR22 Snow groomers IND44
Combine harvesters AGR24 Compressors IND50
Lawn and garden AGR25 Petroleum industry IND59
Sprayers AGR26 Mining equipment IND61
Agricultural - other AGR28 Locomotive/rail traction IND75
Wood chippers AGR39 Pump sets IND84
Forestry harvesters AGR85 Sweepers IND87
Construction Material handling

Application group/sub-application Code Application group/sub-application Code
Self propelled drills CON29 Aircraft baggage handlers MAT14
Excavators CON30 Telescopic handlers MAT40
Backhoe loaders CON31 Cranes MAT54
Wheeled shovel loaders CON32 Access platforms MAT68
Bulldozer CON33 Forklift trucks MAT70
Scrapers CON34 Rough terrain, forklift trucks MAT71
Graders CON35 Towing tractors MAT72
Dumpers CON36 Side loaders MAT73
Trenchers CON37 Straddle carriers MAT76
Skid steer loaders CON38
Mini excavators CON41
Pavers CON51
Road rollers CON53
Construction - other CON69

Option selection procedure
To 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 form
Selection
Question Range
(one per question)
1 Sub application code See page 10
EPA TIER 4 Interim
2 Emission standard
EEC Stage IIIB
12
3 Voltage
24
Up to 1676 metres
4 Maximum altitude
Up to 3000 metres
5 Maximum ambient temperature °C
6 Minimum start temperature °C
7 Expected oil change period Up to 500 hours
8 Average load factor See page 12
9 Average usage (per year) Hours
10 Expected engine life (years) Years
11 Special fuel requirements ULS Diesel
PTO
Nm
LHS
12 Front end drive - timing case
PTO
Nm
RHS
13 Front end inertia, including crankshaft pulley kg m²
14 Rear end inertia, including flywheel kg m²
15 EOS specification
For electronic options,
see page 165
16 PTO torque from crankshaft pulley Nm

Option 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 H 0 1 0 0
Lubricating oil filters and coolers J 0 1 3 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 Z C 0 0 2
Heater/starter switch Z E 0 0 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 - B litres
Typical machine load factor is:
A ⋅ Litres
----------------------- × 100 = C %
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 Power Weighted
% kW power
Maximum Rated speed power 20 x 129,5 = 25,9
Maximum torque speed power 40 x 95,0 = 38,0
Idle speeds (high/low power) 40 x 0 = 0,0
100 63,9
Estimated machine load factor is:

63, 9-
-------------- × 100 = 49 %
129, 5
If further assistance is required please contact Cat Applications department.

Option selection template
Option group Option code Description
A Rating
AM ECM
F Fan drive
FD Belt tensioner
K Crank pulley
KD Secondary crank pulley
Front end
M Fan
MD Fan extension
N Alternator
NL Alternator branding
P Belt driven auxiliaries
Q Timing case
QD Gear driven auxiliaries
B Adaptor plate
C Flywheel housing
Back end
D Flywheel and starter ring

E Starter motor
EL Starter motor branding
S Turbocharger, manifold
SA Soot sensor
SD Turbo exhaust outlet connections
Aspiration
SF Aftertreatment
SU Engine to after treatment flexpipe kit
T Induction connections
TD Inlet air filter
U Exhaust manifolds
UD Exhaust manifold outlet connections
G Lubricating oil sump
GD Dipstick
ZG Sump drain
H Breather
HC Top cover oil filler
Oil
HL Breather branding
HD Timing case oil fillers
J Lubricating oil filter and cooler
JD Lubricating oil filter branding
R Balancer
V Fuel filter secondary
Fuel
VD Fuel filter secondary branding

ZV Fuel filter primary
L Coolant pump inlet
Coolant
LD Thermostat housing, outlet connection

ZM Radiator
ZZ Cab heater connections
W Cold start aid
ZA Resistor and regulators
Controls
ZE Heater switch
ZJ Lubricating oil pressure switch
ZL Coolant temperature gauge and sender
ZN Engine wiring harness
X Lifting eyes
Y Paint
Dress
ZC Engine mountings
ZY Emissions labels

General arrangement drawings
Side mounted turbocharger

C4.4 ACERT TAD - Left view
51976_DPF_GA / 01
X X2
845.1 OVERALL
689
631.4
540
411 156.4
97.5 ECM CONNECTION 55.6
47.6
35
4-M 12 X 1.75 X 24.5

352.5
281 ECM CONNECTION

481.2
250.9
88.9
17.5
76.2
451
Y Y
73.3
96.8
161
49.2
247.7
94 61.6
233.5
4-M 12 X 1.75 X 20
304.5
321.3
365.4
431.8
479.5
553
569.7
630 28.6
X X2

C4.4 ACERT TAD - Front view
51976_DPF_GA / 01
732 OVERALL
340.2 OUTLET
299.6 INLET
237 15 THERMOSTAT
ALTERNATOR PULLEY
60 EFF.
4-M8 X 1.25
EQUISPACED ON
50.8 O.D. 63.5 P.C.D.
41
363.3 OUTLET
OVERALL
EARTH
TERMINAL
316
INLET
M6 X 1
285
885.2
13.9
246.5
54.8
100.5
Y 57
Y
20.9
210.6
66.9
66.9
29.5
266.4
BATTERY
TERMINAL
M10 X 1.5
4-M16 X 2 X 25
20 REMOVAL
128 128
130.3 129.8
CRANK PULLEY 144.5
200 EFF.
151.9
6-M12 X 1.75
144.5 156 EQUISPACED ON
ON 110 P.C.D.
223.2 200
270.7 202.6
286

C4.4 ACERT TAD - Right view
51976_DPF_GA / 01
X2 X
523 THERMOSTAT
50.9 282.3
31
57.1 THERMOSTAT
THERMOSTAT
47.6
570
4-M12 X 1.75 X 24.5
560.2
88.9
17.5
Y Y
76.2
247.7
49.2
28.6
MOUNTING HOLE
151 4-M12 X 1.75 X 20
55.6 165
247.6
264
321.3
431.8 47.6
515
605 FIRST GROOVE
X2 X

C4.4 ACERT TAD - Rear view
51976_DPF_GA / 01
151
35
80 O.D.
561.6
483.7
EXHAUST
278.3
Y Y
20.5 MOUNTING HOLE-REAR

BOTH SIDES
12-M 10 X 1.5 X 20
EQUISPACED ON
428.6 P.C.D.
238.1 238.1
MOUNTING HOLE MOUNTING HOLE
MOUNTING HOLE
MOUNTING HOLE
241.3 241.3
296.8 EXHAUST
260.4
260.4

C4.4 ACERT TAD - Plan view
51976_DPF_GA / 01
Subject to change at Production cut in
X X2
337.5 INLET
105
80 O.D.
INLET
45
W W
119.5
134.6
243.5
199.5 ECM CONNECTION

63.5
486.2
X X2

Top mounted turbocharger
C4.4 ACERT TAD - Left view
51980_DPF_GA / 01
X X2
845 OVERALL
673.5
468
449.1
411 BREATHER FILTER
97.5 156.4
31.2
57.1 THERMOSTAT O.D.

50 55.6
47.6
41
660.7
570
318.8
281
88.9
250.9
183.1
Y 451 Y
76.2
162.4
223.2
161 BREATHER VENT
94 23
23.8
115
28.6
233.4
237
283.2
305
365.4
452.2
567.2
574.7
630
X X2

C4.4 ACERT TAD - Front view
Subject to change at Production cut in 51980_DPF_GA / 01
661 OVERALL
163.3
243.5 BREATHER FILTER
202
135 THERMOSTAT
53.3
ALTERNATOR PULLEY 35 X 40
.
O.D
60 EFF.
80
4 M8 X 1.25
ON 63.5 PCD
INLET
605.7
565
931 OVERALL
EARTH
TERMINAL
M6 X1
316
100.5
310
54.8
69.8
21.4
69.8
57
Y Y
20 REMOVAL
210.8
8.1
29.5
240.2
96.4
BATTERY
TERMINAL
M10 X1.5
CRANK PULLEY 100 100

200 EFF.
223.2 152
6 HOLES
M12X1.75
156 BREATHER VENT
ON 110 PCD
237 200
270.7 202.6
305

C4.4 ACERT TAD - Right view
51980_DPF_GA / 01
X2
X
598.5
523 THERMOSTAT
504.3
120.4 164.4
47.6 55.6
12
12
THERMOSTAT
569.7
88.9
Y Y
76.2
223.2
115
165
185
247.6
264
367.7
515.4
605 FIRST GROOVE
X2

C4.4 ACERT TAD - Rear view
51980_DPF_GA / 01
226.2
280 159.2
193.2 ECM 40
.
O.D
80
27
501.4 EXHAUST
FILL
ER
564.6
225.1
20
20
5.9
5.9
Y Y
8
15
18
BOTH SIDES
126 126
232.1
238.1 238.1
250.9 263.3 12 HOLES

M10X1.5
272.5 ON 428.6 PCD
305
312

C4.4 ACERT TAD - Plan view
51980_DPF_GA / 01
X2
X
W W
134.6
63.5
486.2
X2
X

Series turbocharger
C4.4 ACERT TTAD - Left view
OPTION CODE 51979_DPF_GA / 01
X X2
868 OVERALL
724.3 120.2
631.4
540
411
97.5
14.3 47.6
46.1
31.2
35
640 EXHAUST
570
481.2
318.8
88.9
281
250.9
183.1
451
17.5
76.2
Y Y
390
137
49.2
23
24.3
145.1 84.1
220.5
237
305
431.8
479.5
533.3
571.5
28.6
630
X X2

C4.4 ACERT TTAD - Front view
749 OVERALL
377.2 243.5
309.8 129.5
225.4 15
1
57.
50 O.D.
ALTERNATOR PULLEY
60 EFF.
EARTH 4 M8 X 1.25
TERMINAL ON 63.5 PCD
M6 X 1
41
560.2
894 OVERALL
65 O.D.
293 INLET
316
285
37.8
54.8
29
20.9
100.5
66.9
13.9
Y Y
66.9
57
94.6
172.9
161
223.6
223.6
234.3
20 REMOVAL
BATTERY
TERMINAL 6 HOLES
M10 X 1.5 94 M12X1.75
ON 110 PCD
128 128
129.5 129.5
CRANK PULLEY
200 EFF. 144.5 144.5
152 156
186.7
201.7 202.6
222.9
237
270.7 286

C4.4 ACERT TTAD - Right view
X2
523 THERMOSTAT
338.1
287.4
14.3
47.6
457 EXHAUST
88.9
35.5
17.5
69.7
76.2
Y Y
49.2
140
165
185
220.5
247.6
264
308.5
365.4
389.5
431.8
479.5
515
605 FIRST GROOVE

X
X2

C4.4 ACERT TTAD - Rear view
238.8
280 151
35
561.6
483.7
224.7
Y Y
232.1
238.1 238.1
312

C4.4 ACERT TTAD - Plan view
X X2
105
31
80 O.D.
45
W W
119.5
134.6
63.5
486.2
X X2

4
Options 4
Mechanical options
Introduction
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.

Ratings
The 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 165.

Maximum intermittent ratings
Industrial 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.
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.

C4.4 ACERT TAD
Turbocharged air to air cooled - balanced and non balanced
Max. rating Torque Nm Power Option
Max. TBU % Rating
kW (bhp) @ rpm @ rpm curve code
61.5 kW @ 2200 347.0 Nm @ 1400 30 C T3660 AD401
65.9 kW @ 2200 372.0 Nm @ 1400 30 C T3654 AD424
70.0 kW @ 2200 400.0 Nm @ 1400 32 C T3658 AD402
(1) 450.0 Nm @ 1400 39 C T3656 AD403
74.5 kW @ 2200
82.0 kW @ 2200 450.0 Nm @ 1400 26 C T3634 AD404
85.9 kW @ 2200 500.0 Nm @ 1400 34 C T3648 AD405
91.0 kW @ 2200 500.0 Nm @ 1400 27 C T3644 AD408
92.6 kW @ 2200 (1) 530.0 Nm @ 1400 32 C T3640 AD419
97.9 kW @ 2200 530.0 Nm @ 1400 25 C T3632 AD414
102.1 kW @ 2200 560.0 Nm @ 1400 26 C T3636 AD409
106.0 kW @ 2200 560.0 Nm @ 1400 22 C T3638 AD406
(1) 560.0 Nm @ 1400 17 C T3584 AD416
110.1 kW @ 2200
1. IOPU ratings.
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 165”
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 192
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***.

C4.4 ACERT TTAD
Turbocharged air to air cooled - balanced and non balanced
Max. rating Power
Torque Nm @ rpm Max. TBU % Rating Option code
kW (bhp) @ rpm curve
105.1 kW @ 2200 630.0 Nm @ 1400 38 C T3624 AD502
112.0 kW @ 2200 650.0 Nm @ 1400 34 C T3744 AD510
117.0 kW @ 2200 683.0 Nm @ 1400 35 C T3626 AD504
(1) 750.0 Nm @ 1400 33 C T3586 AD503
129.4 kW @ 2200
1. IOPU ratings.
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 165”
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 192
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***.

ECM
Description Option
ECM fuel cooled AM001
(1)
ECM air cooled AM002
ECM fuel cooled, high position AM003
1. Can only be used if the under bonnet temperatures are acceptable. Please refer to the Applications and Instal-
lation guide for details.
Note: Incompatibilities TBC.

AM001 - ECM fuel cooled
AM002 - ECM air cooled

AM003 - ECM fuel cooled

Adaptor plate
Description Option
Not required B0000
B0000 - Not required

Flywheel housings
Option only available upon approval by the Applications and Installations Department and is subject to
mandatory installation appraisal
Stressed cylinder block
Description Option
Not required, starter spigot on LHS of block C1000
C1000 - Not required, starter spigot on LHS of block
Non stressed cylinder block
Description Option
(1) (2)
Not required, customer to supply housing with LHS starter C0050
(1) (3)
Not required, customer to supply housing with RHS starter C0051
(3)
Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter with sealed inspection plate cover C0001
(3)
Cast iron SAE 3, 135,0 mm (5.32 in) deep, RHS starter with high mounting pads C0002
(3)
Adaptor plate for combine harvesters, RHS starter C0006
(2) (4)
Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter C0010
(2) (4)
Similar to C0010 but with increased access aperture C0011
(4)
Cast iron SAE 2, 156,4 mm (6.16 in) deep, LHS or RHS starter C0021
(3)
Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter as C0001 less torque convertor access hole C0022
(2) (4)
Cast iron SAE 3, 156,4 mm (6.16 in) deep, LHS starter less torque converter access hole C0023
(3)
Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter C0030
(3)
Cast iron SAE 3, 84,0 mm (3.31 in) deep, RHS starter as C0030 with different speed sensor tapping C0031
1. Not compatible with E0012.
2. Incompatible with E0100/E0200/E0205/E0311.
3. Incompatible with E0121/E0206/E0207/E0301.
4. Incompatible with QD042.
Flywheel housing design

11.25 22.5
22.5
45
16 HOLE 8 HOLE
SPACING SPACING
12 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
in the table below.
‘A’ diameter mm (in) Tapped holes

SAE ‘B’ diameter ‘C’ diameter
number Tolerance mm (in) mm (in)
Nominal size Quantity Size mm
-0.000 to
3 409,6 (16.125) +0,13 (+0.005) 450,9 (17.75) 428,6 (16.875) 12 10

‘A’ diameter mm (in) Tapped holes
SAE ‘B’ diameter ‘C’ diameter
number Tolerance mm (in) mm (in)
Nominal size Quantity Size mm
-0.000 to
2 447,7 (17.625) +0,13 (+0.005) 489,0 (19.25) 466,7 (18.375) 12 10
C0001 - Cast iron SAE 3, 156,4 mm (6.16 in) deep with sealed inspection plate cover
OPTION CODE MK_C0001 / 00
CONFIGURATIONS: 339-5413 / 01
Z 329-7880 / 01
238.1 238.1
X
171.5 218 1-M16 x 1.5 47.6 55.6
PLUGGED
z
BOTH SIDES
.3
41
45 VIEW ON ARROW B
PL 45
88.9
U GG 38.1
ED 4-M12 x 1.75
14
yx yx
BOTH SIDES
76.2
Y y x z
22
82
8.5
8.5
115
12-M10 x 1.5 x 20
145
22
A
DRILL PATTERN
FLANGE PATTERN
TO No.3 S.A.E.
6-M12 x 1.75
11
136 M10 x 1.5 x 20
B 0.025 156.4
160
11
88.925
62.5
180 X
9
4.8 8.455
62.5
Z SEALED INSPECTION
DEE 0 .0 2 HOLE COVER
11 P 5
2-M10 x 1.5
VIEW ON ARROW A

C0002 - Cast iron SAE 3, 135,0 mm (5.32 in) deep with high mounting pads
Z
238.1 238.1 CONFIGURATIONS: 329-7881 / 01
339-5414 / 01
171.5 218
41
X
-C- 47.6 55.6
B 1-M16 x 1.5
PLUGGED
PL
UG
VIEW ON ARROW B
38. D
GE
1
30
88.9
4-M12 x 1.75 x 24
BOTH SIDES
233
76.2
14
12-M10 x 1.5 x 20
Y DRILL PATTERN Y
FLANGE PATTERN
82
143.7
177.8
115
104.8 TO No. 3 S.A.E. A

145
3-M10 x 1.5
62.5 11
M10 x 1.5 x 20
6-M12 x 1.75 136
135
11
62.5
160
88.925 0.025 X
180
5 D 98.45
62.5
EE 5
Z P 0.0
2-M10 x 1.5 11 25
VIEW ON ARROW A
C0006 - Adaptor plate for combine harvesters

Z CONFIGURATIONS: 329-7882 / 00
210.9 218
154.5 X
50.8 2-M10 x 1.5 x 20 25
8- 11.2
212.7
56.4
154.5
0.0635
A
Y Y
74.7
409.5115
159.8
212.7
62.9 8.8
0.025
88.925
62.9
8.8
50.8
28.5
62.9
149 5 D 98.45
EE 5 X
P 0.0
205.3 3- 11.2 8.8 25
Z VIEW ON ARROW A

C0010 - Cast iron SAE 3, 135,0 mm (5.32 in) deep, LHS starter
1-M16 x 1.5
y xy x
PLUGGED CONFIGURATIONS: 329-7883 / 01
41
X Z
z
19.1 238.1 238.1
47.6 B
214.4
VIEW ON ARROW B
12-M10 x 1.5 x 20
DRILL PATTERN
FLANGE PATTERN
TO No.3 S.A.E. 30
88.9
1 D
2-M12 x 1.75 x 24 38. GGE
L U
BOTH SIDES P
233
39.7
Y z x Y
2-M12 x 1.75
41.3
BOTH SIDES
18
A
143.7
221
177.8
21.7 59.7
88.9
25
0.02
5 21.7 3-M10 x 1.5
PLUGGED
59.7
170.5
135
5
0.02 P
59.7
C
X 55 D EE
98.4 5
Z
21.7 3-M10 x 1.5
INSPECTION
VIEW ON ARROW A HOLE COVER VIEW ON ARROW C
C0011 - Similar to C0010 but with increased access aperture

Z X
238,1 238,1
1-M16 x 1.5 CONFIGURATIONS:135 329-7884 / 00
214,4 47,6 19,1
X
41
starter motor mounting Z

19.1 B 12-M10 X 1,5 X 20
drill pattern
238.1
FLANGE AND SPIGOT
238.1
47.6 VIEW ON ARROW B TO NO.3 S.A.E.
214.4
4-M12 X 1,75 X 24
BOTH SIDES B
30°
12-M10 x 1.5 x 20
DRILL PATTERN
30
88,9
FLANGE PATTERN
TO No.3 S.A.E.
A
88.9
39,7
3
23
233
2-M12 x 1.75 x 24
39.7
Y Y
Y BOTH SIDES Y
41,3
41.3
2-M12 x 1.75 104.8 104.8

143.7
BOTH SIDES
222,6
177.8
221
21,7 59,7
A 21.7 59.7
21,7
88.92
5
21.7
0.025 88,95
41
ø 88,90
59,7
59.7
M16 X 1,5
135
PLUGGED
X
X Z5 Z INSPECTION HOLE
59.7
0.02 P
59,7
5 E E 98,48 COVER
5 5D
98.4 ø 98,43 X 5 3-M10
DEEPx 1.5
3-M10 x 1.5
VIEW ON ARROW B
21.7
21,7 3-M10 X 1,5
3713K033 FLYWHEEL HOUSING

VIEW ON ARROW A View on arrow A

C0021 - Cast iron SAE 2, 156,4 mm (6.16 in) deep, LHS or RHS starter
Z CONFIGURATIONS: 329-7885 / 00
260.4 260.4
214.6 216.5 343-4356 / 00
X
B 63.5 48.4
12-M10 x 1.5 x 20
DRILL PATTERN
FLANGE PATTERN
TO No.2 S.A.E.
2-M12 x 1.75 x 24
BOTH SIDES
30
88.9
2-M12 x 1.75
BOTH SIDES
38.2
252
25.4
Y Y
1-M16 x 1.5
PLUGGED
38.1
104.8 104.8
143.7
A
41
177.8
241
3-M10 x 1.5
PLUGGED VIEW ON ARROW B
11
INSPECTION M10 x 1.5

HOLE COVER 62.5 5 5.5 63.3
0.02
25 M10 x 1.5 156.4
88.9
C 2- X
11
62.5
63.3
5.5
2-
Z 5 DE 98.455
62.5
EP
63.3
0.02
5
11 2-M10 x 1.5 x 20
VIEW ON ARROW C 5.5
2-M10 x 1.5 x 20 VIEW ON ARROW A
C0022 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, RHS starter
Z OPTION CODE MK_C0022 / 00
238.1 238.1 41.3
218
1-M16 x 1.5 X
PLUGGED 47.6 55.6
VIEW ON ARROW C
12-M10 x 1.5 x 20
88.9
45
45 DRILL PATTERN
FLANGE PATTERN
TO No.3 S.A.E.
76.2
Y Y
4-M12 x 1.75
22
BOTH SIDES
6.5
82
A
6.5
115
22
41.3
143.7
143.7
145
177.8
151.5
104.8 104.8 1-M16 x 1.5

PLUGGED
6-M12 x 1.75
C VIEW ON ARROW B
B
136 136 156.4
3-M10 x 1.5
62.5 11
PLUGGED
160 180 M10 x 1.5 x 20 X
Z 0.025
88.925
11
62.5
D
INSPECTION 98
4.8 D .455
62.5
HOLE COVER EEP 0.025

83.3
2-M10 x 1.5 11
VIEW ON ARROW D 2-M8 x 1.25 VIEW ON ARROW A

C0023 - Cast iron SAE 3, 156,4 mm (6.16 in) deep, LHS starter less torque converter access hole
X Z
103.2 238.1 238.1
55.6 214.4
2-M12 x 1,75 x 24
BOTH SIDES
2-M12 x 1,75 M10 x 1.5

88.9
BOTH SIDES
39.7
76.2
Y Y
115
A
145
21.7 59.7
21.7
136
59.7 59.7
4-M12 x 1.75
3-M12 x 1.75 160
12-M10 x 1.5 x 20
25
0.0 INSPECTION DRILL PATTERN
25 21.7 HOLE COVER FLANGE PATTERN
9
X 88. VIEW ON ARROW A
Z TO No. 3 S.A.E.
Z 339-5415 / 01
238.1 238.1 X
47.6
171.5 218 14.3
12-M10 x 1.5 x 20
DRILL PATTERN
FLANGE PATTERN
TO No. 3 S.A.E.
2-M12 x 1.75
88.9
BOTH SIDES
PL 38.1 45
UG
GE 2-M12 x 1,75 x 24
D
14
BOTH SIDES
76.2
Y z Y
A
82
115
143.7
145
104.8 104.8
177.8
8.5
22
6-M12 x 1.75 63.5
3-M10 x 1,5
B PLUGGED M10-1.5
63.5
136 84.1
0.025 X
160 98.455 5 DEEP
63.5
25
0.0
41.3
180
5
.92 2-M10 x 1,5 x 24.5
Z 1-M16 x 1.5 88
PLUGGED
VIEW ON ARROW A
VIEW ON ARROW B

Z
238.1 238.1 X
47.6
171.5 218 14.3
12-M10 x 1.5 x 20
DRILL PATTERN
FLANGE PATTERN
TO No. 3 S.A.E.
88.9
2-M12 x 1.75
PL 38.1 BOTH SIDES
UG 45
GE
14
D 2-M12 x 1,75 x 24
76.2
BOTH SIDES
Y Y
82
115
A
145
8.5
143.7
177.8
22
6-M12 x 1.75
3-M10 x 1,5 62.5 11

B PLUGGED 88.9
25
104.8 104.8 0.02
M10-1.5 5 84.1
62.5
136 X
160
41.3
62.5
1-M16 x 1.5 25
11
180 PLUGGED 0.0 EP
E
y
455 5D
Z 98. 11
2-M10 x 1,5 x 24.5
z
VIEW ON ARROW A
VIEW ON ARROW B

Flywheels
Non-stressed cylinder block
Description Option
Not required D0000
For Centaflex couplings D0003
For SAE, Borg and Beck, twin disc clutches without pilot bearing housing D0004
As D0004 but with pilot bearing housing D0005
For Clark 18000 torque converters D0008
For Borg Warner torque converters D0014
For Allison AT545 transmission D0030
For SAE transmissions D0044
For Spicer transmissions D0045
For hydrostatic transmissions D0046
For various transmissions D0053
For customer transmissions D0064
For ZF115 transmissions D0070
For use with ZFWG9 transmissions D0092
Stressed cylinder block

Description Option
(1)
(1)
(1)
(1)
(1)
For Borg Warner torque converters D0114
1. 115 tooth starter ring fitted.
Notes:
The masses and inertias shown on the drawings are for the flywheel only. Mass and inertia is shown as per
option drawing
All the flywheels listed above are fitted with 126 tooth starter ring, except where indicated.

D0000 - Crankshaft palm
X X2
22,2
20,6
1,02 Max Z
10 bolt fixing 30°
46,99
46,96
Ø 38,1
30°
Ø 22,2
30°
133,32
133,27
Ø 76,2
Y Y
30°
Ø
30°
35,92 0,8 x 60° Incl
34,48
Ø 11,5 X 25,4
28,6 Z
10 holes ½ - 20 UNF X 19 on 107,95 P.C.Ø.

55,6 Crankshaft palm
X X2
Crankshaft to flywheel fixing
D0003 - For Centaflex couplings

OPTION CODE MK_D0003 / 00
CONFIGURATION 3297895
X Z
54.3
6-M12 X 1.75 X 24 A 6-M16 X 2 X 32
32.8 ON 165.1 P.C.D. 15 ON 165.1 P.C.D.
45
50.8
15
136.04
136.00
387.4
260.4
336.6
15
Y Y
63
81.6 A
X Z
Mass 33.4 kg
2 2
SECTION A-A Inertia mk 0.70 kg m
2 2
GD 2.80 kg m

D0004 - For SAE, Borg and Beck, twin disc
Z 117 X
8-3/8 - 24 UNF X 25.4 80.4
A EQUISPACED ON
333.4 P.C.D. 67.7
8-3/8 - 24 UNF X 25.4 32.8
EQUISPACED ON
295.3 P.C.D.
79.356
79.413
352.425
352.552
314.325
314.401
219.037
219.139
276
390
225
164
Y Y
54.2
70.9
8-M8 X 1.25 X 14.3 A 102.7
EQUISPACED ON
203.2 P.C.D. 120.2
Z X
SECTION A-A
Mass 49.1 kg
2 2
Inertia mk 1.20 kg m
2 2
GD 4.80 kg m
D0005 - As D0004 but with pilot bearing housing

86.7
Z X
70.9
A
8-3/8 - 24 UNF X 25.4 56.5
8-3/8 - 24 UNF X 25.4 EQUISPACED ON
EQUISPACED ON 54.2
295.3 P.C.D.
333.4 P.C.D. 32.8
71.984
71.958
352.425
352.552
219.037
219.139
314.325
z
314.401
276
390
225
164
Y
x
Y
67.7
8-M8 X 1.25 X 14.3 80.4
EQUISPACED ON 102.7
203.2 P.C.D. A
117
Z 120.2 X
Mass 49.8 kg
2 2
2 2
GD 4.80 kg m

D0008 - For Clark 18000 torque converters (non stressed)
Z X
51.2
A 8- 11 C/BORED 26 X 4.8
EQUISPACED ON 32.8
342.9 P.C.D.
51.986
51.967
384
305
Y Y
68.7
Z X
SECTION A-A Mass 21.2 kg
2 2
2 2
GD 1.96 kg m
D0014 - For Borg Warner torque converters (non stressed)

Z X
62.6
54.2
A 6-5/16 - 18 UNC X 19
EQUISPACED ON 32.8
319.1 P.C.D.
19.088
19.063
38
266.6
384
303
Y Y
69.06
68.80
A
Z X
SECTION A-A
Mass 24.6 kg
2 2
2 2
GD 2.16 kg m

D0030 - For Allison AT545 transmission
Z 85.9 X
6- 10.9
EQUISPACED ON 73.5
A 375 P.C.D.
55.2
73.137
73.155
43.29
43.35
40
10
400
383
Y Y
32.8
6- 32 45.7
A
EQUISPACED ON
298.4 P.C.D. 74.2
95.4
Z X

2 2
2 2
GD 1.52 kg m
D0044 - For SAE transmissions

Z X 117
80.4
67.7
A 32.7
352.425
352.552
314.4
219.1
276
390
225
164
79
Y Y
54.2
A
70.9
102.7
120.2
Z X
SECTION A-A
Mass 49.5 kg
2 2
2 2
GD 4.80 kg m

D0045 - For Spicer transmissions
X Z
64 8-M8 X 1.25 X 16
EQUISPACED ON
55.6 61.8 360 P.C.D. A
43.3
266.7
343
384
Y Y
32.8
71.19 A
69.49
X Z
Mass 24.8 kg
2 2
2 2
GD 2.16 kg m
D0046 - For hydrostatic transmission

X Z
89.2
81.2
67.2 8-3/8 - 24 UNF X 25 A
54.2 EQUISPACED ON
295.3 P.C.D.
314.325
314.401
390
225
165
319
80
Y Y
32.8
117.2
A
X Z
Mass 45.7 kg
2 2
SECTION A-A GD
2
4.44 kg m
2

D0053 - For various transmissions
X Z
120.2
80.4
67.7 6-M10 X 1.5 X 20 A
54.2 EQUISPACED ON
244.5 P.C.D.
357.089
357.000
263.50
263.45
314.4
219.1
276
390
225
164
79
Y Y
32.8
71.9 8-M10 X 1.5 X 20
102.7 EQUISPACED ON A
333.4 P.C.D.
117
X Z

2 2
2 2
GD 4.72 kg m
D0056 - For various transmissions stressed cylinder block

OPTION CODE MK_D0056
MK_D0056 // 01
01
X X2 Z
28.6
14.9
A 6-M12 X 1.75 X 30
13 EQUISPACED ON
6.6 330.2 P.C.D.
39.988
39.967
30
354.49
354.23
290
364
Y Y
25.6
49.6 A
53.6
X X2 Z
SECTION A-A
Mass 31.2 kg
2 2
2 2
GD 2.60 kg m

D0063 - For customer transmission stressed cylinder block
X X2 Z
A
6-M8 X 1.25 X 19 15
14.9 EQUISPACED ON
342 P.C.D.
363
150
Y Y
62
30.01
30.06
4- 24 X 12
24.3 EQUISPACED ON
254 P.C.D.
25.2
A
28.6
X X2 Z
Mass 23.7 kg
2 2
2 2
GD 1.80 kg m
D0064 - For customer transmission

X
Z
66.2
49.2
6-M10 X 1.5 X 20
32.8 A EQUISPACED ON
177.5 P.C.D.
50.8
197.00
197.05
160
260
387
336
Y Y
63
A
71.7
X
Z
Mass 28.3 kg
2 2
2 2
GD 2.48 kg m

X X2 Z
28.6
25.6 A
14.9
370.2
370.0
165
330
381
Y Y
55
47
40
31.6
12-M8 X 1.25 X 25
46.6 A EQUISPACED ON
345 P.C.D.
49.6
X X2 Z
SECTION A-A
Mass 38.4 kg
2 2
2 2
GD 3.00 kg m

X X2 Z
34
A
19.6
52.0
52.3
303
362
65
Y Y
14.9
4-5/16 - 16 UNC X 22
16.4 A
EQUISPACED ON
28.6 333.4 P.C.D.
X X2 Z
SECTION A-A
Mass 24.4 kg
2 2
2 2
GD 2.04 kg m

D0070 - For ZF115 transmission
X Z
86.4
72.9
A 4- 11
32.8 45 EQUISPACED ON
333.4 P.C.D.
40.000
40.039
65
275
210
Y 386 Y
4- 30 X 15
EQUISPACED ON
94.7 A
316 P.C.D.
X Z
SECTION A-A
Mass 44.3 kg
2 2
2 2
GD 3.48 kg m
D0092 - For ZFWG9 transmission

X Z
73.3
54.2 8-M10 X 1.5 X 25
EQUISPACED ON
32.8 A 350 P.C.D.
55
45
30
31
306.6
276
384
Y Y
69.4
A
78.3
X Z
SECTION A-A
Mass 26.4 kg
2 2
2 2
GD 2.36 kg m

D0114 - For Borg Warner torque converters (stressed cylinder block)
X X2 Z
34
27.6
19.6 6- 6.7 X 27
5/16-18 UNC X 22
14.9 A
EQUISPACED ON
319.1 P.C.D.
38
19.1
266.4
352.4
303
Y Y
35.4 A
28.6
X X2 Z
SECTION A-A
Mass 24.0 kg
2 2
2 2
GD 1.92 kg m

Starter motors
Description Option
Not required E0000
Studs only for LHS starter E0012
Studs only for RHS starter E0013
(1)
12V, 4.0 kW, RHS, suitable for dry back end only E0100
(2)
12V, 4.0 kW, LHS, suitable for dry back end only E0121
12V, 4.0 kW, Ag block only, high solenoid, suitable for dry back end only, for use with AM003 (high ECM) E0141
12V, 4.0 kW, RHS, suitable for wet back end only E0161
(1)
(1)
(2)
(2)
(2) (3)
(1) (3)
1. Incompatible with C0010/C0011.
2. Incompatible with LHS Horizontal oil filter J0060.
3. For customer engine applications down to a minimum of -10°C and to suit bare engine applications e.g, IOPU
and Genset. Recommendation to conduct cold chamber testing and optimization to obtain "rotating electrics"
team sign off at this temperature.
E0012 - Studs only for LHS starter
Not available at time of print

E0013 - Studs only for RHS starter
E0100 - 12V, 4.0 kW, RHS, suitable for dry back end only
OPTION CODE MK_E0100 /2
BATTERY TERMINAL
M10 X 1.5
243.1 77.9
32
90
178.3 76
61
98
80.1
95
29.5
234.1 MAX 29.9

90
4.2
264 MAX
8
3- 10.9 ON EARTH TERMINAL PINION

127 P.C.D. M10 X 1.5 NO. OF TEETH 10
D.P. 8/10
PRESSURE ANGLE 20
P.C.D. 31.75

E0121 - 12V, 4.0 kW, LHS, suitable for dry back end only
OPTION CODE MK_E0121 / 00
BATTERY TERMINAL
M10 X 1.5
90 77.9 264 MAX
28
76 178.3 MAX
61
100.6
83.4
11.2
90
29.9 243.1 27.8

20
PINION
NO. OF TEETH 10
D.P. 8/10 EARTH TERMINAL
3- 10.9 ON PRESSURE ANGLE 20 M10 X1.5
127 P.C.D. P.C. D. 31.75
E0141 - 12V, 4.0 kW, Ag block only, suitable for dry back end only, for use with AM003 (high ECM)
BATTERY TERMINAL
M10 X 1.5
77.9 264 MAX 49

90
76 178.3 MAX
83
61
62
95
90
234 MAX
30
29.9 243.1
5
PINION
NO. OF TEETH 10
D.P. 8/10
3- 10.9 0N PRESSURE ANGLE 20 EARTH TERMINAL
127 P.C.D P.C.D. 31.75 M10 X 1.5

BATTERY TERMINAL 294.1

M10 X 1.5
242.2 MAX
42
90
204.4
61
89
70.2
95
29.5
285.1 MAX 33.5
90
5.2 315 MAX
8
3- 11.8 ON EARTH TERMINAL PINION
127 P.C.D. M10 X 1.5 NO. OF TEETH 10
D.P. 8/10
PRESSURE ANGLE 20
P.C.D. 31.75
BATTERY TERMINAL
M10 X 1.5
264 MAX 77.9
32
90
178.3 MAX 76
98
80
95
96
29.7
90
234.1 MAX
4.2 243.1 29.9

8
EARTH TERMINAL
3- 10.9 ON M10 X 1.5 PINION
127 P.C.D. NO. OF TEETH 10
D.P. 8/10
PRESSURE ANGLE 20
P.C.D. 31.75

BATTERY TERMINAL
M10 X 1.5
90 77.8 264 MAX
76 178.3 MAX
28
61
101
11.2
83.4
95
90
234.1
27.8
29.9 243.1
EARTH TERMINAL 3- 10.9 ON

20
PINION M10 X 1.5 127 P.C.D.

NO. OF TEETH 10
D.P. 8/10
PRESSURE ANGLE 20
P.C.D. 31.75
BATTERY TERMINAL
M10 X 1.5
315 MAX 25
90
29.5 242.2 MAX
61
103
85.6
90
30
285.1 MAX
33.5 294.1
20
PINION
NO. OF TEETH 10
3- 11.7 ON D.P. 8/10
EARTH TERMINAL
127 P.C.D. PRESSURE ANGLE 20
M10 X 1.5
P.C.D. 31.75

BATTERY TERMINAL
M10 X 1.5
74.7 225.2 MAX

90
72.8 167.1 MAX
40
61
91.6
72.4
90
90
10.1
29.4 200.4 MAX 23.1
20
202.7
PINION EARTH TERMINAL

3-
127 P.C.D.
NO. OF TEETH 10 M10 X 1.5

10.9
D.P. 8/10
PRESSURE ANGLE 20
ON
P.C.D. 31.75
BATTERY TERMINAL
M10 X 1.5 225.2 MAX 74.7
32 167.1 MAX 72.8
90
98.1
80.1
61
90
17.7
90
200.4 MAX 29
3- 10.9 ON 48.4
202.7
8
127 P.C.D.
PINION
NO. OF TEETH 10
D.P. 8/10
EARTH TERMINAL PRESSURE ANGLE 20
M10 X 1.5 P.C.D. 31.75

Fan drive
Standard duty multi-vee belt
Drive
Description Option
ratio
N/A Fan drive not required only available with N0000 F0000
N/A No fan drive supplied. Additional pulley and bracket supplied to complete drive F1000
Fan centre 262mm (10.31 in) no pulley or belts F0501
N/A Fan centre 356mm (14.02 in) no pulley or belts F0503
(1)
Fan centre 310 mm (12.20 in) pulley dia. 200 mm F0177
0.85:1 (1)
(2)
1.00:1 (2)
(1) (3)
1.02:1 (1)
(1)
(1)
1.13:1 (1)
(1)
(2) (3)
(2)
1.20:1 (2)
(2)
(2)
(2)
1.33:1 (2)
(2)
(1)
(1)
1.36:1 Fan centre 285 mm (11.22 in) pulley dia. 125 mm F0192
(1)
1. For use with 170 mm crankshaft pulley K0030/K0130.
2. For use with 200 mm crankshaft pulley K0020,/K0120.
3. Not available with FD000 or FD001.
F0000 - Fan drive not required

F0133 - Fan centre 356 mm (14.02 in) pulley dia. 200 mm
FAN OPTION CODE MK_F013X / 01
OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0133 356
1:1
F0137 310
REFER TO 'MD' OPTIONS FOR
Z FAN EXTENSION DIMENSIONS X X2
200 15.2 68.5 605 28.6
EFFECTIVE TO FIRST GROOVE
HOUSING SHOWN MAY
41
FAN HEIGHT NOT BE THAT SPECIFIED
4 - M8 x 1.25
EQUISPACED
ON 63.5 P.C.D. TO SUIT 8 RIB
MULTI-V DRIVE BELT
Y Y
Z X X2
NOTE: OPTION CODES WITH FAN HEIGHTS OVER 333 mm
INCLUDE IDLER PULLEY- SEE SEPARATE DRAWING

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0133 356
1:1
F0137 310
200 15.2 68.5 605 28.6
HOUSING SHOWN MAY

41
NOT BE THAT SPECIFIED

FAN HEIGHT
4 - M8 x 1.25
EQUISPACED
ON 63.5 P.C.D. TO SUIT 8 RIB
MULTI-V DRIVE BELT
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0141 262
F0142 285
1.2 : 1
F0143 356
F0147 310
167 15.2 68.5 605 28.6
41 HOUSING SHOWN MAY

FAN HEIGHT
TO SUIT 8 RIB
4 - M8 x 1.25 MULTI-V DRIVE BELT
EQUISPACED
ON 63.5 P.C.D.
Y Y

Z INCLUDE IDLER PULLEY- SEE SEPARATE DRAWING
X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0141 262
F0142 285
1.2 : 1
F0143 356
F0147 310
167 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY

FAN HEIGHT
TO SUIT 8 RIB
EQUISPACED
ON 63.5 P.C.D.
Y Y

Z INCLUDE IDLER PULLEY- SEE SEPARATE DRAWING X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0141 262
F0142 285
1.2 : 1
F0143 356
F0147 310
167 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY
FAN HEIGHT
TO SUIT 8 RIB
EQUISPACED
ON 63.5 P.C.D.
Y Y

Z INCLUDE IDLER PULLEY- SEE SEPARATE DRAWING
X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0141 262
F0142 285
1.2 : 1
F0143 356
F0147 310
167 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY

FAN HEIGHT
TO SUIT 8 RIB
EQUISPACED
ON 63.5 P.C.D.
Y Y

Z INCLUDE IDLER PULLEY- SEE SEPARATE DRAWING X X2

OPTION CODE MK_F01XX / 01
Z X X2
28.6
65
200
637.5
75
Y Y
Z X X2
NOTE: IDLER PULLEY FOR OPTION CODES

WITH FAN HEIGHTS OVER 333 mm

Z X X2
28.6
65
200
637.5
75
Y Y
Z X X2


Z X X2
28.6
65
200
637.5
75
Y Y
Z X X2


Z X X2
28.6
65
200
637.5
75
Y Y
Z X X2


FAN OPTION CODE MK_F0162 / 01
OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0161 262
1.02 : 1
F0162 285

Z FAN EXTENSION DIMENSIONS
X X2
167 15.2 68.5 605 28.6
41
FAN HEIGHT
4 - M8 x 1.25 TO SUIT 8 RIB

EQUISPACED MULTI-V PULLEY
ON 63.5 P.C.D.
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0161 262
1.02 : 1
F0162 285

X X2
167 15.2 68.5 605 28.6
41
FAN HEIGHT

ON 63.5 P.C.D.
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0173 356
0.85 : 1
F0177 310
Z REFER TO 'MD' OPTIONS FOR X X2

FAN EXTENSION DIMENSIONS
200 15.2 68.5 605 28.6
HOUSING SHOWN MAY
41
FAN HEIGHT
TO SUIT 8 RIB
MULTI-V PULLEY
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0173 356
0.85 : 1
F0177 310
Z REFER TO 'MD' OPTIONS FOR X X2

200 15.2 68.5 605 28.6
HOUSING SHOWN MAY

41

FAN HEIGHT
TO SUIT 8 RIB
MULTI-V PULLEY
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0181 262
F0182 285
1.13 : 1
F0183 356
F0187 310
Z X X2
150 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY
FAN HEIGHT

ON 63.5 P.C.D.
Y Y
Z NOTE: OPTION CODES WITH FAN HEIGHTS OVER 333 mm X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0181 262
F0182 285
1.13 : 1
F0183 356
F0187 310
Z X X2
150 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY

FAN HEIGHT

ON 63.5 P.C.D.
Y Y

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0181 262
F0182 285
1.13 : 1
F0183 356
F0187 310
Z X X2
150 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY
FAN HEIGHT

ON 63.5 P.C.D.
Y Y

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0181 262
F0182 285
1.13 : 1
F0183 356
F0187 310
Z X X2
150 15.2 68.5 605 28.6
41
HOUSING SHOWN MAY

FAN HEIGHT

ON 63.5 P.C.D.
Y Y

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0191 262
F0192 1.36 : 1 285
F0197 310

X X2
125 15.2 68.5 605 28.6
41
4 - M8 X 1.25 TO SUIT 8 RIB

FAN HEIGHT

ON 63.5 P.C.D.
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0191 262
F0192 1.36 : 1 285
F0197 310

X X2
125 15.2 68.5 605 28.6
41

FAN HEIGHT

ON 63.5 P.C.D.
Y Y
Z X X2

OPTION PULLEY
HEIGHT
CODE RATIO
mm
F0191 262
F0192 1.36 : 1 285
F0197 310

X X2
125 15.2 68.5 605 28.6
41

FAN HEIGHT

ON 63.5 P.C.D.
Y Y
Z X X2
F0501 - Fan centre 262 mm (10.31 in) no pulley or belts

OPTION CODE MK_F0501 / 01
Z X X2
19.7 669 28.6
41
FAN HEIGHT
4 - M8 x 1.25
262
EQUISPACED
ON 63.5 P.C.D.
Y Y
Z X X2

Z X X2
19.7 669 28.6
41
FAN HEIGHT
285
Y Y
Z X X2

Z X X2
19.7 669 28.6
4 - M8 x 1.25
EQUISPACED
ON 63.5 P.C.D.
41
65
200
Y Y
75 32 601.4
Z X X2

Z X X2
19.7 669 28.6
4 - M8 x 1.25
EQUISPACED
41
ON 63.5 P.C.D.
FAN HEIGHT
65
395
200
Y 75 32 601.4
Y
Z X X2

Z X X2
19.7 669 28.6

4 - M8 x 1.25
EQUISPACED
ON 63.5 P.C.D.
41
FAN HEIGHT
310
Y Y
Z X X2

F1000 - No fan drive supplied. Additional pulley and bracket supplied to complete drive
ALTERNATIVE POSITION
FOR IDLER PULLEY
Z (NON A.C. ARRANGEMENTS) X
25 605
TO FIRST GROOVE
80
314
225
25
Y Y
Z PULLEY TO SUIT X
8 RIB MULTI-V
DRIVE BELTS

Belt tensioner
Description Option
No belt auto - tensioner required FD000
(1) (2)
Belt auto - tensioner required, for belt systems without a low RHS A/C compressor FD001
Belt auto - tensioner required, for belt systems with a low RHS A/C compressor FD002
1. For use with P0000, P0001, P0003.
2. Not available with F0141, F0161.
FD000 - No belt auto - tensioner required

FD001 - Belt auto - tensioner required, for belt systems without a low RHS A/C compressor
OPTION CODE MK_FD001 / 03
Z X X2
635
TO SUIT MULTI-V 28.6
DRIVE BELT
ALTERNATOR 237 605 TO FIRST GROOVE
EFFECTIVE
PULLEY
60
125 TYP
316
208 TYP
219
214 666
Y Y
Z X X2

FD002 - Belt auto - tensioner required, for belt systems with a low RHS A/C compressor
OPTION CODE MK_FD002 / 02
ALTERNATOR Z TO SUIT 8 RIB

X X2
PULLEY 237 MULTI-V 635 28.6
DRIVE BELT
EFFECTIVE
140 TYP 605 TO FIRST GROOVE
60
316
219
167 TYP
Y Y
214 666
Z X X2

Lubricating oil sump
Non stressed cylinder block
Description Option
Steel, flat bottomed sump (LHS dipstick only) available with GD000/GD001/GD002/GD004 G0100
Steel, flat bottomed sump (RHS dipstick only) available with GD003 G0200
(1)
Cast iron, flat bottomed sump available with GD001/GD002/GD003/GD004 G0300
Aluminium, shallow rear well sump available with GD000/GD001/GD002/GD003/GD004/GD006 G0600
Aluminium, shallow rear well sump with oil filler pad RHS available with GD003 G0800
Aluminium, high gradeability available with GD001/GD002/GD004/GD006 G1100
1. Not compatible with C0070.
Note: TTAD Ratings AD5** and turbo S7*** require 10 litres.

G0100 - Steel, flat bottomed sump (LHS dipstick only)
OPTION CODE MK_G0100 / 00
X X2 Z
320.1 28.6 351.3
GD002
305.3
233.4
584
220.5
LUB OIL DRAIN
ZG OPTIONS GD004
78.9
70.1
GD001
Y Y
136.9
GD004
156.4
L.H.S.
234.3
GD001
24.3 L.H.S.
145.2 113.3 115.9

220.6 (BOTH SIDES)
533.4
571.6
X X2 Z

G0200 - Steel, flat bottomed sump (RHS dipstick only)
X X2 Z
308.5 28.6
220.5
70.1
GD003
z
Y Y
136.9
234.3
GD003
24.3 R.H.S.
145.1
113.3 115.9
220.5 (BOTH SIDES)
533.3
LUB OIL DRAIN
ZG OPTIONS
571.5
X X2 Z
G0300 - Cast iron, flat bottomed sump

X X2 Z
308.7 28.6 305.3
233.6 220.5 210

GD003
GD004 GD003
77.8
72.2
R.H.S.
69
Y GD001 0.1 Y
GD004
143.7
177.8
L.H.S.
247.7
265.7
GD001
L.H.S.
3- 11.2
67.6 104.9 104.7
321.3 (BOTH SIDES) 114.8 115.3
386.1
LUB OIL DRAIN
476.9 ZG OPTIONS
550.4 Y Y
ADTM3 GD004
GD003
L.H.S.
171.5
571.5 R.H.S.
GD001
L.H.S.
95.1 95.4
124.4 121.2
X X2 Z
FRONT VIEW

G0600 - Aluminium, shallow rear well sump
X X2
356.9 Z
351.3
320.1 28.6
GD002
GD002
308.4
315.4 220.5
233.5
582.2
GD006
GD006
344.2
GD001
68.1
GD003 GD004 L.H.S.
GD001
Y Y
68.3
77.1
162.4
23.8
223.2
240.2
GD003
R.H.S.
GD004
L.H.S.
114.9 (BOTH SIDES) 121.6 121.3

283.2 220.5
LUB OIL DRAIN
566.9 ZG OPTIONS 305.3
X X2
Z
G0800 - Aluminium, shallow rear well sump with oil filler pad RHS
X X2 Z
354.4 28.6 351.3 219.9
319.8 315.4
308.1 220.5
GD002
233
GD002
582.2
GD006 GD006
GD001 GD004
338.4
68.7
GD003
DTM53
Y Y
76.5
68.8
161.8
GD003
223.2
240.2
R.H.S.
7.02
GD004
LUB OIL DRAIN L.H.S.
ZG OPTIONS 23.4
121.7
114.92 (BOTH SIDES) GD001
L.H.S. 305.4 121.7
283.9
566.9
574.7
X X2 Z

G1100 - Aluminium, high gradeability
X X2 Z
354 28.6 315.6
233.2 306.4
221.6
GD006
GD006
GD004 GD004
338.1
L.H.S. GD001
GD001 L.H.S.
Y Y
67.6
76.5
197.4
224.2
462.18
320.9
28.3
162.7
174.2 117.4 117.4
221.45 (TO R.H.S. DRAIN PLUG) 130 139.1
462.2
508.3
513.5
569.2
575.5
X X2 Z

Stressed sump
Description Option
Cast Iron, deep flat bottom sump G2000
Cast Iron, shallow tunnel sump G2100
Cast Iron, deep tunnel sump G2300
(1) (2) (3)
High oil capacity 11.5 litres plus G2500
1. Only available with E0000/E0012.
2. No flywheel housings developed to suit this sump.
3. Please contact Programme Management if you require this option.
G2000 - Cast Iron, deep flat bottom sump

Z X X2 Z
308.6 28.6 6- 13.5

101.9 424
233.5 GD001
339.3 GD004
L.H.S. L.H.S.
GD003 GD004
R.H.S. GD004
GD003 L.H.S. GD003
68.3
77.1
68.3
GD001
R.H.S.
111.1
Y
150
171.5
190.5
GD001
222.4
214.3
255
243.7
230.4
253.2
265.3
L.H.S.
95.3 2-M16 X 2 X 32 LUB OIL DRAIN

ZG OPTIONS
95.3 65.1
220.6 (BOTH SIDES)
111.8 135.7
408.1
135.1 168.3
507.5
136.6
536.8
162.6
568.3
162.6
Z X X2 Z

G2100 - Cast Iron, shallow tunnel sump
Z X X2 Z
279.6 246.1 313.4 28.6

146.9 GD001
237.8 GD003
GD004 L.H.S.
L.H.S. R.H.S.
GD003 GD004
R.H.S. GD004
GD003 L.H.S.
74.1
GD001
78.1
69.2
111.1
Y Y
GD001
150
171.5
190.5
212.7
228.7
228.3
L.H.S.
243.7
240
253.7
264.3
2-M16
95.3 X 2 X 32 6- 13.5
LUB OIL DRAIN
95.3 ZG OPTIONS 65.1
220.6 (BOTH SIDES) 135.7
108.9
408.1 168.3
131.9
508.7
133.2
535.8
161.9 161.9
568.3
Z X X2 Z
G2300 - Cast Iron, deep tunnel sump

Z X X2 Z
248.24
GD004
163.5 L.H.S. GD001
239.3 28.6 L.H.S.
GD004
GD001 GD004
79.3
70
L.H.S.
111.1
Y Y
150
171.5
190.5
213.7
227.3
231.5
253.5
266.6
287.2
GD001
L.H.S.
4-M16 X 2 X 32 LUB OIL DRAIN

ZG OPTIONS 6- 13.5
95.3 220.6 (BOTH SIDES) 65.1

95.3 449.4 135.7
131.1 546.8 168.3
131.1 571.3
161.9 161.9
Z X X2 Z

G2500 - High oil capacity 11.5 litres plus

Lubricating oil dipstick
Description Option
No dipstick GD000
Short LHS GD001
Long LHS, centre top GD002
Short RHS GD003
Medium, LHS GD004
Long LHS available with G0600 and G1100 GD006
Medium, RHS GD007
Note: For all GD options refer to sump drawings for detail.

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
The table below shows the oil capacity of each sump and the angle at continuous operation permitted in all
directions. Gradient figures are measured from the horizontal position.
Oil change period of low capacity sumps under review.
Sump capacities Max/min
Gradient
Option code Litres UK pints US quarts
limitation (1)
Maximum Minimum Maximum Minimum Maximum Minimum
G0100 25 7.0 5.6 12.3 9.9 7.4 5.9
G0200 25 7.0 5.6 12.3 9.9 7.4 5.9
G0300 30 8.3 6.8 14.6 12.0 8.8 7.2
(2) (3) 25 8.0 6.8 14.1 12.0 8.4 7.2
G0300
G0600 30 7.7 6.2 13.6 10.9 8.1 6.5
G0800 30 7.7 6.2 13.6 10.9 8.1 6.5
G1100 40 10.5 8.5 18.5 15.0 11.1 9.0
G1100 (2) (3) tbc 8.6 7.0 15.1 12.3 9.1 7.4
G2000 (2) (3) 35 8.0 7.0 14.1 12.3 8.4 7.4
G2100 (2) (3) 25 6.3 5.0 11.1 8.8 6.7 5.3
G2300 (2) (3) 25 8.0 7.0 14.1 12.3 8.4 7.4
G2500 (2) (3) 25 10.0 7.0 17.6 12.3 10.6 7.4

1. Based on minimum oil level.
2. Balancer fitted.
3. Based on Tier 3 balancer, the tier 4 balancer is likely to reduce oil volumes further - yet tbc.
Note:
Note: For the total oil capacity of the engine, add 1.1 litres, (1.9 UK pints), 1.2 US quarts to the figures in the
above table.

Breather
Description Option
Open breather, filtered H0300
Open breather, filtered, no hose H0320
H0300 - Open breather, filtered

OPTION CODE MK_H0300 / 02
Z X X2
310.5
243.5
REMOVAL
205
411
134
28.6
570.5
588
Y Y
Z X X2

H0320 - Open breather, filtered, no hose
OPTION CODE MK_H0320 / 01
TO SUIT NORMAQUICK V2 NW19 CONNECTOR 363-7651 / 00
Z 490.5 X X2
310.5
243.5
REMOVAL
411
205
134
28.6
25
570.5
533.6
588
OR
ORI ONNE SLOT
ENT CT
E
FEA TION
TUR
C .6
A
12
Y Y
X X2

Top cover oil filler
Description Option
No filler HC000
Top cover filler, rear HC002
Top cover filler, front HC004
HC000 - No filler
OPTION CODE MK_HC000 / 01
Z X X2
525.5
30 REMOVAL
256.8 28.6
123 70.8
21
580.3
540
Y Y
Z X X2

HC002 - Top cover filler, rear
Z X X2
525.5
256.8
123
17 REMOVAL
105 28.6
30 REMOVAL
45
OIL FILLER 21
70.8 73
580.3
563.5
540
Y Y
Z X X2
HC004 - Top cover filler, front

Z X X2
525.5
443
123
17 REMOVAL
256.8 28.6 30 REMOVAL

60 21
OIL FILLER
70.8 73
580.3
563.5
540
Y Z Y
X X2

Lubricating oil filler
Description Option
Not required HD000
Timing case filler, LHS short filler forward facing HD001
Timing case filler, LHS long HD002
Timing case filler, LHS rear facing Q1100, Q30** only HD004
Timing case filler, remote rear face, rearward facing (1) Q1100, Q30** only HD005
Sump filler, RHS G0800 only HD006
Timing case filler, remote side face, rearward facing HD007
Timing case filler, LHS, Mid mounted, extended HD011

1. Please contact programme management if you require this option.
HD000 - Not required

HD001 - Timing case filler, LHS short filler forward facing
OPTION CODE MK_HD001 / 00
X X2 Z
34.4 577.3 28.6 366.2

47.9
69
17
RE
MO
VA
L
331.7
305.4
390.4
Y Y
606.8
X X2 Z

HD002 - Timing case filler, LHS long
X2
Z
592.5 28.6 297
69
17 REMOVAL
494.1
Y X2
Z
HD004 - Timing case filler, LHS rear facing, Q1100, Q30** only
X X2 Z
423.3 28.6 246.6

61
64.1
17
RE
69
MO
VA
L
137.6
106.9
Y Y
272.8
X X2 Z

HD005 - Timing case filler, remote rear face, rearward facing, Q1100, Q30** only
X X2
Z
45 458.4 28.6 180

Ø 27
70
Y
X X2
Z
HD006 - Sump filler, RHS, G0800 only

HD007 - Timing case filler, remote side face, rearward facing
X X2 Z
50 470 28.6 305
27
250.9
Y Y
X X2 Z
HD011 - Timing case filler, LHS, mid mounted, extended

X X2
Z
560 28.6 48 402.9
17
R EM
69
OV
AL
360.7
336.8
422.4
Y
X X2
Z

Lubricating oil filter head
Oil filters
Description Option
Vertically down, LHS J0050
(1)
Horizontal filter, LHS J0060
Vertically down filter head, RHS J0070
(2)
Adaptor LHS for remote oil filter (customer to supply) J0130
1. Incompatible with E0301/E0121.
2. Cat Applications and Engineering approval required prior to selection.
J0050 - Vertically down, LHS

OPTION CODE MK_J0050 / 00
X X2 Z
365.4 28.6 221.9

OIL SAMPLING VALVE
TAPPING-PLUGGED 199.9
M10 X 1
Y Y
8
210.8 MAX
94
20 REMOVAL
X X2 Z

J0060 - Horizontal filter, LHS
Z X X2
OIl SAMPLING VALVE

TAPPING-PLUGGED
M10 X 1
222.5
25
Y Y
60
95
94
210.4 20 REMOVAL
224.4 136.7 MIN

PRESSURE SENSOR
TAPPING-PLUGGED 375 28.6
M12 X 1.5
Z X X2
J0070 - Vertically down filter head, RHS

J0130 - Adaptor LHS for remote oil filter (customer to supply)
X X2
Z
INLET STOR PORT

SAE J1926-1: 1-5/16-12
378 28.6
330
202.2
188.9
53.1
Y Y
201.5
OUTLET STOR PORT
SAE J1926-A: 1-1/16-12
X X2
Z

Front end drive
Description Option
Primary drive, steel, 200 mm diameter K0020
Primary drive, steel, 170 mm diameter K0030
Primary drive, steel, 200 mm diameter, axial PTO K0120
Primary drive, steel, 170 mm diameter, axial PTO K0130
Note: See “Fan drive” for ratios and compatibilities.

K0020 - Primary drive, steel, 200 mm diameter
OPTION CODE MK_K0020 / 00
Z X
635.5
203
604.9
A TO FIRST GROOVE
EFFECTIVE
80.00
80.03
200
Y Y
A 6-M12 x 1.75 EQUISPACED TO SUIT MULTI-V

ON 110 PCD DRIVE BELT
SECTION A-A
Z X
Mass 4.36 kg
2 2
2 2
GD 0.076 kg m

K0030 - Primary drive, steel, 170 mm diameter
Z
X
635.5
173
604.9
A TO FIRST GROOVE
EFFECTIVE
80.03
80.00
170
Y Y
A 6-M12 x 17.5 EQUISPACED

TO SUIT MULTI-V
ON 110 PCD
DRIVE BELT
SECTION A-A
Z
X
Mass 3.85 kg
2 2
2 2
GD 0.048 kg m
K0120 - Primary drive, steel, 200 mm diameter, axial PTO

Z
X
635.7
203
605.1
A TO FIRST GROOVE
EFFECTIVE
80.00
80.03
200
Y Y
A 6-M12 x 1.75 EQUISPACED TO SUIT MULTI-V

ON 110 PCD DRIVE BELT
SECTION A-A
Z
X
Mass 4.36 kg
2 2
2 2
GD 0.076 kg m

K0130 - Primary drive, steel, 170 mm diameter, axial PTO
Z X
635.7
A 605.1
173 TO FIRST GROOVE
EFFECTIVE
80.03
80.00
170
Y Y
6-M12 x 17.5 EQUISPACED

ON 110 PCD TO SUIT MULTI-V
A DRIVE BELT
SECTION A-A
Z X
Mass 3.85 kg
2 2
2 2
GD 0.048 kg m

Secondary crankshaft pulley
Description Option
No secondary pulley KD000
Single groove vee belt 200 mm diameter KD001
KD000 - No secondary pulley
KD001 - Single groove Vee belt 200 mm diameter

Coolant pump
Description Option
Coolant pump - angled inwards inlet L0002
Coolant pump - vertical inlet L0004
L0002 - Coolant pump - angled inwards inlet

OPTION CODE MK_L0002 / 01
Z X X2
640.9 28.6
1/2" - 14PTF
THREAD SAE J476a 632.4
235.1
582.9
379.5
389
57
52
168.2
100.5
27
Y Y
202.6 623.7
293 629.9
1-5/16" - 12 - 2A
THREAD SAE J514
Z X X2

L0004 - Coolant pump - vertical inlet
OPTION CODE MK_L0004 / 00
Z X X2
640.9 28.6
1/2" - 14PTF
235.1 632.4
THREAD SAE J476a
582.9
379.5
389
52
168.2
57
84.5
Y Y
241.1 623.7
1-5/16" - 12 - 2A
293 THREAD SAE J514 629.9
Z X X2

Coolant outlet connection
Description Option
Horizontal outlet connection on LHS, with thermostat assembly LD152
Vertical outlet connection in centre LD156
45° up outlet connection on RHS, with thermostat assembly LD157
LD152 - Horizontal outlet connection on LHS, with thermostat assembly

OPTION CODE MK_LD152 / 00
X X2 Z
PIPE THREAD 204
ISO 228-G1/4 556 28.6
57
50
270
537.7
545
502
Y Y
X X2 Z

LD156 - Vertical outlet connection in centre
X X2 Z
523 57
28.6
50
135
570
Y Y
X X2 Z
LD157 - 45° up outlet connection on RHS, with thermostat assembly

X2 X Z
28.6 523
57
50
15
560
520.7
Y Y
X2 X Z

Fan
Description Option
Fan not required M0000
Diameter 660 mm (26 in) pusher, 7 blade at 26° pitch M0005
Diameter 660 mm (26 in) puller, 7 blade at 26° pitch M0007
Diameter 559 mm (22 in) pusher, 7 blade at 26° pitch M0013
Diameter 559 mm (22 in) puller, 7 blade at 26° pitch M0015
M0000 - Fan not required

M0005 - Diameter 660 mm (26 in) pusher, 7 blade at 26° pitch
OPTION CODE MK_M0005 / 00
4 HOLES TO SUIT M8 FIXINGS 38.7
EQUISPACED ON
DIRECTION OF 63.5 P.C.D.
ROTATION
29.6
660
LEADING EDGE
(26") 41
AIRFLOW DIRECTION
(PUSHER)
FAN
MOUNTING
FACE
A SECTION A-A
REFER TO 'MD' OPTIONS FOR FAN EXTENSION DIMENSIONS

REFER TO 'F' OPTIONS FOR FAN DRIVE MOUNTING DIMENSIONS

M0007 - Diameter 660 mm (26 in) puller, 7 blade at 26° pitch

DIRECTION OF EQUISPACED ON
ROTATION 63.5 P.C.D. 32.6
41
LEADING EDGE
660
(26")
AIRFLOW DIRECTION
(PULLER)
FAN
MOUNTING
FACE
A SECTION A-A

M0013 - Diameter 559 mm (22 in) pusher, 7 blade at 26° pitch


DIRECTION OF EQUISPACED ON
ROTATION 63.5 P.C.D.
24.4
A
559
LEADING EDGE
(22") 41
AIRFLOW DIRECTION
(PUSHER)
FAN
MOUNTING
FACE
A SECTION A-A


M0015 - Diameter 559 mm (22 in) puller, 7 blade at 26° pitch
DIRECTION OF
ROTATION
EQUISPACED ON
A 63.5 P.C.D.
29.6
559
(22")
LEADING EDGE
41
AIRFLOW DIRECTION
(PULLER)
FAN
MOUNTING
FACE
SECTION A-A
A


Fan extension and fixings
Description Option
Extension not required MD000
38.1 mm (1.5 in), fan extension MD003
127 mm (5.0 in), fan extension MD010
MD000 - Extension not required

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
OPTION CODE MK_MD00X / 01
4- 9 5 DIM A
EQUISPACED
ON 63.5 P.C.D.
R0
.4
MA
X
40.919
40.970
1.0
0.5 x 45
Option code Dimension A
MD003 38.1
MD004 50.8
MD005 63.5
MD006 76.2
MD008 103.4

MD010 - 127 mm (5.0 in) - Fan extension
OPTION CODE MK_MD010 / 00
4- 9 5 127
EQUISPACED
ON 63.5 P.C.D.
R0
.4
MA
X
40.919
40.970
1.0
0.5 x 45
( 50.8 ) ( 76.2 )

Alternator
Description Option
(1)
Alternator, bracket and tensioner not required N0000
12V, 100A, alternator N0101
1. Only available with F0000 and FD000.
N0000 - Alternator, bracket and tensioner not required

N0101, N0102, N0200, N0201 - Alternator
OPTION CODE MK_N0101 / 00
OPTION VOLTAGE CURRENT
N0101 12V 100A

N0102 12V 120A
N0200 24V 70A
N0201 24V 85A
X2 X Z
310.2
629
237
28.6 443.6
NOTE A
408.4
316
Y Y
X2 X Z
NOTE A: FOR PULLEY DIMNS. SEE 'FD' OPTIONS VIEWS

N0105, N0206 - Alternator
OPTION CODE MK_N0105 / 00
OPTION VOLTAGE CURRENT
N0105 12V 150A

N0206 24V 100A
Z
X2 X
313
627.9
237
28.6 437.1
NOTE A
408
316
Y Y
Z
X2 X
NOTE A: FOR PULLEY DIMNS. SEE 'FD' OPTIONS VIEWS

Belt driven auxiliaries
Description Option
Not required P0000
Auxiliary drive, single groove pulley, 200 mm diameter P0001
Auxiliary drive, single groove pulley, 140 mm diameter P0003
12V, air conditioning compressor, pad mounted, RHS low P0100
24V, air conditioning compressor, pad mounted, RHS low P0101
P0000 - Not required

P0001 - Auxiliary drive, single groove pulley, 200 mm diameter
OPTION CODE MK_P0001 / 01
THE ADDITION OF THIS AUXILIARY
PULLEY HAS THE EFFECT OF MOVING
THE FAN EXTENSION 2.3 mm FORWARDS
Z X X2
11 665.5 28.6
EFFECTIVE
200
SEE 'F' OPTIONS
12.7
36
Y Y
Z X X2
REFER TO 'F' OPTIONS FOR FAN DRIVE HOUSING
ASSEMBLIES AND FAN HEIGHTS

P0003 - Auxiliary drive, single groove pulley, 140 mm diameter
THE ADDITION OF THIS AUXILIARY
PULLEY HAS THE EFFECT OF MOVING
THE FAN EXTENSION 2.3 mm FORWARDS
Z X X2
11.7 665.5 28.6
EFFECTIVE
140
SEE 'F' OPTIONS
12.7
36
Y Y
Z X X2
REFER TO 'F' OPTIONS FOR FAN DRIVE HOUSING
ASSEMBLIES AND FAN HEIGHTS
P0100 - 12V, air conditioning compressor, pad mounted, RHS low

Z X
333.5 655.5
257 605 TO FIRST GROOVE
403
ELECTRICAL CONNECTOR
A DEUTSCH DT04-2P-E005
INLET 392
7/8 - 14 UNF
133
153
140
EFF.
97
87
Y 11 Y
20.5
OUTLET
3/4 - 16 UNF 3.4
A
45
16.4
14.7
Z X
11.8
13.7
20
SECTION A-A

P0101 - 24V, air conditioning compressor, pad mounted, RHS low
Z X2 X
333.5 28.6 653.8
259 605 TO FIRST GROOVE
257 430.7 ELECTRICAL CONNECTOR

DEUTSCH DT04-2P-E005
250.2 397.2
INLET
*
OUTLET
*
133
153
EFF.
138
97
91.6
Y Y
20.5
Z X2 X
* PORT CONNECTIONS USE A FACE TYPE SEAL.

THE COMPRESSOR IS SUPPLIED WITH BLANKING PLATES.
REFER TO APPLICATIONS ENGINEER FOR FURTHER DETAILS.

Timing case
Description Option
(1)
Timing case, LHS available with QD000/QD005/QD015/QD016/QD017/QD024 Q1000
(1)
Timing case, single LHS available with QD000/QD005/QD015/QD016/QD017/QD024/QD042 Q1030
(2)
Timing case, LHS PTO capability, for use with C1000 only Q1040
(2)
Timing case, LHS PTO capability, for use with C1000 only Q1050
Timing case, no PTO capability available with QD000 Q1100
(3)
Timing case, single RHS PTO light duty available with QD000 Q3000
Timing case, single RHS PTO heavy duty available with QD000 Q3030
(1)
Heavy duty timing case, twin PTO available with QD042/QD055 Q5000
(1)
Heavy duty timing case, twin PTO, less RHS gear available with QD042/QD055 Q5010
1. Incompatible with HD004/HD005.
2. Available with QD000/QD005/QD015/QD016/QD017
3. Incompatible with HD001/HD002/HD007.
Note: Selection of a RHS PTO offering would require an engineering assessment of the following
Duty cycle in normal operation
Potential levels of abusive operation
End of application assembly line testing
Application shake down and pre delivery testing
OEM application sign off process.
to be completed before engine order.
Q1000, Q1030, Q1040, Q1050 - Timing case, LHS PTO
OPTION CODE MK_Q1000 / 00
X X2 MK_Q1030 / 00
539.4
281.1 MK_Q1040 / 00
515.4 28.6 1/2" - 14 NPSI A MK_Q1050 / 00
4 - M12 X 1.75 26
INDICATED B
336.9
101.613
168.1
160.2
159
132.9
100.4
y
97.7
67.9
30
Y Y
4 - M8 X 1.25 18
32.7
40.6
INDICATED A
A
1.3 147.5
10 181.5
190.9
196.1
X X2
223.4
SECTION A-A 250.8
265.3
VIEW ON REAR
279.7

Q1100 - Timing case, no PTO capability
X X2 Z
539.4 281.1
515.4 28.6 1/2" - 14 NPSI
336.9
Y Y
X X2 Z
VIEW ON LEFT
VIEW ON REAR
Q3000, Q3030 - Timing case, single RHS PTO

X X2 Z MK_Q3030 / 00
196.8
539.4
515.4 28.6 192.2
A
2-M10x1.5
30
82.588
161.9
108.9
A
Y Y
55.9
1.2
201.4
10
X X2 Z
SECTION A-A VIEW ON REAR

Q5000 - Heavy duty timing case, twin PTO capability 280 Nm Max.
X X2 OPTION CODE MK_Q5000 / 00
Z
X2 X
28.6
281.1
539.4 LENGTH OF
1/2" - 14 NPSI SPLINE 31
515.4 A
8.8
491.4
483.4 2 - M10 X 1.5 22
4 - M12 X 1.75 22
B
82.6
45
336.9
183.3
110.3
45
Y Y
101.6
162.1
55.7
108.9
37.3
A
11 191.9 1
1
264.9
SECTION B-B
SECTION A-A 337.9 203.3
X X2
GEAR SPLINE DATA
Z
SPLINE FLAT ROOT SIDE FIT DETAILS TO X2 X
ANSI B92.1 CLASS 6 VIEW ON REAR
NUMBER OF TEETH 11
PITCH 16/32
PRESSURE ANGLE 30
BASE DIA (REF) 15.123
Q5010 - Heavy duty timing case, twin PTO, less RHS gear
X X2 Z X2 X
586.3
539.4 281.1
1/2"-14 NPSI
A
28.6
491.4
2-M10 X 1.5 22
45
82.6
B
381
z
336.9
101.6
x
183.3
162.1
110.3
110.3
45
B
Y 1 Y
88.9
55.7
11
37.3
A 191.9 203.4 1
483.4
264.9
9.5
337.9
X X2 Z X2 X
SECTION A-A 4-M12 X 1.75 22 SECTION B-B

VIEW ON REAR

Timing case auxiliaries
Description Option
No auxiliaries QD000
(1)
Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange, 13 tooth spline, fitted LHS QD005
(1)
(1)
(1)
Hydraulic pump drive adaptor, 2 bolt fixing, SAE B flange, 13 tooth spline, fitted LHS QD017
(1) (2)
Adaptor 225cc compressor with SAE A flange, head unload QD024
(1) (2) (3)
630cc compressor, SAE B flange, head unload QD042
(1)
Hydraulic pump drive adaptors, 2 bolt fixings, SAE B flange, 13 tooth spline fitted LHS QD055
1. Incompatible with HD004/HD005.
2. Consult product management for duty cycle acceptance.
3. Incompatible with C0010/C0011/C0023, E0121/E0301, J0060.
Note: Gradeability of compressors, Max. 25° when starting the engine.

QD000 - No auxiliaries
QD005 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE A flange, 13 tooth spline, fitted LHS
OPTION CODE MK_QD005 / 00
X X2 Z
A
221.5
14
7
490.4 28.6
31 4 - M10 X 1.5 18
LENGTH ON 106.4 P.C. DIA
OF SPLINE 8.8 (2 PAIRS S.A.E.
'A' FITTING)
82.58
100.4
9.5
Y Y
SECTION A-A A
VIEW ON REAR
GEAR SPLINE DATA
FLAT ROOT SIDE FIT DETAILS TO
ANSI B92.1 CLASS 6
NUMBER OF TEETH 13
PITCH 16/32
PRESSURE ANGLE 30 X X2 Z
MAJOR DIA 22.504
22.225
PITCH DIA 20.637

X X2 Z
A
221.5
31 7
LENGTH 490.4 28.6
14
OF SPLINE
18
4 - M10 X 1.5
ON 106.4 P.C. DIA
8.9 (2 PAIRS S.A.E.
'A' FITTING)
82.58
100.4
Y 9.5 Y
A
GEAR SPLINE DATA

ANSI B92.1 CLASS 6
NUMBER OF TEETH 11
PITCH 16/32 X X2 Z
PRESSURE ANGLE 30
MAJOR DIA 19.710
PITCH DIA 17.463
Z
X X2
490.4 28.6 221.5

31
LENGTH A
OF SPLINE 118
4
8.8 7
4 - M10 X 1.5
ON 106.4 P.C. DIA
(2 PAIRS S.A.E.
'A' FITTING)
82.58
100.4
9.5
Y A Y
GEAR SPLINE DATA

ANSI B92.1 CLASS 6
NUMBER OF TEETH 9
PITCH 16/32
Z
PRESSURE ANGLE 30 X X2
MAJOR DIA 16.154
15.875
PITCH DIA 14.288

QD017 - Hydraulic pump drive adaptor, 2 bolt fixing, SAE B flange, 13 tooth spline, fitted LHS
X X2 Z
32.43 223.5
LENGTH A
OF SPLINE
483.4 28.6 45
12 5
4 - M12 X 1.75
ON 146.1 P.C. DIA
(2 PAIRS S.A.E.
'B' FITTING)
100.4
Y 12 Y
A
31.6
X X2 Z
GEAR SPLINE DATA
ANSI B92.1 CLASS 6
NUMBER OF TEETH 13
PITCH 16/32
PRESSURE ANGLE 30
MAJOR DIA 22.504
22.225
PITCH DIA 20.637
QD024 - Adaptor 225cc compressor with SAE A flange, head unload

475.4 AIR INLET X X2 Z

Z
351.4 AIR DELIVERY
328 383.7
28.6 343.7
AIR INLET PORT
M26 X 1.5 X 16 334.8 290.7
AIR DELIVERY
319.1 PORT
M22 X 1.5 X 14
288.5
239.1
223.5
217.2
100.4
Y 38 Y
VIEW ON FRONT VIEW ON LEFT VIEW ON REAR 223.4
Z X X2 Z
10 A
9 37 53
GEAR SPLINE DATA 4 - M10 X 1.5
28
FLAT ROOT SIDE FIT DETAILS TO SPACED AS SHOWN

13
ON 106.4 P.C. DIA

82.62
ANSI B92.1 CLASS 6

NUMBER OF TEETH 11
2 - M8 X 1.25
PITCH 16/32
PRESSURE ANGLE 30 23.8
11 TOOTH
MAJOR DIA 19.710 30.2 SPLINE
A
PITCH DIA 17.463 SECTION A-A
HYDRAULIC PUMP DRIVE MOUNTING DETAILS
TO SUIT S.A.E. 'A' FLANGE

QD042 - 630cc compressor, SAE B flange, head unload for use with Q1030
QD042 - 630cc compressor, SAE B flange, head unload, for use with Q5000
FOR USE WITH Q5000 OPTION CODE MK_QD042 / 00
X X2 Z
415.9
298.4 AIR INLET
408.5
260.9 28.6 339.9
AIR DELIVERY
314.5
AIR INLET PORT

M26 X 1.5 X 15
210.6
AIR DELIVERY PORT
194.9 M26 X 1.5 X 15
310.8
270
245.1
228.7
110.3
Y Y
VIEW ON LEFT VIEW ON REAR
19.6 31
11 TOOTH
11 A SPLINE 264.9
53.2
GEAR SPLINE DATA

59
53.2

X X2 Z
82.62
ANSI B92.1 CLASS 6

2 - M10 X 1.5 NUMBER OF TEETH 11
SPACED AS SHOWN PITCH 16/32
19.8 ON 106.4 P.C. DIA
26.2 PRESSURE ANGLE 30
A MAJOR DIA 19.710
HYDRAULIC PUMP DRIVE MOUNTING DETAILS
SECTION A-A PITCH DIA 17.463
TO SUIT SAE 'A' FLANGE

QD055 - Hydraulic pump drive adaptors, 2 bolt fixings, SAE B flange, 13 tooth spline fitted LHS
X X2 Z
495.4 28.6 264.9
32.4 A
LENGTH
OF SPLINE
SEE Q5000 OPTION FOR

OTHER DIMENSIONAL
INFORMATION
110.3
Y Y
A
X X2 Z
GEAR SPLINE DATA
ANSI B92.1 CLASS 6 VIEW ON REAR
SECTION A-A
NUMBER OF TEETH 13
PITCH 16/32
PRESSURE ANGLE 30
MAJOR DIA 22.504
22.225
PITCH DIA 20.637

Balancer
Description Option
Not required R0000
(1) (2) (3)
Balancer R0001
1. G0300/G1100 can be selected.
2. Incompatible with J0070.
3. G2000/G2100/G2300/2500 must be selected.
R0000 - Not required

R0001 - Balancer

Turbocharger
Description Option
(1)
Single side turbocharger, exhaust rearward, compressor up, inward offset S6100
(1)
Single side turbocharger, exhaust rearward, compressor down, outward offset S6101
(1)
Single side turbocharger, exhaust forward, compressor up, outward offset S6102
(1)
Single side turbocharger, exhaust forward, compressor down, outward offset S6105
Single top forward mounted turbocharger, exhaust rearward, compressor up S6300
(2)
Single top forward mounted turbocharger, exhaust rearward, compressor up inward offset S6301
(2)
Single top forward mounted turbocharger, exhaust rearward, compressor horizontal across S6302
Series side turbocharger, exhaust rearward, compressor up S7100
Series side turbocharger, exhaust rearward, compressor across, upward offset S7101
Series side turbocharger, exhaust rearward, compressor horizontal, out downward offset S7102
1. Max. gradeability of 35°.
2. Incompatible with HC004.
Notes:
S6*** only available with AD4**
S7*** only available with AD5**.
S6100 - Single side turbocharger, exhaust rearward, compressor up, inward offset
OPTION CODE MK_S6100 / 00
X2 X Z
282.3 337.6
28.6 U0000
COMPRESSOR
OPTION
8
TCS001
OPTION 50.8
31.8
y
371
SEE TABLE
9.2
246.5
INLET
Y Y
32.1 299.6
337.5 380.8
X RATED POWER COMPRESSOR INLET DIAMETER Z

X2
<=82kW 60MM
>82kW 80MM

S6101 - Single side turbocharger, exhaust rearward, compressor down, outward offset
X Z
337.5 377.8
U000O
32.1 OPTION
299.6
TCS001
OPTION
32
z 50
.8
9.2
246.5
SEE TABLE
121.4
INLET
49
Y Y
335.5
28.6
282.3
COMPRESSOR
X RATED POWER COMPRESSOR INLET DIAMETER Z

X2 <=82kW 60MM
>82kW 80MM
S6102 - Single side turbocharger, exhaust forward, compressor up, outward offset
Z X2
X OPTION CODE MK_S6102 / 00
275.4 23 28.6 80.9 U0000 TCS001
OPTION OPTION
31.8
50.8
COMPRESSOR
358.5
SEE TABLE
25.6
221.9
INLET
32.1
Y Y
275.6
390.9 353.9
Z X2 X
RATED POWER COMPRESSOR INLET DIAMETER

<=82kW 60MM
>82kW 80MM

S6105 - Single side turbocharger, exhaust forward, compressor down, outward offset
S6300 - Single top forward mounted turbocharger, exhaust rearward, compressor up

X2 X Z
28.6 449.1 269.9

COMPRESSOR
60
SEE TABLE
50.8
INLET
163.3
U0000
OPTION
31.8
TCS001
745.3
680.4
605.7
605.7
Y Y
32.1
504.3
X2 X Z
<=82kW 60MM
>82kW 80MM

S6301 - Single top forward mounted turbocharger, exhaust rearward, compressor up inward offset
X2 X Z
271.3
28.6 504.3
151.9
449.1
COMPRESSOR 30
SEE TABLE
31.6
U0000
INLET
OPTION 50.8
32.1
735.4
TCS001
605.7
OPTION
Y Y
163.3
X2 X Z
<=82kW 60MM
>82kW 80MM
S6302 - Single top forward mounted turbocharger, exhaust rearward, compressor horizontal across
X2 X Z
504.3 271.3
449.1 163.3
COMPRESSOR
45.3
SEE TABLE
INLET
32.1
50.8
U0000
OPTION
31.1
660.7
605.7
TCS001
OPTION
Y Y
X2 X Z
<=82kW 60MM
>82kW 80MM

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
Description Option
Soot sensor box with 1.5 metre cable SA001
Soot sensor box with 2.5 metre cable SA002
Soot sensor box engine mounted for use with IOPU/Electropak SA003
SA001/SA002 - Soot sensor box with 1.5/2.5 metre cable

OPTION DESCRIPTION OPTION CODE MK_SA001 / 02
SA001 EXHAUST MONITOR 1.5m LEAD MK_SA002 / 02
SA002 EXHAUST MONITOR 2.5m LEAD
127
101.6
2- 6.6
95.3
1500
26
30
SA003 - Soot sensor box engine mounted for use with IOPU/Genset/Electropak

Turbo Exhaust outlet connection
Description Option
Exhaust elbow rearward up (suits single side turbo) SD001
(1)
Exhaust elbow rearward down (suits single side turbo) SD002
Exhaust elbow rearward straight (suits single side turbo) SD003
Exhaust elbow forward up (suits single side turbo) SD004
Exhaust elbow forward down (suits single side turbo) SD005
Exhaust elbow rearward angled down (suits single side turbo) SD007
Exhaust elbow rearward down, long (suits single top turbo) SD008
Exhaust elbow rearward for use with engine mounted aftertreatment (suits single top turbo) SD010
Exhaust elbow rearward up (suits series side turbo) SD011
Exhaust elbow rearward up, long, (suits single side turbo) SD012
Exhaust elbow rearward down (suits series side turbo) SD014
Exhaust elbow rearward straight (suits single top turbo) SD016
Exhaust elbow rearward straight (suits series side turbo) SD017
1. Incompatible with RHS Flywheel housings, RHS starters and RHS fuel filters.
SD001 - Exhaust elbow rearward up (suits single side turbo)

OPTION CODE MK_SD001 / 00
X2
314.7 15.9
352.7 28.6
Z X U0000
OPTION
CONNECTION TO
170.8 SU OPTION
416.5
400.7
290.7
123.1
APPROX
S6100
OPTION
X2
Y
Z X

SD002 - Exhaust elbow rearward down (suits single side turbo)
Z X2 X
28.6
3.5
405.8 140.1
337.8
U0000
OPTION
S6100
APPROX
OPTION
310.2
10
134.4
CONNECTION TO
SU OPTION
Y Z X2 X Y
SD003 - Exhaust elbow rearward straight (suits single side turbo)

Z X
X2
U0000
CONNECTION TO OPTION
SU OPTION
APPROX
451
S6100
278.3
OPTION
28.6
296.8 63.4
386 76.5
Y
Z X
X2

SD004 - Exhaust elbow forward up (suits single side turbo)
Z X2 X
CONNECTION TO
SU OPTION
431.1 28.6 465.1
APPROX
337 312.2 U0000
OPTION
20
423
411.3
280.4
Y Y
Z X2 X
S6102
OPTION
SD005 - Exhaust elbow forward down (suits single side turbo)

Z
X2 X
28.6 426.5
378 U0000
OPTION 280.3
APPROX
S6105
OPTION
320
86.1
317.2
Y Z Y
X2 X CONNECTION TO
SU OPTION

SD007 - Exhaust elbow rearward angled down (suits single side turbo)
10 OPTION CODE MK_SD007 / 00
W
69.1
X X
X2 X2
W
VIEW ON ARROW A
X2
Z 395.7 28.6 X
U0000
288.3 OPTION
A
S6100
CONNECTION TO
310.1
OPTION
SU OPTION
251.6
41.2
79.1
95.5
Y Y
X2
SD008 - Exhaust elbow rearward down, long (suits single side turbo)
27.5
Z X2 X
244.6 28.6 205.9 36.2 S6302

OPTION
203.2
168.2
CONNECTION TO
SU OPTION
APPROX
U0000
545.8
502.9
OPTION
Y Z X2 X Y

SD010 - Exhaust elbow rearward up for use with engine mounted aftertreatment (suits single top turbo)
S6300
CONNECTION TO OPTION
SU OPTION
Z X2 X
U0000
OPTION
APPROX
113
722
277.7
129.4
562.6
28.6
184.9
Y Z X2 X Y
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)

X2 X
Z
405.8
337.8 28.6
3.5
140.1
U0000
OPTION
APPROX
S7102
352
OPTION
10
CONNECTION TO
134.4
SU OPTION
Y Z X2 X Y

SD016 - Exhaust elbow rearward straight (suits single top turbo)
SD017 - Exhaust elbow rearward straight (suits series side turbo)

Aftertreatment
Non-modular
Description Option
Axial inlet, axial exit, installation angle 180° SF420
Axial inlet, radial exit, exit angle 270°, installation angle 180° SF422
Radial inlet, axial exit, inlet angle 270°, installation angle 180° SF428
Radial inlet, axial exit, inlet angle 90°, installation angle 180° SF430
Radial inlet, radial exit, inlet angle 90°, exit angle 90°, installation angle 180° SF432
SF420 - Axial inlet, axial exit, installation angle 180°

SF420 - Axial inlet, axial exit, installation angle 180°
C4.4 HIGH POWER ENGINE AFTERTREATMENT OPTION CODE: MK_SF420 /00
MK_SF421 /00
SEE DETAIL C
DETAIL C
SCALE 0.200
DETAIL D
SEE DETAIL D SCALE 0.200
SF422 - Axial inlet, radial exit, exit angle 270°, installation angle 180°

Low power engine after treatment not available at time of print

MK_SF425 /00
SEE DETAIL A
DETAIL A
SCALE 0.200
DETAIL B
SCALE 0.200
SEE DETAIL B
C4.4 LOW POWER ENGINE AFTERTREATMENT OPTION CODE: MK_SF426 /00
MK_SF427 /00
SEE DETAIL B
SEE DETAIL A
DETAIL A
DETAIL B
SCALE 0.200
SCALE 0.200

SF428 - Radial inlet, axial exit, inlet angle 270°, installation angle 180°
MK_SF429 /00
SEE DETAIL A
DETAIL B
DETAIL A SCALE 0.200
SCALE 0.200
SEE DETAIL B

MK_SF431 /00
SEE DETAIL A
DETAIL B
DETAIL A SCALE 0.200
SCALE 0.200 SEE DETAIL B

SF432 - Radial inlet, radial exit, inlet angle 90°, exit angle 90°, installation angle 180°

MK_SF433 /00
SEE DETAIL C
SEE DETAIL D
DETAIL C
SCALE 0.200 DETAIL D
SCALE 0.200

MK_SF435 /00
SEE DETAIL C
DETAIL C
SCALE 0.200 DETAIL D
SCALE 0.200
SEE DETAIL D
MK_SF437 /00
SEE DETAIL B
SEE DETAIL A
DETAIL B DETAIL A
SCALE 0.200 SCALE 0.200

MK_SF439 /00
SEE DETAIL B
DETAIL B
SCALE 0.200
DETAIL A
SCALE 0.200 SEE DETAIL A

Engine mounted aftertreatment
Description Option
(1)
Radial exit, exit angle 250°. engine mounted SF450
(2)
(3)
(4)
1. A/T consolidated supply, flex pipe supplied loose with engine (top turbo only).
2. Factory built (side turbo only).
3. A/T consolidated supply, flex pipe supplied loose with engine (side turbo only).
4. Factory built (top turbo only).
Note: Engine mounted aftertreatment, only flex kit SU004 can be selected.
SF450 - Radial exit, exit angle 250°. engine mounted

Engine to aftertreatment, flex pipe
Note: A flexpipe is required on all engines to connect the aftertreatment, Cat will provide the critical
components for the connection system.
Description Code
Flex kit with straight adaptor (supplied loose in engine solution pack) SU001
Flex kit with 45° adaptor (supplied loose in engine solution pack) SU002
Flex kit with 90° adaptor (supplied loose in engine solution pack) SU003
Flex kit to suit engine mounted aftertreatment only SU004
Flexible exhaust installation kit with straight adaptor (SD) 90° elbow (SF) (supplied loose in engine
SU008
solution pack)
Flexible exhaust installation kit with 45° adaptor (SD) 90° elbow (SF) (supplied loose in engine solution
SU009
pack)
Flexible exhaust installation kit with 90° adaptor (SD) 90° elbow (SF) (supplied loose in engine solution
SU010
pack)
SU001 - Flex kit with straight adaptor (supplied loose in engine solution pack)
OPTION CODE MK_SU001 / 01
76.2mm
SLIP JOINT
M8 X 1.25 75mm M10 X 1.5 M10 X 1.5

BALL JOINT M8 X 1.25
75mm
BALL JOINT
53.5 15 55 15
320.2 97
CONNECTION TO
SD OPTION
CUSTOMER SUPPLIED CONNECTION TO

EXHAUST TUBE SF OPTION
180 3
AXIS TO AXIS
TYPICAL BALL JOINT ORIENTATION

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
Description Option
(1)
Forward facing swan neck inlet connection with NRS mixer T0001
Intake angled with NRS mixer T0002
Rearward facing with NRS mixer T0003
1. Incompatible with LD156.
T0001 - Forward facing swan neck inlet connection with low NRS mixer
OPTION CODE MK_T0001 / 00
W
X2 X2
X X
326.3
X2
98.1
W
Z X
VIEW ON ARROW A
A
134.6
63.5
INLET
176.6 50 344.3 66.9

B
254.7 486.2
Y Y
M18 X 1.5 PLUGGED
557.8
28.6
1/8-27 NPTF PLUGGED
570
537
VIEW ON ARROW B
Y Y
Z X X2

T0002 - Intake angled with low NRS mixer
OPTION CODE MK_T0002 / 00
W
X2 X2
X X
326.3
X2
98.1
Z W X
VIEW ON ARROW A
30
50
134.6 63.5
ET
INL
B 176.6 344.3 66.9
254.7 412.8
Y Y
M18 X 1.5 PLUGGED
28.6
557.8
617
537.9
Y 1/8-27 NPTF PLUGGED Y

Z X X2
VIEW ON ARROW B
T0003 - Rearward facing with low NRS mixer

W OPTION CODE MK_T0003 / 00
X2 X2
X X
326.3
X2
98.1
W
Z VIEW ON ARROW A X
A
63.5
INLET
50
B 134.6 279.3
176.6 344.3 66.9
254.7 423
Y Y M18 X 1.5 PLUGGED
28.6
656
1/8-27 NPTF PLUGGED

557.8
537.9
VIEW ON ARROW B
Y Y
Z X X2

Inlet air filter
Description Option
Not required TD000
Standard duty air filter TD001
Heavy duty air filter (supplied loose) TD004
TD000 - Not required

TD001 - Standard duty air filter
FOR USE WITH S7100
OPTION CODE MK_TD001 / 00
Z X
X2
668 357.1 467.7
FILTER ELEMENT REMOVAL
240.3
266 28.6
99.1 TO AMBIENT
TEMPERATURE SENSOR
CONNECT TO
S7100 OPTION
217
422.2
71
210
180
180
Z X
Y X2 Y
AMBIENT TEMPERATURE71.97
SENSOR

TD004 - Heavy duty air filter (supplied loose)

Exhaust manifold
Description Option
Not user selectable(1) U0000
1. Turbocharged engines only.
U0000 - Not user selectable

Exhaust manifold outlet connections
Description Option
Not required UD000
UD000 - Not required

Secondary fuel filter
Description Option
(1)
Single LHS centre V0010
(1)
Twin LHS, centre V0030
(1)
Remote filter arrangement V1301
1. Incompatibilities TBC.
V0010 - Single LHS, centre

V0030 - Twin LHS, centre
V1301 - Remote filter arrangement

Cold starting aid
Description Option
Glow plugs W0011
Glow plugs and ether W0016
Glow plugs, ether and lead W0017
Glow plugs and lead W0018
W0011 - Glow plugs

OPTION DESCRIPTION OPTION CODE MK_W0011 / 00
W0011 GLOWPLUGS & BUSBAR MK_W0016 / 00
W0016 GLOWPLUGS & BUSBAR WITH ETHER
X X2 Z
73.4
BUSBAR
GLOWPLUG
8.1 CUSTOMER CONNECTION
447.6
28.6
Y Y
X X2 Z

W0016 - Glow plugs and ether
W0017 - Glow plugs, ether and lead

OPTION CODE MK_W0017 / 01
X X2 210.6 Z
73.4
BUSBAR CUSTOMER CONNECTION

DEUTSCH CONNECTOR
DTHD-04-1-8-P
CABLE LENGTH: 265mm
608.9
GLOWPLUG
21.2
448.4
28.6
Y X X2 Z Y

W0018 - Glow plugs and lead
X X2 210.6 Z
73.4
BUSBAR CUSTOMER CONNECTION

DEUTSCH CONNECTOR
DTHD-04-1-8-P
CABLE LENGTH: 265mm
608.9
GLOWPLUG
21.2
448.4
28.6
Y X X2 Z Y

Engine lifting eyes
Description Option
Fitted LHS at front and RHS at rear X0011
Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted aftertreatment X0111
Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted aftertreatment
X0113
(SF453 only)
X0011 - Fitted LHS at front and RHS at rear

OPTION CODE MK_X0011 / 01
X X2 Z
631.4 48.1 129.5 151

28.6
R3
2.5
2.5
R3
35
35
538
481.2
483.7
Y Y
X X2 Z
X0111 - Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted
aftertreatment
X0113 - Fitted LHS at front and RHS at rear compatible with IOPU / Genset and engine mounted
aftertreatment (SF453 only)

Engine finish
Description Option
Lacquer Y0000
Cat gold with light preservative Y9012
Cat gold with heavy preservative Y9027
Y0000 - Lacquer
Y9012 - Cat gold with light preservatives
Y9027 - Cat gold with heavy preservative

Electronic options
Cat C4.4 ACERT electronic engines

Refer to eSpec and on-line CEOS system links, with on-line help. Also refer to the “Electrical and Electronics
A + I Guide”


5
Accessories 5
Introduction
This chapter contains all information relating to the mechanical accessories for the C4.4 ACERT engine range.
Before specifying an accessory, read carefully any notes relating to the accessory as these will indicate any
restrictions if this accessory is selected.

Resistors and regulators
Description Option
Not required ZA000
ZA000 - Not required

Fuel cooler
Description Option
Fuel cooler not supplied ZB000
Fuel cooler factory fitted to the front of cooling pack frame ZB001
Fuel cooler supplied loose ZB002
ZB000 - Fuel cooler not supplied

ZB001 - Fuel cooler factory fitted to the front of cooling pack frame
ZB002 - fuel cooler supplied loose

Engine mounting brackets
Description Code
Not required, blanking plugs only ZC000
Front pedestal brackets LHS and RHS ZC002
(1) ZC003
Rear mounting brackets LHS and RHS
(1) ZC004
Front pedestal brackets LHS and RHS, rear mounting brackets LHS and RHS
Front mounting studs and nuts only ZC012
(2) ZC016
Front mounting brackets LHS and RHS
(1) ZC019
Front mounting brackets LHS and RHS
(1) ZC025
Front mounting brackets LHS (horizontal) and RHS (horizontal rearward facing)
(1). Incompatible with C0050/C0051.
(2). Incompatible with C0021.
Maximum g loads (104cycles) Average g loads (106 cycles)

Vertical Fore-aft Side-side Vertical Fore-aft Side-side
ZC000 No mounting feet.
ZC002 ±2g ±1.5g ±1g Stationary applications only
ZC003 ±6g ±4g ±4g ±1.5g ±1.5g ±1.5g
ZC004 TBA TBA TBA Stationary applications only
ZC012 No mounting feet; studs only.
ZC016 ±7g ±8g ±5g ±1.5g ±2.2g ±3g
ZC019 ±9g ±8g ±5g ±6g ±5g ±3g
ZC025 ±4g ±3g ±3g ±2.5g ±2g ±2g
“Maximum” loading can occur up to 104 times during the life of the engine, typically once per hour of operation;
while “Average” loadings can occur up to 106 times or typically 100 times per hour.
These figures are for guidance only; exact capability will depend on the total mass (engine plus customer-fitted
parts) and the number and location of 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

OPTION CODE MK_ZC012 / 00
Z X2 X
179.5 179.5 28.6 479.5
126.5 126.5 431.8

49.2
17.5
Y Y
4-M 12 X 1.75
Z X2 X

ZC016 - Front mounting brackets LHS and RHS
Y 25.9
18
TYPICAL
X2 X
241.5
291.5
W W Z Z
FRONT VIEW
241.5
291.5
28.6 476.8 Y
X2 X
ZC019 - Front mounting brackets LHS and RHS

X2 X
Y
18
TYPICAL
342.2
303.5
28.6 543.2
W W Z Z
368.1
FRONT VIEW
303.5
342.2
25.9
X2 X
Y

ZC025 - Front mounting brackets LHS (horizontal) and RHS (horizontal rearward facing)
X2 X
452.2 Y
18
TYPICAL
322.5
272.5
W W Z Z
FRONT VIEW
263.3
313.3
28.6 367.7
25.9
X2 X
Y

Heater/starter switch
Description Code
Not required ZE000
Heater / starter switch and security lock supplied loose ZE001
ZE000 - Not required

ZE001 - Heater / starter switch and security lock supplied loose
OPTION CODE MK_ZE001 / 00
53.6 72.2 46
56.2
1-375 SERIES BLADE
CONNECTOR
1 2
3
19.7
4 5
MAX PANEL 7 18.5

6-250 SERIES BLADE
CONNECTOR
DETAIL OF PLATE

Oil drain valve
Description Code
Standard sump plug ZG000
Sump oil drain valve fitted LHS (1) ZG001
(1) ZG004
Sump oil drain valve fitted RHS
(1). Compatibilities TBC.
ZG000 - Standard sump plug

ZG001/ZG004 - Sump oil drain valve fitted LHS/RHS
OPTION CODE MK_ZG001 / 00
MK_ZG004/ 00
70
21.3
15.9
DIMENSIONAL POSITIONING OF OIL TAP REFER TO THE SELECTED SUMP OPTION (G)
(ZG001 - LHS, ZG004 - RHS)

Lubricating oil sampling/switch/gauge
Description Code
Not required ZJ000
Lubricating oil sampling valve fitted in filter head ZJ005
ZJ000 - Not required

ZJ005 - Lubricating oil sampling valve fitted in filter head
OPTION CODE MK_ZJ005 / 00
38 15.9
20
M10 X 1
12

Coolant temperature sender and gauge
Description Code
Not required ZL000
ZL000 - Not required

Radiator and mounting group
Description Code
Not required ZM000
Radiator and intercooler fitted, with fan guards (compatible with S7*** turbos) ZM001
Radiator and intercooler fitted, with fan guards (compatible with S6*** turbos) ZM002
Radiator and intercooler fitted, with fan guards (compatible with S7*** turbos) harsh environment
ZM003
protection
Radiator and intercooler fitted, with fan guards (compatible with S6*** turbos) harsh environment
ZM004
protection
Cautions:
An engine is at risk if a heat exchangers effectiveness becomes reduced through environmental
contamination
Customers of Cat should give appropriate maintenance details in their operator and service documents to
prevent this.
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
Description Code
Wiring harness, convoluted, with diagnostic connector ZN020
Wiring harness, convoluted with diagnostic connector, to suit agriculture block only ZN031
Wiring harness, convoluted, without diagnostic connector ZN032
Wiring harness, convoluted, with diagnostic connector for compatibility with large LHS PTOs ZN033
ZN020 - Wiring harness, convoluted, with diagnostic connector

ZN031 - Wiring harness, convoluted with diagnostic connector to suit Ag block only
ZN032 - Wiring harness, convoluted, without diagnostic connector

ZN033 - Wiring harness, convoluted, with diagnostic connector for compatibility with large LHS PTOs

Primary fuel filter
Fuel pre filters
Code
(1) ZV031
Single filter, supplied loose with water separator and sensor, electric lift pump fitted on engine
Single filter, supplied loose with water separator and sensor, electric lift pump off engine ZV032
Single filter, engine mounted with water separator and sensor, electric lift pump fitted on engine ZV073
Single filter, engine mounted with water separator and sensor, electric lift pump off engine ZV074
(1). Incompatibilities TBC.
Note: Contact management for further information.

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
Description Code
Emission label fitted to front cover. Cat decal ZY901
ZY901 - Emission label fitted to front cover. Cat decal

Cab heater connections
Description Code
Not required ZZ000
Feed LHS cylinder head, straight return to rear of timing case ZZ004
Feed LHS cylinder head, angled return to rear timing case ZZ014
Feed LHS cylinder head, angled (45°) return to rear timing case ZZ017
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


6
Technical data 6
Introduction
The information given in the following chapter contains preliminary and target data and should only
be used for preliminary calculations to assist the user to select the option for the C4.4 ACERT project
engine specifications.
If more information is required refer to the C4.4 product team.

Basic technical data
Models C4.4 TAD
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Vertical in-line
Cycle .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 stroke
Induction system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. turbocharged, charge cooled
Combustion system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Direct injection
Bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .105 mm (4.13 in)
Stroke. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .127 mm (5.00 in)
Compression ratio.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16.5 : 1
Cubic capacity ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4,4 litres (269 in³)
Firing order. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1, 3, 4, 2
Rotation.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Clockwise, viewed from front
Basic thread form... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Metric
Cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Liquid
Overall dimensions
Note: Shown on general arrangement drawings (1)

Length (rear face of the block to crankshaft pulley) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .635 mm (25.0 in)
Width . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .845 mm (33.3 in)
Height ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .725 mm (28.5 in)
Weight
Weight of bare TA engine (excludes electrics and backend iron) ... .. non stressed - 400 kg, stressed 430 kg
Weight of coolant and lub oil - bare TA engine . ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... 15 kg
Weight of coolant and lub oil - electropak / IOPU TA engine. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... 20 kg
Weight of DRY TA engine for TMI (includes nominal electrics and backend iron) .. ... .. ... .. ... .. ... .. .. 490 kg
Weight of WET TA engine for TMI (includes nominal electrics and backend iron) .. ... .. ... .. ... .. ... .. .. 505 kg
All values are with standard engine parts fitted, unless otherwise stated.
(1) (2)
(1). Final weight and dimensions will depend on complete specification.

(2). Crankshaft centre line to top of air inlet elbow.

Models C4.4 TTAD
Cylinder arrangement .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Vertical in-line
Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 4 stroke
Induction system.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...series turbocharged charge cooled
Combustion system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Direct injection
Bore . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105 mm (4.13 in)
Stroke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 127 mm (5.00 in)
Compression ratio ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 16.5 : 1
Cubic capacity . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4,4 litres (269 in³)
Firing order .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 3, 4, 2
Rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise, viewed from front
Basic thread form ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Metric
Cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Liquid
Overall dimensions
Note: Shown on general arrangement drawings (1)

Length (rear face of the block to crankshaft pulley). ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 635 mm (25.0 in)
Width .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 930 mm (36.6 in)
Height . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 745 mm (29.3 in)
Weight
Weight of bare TTA engine (excludes electrics and backend iron) .. ... -non stressed -420 kg, stressed 450 kg
Weight of coolant and lub oil - bare TTA engine .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. 15 kg
Weight of coolant and lub oil - electropak / IOPU TTA engine .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. 20 kg
Weight of DRY TTA engine for TMI (includes nominal electrics and backend iron) .. .. ... .. ... .. ... .. ... . 510 kg
Weight of WET TTA engine for TMI (includes nominal electrics and backend iron) . .. ... .. ... .. ... .. ... . 525 kg
Note: All values are with standard engine parts fitted, unless otherwise stated.
(1) (2)
(1). Final weight and dimensions will depend on complete specification.

(2). Dimension from rear face of cylinder block to fan drive pulley face.

Power curves
Further details on power curves will be available on request from the Applications Department when
developed.
Emissions
Emissions cycle - 8M/NRTC
HC g/kWhr <0.19
Nox g/kWhr <3.3
CO g/kWhr <5.0
Pm g/kWhr <0.02
Standards
Rating / performance ISO standards ISO 14396: 2002
Standard barometric pressure 101
Standard atmospheric temperature 25
Fuel injection pump type 1
Production tolerance on power output % 3
Hardware
Single and series turbo charger

Turbo type
hardware set
Fuel injector type Common rail

Max. fuel injection pressure MPa 200
Fuel injection pump type - HP3
Low idle tolerance rpm 800-1200
Start aids - Y
Installation
Maximum air inlet temperature to compressor at 25°C ambient (rise over ambient) °C 10.0
Inlet restriction - maximum air intake - clean filter (depression @ rated speed) kPa 5.0
Inlet restriction - maximum air intake - dirty filter (depression @ rated speed) kPa 8.0
LP turbo
Exhaust back pressure measurement position -
charger outlet
BPV is the out-
Exhaust outlet diameter mm
let pipe
BPV is the out-
Exhaust internal diameter mm
let pipe
Indicator setting for air filter restriction clean kPa 5
Indicator setting for air filter restriction dirty kPa 8
(tested to S.A.E
Airfilter type ISO/SAE J726b or ISO
5011
Cold start
Minimum cranking speed (average) rpm 100
Minimum cranking speed over “top dead centre” rpm 60
Unaided start limit °C -10
Generic performance
Derate strategy for altitude, temperature and humidity, fuel temperature (graphs) - -
Altitude threshold for de-rate m 3000
Torque - 800 rpm (snap or unboosted torque) 'Snap' torque 315
Maximum overspeed limits rpm 3000

T3584 - 110.1 kW, AD416
Engine Model: Curve: T 3584 Sheet 1
C4.4 Issue: 2 Date: 27-Jul-2010
Caterpillar Inc.
©2010 Commercial in Confidence,
proprietary information of Development Target -
Caterpillar Inc. May be Subject to Change
Rating Standards: ISO 14396: 2002 Fuel Types: USA FED Off Highway Europe Off Highway
Production Tolerance On Power Output: +3%, -3% Fuel Specification: EPA Part 1065.703 ULSD EU 2004/26/EC Stage 3B/4
Total Barometric Pressure (kPa): 100 Density (kg/l @ 15°C): 0.840 - 0.865 0.833 - 0.837
Vapour Pressure (kPa): 1 Viscosity (mm²/s @ 40°C): 2.0 - 3.2 2.3 - 3.3
Air Inlet Temperature (°C): 25 Sulphur Content (% mass): 0.0007 - 0.0015 0.001 max
Cetane No: 40 - 50 54 max
Governing Key
610
E denotes electronic governing.
580 560.0
550
Torque, Nm
520
490 E
460
430
400
370
130
120
110.1
110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Performance with fuel oil at 40°C at pump inlet.
Notes: Exhaust Quality Standard Certification Refs (Rated Speeds)
1. For duty cycle refer to the ## CAT Smoke:
DUTY CYCLE MISSING ## rating
US EPA 40 CFR Part 1039.105.
definition(s) in the Caterpillar Industrial
Engine Ratings Guide (LECH3874).
Emissions:
US EPA 40 CFR Part 1039 Tier 4 Interim.
EU NRMM 97/68/EC (as last amended by
2004/26/EC) Stage 3B.
Japanese MLIT Step 4.
Power Standard Certification Refs (Rated Speeds)
UN/ECE R120
Auxiliaries fitted to engine:

Fan - not fitted.
Alternator - off load.
Approved by: Accepted by: Issued by:

R.L.C. Preece M. Verkiel J.H. Flatters
(Legislation Engineer)
Date: 20-Jul-2010 Date: 21-Jul-2010

Rating Curves Data Sheet Curve T 3584 Sheet 2
Note1: Unless otherwise specified, all stated data is for maximum rated speed and 100% load.
General Data Cooling System

Engine Model: C4.4 Heat Rejected @ Rated Speed (kW):
Number Of Cylinders: 4 Heat Rejected @ Peak Torque (kW):
Bore (mm): 105.0 Coolant Flow (litres/min):
Stroke (mm): 127.0 Thermostat - Start To Open (°C): 82
Configuration: Vertical In Line Thermostat - Fully Open (°C): 93
Displacement (litres): 4.4 Recommended Cap Pressure (kPa): 100
Aspiration: Turbocharged Max Top Tank Pressure (kPa): 100 *
* See General Installation Manual
Compression Ratio: 16.5 : 1
Combustion Bowl: Air System
Engine Air Flow (kg/min):
Fuel System
Induction Manifold Pressure (kPa):
Fuel Pump Model: Denso
Injection Timing (°BTDC) - Static: TDC No.1 Charge Air Cooler System
- Dynamic: Charge Air Cooling System: Air-to-Air
HP Rail Pressure (MPa): Max Total Pressure Drop inc Pipes (kPa): 10.0
Fuel Pump Pressure (In) (kPa): Charge Air Cooler Heat Rejection (kW):
Fuel Filter Max Particle Size (micron): 3 - 5 (ISO) Manifold Charge Air Temperature (°C): 55.0
Fuel Return System Type: Return to Tank
Turbocharger
Lubrication System Turbocharger Type:
Lubricating Oil Specification: See Engine Specification Manual Maximum Altitude (m): 3000
Exhaust System Performance Data

Exhaust Flow (kg/min): Friction Power @ Rated Speed (kW):
Exhaust Temperature (°C): Friction Power @ Peak Torque (kW):
Torque @ 800 rev/min (Nm): 370
Cold Start Capability
Unaided Start Limit (°C): -10
Aided Start Limit (°C): -25
For further performance data see table below.
Start Aid (Optional): Glowplugs fitted as standard
Minimum Cranking Speed (rev/min) - unaided: 130
- aided: 100
Performance Data Rating Standard: ISO 14396: 2002 Further Notes:

Speed Torque Power Max Exhaust Max Inlet Governing Tech #4_1
(rev/min) (Nm) (kW) Back Pressure Restriction Categories
(kPa) (kPa) (key on sht 1) AD416
2200 478 110.1 35.0 5.0 E
2100 500 110.0 Please note that the value entered in "Manifold Charge Air
Temperature" field is the value of "Air Charge Cooler Outlet
2000 525 110.0
Temperature"
1950 528 107.8
1900 531 105.7
1800 537 101.2
1700 544 96.8
1650 547 94.5
1600 550 92.2
1500 556 87.3
1400 560 82.1
1300 555 75.6
1200 531 66.7
1100 497 57.3
1000 464 48.6
950 445 44.3
900 427 40.2
800 370 31.0
Internal References
Curve Issue No: 2 DCP Number(s): 004874 TAN Number:
Curve Issue Date : 27-Jul-2010 FIE EDR Number

T3586 - 129.5 kW, AD503
C4.4 ACERT TTAD Issue: 1 Date: 29-Apr-2010
Caterpillar Inc.
750.0 Governing Key

760
720
680
Torque, Nm
640
600
E
560
520
480
440
129.4
130
120
110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
USA 30 CFR Part 7 (MSHA)
UN/ECE R120
Fan - not fitted.

Date: 28-Apr-2010 Date: 29-Apr-2010


Engine Model: C4.4 ACERT TTAD Heat Rejected @ Rated Speed (kW):
Fuel System
Turbocharger

- aided: 100

Speed Torque Power Max Exhaust Max Inlet Governing
(rev/min) (Nm) (kW) Back Pressure Restriction Categories Consolidated Generic Tech#5_1 @ 129 kW - AD503
(kPa) (kPa) (key on sht 1) PSR Request ID : 4945
2200 562 129.4 45.0 5.0 E
2100 587 129.1 Min Exhaust Back Pressure = 20kPa (at rated speed)
2000 614 128.6
Please note that the value entered in "Manifold Charge Air
1950 628 128.2
Temperature " field is the value at "Air Charge Cooler
1900 643 127.9 Outlet Temperature"
1800 676 127.4
1700 708 126.0
1650 720 124.4
1600 729 122.1
1500 743 116.7
1400 750 110.0
1300 720 98.0
1200 675 84.8
1100 615 70.8
1000 550 57.6
950 510 50.7
900 480 45.2
800 450 37.7
Internal References
Curve Issue No: 1 DCP Number(s): TAN Number:
Curve Issue Date : 29-Apr-2010 FIE EDR Number

T3624 - 105.1 kW, AD502
Caterpillar Inc.
Governing Key
700
660 630.0
620
Torque, Nm
580
540
500
E
460
420
380
130
120
105.1 110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

Speed Torque Power Max Exhaust Max Inlet Governing Tech #5
2200 456 105.1 32.0 5.0 E
2000 500 104.7
Temperature"
1950 513 104.8
1900 526 104.7
1800 555 104.6
1700 586 104.3
1650 599 103.5
1600 612 102.5
1500 626 98.3
1400 630 92.4
1300 608 82.8
1200 580 72.9
1100 535 61.6
1000 477 50.0
950 440 43.8
900 418 39.4
800 390 32.7
Internal References

T3626 - 117.0 kW, AD504
C4.4 Issue: 1 Date: 11-Aug-2010
Caterpillar Inc.
Governing Key
720
683.0 E denotes electronic governing.
680
640
Torque, Nm
600
560
520 E
480
440
400
130
117.0
120
110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - 0mm diameter, 0 blades, Perkins
p/n: Fan Not Fitted.

Date: 10-Aug-2010 Date: 10-Aug-2010


Fuel System
Turbocharger

- aided: 100

2200 508 117.0 38.0 5.0 E
Temperature" field is the value of " Air Charge Cooler
2000 558 116.9
Outlet Temperature "
1950 573 117.0
1900 588 117.0
1800 620 116.9
1700 648 115.4
1650 660 114.0
1600 668 111.9
1500 677 106.3
1400 683 100.1
1300 660 89.8
1200 630 79.2
1100 575 66.2
1000 510 53.4
950 465 46.3
900 430 40.5
800 400 33.5
Internal References
Curve Issue Date : 11-Aug-2010 FIE EDR Number

T3632 - 97.9 kW, AD414
Caterpillar Inc.
Governing Key
550 530.0 E denotes electronic governing.
525
500
Torque, Nm
475
450
E
425
400
375
350
130
120
110
97.9
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(kPa) (kPa) (key on sht 1) 98 kW@2200rpm - AD414
2200 425 97.9 32.0 5.0 E
2100 445 97.9 PSR # 5391
2000 465 97.4
1950 473 96.6
Temperature" field is the value at "Air Charge Cooler Outlet
1900 480 95.5 Temperature"
1800 495 93.3
1700 505 89.9
1650 510 88.1
1600 515 86.3
1500 525 82.5
1400 530 77.7
1300 520 70.8
1200 500 62.8
1100 480 55.3
1000 450 47.1
950 435 43.3
900 420 39.6
800 370 31.0
Internal References

T3634 - 82 kW, AD404
Caterpillar Inc.
450.0 Governing Key

450
425
400
Torque, Nm
375
E
350
325
300
275
250
97.5
90.0
82.0
82.5
75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 1000 1200 1400 1600 1800 2000 2200 2400

Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
Korean MoE Tier 3.
UN/ECE R120
Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(rev/min) (Nm) (kW) Back Pressure Restriction Categories Consolidated Generic Tech#4 @ 82kW - AD404
(kPa) (kPa) (key on sht 1)
2400 260 65.3 PSR request ID : 4805
2300 299 72.0
2200 356 82.0 35.0 5.0 E
2100 373 82.0
Temperature"
2000 392 82.1
1950 401 81.9
1900 412 82.0
1800 435 82.0
1700 440 78.3
1650 442 76.4
1600 444 74.4
1500 448 70.4
1400 450 66.0
1300 442 60.2
1200 430 54.0
1100 410 47.2
1000 390 40.8
950 385 38.3
900 380 35.8
800 370 31.0
Internal References

T3636 - 102.1 kW, AD409
Caterpillar Inc.
Governing Key
610
580 560.0
550
Torque, Nm
520
490
460 E
430
400
370
130
120
102.1 110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

Speed Torque Power Max Exhaust Max Inlet Governing Consolidated Generic Tech#4 @ 102.1kW - AD409
(rev/min) (Nm) (kW) Back Pressure Restriction Categories PSR Request ID : 5055
2200 443 102.1 33.0 5.0 E Please note that the value entered in "Manifold Charge Air
2100 463 101.8 Temperature " field is the value at "Air Charge Cooler
Outlet Temperature"
2000 486 101.8
1950 500 102.1
1900 510 101.5
1800 520 98.0
1700 531 94.5
1650 537 92.8
1600 543 91.0
1500 554 87.0
1400 560 82.1
1300 555 75.6
1200 531 66.7
1100 497 57.3
1000 464 48.6
950 445 44.3
900 427 40.2
800 370 31.0
Internal References

T3638 - 106 kW, AD406
Caterpillar Inc.
Governing Key
610
580 560.0
550
Torque, Nm
520
490
E
460
430
400
370
130
120
106.0 110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
1. For duty cycle refer to the ## CAT

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(kPa) (kPa) (key on sht 1) PSR Request ID : 4981
2200 460 106.0 33.8 5.0 E
2000 499 104.5
Outlet Temperature"
1950 504 102.9
1900 510 101.5
1800 520 98.0
1700 531 94.5
1650 537 92.8
1600 543 91.0
1500 554 87.0
1400 560 82.1
1300 555 75.6
1200 531 66.7
1100 497 57.3
1000 464 48.6
950 445 44.3
900 427 40.2
800 370 31.0
Internal References

T3640 - 92.5 kW, AD419

Caterpillar Inc.
Governing Key
550 530.0 E denotes electronic governing.
525
500
Torque, Nm
475
450
425
E
400
375
350
92.6 97.5
90.0
82.5
75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

2200 402 92.6 30.6 5.0 E
2000 442 92.6
Temperature"
1950 453 92.5
1900 464 92.3
1800 491 92.6
1700 505 89.9
1650 510 88.1
1600 515 86.3
1500 523 82.2
1400 530 77.7
1300 520 70.8
1200 508 63.8
1100 497 57.3
1000 464 48.6
950 445 44.3
900 427 40.2
800 370 31.0
Internal References

T3644 - 91 kW, AD408
Caterpillar Inc.
Governing Key
520
500
480
Torque, Nm
460
440
420
400 E
380
360
91.0
97.5
90.0
82.5
75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

2200 395 91.0 30.3 5.0 E PSR Request ID : 5056
2100 412 90.6
2000 430 90.1
1950 438 89.4
Outlet Temperature"
1900 448 89.1
1800 467 88.0
1700 490 87.2
1650 492 85.0
1600 494 82.8
1500 499 78.4
1400 500 73.3
1300 485 66.0
1200 470 59.1
1100 450 51.8
1000 430 45.0
950 423 42.1
900 415 39.1
800 370 31.0
Internal References

T3648 - 85.9 kW, AD405
Caterpillar Inc.
Governing Key
520
500
480
Torque, Nm
460
440
420
400
380 E
360
97.5
85.9 90.0
82.5
75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(rev/min) (Nm) (kW) Back Pressure Restriction Categories AD405
(kPa) (kPa) (key on sht 1) Please note that the value entered in "Manifold Charge Air
2200 373 85.9 29.0 5.0 E Temperature" field is the value of "Air Charge Cooler Outlet
2100 390 85.8 Temperature"
2000 410 85.9
1950 420 85.8
1900 431 85.8
1800 450 84.8
1700 466 83.0
1650 475 82.1
1600 485 81.3
1500 495 77.8
1400 500 73.3
1300 485 66.0
1200 470 59.1
1100 450 51.8
1000 430 45.0
950 423 42.1
900 415 39.1
800 370 31.0
Internal References

T3654 - 65.9 kW, AD424
Caterpillar Inc.
Governing Key
400
375
350
Torque, Nm
325
300 E
275
250
225
200
97.5
90.0
82.5
75.0
65.9
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 1000 1200 1400 1600 1800 2000 2200 2400

Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(kPa) (kPa) (key on sht 1) PSR request ID : 4815
2400 215 54.0
2200 286 65.9 30.0 5.0 E
Temperature"
2100 300 66.0
2000 315 66.0
1900 331 65.9
1800 350 66.0
1700 356 63.4
1600 361 60.5
1500 367 57.6
1400 372 54.5
1300 367 50.0
1200 361 45.4
1100 355 40.9
1000 340 35.6
950 337 33.5
900 335 31.6
800 330 27.6
Internal References

T3656 - 74.5 kW, AD403
Caterpillar Inc.
Governing Key
470 450.0
440
410
Torque, Nm
380
350
E
320
290
260
230
97.5
90.0
82.5
74.5
75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 1000 1200 1400 1600 1800 2000 2200 2400

Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(rev/min) (Nm) (kW) Back Pressure Restriction Categories Consolidated Generic Tech#4 @ 74.5kW - AD403
2400 236 59.3 PSR request ID : 4814
2300 271 65.3
2200 323 74.5 32.4 5.0 E
2100 338 74.3
Temperature"
2000 355 74.4
1950 364 74.3
1900 373 74.2
1800 394 74.3
1700 415 73.9
1650 423 73.0
1600 430 72.0
1500 442 69.4
1400 450 66.0
1300 438 59.6
1200 420 52.8
1100 395 45.5
1000 370 38.7
950 355 35.3
900 350 33.0
800 340 28.5
Internal References

T3658 - 70.0 kW, AD402
Caterpillar Inc.
Governing Key
420
400.0
405
390
Torque, Nm
375
360
345
330
315
E
300
97.5
90.0
82.5
70.0 75.0
67.5
60.0
Power, kW
52.5
45.0
37.5
30.0
22.5
15.0
7.5
0.0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

2200 304 70.0 30.9 5.0 E
2000 334 70.0
Temperature"
1950 343 70.0
1900 352 70.0
1800 371 69.9
1700 380 67.6
1650 385 66.5
1600 390 65.3
1500 395 62.0
1400 400 58.6
1300 393 53.5
1200 385 48.4
1100 370 42.6
1000 350 36.7
950 340 33.8
900 330 31.1
800 323 27.1
Internal References

T3660 - 61.5 kW, AD401
Caterpillar Inc.
Governing Key
385
370
355 347.0
Torque, Nm
340
325
310
295
280
E
265
61.5 65
60
55
50
45
40
Power, kW
35
30
25
20
15
10
5
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

2200 267 61.5 28.0 5.0 E
2000 293 61.4
Temperature"
1950 301 61.5
1900 309 61.5
1800 325 61.3
1700 334 59.5
1650 337 58.2
1600 339 56.8
1500 343 53.9
1400 347 50.9
1300 340 46.3
1200 330 41.5
1100 317 36.5
1000 305 31.9
950 300 29.8
900 293 27.6
800 280 23.5
Internal References

T3744 - 112.0 kW, AD510
Caterpillar Inc.
Governing Key
700
650.0
660
620
Torque, Nm
580
540
500 E
460
420
380
130
112.0 120
110
100
90
80
Power, kW
70
60
50
40
30
20
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Speed, rev/min
Emissions:
2004/26/EC) Stage 3B.
UN/ECE R120

Fan - not fitted.



Fuel System
Turbocharger

- aided: 100

(rev/min) (Nm) (kW) Back Pressure Restriction Categories Tech#5_1- AD510
2200 486 112.0 35.6 5.0 E Please note that the value entered in "Manifold Charge Air
2100 507 111.5 Temperature " field is the value at "Air Charge Cooler
Outlet Temperature"
2000 531 111.2
1950 543 110.9
1900 555 110.4
1800 584 110.1
1700 613 109.1
1650 627 108.3
1600 638 106.9
1500 645 101.3
1400 650 95.3
1300 634 86.3
1200 605 76.0
1100 555 63.9
1000 494 51.7
950 453 45.1
900 424 40.0
800 395 33.1
Internal References

Cylinder block views non-stressed block
Non-stressed block and head - left hand side view
OPTION CODE HEAD HIGH & LOW POWER OPTION MK_ACE
BLOCK OPTION MK_ACA
THIS DRAWING IS FOR THE INDUSTRIAL BLOCKS ONLY.
X
( 572 )
A 554 ( 65.2 )
( 504.7 )
E
406.7
49.2
18.9
56.9
1.1
5.1
17.5
Y Y
35 D
49.2
B
DETAILS OF CUSTOMER RELEVANT HOLES. C 59.9
102.2
REF QTY SIZE REMARKS
138.2
A 1 1/2-14 NPSI X 15 WATER FEED TO CABIN HEATER 236.2
259
FRONT TWO ONLY ADVILABLE WHEN
B 2 M12 X 1.75 X 20
FRONT MOUNTS ARE USED. 479.5
CUSTOMER FIXING POINT OR FUEL
C 4 M10 X 1.5 X 20 X
FILLTER BRACKET
CUSTOMER FIXING POINT BUT
D 1 M12 X 1.75 X 14 LH SIDE
TAPPING DEPTH IS RESTRICTED
CUSTOMER FIXING POINT OR FUEL
E 6 M8 X 1.25 X 16
FILLTER BRACKET SHEET 1 OF 5

Non-stressed block and head - front view
BLOCK OPTION MK_ACA
Z
106
101
85 134
63 63
55
55
J
J F
G G
437.7
447.7
375.2
380.2
370.7
325.5
269.5
255.5
248
DETAILS OF CUSTOMER RELEVANT HOLES.
Y Y
13.9
J
20.9
66.9
F 1 M10 X 1.5 X 19 AVAILABLE IF NO COMPRESSOR BRACKET 38
J 38
AVAILABLE IF HEAD MOUNTED
G 8 M10 X 1.5 X 17 128 128
FAN DRIVE IS USED
AVAILABLE IF SIDE MOUNTING
H 4 M16 X 2 X 25
PADS ARE USED. Z
AVAILABLE IF BLOCK MOUNTED
J 4 M10 X 1.5 X 19 FRONT
FAN DRIVE IS USED
K 2 M10 X 1.5 X 19 CUSTOMER FIXING POINT SHEET 2 OF 5
Non-stressed block and head - right side view

BLOCK OPTION MK_ACA
X
555.7
505.7
494
404
365
245
164 L
125
44 L M
9
L
487.7
366.7
393.7
DETAILS OF CUSTOMER RELEVANT HOLES. N

49.2
56.9
16.1
165.1
145.1

Y Y
L 10 M10 X 1.5 X 19 CUSTOMER FIXING POINT
M 1 M8 X 1.25 X 16 CUSTOMER FIXING POINT R

86.1
66.1
49.2
17.5
59.9
AVAILABLE IF NO COMPRESSOR Q
N 4 M10 X 1.5 X 17 138.2 P
BRACKET FITTED
FRONT TWO ONLY ADVILABLE 259
P 2 M12 X 1.75 X 20
WHEN FRONT MOUNTS ARE USED. 415
479.5
Q 4 M10 X 1.5 X 22 CUSTOMER FIXING POINT
501
CUSTOMER FIXING POINT BUT
R 1 M12 X 1.75 X 14 X
TAPPING DEPTH IS RESTRICTED RH SIDE SHEET 3 OF 5

Non-stressed block and head - rear side view
BLOCK OPTION MK_ACA
Z
176
176.5
168
72
40.9 41
34 36
33 35
12
S
V U
S
U
451.7
U
429.7
S
490.7
409.7
458.7
408.7
390.7
368.7
389.7
364.7

AVAILABLE IF ON ENGINE Y Y
S 3 M8 X 1.25 X 14
ECM FITTED.
T 2 M12 X 1.75 X 25 CUSTOMER FIXING POINT
Z
U 6 M10 X 1.5 X 19 CUSTOMER FIXING POINT
AVAILABLE IF NO AIR FILTER REAR
V 2 M8 X 1.25 X 16 SHEET 4 OF 5
BRACKET FITTED.
Non-stressed block and head - plan view

BLOCK OPTION MK_ACA
X
560.5
538.5
X
112
74
W W
9
174
453
W 554
X
PLAN VIEW

AVAILABLE IF NO AIR CON
W 1 M10 X 1.5 X 19
BRACKET FITTED
X 2 M8 X 1.25 X 16 CUSTOMER FIXING POINT
Y 1 M8 X 1.25 X 16 SHEET 5 OF 5
BRACKET FITTED

Cylinder block views stressed block
Stressed block and head - left hand side view
BLOCK OPTION MK_ACA
THIS DRAWING IS FOR THE AGRICULTURAL BLOCKS ONLY.
X
X2
( 572 ) ( 65.2 )
554
28.6
258.9
( 504.7 )
406.7
B
49.2
56.9
18.9
5.1
Y Y
7.9 D
DETAILS OF CUSTOMER RELEVANT HOLES B
( 88.9 )
138.2
REF QTY SIZE REMARKS C 174.2
B
236.2
A 1 1/2-14 NPSI X 15 WATER FEED TO CABIN HEATER C 259
B 5 M8 X 1.25 X 16 CUSTOMER FIXING POINT X2
C 4 M10 X 1.5 X 20 CUSTOMER FIXING POINT LH SIDE

X
CUSTOMER FIXING POINT BUT TAPPING
D 1 M12 X 1.75 X 14 SHEET 1 OF 5
DEPTH IS RESTRICTED

Stressed block and head - front view
BLOCK OPTION MK_ACA
Z
106
101 134
85
63 63
55 55
38 38
K K
E F
G G
447.7
437.7
380.2
375.2
370.7
325.5
269.5
255.5
248
Y Y
E 2 M10 X 1.5 X 19 CUSTOMER FIXING POINT
H
6.4
F 1 M10 X 1.5 X 19 AVAILABLE IF NO COMPRESSOR BRACKET
J 133.4 152.4
AVAILABLE IF HEAD MOUNTED
G 8 M10 X 1.5 X 17
69.9
FAN DRIVE IS USED 174.6 171.5
17 HOLE WITH
H 2 CUSTOMER BOLSTER ( 213 ) ( 235.9 )
21.01/21.21 C/B
J 2 M16 X 2 X 32 CUSTOMER BOLSTER
Z
AVAILABLE IF BLOCK MOUNTED
K 4 M10 X 1.5 X 19 FRONT
FAN DRIVE IS USED SHEET 2 OF 5
Stressed block and head - right side view

BLOCK OPTION MK_ACA
X
555.7
505.7
494
404
365
X2 245
164
125
44
9
28.6 P P
Q
M
487.7
393.7
366.7

285
N
16.1
165.1

49.2
56.9
CUSTOMER FIXING POINT BUT Y Y

L 1 M12 X 1.75 X 14
TAPPING DEPTH IS RESTRICTED
M 5 M10 X 1.5 X 20 CUSTOMER FIXING POINT L
7.9
M
AVAILABLE IF NO COMPRESSOR 138.2
66.1
N 2 M10 X 1.5 X 20
BRACKET FITTED 259
485
P 10 M10 X 1.5 X 19 CUSTOMER FIXING POINT 501
X2
Q 1 M8 X 1.25 X 16 CUSTOMER FIXING POINT X RH SIDE SHEET 3 OF 5

Stressed block and head - rear side view
BLOCK OPTION MK_ACA
Z
176
176.5
168
72
40.9
41
34
36
33
35
U 12
R S
S
U
R
451.7
S
429.7
490.7
T
409.7
458.7
408.7
390.7
368.7
389.7
364.7
231.8
Y Y
R 6 M10 X 1.5 X 19 CUSTOMER FIXING POINT

85.7 54
AVAILABLE IF ON ENGINE
S 3 M8 X 1.25 X 14
ECM FITTED.
Z
T 2 M12 X 1.75 X 25 CUSTOMER FIXING POINT
REAR
AVAILABLE IF NO AIR FILTER
U 2 M8 X 1.25 X 16 SHEET 4 OF 5
BRACKET FITTED.
Stressed block and head - plan view

BLOCK OPTION MK_ACA
X
X2
560.5
538.5
V
112
74
W W
9
174
X
W
453
554
X2
X
PLAN VIEW
V 2 M8 X 1.25 X 16 CUSTOMER FIXING POINT

W 1 M8 X 1.25 X 16
BRACKET FITTED
X 1 M10 X 1.5 X 19
BRACKET FITTED SHEET 5 OF 5

Cold start system
Cold Start System and Battery Performance
The conditions which follow will decide the minimum temperatures at which the engine will start:
Starter motor performance
Battery type
Lubricating oil grade
Cold start aid.
For more information on the minimum start temperatures and types of starter motors etc, refer to the Cat
Installation manual or your local distributor.
Equipment required for cold temperatures
The chart below gives the minimum temperature at which a selection of engine oil, battery and starter motor
will start the engine. The temperatures shown are for an engine fitted to a manual gearbox and with the clutch
disengaged to give an increase in cranking speed.
Predicted starter motor battery CCA (SAE) for

C4.4 - very low parasitic load applications, i.e. Gensets
This document is based on test data, contains extrapolations and is subject to change as testing continues
Temperature °C -5 -10 -15 -20 -25 below -25

Maximum CCA (SAE)
Cold start aid Glowplugs --> Rating
Do not exceed
Starter motor and battery CCA
12V 3.0 kW 850 950 select 12V 4.0 kW --> Contact IPSD 950
Applications
12V 4.0 KW 750 850 1200 1200 1500 Engineer 2400
24V 4.5 kW 660 660 660 660 660 660
24V 5.5 kW 660 660 660 660 660 1200


C4.4 - medium to high parasitic load applications, i.e. telehandler, tractor, etc
Temperature °C -5 -10 -15 -20 -25 below -25

Maximum CCA (SAE)
Cold start aid Glowplugs --> Rating
Do not exceed
12V 3.0 kW select 12V 4.0 kW --> Contact IPSD 950

Applications
12V 4.0 KW 950 950 1500 1900 2400 Engineer 2400
24V 4.5 kW 660 660 select 24V 5.5kW 660
24V 5.5 kW 660 660 950 920 1200 1200
Batteries that meet this specification should give suitable start performance. If the auxiliary loads are large it
may be necessary to specify a battery with a higher ampere-hour capacity (or reserve capacity) or to use a
separate battery system. Any battery which is chosen because of its higher reserve capacity must not have
inferior high rate discharge characteristics.
Battery to starter lead resistance
The resistance of the lead(s) used between the battery/batteries and the starter motor must not be more than
0.0017 Ω for the 12 V systems and 0.0034 Ω for the 24 V systems. more detailed information on the types of
battery is available in the Cat Product Support Publications.
Caution: Ignition circuit resistance should be no more than 30m Ω contact.
Note: See Application and Installation Document for all other information regarding the application and
specification of starting systems.

Cooling system
Maximum coolant temperature with 1,0 Bar (14.7 lbf/in²) pressure cap fitted to the system the coolant
temperature must not exceed 108°C (226.4 °F) at sea level. This temperature must be reduced at high
altitudes - see the tables in the Cat Installation Manual - and when any other than 50/50 coolant is used. The
minimum requirement for temperature measurement, is a warning light or dial gauge which covers the coolant
temperature range.
Note: If tests are to be conducted to establish the ambient ≥clearance of a cooling system, the system must
be filled with a solution of 50% antifreeze and 50% coolant and be suitable for operating worldwide in ambient
temperatures of up to 48°C (118.4 °F).
Engine coolant capacities - typical values.
Engine type Litre UK pint US quart Oil cooler fitted
C4.4 ACERT TAD 9 16.3 8.2 Yes

C4.4 ACERT TTAD 9.4 17.1 8.5 Yes
Radiators
The engine must be installed so that there is no air restriction to the flow of air through the radiator. The
discharged hot air from the radiator must not be sent through the radiator again because the ambient air
temperature will then be lifted above the safe temperature for engine operation. Baffles can be fitted to prevent
this. When the radiator is installed, or a change made to the design of the basic cooling system for the purpose
of radiator installation, or if the installation space is restricted, then a cooling test must be made before the
installation can be approved. For more information about cooling tests refer to the Cat Product Support
Publications.
Please note that the figures shown in the tables below are estimates - ±5% of measured results.
Radiator coolant flow rates
Engine type Flow L/min Pressure kPa
engine speed rpm
800
1000 80
1200 106
1400 123 138
C4.4 ACERT 1600 141 148
1800 159 162
2000 176 178
2200 194 195
2400 212
engine speed rpm
800
1000
1200 99 128
1400 116 138
C4.4 ACERT 1600 133 148
1800 152 160
2000 166 173
2200 183 188
2400

Cab heater coolant flow rates
engine speed rpm
800
1000
1200 11
1400 13
C4.4 ACERT 1600 14
1800 16
2000 18
2200 20
2400
engine speed rpm
800
1000
1200 11
1400 13
C4.4 ACERT 1600 14
1800 16
2000 18
2200 20
2400
Engine components may become damaged or fail due to excess temperature if coolers (fuel, air charge or
coolant) are allowed to become clogged with debris. Customers should be made aware of this, particularly if
their machine is likely to be operated in dirty/contaminated environment.
Notes:
The table above shows coolant flow rates through a typical pressurised radiator system with the thermostat
fully open. The coolant flow rates are with a system resistance (radiator and piping) of 35 kPa (5.08 psi).
The cab heater feed is only permitted to be taken from the LHS front of the cylinder head. It is not permitted
for customers to add additional feeds.
The figures shown in the tables above are estimates ± 5% of measured results.

Tier IV under - bonnet temperatures
The engine will be designed to operate in average under-bonnet temperatures as described below:
Ambient temperature in Max. time at Max. ambient
Engine state % of engine life
engine bay °C temperature
Stopped, but must be
120 2 20 minutes
startable (heat soak)
105 Running 13 3 hours
85 Running 85 Indefinite
Note: These temperatures represent the average air temperature, away from any hot-spots such as the
turbocharger.
Heat balance
The following tables show the total heat passed to radiation, exhaust and coolant for typical ratings. The values
are for engines under full load conditions and different speeds. The total heat rejection figure includes the heat
remove from the lubricant, and the heat removed by the air to air charge cooler.
Exhaust system
Air flow
The airflow rates for typical ratings. The air flow rate is quoted at the maximum permitted clean filter restriction
of 5 kPa back pressure (at maximum rated speed).
All data taken at standard 101 kPa atmospheric pressure, 25°C ambient temperature, nominal BP and
operative thermostat unless otherwise stated.
Exhaust back pressure measured between turbo outlet and engine installed BPV.
Note: Data subject to change, contact Cat for latest information.

T3584, 110.1 kW - AD416
Detail Unit Value 1200 1400 1600 1800 2000 2200
T Curve Number - 3684
Rated Speed rpm 2200
Gross Torque Nm per speed 531 560 550 537 525 478
Gross engine Power kW per speed 67 82 92 101 110 110
Nett Engine Power kW per speed 59.8 74.5 83.35 91.5 99.1 97.9
BMEP kPa per speed 1496 1583 1553 1531 1492 1347
Torque Back up - max % 17.15
Installation
COMPRESS OUT PRESS kPa abs. kPa per speed 203 226 243 250 253 256
Air Temp. before charge cooler (ATAAC in Temp.) °C per speed 126 138 144 152 156 158
Charge cooler - pressure drop across kPa per speed 4.2 5.0 5.8 6.8 8.5 10.0
Air Temp. after charge cooler (ATAAC out Temp.) °C per speed 55.1 55.0 54.7 54.6 55.1 55.0
Inlet manifold pressure - kPa per speed 96.9 117.6 132.0 136.7 137.2 139.0
Air mass flow (wet) (Intake Air flow) kg/min per speed 4.5 5.6 6.7 7.5 8.3 9.0
Air volume flow (wet) m³/min per speed 3.8 4.8 5.7 6.4 7.2 7.7
Exhaust back pressure restriction (Max.) kPa 35
Exhaust back pressure restriction (Min.) kPa 10
Exhaust temperature - turbo inlet (Turbine Inlet
°C per speed 644 637 608 626 630 603
Temp.)
Exhaust temperature - turbo outlet (Turbine Outlet
°C per speed 516 502 471 486 490 461
Temp.)
Exhaust gas flow rate volume (wet) m³/min per speed 3.7 4.6 5.4 6.1 6.8 7.3
Exhaust gas mass flow (kg/sec) (wet) kg/min per speed 4.7 5.9 7.0 7.9 8.7 9.4
Performance
BSFC g/kWhr - All speeds, all loads (ISO-SFC
g/kW.hr per speed 222.2 215.4 212.3 215.9 218.8 222.0
plot)
End of Life Fuel Consumption (End of Life Fuel
g/kW.hr per speed
BSFC)
Fuel Consumption litres /hour - All speeds. all
litres/hr per speed 17.64 21.2 23.46 26.54 29.18 29.456
loads (ISO-SFC plot)
Peak Cylinder Pressure bar per speed 98.44 111 124.2 130.2 138.9 141.42
Smoke (AVL) Steady state, full load AVL SN N/A 0.68 0.595 0.324 0.506 0.642 0.564
Overall Thermal efficiency (nett) % 38%
Heat Balance (PEG57) - EOL, 101kPa Ambient, 25°C Inlet Temp.
energy in fuel kWt per speed 176 211 234 264 290 293
energy to exhaust kWt per speed 68.3 83.6 95.6 109.6 122.2 126.1
energy to charge coolers (From AFT CLR) kWt per speed 5.3 7.7 10.0 12.3 14.1 15.4
energy to radiation kWt per speed 12.29 14.77 16.35 18.49 20.33 20.523
energy to coolant and lubricating oil kWt per speed 44.2 47.1 47.3 51.9 56.3 56.3
Heat Rejection to Radiator (REJ to JW) kWt per speed 46.8 51.9 53.7 60.4 66.2 67.2
Heat Rejection to EGR coolant kW kWt per speed 2.605 4.874 6.491 8.501 9.949 10.928
energy to residual losses (alternator etc.) kWt per speed 6.1 6.4 6.7 6.85 7 7.2
energy to cooling fan (puller) kWm per speed 0.8 1.2 2.15 2.85 3.9 5
energy to power output (nett) kWm per speed 59.8 74.5 83.35 91.5 99.1 97.9
Oil System Data
Lub Oil Rail Pressure kPa-g per speed 347.9 363.9 369.1 372.6 374.2 378.87
Lub Oil Rail temperature °C per speed 101 102.2 103 103.8 104.7 105.07
Additional test data
Rating category - A , B, C, D or E? - C

T3586, 129.4 kW - AD503
Gross engine Power kW per speed 84.8 110 122.1 127.4 128.6 129.4
Torque Back up - max % 33
Installation
Exhaust back pressure restriction (Max.) kPa 45.0
Exhaust back pressure restriction (Min.) kPa 12.0
°C per speed 647 644 629 616 607 600
Temp.)
°C per speed 479 470 457 454 451 449
Temp.)
Performance
g/kW.hr per speed 215.3 208.1 208.7 210.5 214.3 217.5
plot)
g/kW.hr per speed
BSFC)
Fuel Consumption litres /hour - all speeds, all
Peak Cylinder Pressure bar per speed 128.2 151.3 161.8 155 154.3 160.05
energy to coolant and lubricating oil kWt per speed
Heat Rejection to EGR coolant kW kWt per speed
energy to cooling fan (puller) kWm per speed 1.3 2 3.1 4.3 6 8
Oil System Data
Lub Oil Rail Pressure kPa-g per speed 336 347.3 353.8 360.6 364.6 371.63
Lub Oil Rail temperature °C per speed 100.8 102.2 103 103.3 103.6 103.95

T3624, 105.1 kW - AD502
Nett Engine Power kW per speed 65.5 84 92.7 93.45 91.7 89.9
Installation
°C per speed 590 591 587 573 543 511
Temp.)
°C per speed 448 436 440 435 409 366
Temp.)
Performance
BSFC g/kWhr - all speeds, all loads (ISO-SFC
g/kW.hr per speed 212.4 211.7 211.2 212.8 216.3 220.2
plot)
End of Life Fuel Consumption
g/kW.hr per speed
(End of Life Fuel BSFC)
Peak Cylinder Pressure bar per speed 103.4 126.8 128.1 125.7 132.1 150.86
energy to power output (nett) kWm per speed 65.5 84 92.7 93.45 91.7 89.9
Oil System Data
Lub Oil Rail temperature °C per speed 100.2 101.3 102 102.3 102.7 103.61

T3626, 117.0 kW - AD504
Installation
°C per speed 619 610 605 592 583 551
Temp.)
°C per speed 463 447 448 443 441 405
Temp.)
Performance
g/kW.hr per speed 212.4 208.2 208.9 211.1 214.9 218.7
plot)
g/kW.hr per speed
BSFC)
energy to charge coolers
kWt per speed 9.7 14.7 17.2 18.4 18.4 22.1
(From AFT CLR)
Oil System Data
Lub Oil Rail temperature °C per speed 100.9 102.2 102.8 103.3 103.4 104.29

T3632, 97.9 kW - AD414
Installation
°C per speed 633 627 593 595 579 564
Temp.)
°C per speed 509 495 461 457 438 425
Temp.)
Performance
g/kW.hr per speed 224.0 217.8 215.4 218.4 221.3 227.1
plot)
g/kW.hr per speed
BSFC)
Fuel Consumption litres /hour - all speeds, all
kWt per speed 4.3 6.8 8.8 10.9 12.9 14.3
(From AFT CLR)
energy to radiation kWt per speed 11.65 14 15.41 17.1 18.19 18.717
Heat Rejection to Radiator
kWt per speed 45.5 50.1 51.4 58.1 62.3 63.3
(REJ to JW)
Oil System Data

T3634, 82.0 kW - AD404
T curve number - 3634
Rated speed rpm 2200
Gross torque Nm per speed 429 449 443 434 391 356
Gross engine power kW per speed 54 66 74 82 82 82
Nett engine power kW per speed
Torque back up, Max. % 26
Installation
Compress out press kPa abs. kPa per speed 189 199 206 221 223 211
Air Temp. before charge cooler, (ATAAC in
°C per speed 108 114 118 127 129 124
Temp.)
Air temperature after charge cooler, (ATAAC out
°C per speed 52.0 52.9 51.0 54.0 52.7 54.5
Temp..)
Air mass flow (wet), (intake air flow) kg/min per speed 4.2 4.9 5.5 6.2 6.7 6.9
Exhaust temperature, turbo inlet, (turbine inlet
°C per speed 571 599 594 568 543 554
Temp.)
Exhaust temperature, turbo outlet, (turbine outlet
°C per speed 461 483 477 447 424 441
Temp.)
Performance
BSFC g/kWhr - all speeds, all loads (ISO-SFC
g/kW.hr per speed 219.0 220.0 218.0 216.0 219.0 227.0
plot)
End of life fuel consumption, (end of life fuel
g/kW.hr per speed
BSFC)
Fuel consumption litres /hour, all speeds. all loads
(ISO-SFC plot)
Peak cylinder pressure bar per speed 91.6 98.9 104 117 117 113
Overall thermal efficiency (nett) %
Heat balance (PEG57) - EOL, 101 kPa ambient, 25°C inlet Temp.
Energy in fuel kWt per speed 142 174 194 212 216 223
Energy to exhaust kWt per speed 58.5 70.9 78.8 85.0 88.9 94.9
Energy to charge coolers (From AFT CLR) kWt per speed 3.9 5.0 6.1 7.6 8.6 8.0
Energy to radiation kWt per speed 9.93 12.2 13.6 14.8 15.1 15.6
Energy to coolant and lubricating oil kWt per speed 33.2 39.0 41.2 42.6 42.5 46.1
Heat rejection to radiator (REJ to JW) kWt per speed 36.3 44.0 48.6 52.9 54.2 57.0
Heat rejection to EGR coolant kW kWt per speed 3.11 5 7.35 10.3 11.6 10.9
Energy residual losses (alternator etc.) kWt per speed 6.1 6.4 6.7 6.85 7 7.2
Energy cooling fan (puller) kWm per speed
Energy power output (nett) kWm per speed
Oil system data
Lubricating oil rail pressure kPa-g per speed 364 368 372 371 378 385
Lubricating oil rail temperature °C per speed 99.1 99.8 100 101 101 102

T3636, 102.1 kW - AD409
Installation
Air Temp. before charge cooler
°C per speed 121 134 143 148 152 155
(ATAAC in Temp.)
Air Temp. after charge cooler
°C per speed 54.9 55.0 54.8 54.6 54.6 55.6
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 4.5 5.6 6.6 7.4 8.0 8.8
(Intake Air flow)
Exhaust temperature - turbo inlet
°C per speed 644 637 603 609 595 579
(Turbine Inlet Temp.)
Exhaust temperature - turbo outlet
°C per speed 518 505 468 472 457 442
(Turbine Outlet Temp.)
Performance
g/kW.hr per speed 220.7 223.7
plot)
g/kW.hr per speed
Peak Cylinder Pressure bar per speed 99.84 111.4 123 128.8 135 138.66
kWt per speed 5.0 7.4 9.8 11.6 13.1 14.8
(From AFT CLR)
kWt per speed 46.8 51.6 53.1 59.0 63.6 64.4
(REJ to JW)
Oil System Data
Lub Oil Rail temperature °C per speed 101 102.2 102.8 103.3 103.9 104.23

T3638, 106.0 kW - AD406
Installation
°C per speed 646 640 605 609 606 593
Temp.)
°C per speed 522 508 472 473 471 457
Temp.)
Performance
g/kW.hr per speed 224.7 217.0 214.0 217.3 220.1 224.6
plot)
g/kW.hr per speed
BSFC)
Oil System Data

T3640, 92.5 kW - AD419
Installation
°C per speed 642 630 596 594 564 552
Temp.)
°C per speed 519 502 465 459 427 420
Temp.)
Performance
g/kW.hr per speed 217.5 226.2
plot)
g/kW.hr per speed
BSFC)
kWt per speed 4.5 6.5 9.1 10.9 12.6 13.5
(From AFT CLR)
energy to radiation kWt per speed 11.9 14.1 15.5 17 17.4 17.8
kWt per speed 46.0 50.3 51.1 57.5 59.0 60.0
(REJ to JW)
Heat Rejection to EGR coolant kW kWt per speed 2.8 5 6.2 10.2 11.9 11.8
Oil System Data
Lub Oil Rail Pressure kPa-g per speed 351 365 369 369 373 383

T3644, 91.0 kW - AD408
Installation
°C per speed 109 123 136 146 150 152
(ATAAC in Temp.)
°C per speed 55.2 55.1 55.0 54.9 55.0 55.3
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 4.1 5.3 6.4 7.0 7.8 8.6
(Intake Air flow)
°C per speed 607 611 586 579 552 544
°C per speed 490 488 456 443 415 410
Performance
BSFC g/kWhr - All speeds, all loads
g/kW.hr per speed 223.3 219.1 217.4 220.1 223.1 228.7
(ISO-SFC plot)
g/kW.hr per speed 232.05
Fuel Consumption litres /hour
All speeds. all loads (ISO-SFC plot)
Overall Thermal efficiency (nett) % 36% 35.6%
kWt per speed 3.7 6.0 8.7 10.8 12.5 13.8
(From AFT CLR)
kWt per speed 42.3 47.1 49.8 55.7 57.3 58.7
(REJ to JW)
Oil System Data
Lub Oil Rail Pressure kPa-g per speed 355 367.6 371.6 374.5 377 383.89

T3648, 85.9 kW - AD405
Nett Engine Power kW per speed 52.2 65.7 72.45 75.1 75 73.7
Installation
°C per speed 111 120 135 139 148 149
(ATAAC in Temp.)
°C per speed 55.6 54.6 55.3 54.5 55.1 55.8
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 4.1 5.2 6.4 6.9 7.7 8.4
(Intake Air flow)
°C per speed 609 616 583 569 544 534
°C per speed 491 491 454 437 409 401
Performance
BSFC g/kWhr - All speeds,
g/kW.hr per speed 223.6 218.0 215.7 218.6 221.2 226.6
all loads (ISO-SFC plot)
g/kW.hr per speed
Overall Thermal efficiency (nett) % 36% 0.3559
kWt per speed 3.8 5.8 8.5 9.7 12.1 13.1
(From AFT CLR)
kWt per speed 42.6 48.0 49.3 54.1 56.6 57.9
(REJ to JW)
energy to power output (nett) kWm per speed 52.2 65.7 72.45 75.1 75 73.7
Oil System Data

T3654, 65.9 kW - AD424
Installation
°C per speed 92 107 113 117 120 120
(ATAAC in Temp.)
°C per speed 51.1 53.6 54.4 54.1 54.6 56.4
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 3.7 4.6 5.2 5.7 6.2 6.8
(Intake Air flow)
Exhaust temperature - turbo inlet o
C per speed 539 521 508 502 498 509
Exhaust temperature - turbo outlet o
C per speed 452 423 406 399 393 401
Performance
g/kW.hr per speed 216 213.1 212.6 213 218.7 227.8
plot)
g/kW.hr per speed
kWt per speed 2.5 4.2 5.1 6.0 6.9 7.3
(From AFT CLR)
kWt per speed 30.2 33.7 36.9 41.3 43.8 48.1
(REJ to JW)
Oil System Data
Lub Oil Rail Pressure kPa-g per speed 374.4 378.9 384 390.9 396.8 400.76

T3656, 74.5 kW - AD403
Installation
°C per speed 104 116 121 122 126 122
(ATAAC in Temp.)
°C per speed 52.5 53.5 55.4 52.7 55.5 55.5
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 4.0 4.9 5.5 6.0 6.5 6.8
(Intake Air flow)
°C per speed 573 569 572 541 526 538
°C per speed 477 463 462 433 415 427
Performance
g/kW.hr per speed 213.9 209.2 210.8 210.5 214.1 222.4
plot)
g/kW.hr per speed
kWt per speed 3.4 5.1 6.1 6.9 7.7 7.5
(From AFT CLR)
kWt per speed 34.3 39.9 43.5 46.0 48.6 51.9
(REJ to JW)
Oil System Data
Lub Oil Rail temperature °C per speed 99.3 100 100.7 101.4 101.9 102.2
ADDITIONAL TEST DATA

T3658, 70.0 kW - AD402
Nett Engine Power kW per speed 41.5 51 56.45 60.2 59.1 57.8
Installation
°C per speed 96 108 114 117 121 118
(ATAAC in Temp.)
°C per speed 53.5 54.8 55.4 53.5 54.9 54.4
(ATAAC out Temp.)
Air mass flow (wet)
kg/min per speed 3.7 4.7 5.3 5.9 6.4 6.8
(Intake Air flow)
°C per speed 561 543 533 520 508 520
°C per speed 472 446 433 417 402 413
Performance
g/kW.hr per speed 214.7 210.1 209.6 209.6 215 223.92
plot)
Peak Cylinder Pressure bar per speed 95.86 107.2 103.6 112.9 112 106.74
kWt per speed 2.7 4.2 5.2 6.2 7.0 7.2
(From AFT CLR)
kWt per speed 32.4 35.8 39.7 44.0 45.7 49.2
(REJ to JW)
energy to power output (nett) kWm per speed 41.5 51 56.45 60.2 59.1 57.8
Oil System Data

T3660, 61.5 kW - AD401
Gross Torque Nm per speed 347 339 325 293 267
Gross engine Power kW per speed 51 57 61 61 62
Nett Engine Power kW per speed -6.9 43.27 47.95 51.56 50.47 49.312
BMEP kPa per speed 991 968 928 837 763
Installation
COMPRESS OUT PRESS kPa abs. kPa per speed 188 192 197 203 207
°C per speed 104 106 109 113 116
(ATAAC in Temp.)
Charge cooler - pressure drop across kPa per speed 10.0
°C per speed 55.0
(ATAAC out Temp.)
Inlet manifold pressure - kPa per speed 106.3
Air mass flow (wet)
kg/min per speed 4.6 5.0 5.2 5.6 6.3
(Intake Air flow)
Air volume flow (wet) m³/min per speed
°C per speed 478
°C per speed 362
Exhaust gas flow rate volume (wet) m³/min per speed
Exhaust gas mass flow (kg/sec) (wet) kg/min per speed
Performance
g/kW.hr per speed 216.8 214.1 216.0 224.9 235.5
plot)
litres/hr per speed 17.248
Peak Cylinder Pressure bar per speed <165
Smoke (AVL) Steady state, full load AVL SN N/A N/A
Overall Thermal efficiency (nett) %
energy in fuel kWt per speed
energy to exhaust kWt per speed 57.9 62.7 64.7 68.0 76.3
kWt per speed 3.7 4.3 4.8 5.4 6.5
(From AFT CLR)
energy to radiation kWt per speed 9.34 10.29 11.2 11.68 12.28
energy to coolant and lubricating oil kWt per speed N/A
kWt per speed 34.5 38.1 44.3 48.4 50.3
(REJ to JW)
energy to power output (nett) kWm per speed -6.9 43.27 47.95 51.56 50.47 49.312

T3744, 112.0 kW - AD510
Torque Back up - Max. % 33.74
Installation
°C per speed 152 178 178 173 173 186
(ATAAC in Temp.)
°C per speed 54.4 55.1 54.9 54.7 54.5 55.4
(ATAAC out Temp.)
Inlet manifold pressure kPa per speed 142.2 182.2 185.0 177.2 171.8 189.0
Air mass flow (wet)
kg/min per speed 5.2 6.8 7.7 8.3 8.9 9.9
(Intake Air flow)
°C per speed 603 596 591 581 567 530
Temp.)
°C per speed 453 436 438 436 427 381
Temp.)
Performance
g/kW.hr per speed 212.1 209.4 209.2 212.0 214.2 219.4
plot)
g/kW.hr per speed
kWt per speed 8.5 13.9 15.9 16.5 17.5 21.7
(From AFT CLR)
kWt per speed 48.3 55.9 60.5 63.9 66.9 69.4
(REJ to JW)
Oil System Data

Induction system
Air filters
Cat classifies air filters according to duty, which relates to dust-holding capacity. The choice of duty depends
upon the engine type, the dust concentration in which it will operate, and the service life required. The two duty
categories considered by Cat:
Medium Duty: Specification – minimum dust-holding capacity (tested to S.A.E J726b or ISO 5011): 10 gram
SAE coarse test dust/cu. ft./min of airflow
Heavy Duty: Specification – minimum dust-holding capacity (tested to S.A.E. J726b or ISO 5011): 25 gram
SAE coarse test dust/cu. ft./min of airflow.
Inlet restriction
The following table shows the maximum allowable depression at the engine for clean filters. It also shows the
depression at the engine at which dirty elements must be replaced.
Maximum permitted depression at
Engine type Measurement taken at Units rated speed
Clean filter Dirty filter
mm H20 510 810
C4.4 ACERT Turbocharger intake in H20 20 32
kPa 5 kPa 8 kPa
Restriction indicator
For all filters a restriction indicator should be fitted, as it enables maximum life to be obtained from the air filter
element without exceeding the engine restriction limits. Without an indicator the filter must be serviced at fixed
periods. However, dust conditions vary so much that this results in either premature element renewal or
excessive induction restriction.
Details of filter restriction indicators used by :
Mechanical floating ball systems
Indicators are set to operate at 8 kPa.
It is recommended that either vacuator valves or a cyclone system is fitted to air filters. This provides auto
emptying of dust/water from the filter; thereby increasing it’s service life.

Fuel specifications
For Tier 4 Interim engines
The C4.4 ACERT is capable of running of fuels with cetane number reduced to 40.
Fuels specifications that will be available in the 2011 time frame are still relatively unknown. In order to set a
standard we have based the below objectives on current known specifications with the expected changes
documented next to them. If any of these assumptions change the fuel specification may need reviewing. As
this is not a comprehensive list of all fuels a table of properties will be developed to guide our customers on
other fuel specifications not listed below. As long as the fuels conform to these properties it can be used on
Tier 4 Interim engines.
The Tier 4 Interim engines must be able to run on the below fuels:
Specification
Grade class Fuel description Comments
standard
Grade
A to F Assumes 10 ppm sulfur level will be achieved.
EN590 European automotive fuel (Derv)
ad Class (current sulfur level - 50 ppm)
0 to 4
US special purpose light middle distillate 15 ppm
1-D S15
sulfur
ASTM D975
US general purpose middle distillate 15 ppm
2-D S15
sulfur
CARB Diesel
This standard supersedes VV-F-800. This is fuel
Not compatible unless sulfur level reduced in
used by USA Federal Agencies in ground
specification <15 ppm (current sulfur level - 500).
1-D low sulfur compression ignition engines. It is also know as
Should follow ASTM standard as document is
NATO F54. Base specification is the same as
written.
ASTM D975
A-A-52557A
This standard supersedes VV-F-800. This is fuel
Not compatible unless sulfur level reduced in
used by USA Federal Agencies in ground
specification <15 ppm (current sulfur level - 500).
2-D low sulfur compression ignition engines. It is also know as
Should follow ASTM standard as document is
NATO F54. Base specification is the same as
written.
ASTM D975
Special No1
No1 Japanese automotive diesel. Different classes Standard doesn't specify lubricity limit. Survey
JIS K2204
No2 correspond to season and district where used data shows that lubricity is generally OK.
No3
Special No3
Fuel oil for agricultural and industrial engines, Assumes 10 ppm sulfur will be achieved (current
BS 2869 Class A2
(red diesel) sulfur level - 1000 ppm).
Blend of bio diesel meeting EN 14214 or ASTM
B5-B7 D6751 with EN590 or ASTM D975 standard
Mineral diesel fuels.
Target but needs validation. Additives may have
Blend of bio diesel meeting EN 14214 or ASTM
to be reviewed as an option once validation has
B6 - B20 Max. D6751 with EN590 or ASTM D975 standard
started and Programme Management are
Mineral diesel fuels.
consulted first.

Fuel system
Low pressure fuel system - recommended layout

Lubrication system
Lubricating oil specification
Cat require the use of the following oil. Failure to use the appropriate specification of oil will reduce the life of
your engine and After-treatment system.
Minimum Specification
Engine type
For engines with After-treatment.
API CJ-4
C4.4 ACEA E9
ECF3
Oil change period is 500 hrs on API CJ-4 and higher specification oils.
The life of your after-treatment system is defined by the accumulation of ash on the filter surface. Ash is the
incombustible part of the engine particulate matter which the system is designed to collect. Whilst this is a very
small percentage of the particulate matter (<1%) it is left behind as the soot burns off and will eventually block
the filter, causing loss of performance and increased fuel consumption. The majority of the ash comes from
the engine oil which is gradually consumed during normal operation and passes out through the exhaust. It is
vital you use the appropriate grade of oil in order to meet the claimed life expectancy of your product. The oils
listed in the manual have been carefully selected for their low ash content and are therefore recommended.
Maintenance intervals for engines that use biodiesel
The oil change interval can be adversely affected by the use of biodiesel. Use oil analysis in order to monitor
the condition of the engine oil. Use oil analysis also in order to determine the optimum oil change interval.
Caution: The following engine oils are not approved by Cat and must not be used: CC, CD, CD-2,
CF-4, CG-4, CH-4 and CI-4"
Lubrication oil temperature
The maximum permissible lubricating oil temperature measured in the main gallery is 125°C (257°F) for
continuous operation and 135°C (275°F) for intermittent operation.
Intermittent is defined as of up to 1 hr in any 24 hr period with a 12 hr period between.
Recommended viscosity grades
Caution: Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature
range in which the engine will run as shown in the chart below.
V is c o s tiy g r a d e
1 5 W -4 0
1 0 W -4 0
1 0 W -3 0
5 W -4 0
5 W -3 0
0 W -4 0
0 W -3 0
0 W -2 0
-5 0 -4 0 -3 0 -2 0 -1 0 0 1 0 2 0 3 0 4 0 5 0 6 0
A m b ie n t T e m p e r a tu r e D e g C
Lubricating oil pressure

At normal operating temperatures, the lubricating oil pressure for a warm engine throughout the maximum
torque speed to rated speed range, should be TBC.

Electrical system
4.4 litre factory installed wiring and components
Engine mandatory wiring
Machine specific wiring
PV / PROD clean emissions module
Machine Specific Wiring

Engine Air Inlet Temperature
Diagnostic
Connector
DPF Soot Load

Sensor Power
A5:E2
Includes: keyswitch, battery,

CAN C 120 Ohm start-aid relays, lamps, etc.
Terminating Resistor
Customer CAN C Link for DPF

Soot Load Sensor
Harness
DPF Sensor PV / PROD Clean Emissions Module

connections on J1
J1
(70 way)
Aftertreatment ID
Engine Mandatory
Wiring
DPF Intake
Temperature Sensor
Water in fuel switch
DPF
DPF Soot Load

Antenae
DPF Soot Load

Sensor
Install In <85 Deg C

Ambient Temp Location
e.g. Cab Mounting
CAN C 120 Ohm

Terminating Resistor

Starter motors
Cold Start System and Battery Performance
The conditions which follow will decide the minimum temperatures at which the engine will start:
Starter motor performance
Battery type
Lubricating oil grade
Cold start aid.
For more information on the minimum start temperatures and types of starter motors etc, refer to the Cat
Installation Manual or your local distributor.
Equipment required for cold temperatures
The chart below gives the minimum temperature at which a selection of engine oil, battery and starter motor
will start the engine. The temperatures shown are for an engine fitted to a manual gearbox and with the clutch
disengaged to give an increase in cranking speed.
Applications that use automatic gearboxes or other high drag equipment should use the next most powerful
battery combination to get the same start temperature and engine cranking speed.
very “low parasitic load applications”, i.e Gensets and IOPU
Engine oil 15W40 10W40 5W30
Maximum CCA
Temperature -5 -10 -15 -20 -25 below -25
(SAE) Rating
Cold start aid Glowplugs -->
Do not exceed
Contact IPSD
12V 3.0 kW 850 950 Select 12V 4 kW --> 950
Applications
12V 4.0 kW 750 850 1200 1200 1500 2400
Engineer
24V 4.5 kW 660 660 660 660 660 660
24V 5.5 kW 660 660 660 660 660 1200

medium to “high parasitic load applications”, i.e telehandler, tractor, etc
Engine oil 15W40 10W40 5W30
Maximum CCA
Temperature -5 -10 -15 -20 -25 below -25
(SAE) Rating
Cold start aid Glowplugs -->
Do not exceed
Contact IPSD
12V 3.0 kW Select 12V 4kW --> 950
Applications
12V 4.0 kW 950 950 1500 1900 2400 2400
Engineer
24V 4.5 kW 660 660 select 24V 5.5 kW --> 660
24V 5.5 kW 660 660 950 950 1200 1200
Resistance of battery cables A, B, and C not to exceed 0.0017 Ω.
Note: See Application and Installation Document for all other information regarding the application and
specification of starting systems.
Caution: For starting below -25ºC, please consult your application engineer
Batteries that meet this specification should give suitable start performance. If the auxiliary loads are large it
may be necessary to specify a battery with a higher ampere-hour capacity (or reserve capacity) or to use a
separate battery system. Any battery which is chosen because of its higher reserve capacity must not have
inferior high rate discharge characteristics.

Battery to starter lead resistance
The resistance of the lead(s) used between the battery/batteries and the starter motor must not be more than
0.0017 Ω for the 12 V systems and 0.0034 Ω for the 24 V systems. more detailed information on the types of
battery is available in the Cat Product Support Publications.
Note: Ignition circuit resistance should be no more than 40 mΩ contact.
T4i EMSD Starter Motor Data (for IPSD) Medium Duty Heavy Duty
Description
Voltage V 12 12 24 24 24
Power kW 3 4 4.5 5.5 8.5
Flywheel housing :Starter SAE 3:1 3:1 3:1 3:1 2:3
Side LHS RHS LHS LHS-Ag RHS LHS RHS LHS RHS LHS RHS
Option code E0301 E0311 E0121 E0141 E0100 E0206 E0205 E0207 E0200 n/a n/a
Application Information
Maximum battery (SAE) CCA 950 2410 680 1200 1400
Minimum battery (SAE) CCA 650 650 680 680 1300
Maximum mean
600 1000 600 600 700
cranking current A
Activation type IMS/Sol. Sol. Sol. Sol. IMS IMS
Maximum pull-in current
68 68 30 2 @-40°C 2
@-20°C A
Maximum hold-in current
20 20 6 2 @-40°C 2
@-20°C A
Recommended fuse rating A 25A 25A TBC N/A N/A
Maximum motor circuit
1.7 1.7 3.4 3.4 20
resistance mΩ
Maximum activation circuit
40 40 135 135 135
resistance mΩ
No (starter is
Wet flywheel housing compatible No No No Yes
wet-comp)
Design
Pinion number of teeth 10 10 10 10 12
Solenoid angle ° 60 40 48 36 40 48 40 45 50 N/A N/A
Flange fixing size 10.5 10.5 10.5 12.7 M12
Mass
8.5 10.5 10.5 11 13.7
kg

Cold start oil specification
Temp. °C Oil specification
-5 15W40
15W40
15W40
15W40
15W40
-10 15W40
15W40
15W40
15W40
15W40
-15 15W40
10W40
10W40
-18 10W40
10W40
-20 10W40
5W30
5W30
5W30
5W30
-25 5W30
5W30
5W30
5W30
5W30
-30 5W30

Medium duty alternator data
T4i EMSD alternator data (for IPSD)
Description
Family 13SI 18SI 13SI 18SI
Voltage V 12 12 24 24
Current A 100 120 150 175 55 80 100
Option code 101 102/107 105 N/A 200 201 206
Application information
Speed rating (continuous) rpm 18000 18000 18000 18000
Speed rating (intermittent) rpm 21000 21000 21000 21000
Operating Temp. (Min.) °C -40 -40 -40 -40
Operating Temp. (Max.) °C 125 125 125
Rear cover Temp. limit °C 246 246 246 246
Regulator hot shut down Temp °C 145 140 145 140
Self excita-
Excitation Self excitation Self excitation Self excitation
tion
Tacho output PPR 6 6 6 6
Warning lamp wattage W 2 2 2 4
Load dump protection (clipping
V 40 40 60 60
voltage)
Maximum charging line voltage drop V 0.5 0.5 0.5 0.5
Design
IP rating (bearing) 56 56 56 56
IP rating (regulator) 54 54 54 54
IP rating (brush box) 33 33 33 33
Mass actual kg na na na 7.650 5.810 6.115 na
Mass kg 5.4 6.2 7.6 5.8 6.3 7.6

Engine mountings
Standard methods
There are four standard methods available:
1 The engine can be installed on solid mountings, independent of the driven machinery but on a common
base.
2 The complete engine and machine, can be installed on solid mountings on a frame. Install the frame on
flexible mountings on a solid base.
3 Install the engine on flexible mountings, independent of the machine and install a drive shaft between the
engine and the machine.
4 Connect the engine and machine together, and install the complete unit on flexible mountings.
Flexible mountings
The purpose of the flexible mountings must be to:
Control the movement of the engine at normal speed and during engine start and stop procedure.
Remove as much vibration as possible from the frame of the machine.
Give the engine support and hold it during sudden increase or decrease in speed, shock loads or operation
on gradients.
Prevent stress to the engine, caused through distortion of the machine and the engine frame.
Control the movement of the engine inside the capacity of any drive shaft.
Note: Further information about engine mountings can be found in the Cat Product Support Publications.

Torsional vibration
In generators, pumps and compressors etc., where the moment of inertia of the driven machinery is high,
torsional vibration can cause extra stresses at certain speeds. It is recommended that applications such as
these are analysed by Cat.
Similar stresses can also occur with low inertia equipment that is driven off the front of the engine. As a general
guideline the inertia of any equipment driven off the front of the engine should be less than 0.015 kgm². This
equipment could include auxiliary crankshaft pulleys for belt driven PTO and couplings for axial PTO taken
directly off the crankshaft nose. Higher inertia arrangements may be acceptable, however it is recommended
that these be analysed by Cat.
For the system to be analysed and to ensure the correct performance of the engine etc., the information
required by Cat is the mass/elastic details of all the equipment driven from the front and rear of the engine.
More information about the mass/elastic system calculations is given in the Cat installation manual.
Flywheel/cylinder block bending moments
The dynamic bending moment at the rear face of the block, when fitted with a standard SAE housing that is
not bolted to the sump, must not exceed the values in the table below.
The housing and housing to block sealing/fixing integrity that is the limiting factor.
Flywheel housing Dynamic vertical bending moment Nm Dynamic lateral bending moment Nm
SAE3 ± 3000 Nm ±1700 Nm
The table above identifies the maximum bending moments in the vertical and lateral directions, (for 1million
load applications). To determine the allowable static bending moment in the vehicle, typical bulk accelerations
of the whole vehicle transmission system must be known for a typical application.
The maximum static bending moment must be calculated from this based on the maximum ‘g’ loads for your
application type."
For example:
Maximum static bending moment at the rear face of block for an SAE 3 housing :
Vertical Capacity, average loading 106 cycles. Installation target +/- 3g
3000 Nm / 3g = +/-1000 Nm static vertical Bending moment.
Lateral Capacity, average loading 106 cycles. Installation target +/- 2g
1700 Nm / 2g = +/- 850 Nm static lateral Bending moment
The bending moment at all mounting pads must be limited to:-
Front mounting pads TBD
Flywheel housing mounting pads TBD
(associated with 10g vertical shock loads)"

C4.4 Ag engine block fitted with a structural sump.
For applications where a structural sump is fitted, and the transmission /drum flywheel housing/backplate is
bolted to the Ag block and sump, the load carrying capacity is significantly increased. Failure of the bolted parts
or interface clamped face integrity are the limiting factors.
For applications that use a stressed sump, i.e agricultural tractors fitted with tyres without a chassis where the
engine and sump connect the front and transmission/rear wheels, the following are typical bending limits.
The limit at the rear face of the block/transmission interface in the vertical plane for 1 million cycles: +/-
40000 Nm. *
The limits at the front of the engine at the bolster/block/sump interface in the vertical plane for 1 million cycles:
+/-24000 Nm. *"
Comments applicable to all installations.
Drive line/transmission system resonance.
In some applications it will be necessary to check for drive line system resonance with nodes at the block/
transmission system interface.
The bending limits at the interface tabulated above still apply, but the resonance condition and bulk
accelerations of the transmission system are not assumed to act simultaneously. If a resonance exists, that
can be excited in the engines normal operating speed range, and the mode shape indicates a node at the
transmission interface, the resonant bending moment/critical stresses have to be determined by measurement
before the installation can be approved.
Failure to meet the above acceptance criteria.
If the above criteria cannot be met , the requirements should be passed to the Applications Department for a
detailed investigation .
The C4.4 engine block engine is fitted with a structural sump in a tractor fitted with tyres.
There are currently no lateral limits determined for this application arrangement.

Power take off
The various methods of transmitting drive from the engine and data required for satisfactory operation is given
in this power take-off section.
Crankshaft thrust loading
Maximum permissible thrust loads for crankshaft (continuous operation) (1)
With typical torque converter transmission With clutch operation
2,900 N (652 lbf) 5,800 N (1303 lbf)
(1). The thrust loads shown in the table above apply to either forward, or rearward, movement of crank-
shaft.
Crankshaft driven axial power take off

Power take off is also available from the front of the crankshaft through the crankshaft. 750 Nm is available
with this method by either axially, belt driven, or a combination of both (when the heavy duty crankshaft pulley
option is selected).
Note: It is recommended that crankshaft axial driven power take off arrangements are analysed by Cat. See
the torsional vibration section for more information about the limitations of the crankshaft driven power take off.
Torsional vibration
In generators, pumps and compressors etc, where the moment of inertia of the driven machinery is high,
torsional vibration can cause extra stresses at certain speeds. It is strongly recommended that applications
such as these are analysed by Cat. Similar stresses can also occur with low inertia equipment that is driven
off the front of the engine. As a general guideline the inertia of any equipment driven off the front of the engine
should be less than 0.02 kgm². This equipment could include auxiliary crankshaft pulleys for belt driven PTO,
and couplings for axial PTO taken directly off the crankshaft pulley. Higher inertia arrangements may be
acceptable, however it is strongly recommended that these be analysed by Cat.
For the system to be analysed and to ensure the correct performance of the engine etc, the information
required by Cat is the mass/elastic details of all the equipment driven from the front and rear of the engine.
More information about the mass/elastic system calculations is given in the Cat installation manual.

Crankshaft front over hung load (OHL) capability
It is possible to take power from the front crankshaft pulley via belts, chains, etc. This type of PTO generates
a bending moment on the front of the crankshaft. Excessive bending moments can cause issues excessive
stresses on the crankshaft.
The diagram below shows the maximum overhung load that can be applied to the crankshaft by a belt driven
PTO (this includes our fan belts) (viewed from the front of the engine). The radial load is taken at the main
crankshaft pulley location (103 mm from front face of cylinder block) and is measured in kN. Loads taken from
an auxiliary pulley (mounted forwards of the standard crankshaft pulley) should be scaled using moments
taken from the front face of the cylinder block.
A Cat standard 8 rib belt drive arrangement (powering a fan, alternator, etc) applies a maximum load of 2 kN
in a vertical (0°) direction onto the crankshaft pulley (103 mm from front face of cylinder block).
This load needs to be taken into consideration if the engine takes a Cat belt drive arrangement.
C4.4 ACERT TAD crankshaft front over

Crankshaft rear over hung load (OHL) capability
Attaching large/heavy unsupported transmission components to the engine’s flywheel increases the loads on
the engine’s crankshaft and bearings. There is a limit to the amount of mass and bending moment the
crankshaft can support. The full rear OHL capability has not yet been established for the C4.4 engine. It is
therefore strongly recommended that applications taking heavy flywheels/transmission components are
reviewed by Cat (until an OHL limit becomes available).
Flywheel Inertia
The engine flywheel inertia and mass must be contained within certain limits. Excessive inertia can cause high
torsional vibrations. The inertia and mass limits are detailed below. Additional mass and inertia may still be
acceptable. Please contact Cat if the application needs to operate with values above the limits listed below:
Maximum flywheel mass = 50kg
Maximum flywheel inertia (including transmission components fixed to the flywheel) = 1.2kg.m²
Minimum flywheel inertia (including transmission components fixed to the flywheel) = 0.4kg.m²

Alternative side mounted PTO
Gear driven PTO arrangements are available in a variety of locations by selecting different options.
When viewed from the rear:
Q1000: Gearcase: PTO located at the rear of the gearcase, on the left hand side of the engine,
for light duty operation.
for medium duty operation.
Q1100 Gearcase: No PTOs are available.
Q3000 Gearcase: PTO located at the rear of the gearcase, on the right hand side of the engine,
Q3030 Gearcase: PTO located at the rear of the gearcase, on the right hand side of the engine,
Q5000 Gearcase: PTO located at the rear of the gearcase, on both sides of the engine,
for heavy duty operation.
Q5010 Gearcase: PTO located at the rear of the gearcase, on the left hand side of the engine ,
for heavy duty operation.
Cautions:
Light, medium and heavy duty refer to the capability of the main idler gear fitted in a particular option.
The power and torque transmitted through the PTO at any speed, must not exceed the figures shown in
the following tables.
Note: For rotation, ratio and speed, see illustration and tables on the following pages.

Side mounted PTO position
1
2 1
A B
1
2
C
PTO position
A1/B1/C1 A2 B2 C2/C3
Q1000/Q1030/
Crankshaft Q3000/Q3030 Q5000/Q5010
Q1040/Q1050
Note: The view of the gear train in the illustration above is from the front of the engine.

Side mounted PTO operating data
These conditions must be met under all machine operating conditions including factory and/or dealer testing
for end of line or delivery approval.
Consideration must be given to the effect of climatic conditions on PTO loads.
Typical examples of use are lifting equipment such as loaders, telescopic handlers and fork lift trucks where
the PTO is used at a high load for short periods (approximately 30 seconds) for a relatively low proportion of
the engine life.
Where the PTO gear is not supplied by Cat, details for suitable gear designs should be obtained from
Option Rotation Engine speed Max PTO torque (Nm)

PTO gear teeth
QD Q (viewed from front) ratio Continuous ** Intermittent **
Q1000
CW (concentric to spigot) 36 1.00 99 142
Q1040
Q1030
Q1050
QD000*
Q3000 ACW (concentric to spigot) 21 1.71 53 76
Q3030 ACW (concentric to spigot) 21 1.71 76 ---
Q5000
ACW (concentric to spigot) 36 1.00 196 280
Q5010
Q1000
CW (offset to PTO spigot) 34 1.06 99 142
QD005 QD015 Q1040
QD016 Q1030
CW (offset to PTO spigot) 34 1.06 147 210
Q1050
Q1000
Q1040
QD017
Q1030
Q1050
Q1000
QD024 CW (concentric to spigot) 36 1.00 0 0
Q1030
Q1030 CW (concentric to spigot) 36 1.00 0 0
QD042 Q5000
ACW (concentric to spigot) 36 1.00 0 0
Q5010
Q5000
QD055 ACW (concentric to spigot) 36 1.00 196 280
Q5010
RHS Q5000 ACW (concentric to spigot) 28 1.29 71 101
TWIN Q5000 The sum of PTO torque at the crankshaft must not exceed the specified limits for Q5000 / QD055.
PTO Torque at Crankshaft = Σ[(Speed Ratio) x (PTO Torque)]
Notes:
The blanking plate supplied with RHS PTO cases, Q3000 and Q3030, is designed for test and transit only.
The blanking plate supplied with LHS SAE-A splined drives, QD005, QD015 and QD016, is designed for
test and transit only.
The blanking plate supplied with compressors, QD024 and QD042, is designed for test and transit only.
Compressor options
The PTO torque listed above is available from the back of the compressor and is additional to the
compressor drive torque
All RHS PTO applications require Perkins Engineering approval.

Application of PTO load:
Rate of pressure rise measured at the pump outlet should be less than 4000 bar/second. Instantaneous
pressure overshoot on load application should not exceed 10%
Due to potential high rotational speeds of the hydraulic pump, approval should be obtained from the pump
manufacturer.
All compressor use requires approval from your applications engineer.
Maximum compressor duty cycle must not exceed 50%.
Where the PTO gear is not supplied by Cat, details of suitable gear designs should be obtained from Cat. Final
approval from Cat is required for this gear.
Typical uses (continuous duty)
These include any type of auxiliary attachments running frequently for a period of more than 30sec.
Examples: Fixed speed hydraulic fans, screening conveyors, drills and brushes, crushers.
Typical uses (intermittent duty)
These include infrequent operations for a period of less than 30 sec.
Examples: Telehandler boom, forklift mast, forklift side shift, steering pumps.
Note: The above examples are indicative and are provided for convenience. If in doubt, a full assessment
should be done.

Customer fitted pumps
Customers must ensure that their PTO pump is compatible with other options selected.
The first mode of vibration of the pump when mounted on the timing case must exceed 165 Hz.
It is expected that a bracket will be required if the bending moment exceeds the value shown in the table
below:
Max. static bending moment
Timing Case Option Engine speed rpm
Customer fitted pumps (Nm)
Q1000
Q1030
2200 0.0
Q1040
Q1050
Q3000
2200 10.0
Q3030
Q5000 (LHS)
2200 15.0
Q5010 (LHS)
Q5000 (RHS) 2200 15.0
Where the engine is supplied with a single or twin cylinder compressor, a support bracket is also supplied. No
additional support is required for pumps mounted on the back of the compressor.
Applications sign-off
Sign-off should include a modal analysis of the PTO installation.
If a physical test is not done, there must be a statement which will include the reason why it has not been done,
and the basis for signing-off the PTO Pump installation. The statement should include details of the hydraulic
circuit design authority and evidence that the design meets the criteria stated in Table-(1). A waiver should be
obtained from the applications engineering manager.
PTO pump sign-off should include a hydraulic pressure measurement of the installation, validating Max.
system pressure and Max. rate of pressure rise at the PTO pump outlet port. An assessment must be made
of Max. pressure and Max. rate of pressure rise under the most severe operating conditions.
If a physical test is not done, there must be a statement which will include the reason why it has not been done,
and the basis for signing-off the PTO Pump installation. The statement should include details of the hydraulic
circuit design authority and evidence that the design meets the criteria stated in the Table. A waiver should be
obtained from the Applications Engineering Manager.
Duty cycles - assessment and sign-off criteria

This section will help customers understand whether their PTO duty cycle operates within acceptable limits.
Torques refer to PTO gear torque. Where multiple pumps are used on a PTO drive, the combined load must
be used.
Load factor is defined as :- ratio of time-averaged load to maximum PTO load.
Σ [ ( Operating ⋅ Torque ) × ( OperatingTime ) ]

Load Factor = -------------------------------------------------------------------------------------------------------------------------------------------
[ ( Max ⋅ Pump ⋅ Operating ⋅ Torque ) × ( Total ⋅ Time ) ]
Max. pump operating torque = Max. PTO torque (intermittent), see table 1.

Continuous duty cycle
Is defined as a cycle operating up to 'maximum continuous torque' for periods of greater than 30 sec.
Operating torque must not exceed Max. PTO torque (continuous), see table 1.
If the two above conditions are met, load factor will not exceed 70%.
*Max. pump operating torque = Max. PTO torque (intermittent), see table 1.
Fig (1) : Continuous duty cycle operating zone
Typical uses: Fixed speed hydraulic fans, screening conveyors, drills and brushes, crushers.

Intermittent duty cycle
Is defined as a cycle operating up to 'maximum intermittent torque' for up to 30 sec followed by a drop to below
50% of 'maximum intermittent torque' for a longer period.
e.g.
Cycle operating at 100% torque for a period of 30 sec followed by a drop to below 50% torque for a period
longer than 30 sec.
Cycle operating at 100% torque for a period of 10 sec followed by a drop to below 50% torque for a period
longer than 10 sec.
Periods of duty as defined by the continuous duty cycle can be included
Load factor must not exceed 70%.
Max. pump operating torque = Max. PTO (intermittent), see table 1.
Fig (2) : Intermittent duty cycle operating zone

Typical Uses: Telehandler boom, forklift mast, forklift side shift, steering pumps.
Notes on duty cycles:
1 Any failure investigation will be performed on the basis of full assessment and sign-off criteria, including
modal analysis and pressure measurements.
2 A full sign-off assessment will include in-depth duty cycle analysis consisting of calculations of 'load factor'
considering 'time spent under different load conditions' and different climatic conditions.

Mass elastic data
4.4 litre below 110 kW
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Pulley Gear/Ns Palm
Inertia (mk²) (kgm²)
Geartrain and Palm and

Pulley Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
crank nose flywheel
0.0075
Pulley 0.0050 0.0334 0.0313 0.0330 0.0456
+ flywheel
Stiffness (Nm/rad)
A B C D E F
1.102E6 1.619E6 1.130E6 1.079E6 1.190E6 1.984E6
Firing Order
0 540 180 360
Bore diameter (m) 0.105

Stroke (m) 0.127
Connecting rod length (m) 0.219
Reciprocating mass (kg) 2.642
Crank nose diameter (m) 0.051
Crank pin diameter (m) 0.068
Crank main diameter (m) 0.084

4.4 litre above 110 kW
Pulley Gear/Nose Palm
Inertia (mk²) (kgm²)
Geartrain and Palm and

Pulley Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
crank nose flywheel
0.0083 + fly-
Pulley 0.0051 0.0345 0.0328 0.0350 0.0522
wheel
Stiffness (Nm/rad)
A B C D E F
1.044E6 1.807E6 1.256E6 1.292E6 1.393E6 2.324E6
Firing Order
0 540 180 360
Bore diameter (m) 0.105

Stroke (m) 0.127
Connecting rod length (m) 0.219
Reciprocating mass (kg) 2.642
Crank nose diameter (m) 0.051
Crank pin diameter (m) 0.068
Crank main diameter (m) 0.084

Centre of gravity
For a dry engine with standard parts fitted, measurements are from rear face of block/centre line of crank.
Centre of gravity of bare turbocharged aftercooled engine, to RHS looking at rear (X) 0 mm
Centre of gravity of bare turbocharged aftercooled engine, forward from rear of the block (Z) 280 mm
Centre of gravity of bare turbocharged aftercooled engine, vertically from centre line of crank (Y) 230 mm
Centre of gravity of bare twin turbocharged aftercooled engine, to RHS looking at rear (X) 0 mm
Centre of gravity of bare twin turbocharged aftercooled engine, forward from rear of the block (Z) 270 mm
Centre of gravity of bare twin turbocharged aftercooled engine, vertically from centre line of crank (Y) 205 mm

De-ratings
Allowances for engine driven auxiliary equipment
If the engine operates in the ambient conditions shown on the power curve, the only allowances which must
be made are for the power used by accessories such as the fan and the alternator. The amount of power used
by accessories driven by the engine must be decided so that the net horsepower available at the flywheel can
be found. For details of the power absorbed by the compressors, the exhauster and the fans, see “De-ratings”
on page 277 to page 285.
De-rating
If the engine operates in ambient conditions other than the conditions shown on the power curve, then suitable
allowances must be made for any change in inlet temperature, barometric pressure or humidity.
Inlet air temperature
High inlet air temperature to the engine can cause loss of power and heat problems with the cooling system,
the lubricating oil and hydraulic systems. This may be either due to high ambient temperatures, or because the
engine is being used inside a building or structure of a machine which requires more air flow.
Altitude
The C4.4 ACERT TAD and C4.4 ACERT TTAD turbocharged charge cooled engines are capable of operating
at altitudes of up to 3000 metres without derate other than due to changes in ambient and atmospheric
conditions. Turbochargers are approved for operation up to 3000 metres.
Humidity
The amount by which the rating will be reduced because of humidity, will be according to the percentage
humidity and the ambient temperature (not the inlet air temperature).
Temperature
For the effects on the fuel oil changes in temperature and specific gravity, refer to Cat Application Engineers.
Engine ratings given by Cat are corrected to the reference conditions shown in the rating standards.

Compressor single cylinder 225cc - free air delivery
278
INTERIM LIMIT OF 7 BAR - CONSULT PRODUCT MANAGEMENT FOR OPERATING PRESSURE GREATER THAN THIS
400
350
8 BAR
300
R
Single cylinder 225cc - free air delivery
10 B A
Compressor performance curves
1 2 BAR
250
200
150
F.A.D. (I/min)
100
50
0
1000 1500 2000 2500 3000
Speed revs/min
The compressor is water cooled and governor controlled

Compressor single cylinder 225cc - delivered air temperature
200
180
160
Single cylinder 225cc - delivered air temperature
10 BAR
140
8 BAR
120
D.A.T. (Deg.C)
R
12 BA

100
80
1000 1500 2000 2500 3000
Speed (revs/min)
279
Compressor single cylinder 225cc - power consumption
280
R R
1 0 BA 12 BA
4
Single cylinder 225cc - power consumption
8 BAR
3
Power Consumption ( kW)

EAD and LINE
0 BAR H
1
0
1000 1500 2000 2500 3000
Speed (revs/min)

Compressor single cylinder 225cc - air charging time to pressurise a 50 litre receiver
300
250
14
BA
R
200
12
BA
R
150 10 B
AR
Time/secs.
8 BA
R
100

6 BAR
4 BAR
50
2 BAR
Single cylinder 225cc - air charging time to pressurise a 50 litre receiver
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Speed/revs/min
281
282
630cc ESS Compressor
Free Air Delivery
1200
1100
1000
900
800
700
600
F.A.D. (l/min)
500
400
Twin cylinder, 630cc, ESS (Energy Saving System), free air delivery
300
200
100
0
500 1000 1500 2000 2500 3000
Speed (rev/min)
12 bar 10 bar 8 bar 0 bar + ESS 30/01/2006

Delivered Air Temperature
260
240
220
200
180
160
140
120
D.A.T. (°C)

100
80
60
Twin cylinder, 630cc, ESS (Energy Saving System), delivered air temperature
40
20
0
500 1000 1500 2000 2500 3000
Speed (rev/min)
283
284
Power Consumption
12
11
10
Power Consumption (kW)

4
3
Twin cylinder, 630cc, ESS (Energy Saving System), power consumption
0
500 1000 1500 2000 2500 3000
Speed (rev/min)

Fan performance curve
26 inch diameter
60
50
4000 rpm
40
Power (kW)
3500 rpm
30
3000 rpm
20
2500 rpm
10
2000 rpm
1500 rpm
1000 rpm
0
0 2 4 6 8 10 12
Airflow (m³/s)
5000
3500 rpm 4000 rpm
4500
4000
3000 rpm Not available at time of print
3500
Static Pressure (Pa)
3000
2500 rpm
2500
2000
2000 rpm
1500
1000 1500 rpm
500 1000 rpm
0
0 2 4 6 8 10 12
Airflow (m³/s)
Option code: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... . M0005 /M0007 ('standard fan')
Part number: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. 3594816
Diameter: . .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... . 660 mm 26.0 in
Air flow direction: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. Pusher/Puller
No. of blades: .. .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... 7
Blade material: .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... . Composite
Hub material: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. Steel
Max. fan speed: .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. 4488 rpm
22 inch diameter
60
50
4000 rpm
40
Power (kW)
3500 rpm
30
3000 rpm
20
2500 rpm
10
2000 rpm
1500 rpm
1000 rpm
0
0 2 4 6 8 10 12
Airflow (m³/s)
5000
3500 rpm 4000 rpm
4500
4000
3000 rpm
3500
Static Pressure (Pa)
3000
2500 rpm
2500
2000
2000 rpm
1500
1000 1500 rpm
500 1000 rpm
0
0 2 4 6 8 10 12
Airflow (m³/s)
Option code:.. .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. M0013/M0015 ('standard fan')
Part number: . .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... ..3615559
Diameter: .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. 559 mm (22.0 in)
Air flow direction:.. .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... . Pusher/Puller
No. of blades: .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... 7

Blade material:.. .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. Composite
Hub material: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. . Steel
Max. fan speed: .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. . 4488 rpm
Performance curve no: ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. ... .. .. TBA

Important notes
Company liability
The engine supplied must only be used for the purpose given in the Companies ‘Acknowledgement of Order’
and to the Companies specific instructions for its installation and operation. It must not be used, or passed to
any other person, for any other purpose or be installed by any other method except with the Companies written
approval.
The application and installation of the engine must be suitable for the needs of the machine in which it is
installed and the conditions in which it will have to operate.
The Company does not have direct control of the type of application and how the engine is installed and used
in it and cannot be held responsible for any loss or damage where the person or persons that installed the
engine, or the user, have not followed the advice given by the company.
It is very important to ensure that the installation of the engine is according to the health and safety legislation
of the country in which the engine is to operate.
Installation
The engine must:
have the necessary power and torque characteristics for the machine in which it is installed so that it can
operate in all necessary environmental conditions
be connected securely and correctly to the driven load according to operation needs and torsional vibration
characteristics
be given protection from adverse atmospheric conditions and supplied with the correct clean fuel,
lubricating oil and air
have the correct maintenance and operation according to Cat instructions as given in the installation,
operation and service books.
It is also important that:
All parts that rotate, such as pulleys, flywheels, fans, shafts, couplings and drive belt systems must have a
protection guard fitted over them with a warning that fingers must not be put through the guards
Electrical terminations are shielded to prevent external short circuits. All cables that supply current must be
protected by insulation and all electrical equipment must have a suitable and secure connection to ground
The exhaust system must have a suitable heat shield or lagging where it can be a danger to persons.
Warning! All build lists referenced in this publication exclude any fan guarding or hot surface protection
features. To the extent that it is lawfully possible, the Company accepts no responsibility whatsoever for any
injury, damage or death, whether to property or persons, arising directly or indirectly from this exclusion.
Legislation
Specific legislation for each country cannot be given here because of the amount and continuous changes that
occur. OEM are responsible for the compliance of their Machine when placed into market or services. The
subjects which can effect operation are:
Gaseous and particulate emissions
Engine power
Exhaust smoke opacity
Noise
Electro Magnetic Compatibility
Product Safety
Operation in explosive atmosphere or areas where there are flammable materials
Operation where ventilation is limited or health is important
Safe disposal of hazardous substance.
Warranty
This can be made invalid if the engine is not installed or operated/maintained according to Cat instructions.

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Cat™ C4.

ENGINE SPECIFICATION MANUAL

C4.4 ACERT Four cylinder diesel engines for

Publication TPD1752 Issue 7.

2 The engine range

The following pages contain a detailed table of contents

2 The engine range

General arrangement drawings

Engine Specification Manual, TPD1752 Issue 7, February 2012 iii

iv Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 v

vi Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 vii

viii Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 ix

x Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 xi

xiv Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 xv

xvi Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 1

Chapter 2: The engine range

Chapter 3: Engine specification

Chapter 6: Technical data

2 Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 3

ULS Ultra Low Sulfer

4 Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine type codes

Engine Specification Manual, TPD1752 Issue 7, February 2012 5

6 Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 7

8 Engine Specification Manual, TPD1752 Issue 7, February 2012

Mandatory specification requirements

Engine Specification Manual, TPD1752 Issue 7, February 2012 9

Construction Material handling

10 Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 11

Machine load factor

Method 1 - To estimate machine load factor

Method 2 - To estimate machine load factor

Estimated machine load factor is:

If further assistance is required please contact Cat Applications department.

12 Engine Specification Manual, TPD1752 Issue 7, February 2012

D Flywheel and starter ring

VD Fuel filter secondary branding

LD Thermostat housing, outlet connection

Engine Specification Manual, TPD1752 Issue 7, February 2012 13

Side mounted turbocharger

97.5 ECM CONNECTION 55.6

4-M 12 X 1.75 X 24.5

281 ECM CONNECTION

14 Engine Specification Manual, TPD1752 Issue 7, February 2012

Engine Specification Manual, TPD1752 Issue 7, February 2012 15

605 FIRST GROOVE

16 Engine Specification Manual, TPD1752 Issue 7, February 2012

20.5 MOUNTING HOLE-REAR

Engine Specification Manual, TPD1752 Issue 7, February 2012 17

Subject to change at Production cut in

199.5 ECM CONNECTION

18 Engine Specification Manual, TPD1752 Issue 7, February 2012

57.1 THERMOSTAT O.D.

Engine Specification Manual, TPD1752 Issue 7, February 2012 19

CRANK PULLEY 100 100