Caterpillar 3024C Engine For Caterpillar Built Machine Service Repair Manual – PDF Download

SENR5004-02 SENR5005-03 SENR5006-04

3024C Engine for Caterpillar Built Machines S/N –

3024C Engine for Caterpillar Built Machines Section Total Page

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SENR5004-02 Specifications INDEX Engine Design Fuel Injection Lines Fuel Injection Pump Fuel Injection Nozzles Fuel Transfer Pump Rocker Shaft Valve Mechanism Cover Cylinder Head Valves Cylinder Head Exhaust Manifold Camshaft Camshaft Lobe Lift Retainer Plate for the Camshaft Engine Oil Lines Engine Oil Filter Engine Oil Relief Valve Engine Oil Pump Engine Oil Pressure Engine Oil Pan Oil Suction Tube and Oil Strainer Water Temperature Regulator Water Temperature Regulator Housing Cylinder Block Crankshaft Measure Wear on the Crankshaft Measure the Main Bearing Clearance Crankshaft Main Bearing Cap Connecting Rod Bearing Journal Main Bearing Journal Connecting Rod Markings on the Connecting Rod Distortion of the Connecting Rod Piston and Rings Markings on the Piston Piston Rings Pistons Housing (Front) Gear Group (Front) Flywheel Flywheel Housing Crankshaft Pulley Belt Tension Chart Fan Drive Engine Lifting Bracket Alternator and Regulator Electric Starting Motor Starting Motor

Start Relays Coolant Temperature Switch Engine Oil Pressure Switch Glow Plugs Fuel Shutoff Solenoid

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SENR5005-03 Systems Operation INDEX Engine Design 3024C Engine General Information Engine Description Lifting the Engine 3024C Engine Model Views Fuel System General Operation of the Fuel System Governor Fuel Injection Pump Fuel Injection Nozzles Fuel Transfer Pump Glow Plugs Air Inlet and Exhaust System Cylinder Head And Valves Lubrication System Cooling System Basic Engine Cylinder Head and Block Pistons and Connecting Rods Timing Gear Case and Gears Electrical System Engine Electrical System Automatic Shutdown System Automatic Shutdown Conditions Charging System Components Alternator Regulator Starting System Components Solenoid Electric Starting Motor Other Components Circuit Breaker SENR5005-03 Testing and Adjusting Troubleshooting Introduction Troubleshooting The Fuel Injection Nozzles On The Engine The engine is difficult to start or the engine runs rough.

The engine exhaust has too much black smoke.

The engine has lost power and the engine uses too much fuel.

The engine is misfiring, running rough, or running poorly.

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester Back leakage The fuel injection nozzle does not inject fuel in the correct quantity or in the correct pattern.

Troubleshooting the Engine

The engine will not start.

The engine starts and the engine runs for a brief period of time and the engine stops.

The engine misfires or the engine runs rough.

The engine runs evenly, but the engine loses power.

The engine lacks power.

The engine has excessive vibration.

The engine has excessive combustion noise.

The engine has excessive valve compartment noise.

Engine oil is in the cooling system.

Engine knock occurs.

The rocker arm has insufficient movement and the valve lash exceeds the specification.

A cylinder head valve is loose.

Oil condenses at the exhaust.

The valve lash is less than the required specification.

Engine components have early wear.

Coolant is in the engine oil.

The engine exhaust has too much black smoke or too much gray smoke.

The engine exhaust has too much white smoke or too much blue smoke.

The engine has low oil pressure.

The engine oil pressure is too high.

The engine uses too much engine oil.

The engine overheats.

The exhaust temperature is too high.

The starting motor does not turn or the starting motor turns too slowly.

The starting motor turns, but the pinion gear does not engage the flywheel ring gear.

The engine does not crank or the engine rotates slowly when the keyswitch is in the start position.

The starting motor continues to run after the ignition switch is released.

The pinion gear does not disengage after the engine starts to run.

The alternator does not charge the battery or the alternator charge rate is slow or irregular.

The alternator charges the battery to a voltage that is too high.

The alternator is noisy.

Fuel System - Inspect Air in Fuel - Test Engine Speed - Check Finding Top Center Position for No. 1 Piston Fuel Injection Nozzle - Test Inspection and Cleaning of the Fuel Injection Nozzles Leakage Test Pressure Test Test for the Nozzle Spray Pattern Fuel Injection Timing - Check Fuel Quality - Test Fuel System - Prime Fuel System Pressure - Test Gear Group (Front) - Time Air Inlet and Exhaust System - Inspect Exhaust Temperature - Test Measure the Exhaust Temperature Engine Crankcase Pressure (Blowby) - Test Compression - Test Compression Engine Valve Lash - Inspect/Adjust Valve Lash Check Valve Lash Adjustment Valve Depth - Inspect Valve Guide - Inspect

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100 101 102 104 106 107 108

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Engine Oil Pressure - Test Engine Oil Pump - Inspect Excessive Bearing Wear - Inspect Excessive Engine Oil Consumption - Inspect Engine Oil Leaks on the Outside of the Engine Engine Oil Leaks into the Combustion Area of the Cylinders Cooling System - Check - Overheating Cooling System - Inspect Cooling System - Test Test Tools For The Cooling System Making the Correct Antifreeze Mixtures Checking the Filler Cap Testing The Radiator And Cooling System For Leaks Cooling System Conditioner Water Temperature Regulator - Test Water Pump - Inspect Piston Ring Groove - Inspect Inspect the Piston and the Piston Rings Inspect the Clearance of the Piston Ring Inspect the Piston Ring End Gap Connecting Rod - Inspect Distortion of Connecting Rod Inspect the Bearings and Piston Pin for Wear Connecting Rod Bearings - Inspect Main Bearings - Inspect Cylinder Block - Inspect Cylinder Head - Inspect Piston Height - Inspect Flywheel - Inspect Alignment of the Flywheel Face Flywheel Runout Flywheel Housing - Inspect Face Runout (Axial Eccentricity) of the Flywheel Housing Bore Runout (Radial Eccentricity) of the Flywheel Housing Gear Group - Inspect Alternator - Test Battery - Test Charging System - Test Alternator Regulator Coolant Temperature Switch - Test Electric Starting System - Test Engine Oil Pressure Switch - Test Fuel Shutoff Solenoid - Test Glow Plugs - Test Continuity Test Glow Plug Circuit

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SENR5006-04 Disassembly and Assembly INDEX Fuel Transfer Pump - Remove Removal Procedure Fuel Transfer Pump - Install Installation Procedure Fuel Injection Lines - Remove and Install Removal Procedure

Installation Procedure Fuel Injection Nozzles - Remove Removal Procedure Fuel Injection Nozzles - Install Installation Procedure Fuel Shutoff Solenoid - Remove and Install Removal Procedure Installation Procedure Governor - Disassemble Disassembly Procedure Removal of the Governor Weight Assembly Removal of the lever for the Engine Stop Remove the linkage for the fuel injection pump Remove the Speed Control Lever for the Engine Governor - Assemble Assembly Procedure Install the Speed Control Lever for the Engine Install the Linkage for the Fuel Injection Pump Installation of the Lever for the Engine Stop Installation of the Governor Weight Assembly Fuel Injection Pump - Remove Removal Procedure Fuel Injection Pump - Install Installation Procedure Exhaust Manifold - Remove and Install Removal Procedure Installation Procedure Inlet and Exhaust Valve Springs - Remove and Install Removal Procedure Installation Procedure Inlet and Exhaust Valves - Remove and Install Removal Procedure Removal Procedure (Alternate Method) Installation Procedure Installation Procedure (Alternate Method) Engine Oil Line - Remove and Install Removal Procedure Installation Procedure Engine Oil Relief Valve - Remove and Install Removal Procedure Installation Procedure Engine Oil Pump - Remove Removal Procedure Engine Oil Pump Idler Hub Engine Oil Pump - Install Installation Procedure Idler Hub Engine Oil Pump Water Pump - Remove Removal Procedure Water Pump - Install Installation Procedure Water Temperature Regulator - Remove and Install Removal Procedure Installation Procedure

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Flywheel - Remove Removal Procedure Flywheel - Install Installation Procedure Crankshaft Rear Seal - Remove Removal Procedure Crankshaft Rear Seal - Install Installation Procedure Flywheel Housing - Remove and Install Removal Procedure (Engines with Flywheel Housing and Back plate) Removal Procedure (Engines with Flywheel Housing) Installation Procedure (Engines with Flywheel Housing and Back plate) Installation Procedure (Engines with Flywheel Housing) Crankshaft Pulley - Remove and Install Removal Procedure Installation Procedure Crankshaft Front Seal - Remove Removal Procedure Crankshaft Front Seal - Install Installation Procedure Housing (Front) - Remove Removal Procedure Housing (Front) - Install Installation Procedure Crankcase Breather - Remove and Install Removal Procedure Installation Procedure Valve Mechanism Cover - Remove and Install Removal Procedure Installation Procedure Rocker Shaft and Pushrod - Remove Removal Procedure Rocker Shaft - Disassemble Disassembly Procedure Rocker Shaft - Assemble Assembly Procedure Rocker Shaft and Pushrod - Install Installation Procedure Cylinder Head - Remove Removal Procedure Cylinder Head - Install Installation Procedure Lifter Group - Remove and Install Removal Procedure Installation Procedure Camshaft - Remove Removal Procedure Camshaft - Install Installation Procedure Engine Oil Pan - Remove and Install Removal Procedure Installation Procedure Pistons and Connecting Rods - Remove Removal Procedure Pistons and Connecting Rods - Disassemble Disassembly Procedure

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Pistons and Connecting Rods - Assemble Assembly Procedure Pistons and Connecting Rods - Install Installation Procedure Connecting Rod Bearings - Remove Removal Procedure Connecting Rod Bearings - Install Installation Procedure Crankshaft Main Bearings - Remove Removal Procedure Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft Main Bearings - Install Installation Procedure Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft - Remove Removal Procedure Crankshaft - Install Installation Procedure Bearing Clearance - Check Measurement Procedure Coolant Temperature Switch - Remove and Install Removal Procedure Installation Procedure Engine Oil Pressure Switch - Remove and Install Removal Procedure Installation Procedure Glow Plugs - Remove and Install Removal Procedure Installation Procedure V-Belts - Remove and Install Removal Procedure Installation Procedure Alternator - Remove and Install Removal Procedure Installation Procedure Electric Starting Motor - Remove and Install Removal Procedure Installation Procedure

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1

INDEX

SENR5004-02

3024C Engine for Caterpillar Built Machines Specifications Engine Design

INDEX

1 3

Fuel Injection Lines

4

Fuel Injection Pump

5

Fuel Injection Nozzles

6

Fuel Transfer Pump

7

Rocker Shaft

8

Valve Mechanism Cover

9

Cylinder Head Valves

10

Cylinder Head

13

Exhaust Manifold

15

Camshaft

16

Camshaft Lobe Lift Retainer Plate for the Camshaft Engine Oil Lines

18

Engine Oil Filter

19

Engine Oil Relief Valve

20

Engine Oil Pump

21

Engine Oil Pressure

23

Engine Oil Pan

24

Oil Suction Tube and Oil Strainer Water Temperature Regulator

25

Water Temperature Regulator Housing Cylinder Block

26

Crankshaft

27

Measure Wear on the Crankshaft Measure the Main Bearing Clearance Crankshaft Main Bearing Cap Connecting Rod Bearing Journal

30

Main Bearing Journal

31

Connecting Rod

32

Markings on the Connecting Rod Distortion of the Connecting Rod Piston and Rings

34

Markings on the Piston Piston Rings Pistons Housing (Front)

36

Gear Group (Front)

37

Flywheel

38

Flywheel Housing

39

SENR5004-02

2

Crankshaft Pulley

40

Belt Tension Chart

41

Fan Drive

42

Engine Lifting Bracket

43

Alternator and Regulator

44

Electric Starting Motor

45

Starting Motor Start Relays Coolant Temperature Switch

47

Engine Oil Pressure Switch

48

Glow Plugs

49

Fuel Shutoff Solenoid

50

SENR5004-02

3

001

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Design

Illustration 1 g00296424 Cylinder and valve location, (A) Exhaust valve (B) Inlet valve

Bore ... 84.0 mm (3.30 inch) Stroke ... 100.0 mm (3.94 inch) Displacement ... 2.2 L (135.23 in3) Cylinder arrangement ... In-line Type of combustion ... Indirect injection Compression ratio ... 23.3:1 Number of cylinders ... 4 Valves per cylinder ... 2 Valve lash Inlet valve ... 0.2 mm (0.008 inch) Exhaust valve ... 0.2 mm (0.008 inch) Firing order ... 1, 3, 4, 2 When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction. ... Clockwise When the camshaft is viewed from the front of the engine, the camshaft rotates in the following direction. ... Clockwise The front of the engine is opposite the flywheel end of the engine. The left side and the right side of the engine are determined from the flywheel end. Number 1 cylinder is the front cylinder of the engine.

001 : Specifications

4

002

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fuel Injection Lines

Illustration 1

g00818680

(1) Tighten the union nuts for the fuel injector to the following torque.

C0.5, C0.7 and C1.6 ... 20 N路m (14.75 lb ft) C1.1/3011C, C1.5/3013C, C2.2/3024C and C2.2/3024CT engines ... 23 N路m (17 lb ft) (2) High pressure fuel supply line (3) Low pressure fuel return line (4) Tighten the banjo bolt to the following torque. ... 2.5 N路m (22 lb in)

Illustration 2

g00818888

(5) Tighten the nut to the following torque. ... 27 N路m (20 lb ft) (6) Washers for the fuel return line (7) Washer for the fuel injector (8) Washers for the banjo bolt Note: All washers must be replaced when the fuel lines are removed.

002 : Specifications

5

003

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fuel Injection Pump

Illustration 1

g00819040

Type of fuel injection pump ... In-line cassette Direction of rotation of the camshaft for the fuel injection pump ... Clockwise from the drive end, (1) Tighten the union nut that connects the low pressure fuel line to the fuel injection pump to the following torque. ... 2.5 N·m (22 lb in) (2) Tighten the mounting nuts to the following torque. ... 15 N·m (11 lb ft) (3) Tighten the four delivery valve holders to the following torque. ... 42 N·m (31 lb ft) (4) Shim (5) Tighten the mounting bolts to the following torque. ... 15 N·m (11 lb ft) The shim adjusts the timing of the fuel injection pump. A thicker shim retards the timing. A thinner shim advances the timing. The timing changes one degree for each 0.10 mm (0.004 inch) difference in the thickness of the shim. More than one shim can be used. If the fuel injection pump is reinstalled, a new shim, which is the same thickness as the original shim, must be installed.

If any of the following new components are installed, a new shim which has a thickness of 0.5 mm (0.020 inch) must be used in order to correctly adjust the timing of fuel injection. ¡ Camshaft ¡ Cylinder block The following thicknesses of shims are available: ¡ 0.10 mm (0.004 inch) ¡ 0.20 mm (0.008 inch) ¡ 0.30 mm (0.012 inch) ¡ 0.40 mm (0.016 inch) ¡ 0.50 mm (0.020 inch)

003 : Specifications

6

004

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fuel Injection Nozzles

Illustration 1

g01111978

(1) Tighten the fuel injection nozzles to the following torque.

C1.1/3011C, C1.5/3013C, C2.2/3024C and C2.2/3024CT ... 64 N¡m (47.2 lb ft) (2) Tighten the fuel injection nozzles to the following torque.

C0.5, C0.7 and C1.6 ... 64 N¡m (47.2 lb ft) Note: Remove the original seat washer from the hole for the fuel injector. Do not reuse the original seat washer.

Note: Apply a 2 mm ( 0.0787 inch) bead of 239-3312 Sealant to the first 6 mm ( 0.2362 inch) of the thread to the fuel injection nozzle.

The fuel injection nozzle (1) will open at the following pressure. ... 14707 kPa (2133 psi) The fuel injection nozzle (2) will open at the following pressure. ... 11769 kPa (1707 psi) Leakage in 10 seconds ... 0 drops

004 : Specifications

7

005

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fuel Transfer Pump

Illustration 1

g00819278

(1) Tighten the adjustment screw for the fuel transfer pump to the following torque. ... 2.5 N¡m (1.8 lb ft) (2) Fuel transfer pump (3) Flange for the fuel transfer pump Note: The fuel inlet for the fuel transfer pump can be rotated 360 degrees. The fuel inlet is adjustable in 15 degree increments.

Note: The flange of the fuel transfer pump has two sets of locating holes. This allows the fuel transfer pump to be mounted in four positions for the outlet connection., (4) O-ring (5) Tighten the mounting bolts to the following torque. ... 6 N¡m (4.4 lb ft)

005 : Specifications

8

Specifications

006 3024C Engine for Caterpillar Built Machines, SENR5004-02

Rocker Shaft

Illustration 1

g01335378

Note: Before assembly, lubricate the components with clean engine oil., (1) Tighten the bolts for the housing of the rocker shaft to the following torque. ... 10 N·m (89 lb in) (2) Tighten the nuts for the housing of the rocker shaft to the following torque. ... 33 N·m (24 lb ft) (3) Housing for the rocker shaft assembly

Illustration 2

g00819413

Illustration 3

g00819419

(4) Rocker shaft Diameter of the rocker shaft ... 14.95 to 14.97 mm (0.589 to 0.590 inch) (5) Stud

(6) Tighten the locknut to the following torque. ... 14 N·m (10 lb ft) (7) Adjustment screw for the rocker arm (8) Rocker arm (9) Rocker arm clearance on the rocker shaft Minimum permissible clearance ... 0.030 to 0.093 mm (0.0012 to 0.0037 inch) Maximum permissible clearance ... 0.2 mm (0.01 inch)

006 : Specifications

9

007

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Valve Mechanism Cover

Illustration 1

g00819350

(1) Tighten the bolts to the following torque. ... 14 N·m (10 lb ft) (2) Tighten the bolts to the following torque. ... 14 N·m (10 lb ft) (3) Connector for the engine crankcase breather (4) Gasket (5) Tighten the cap nuts to the following torque. ... 14 N·m (10 lb ft) (6) Valve mechanism cover (7) Housing for the rocker shaft assembly (8) Seal

007 : Specifications

10

008 3024C Engine for Caterpillar Built Machines, SENR5004-02

Cylinder Head Valves

Illustration 1 g00845814 Cross section view of the cylinder head valves in the cylinder head

Illustration 2 g00845818 Typical example of the cylinder head and the valves The arrow points toward the front of the engine.

(1) Collet which consists of two pieces (2) Valve spring cap (3) Valve spring Free length ... 33.5 to 35.0 mm (1.32 to 1.38 inch) Length of valve spring under test force ... 30.40 mm (1.197 inch) Test force ... 69 to 79 N (16 to 18 lb) (4) Valve guide seal for the exhaust valve Type ... Black garter spring Label on the black garter spring ... "EX" (5) Recess for spring

008 : Specifications

Specifications

11

Illustration 3

g00845819

(6) Valve guide (A) Clearance between the valve and valve guide ... 0.030 to 0.060 mm (0.0012 to 0.0024 inch) Clearance between the valve and valve guide ... 0.20 mm (0.0079 inch) (A) Standard clearance for the exhaust valve ... 0.050 to 0.075 mm (0.0020 to 0.0030 inch) Service limit for the exhaust valve ... 0.25 mm (0.010 inch) (7) Exhaust valve stem Diameter of the exhaust valve stem ... 6.940 to 6.950 mm (0.2732 to 0.2736 inch) Service limit ... 6.840 mm (0.2693 inch) (8) Inlet valve stem Diameter of the inlet valve stem ... 6.955 to 6.970 mm (0.2738 to 0.2744 inch) Service limit ... 6.890 mm (0.2710 inch) (9) Valve face angle Valve face angle ... 45 degrees Valve seat angle ... 45 degrees

Illustration 4

g00845823

(B) Thickness of the valve head Exhaust valve ... 0.925 to 1.075 mm (0.03642 to 0.04232 inch) Service limit for the exhaust valve ... 0.50 mm (0.020 inch) Inlet valve ... 0.925 to 1.075 mm (0.03642 to 0.04232 inch) Service limit for the inlet valve ... 0.50 mm (0.020 inch)

008 : Specifications

12

Illustration 5

g00845825

(C) Valve depth below the cylinder head face Valve depth for the exhaust valve ... 0.65 to 0.95 mm (0.026 to 0.037 inch) Service limit for the exhaust valve ... 1.8 mm (0.07 inch) Valve depth for the inlet valve ... 0.65 to 0.95 mm (0.026 to 0.037 inch) Service limit for the inlet valve ... 1.8 mm (0.07 inch) (10) Cap (11) Valve guide seal for the inlet valve Type ... Silver garter spring (12) Cylinder head (13) Gasket The code number that is printed on the gasket should face the cylinder head., (14) Pushrod Diameter of pushrods ... 6.30 mm (0.248 inch) Length of the pushrod ... 205.1 to 205.9 mm (8.08 to 8.11 inch)

Illustration 6

g00845827

(15) Valve seat insert (D) Standard width for the exhaust valve ... 1.94 to 2.16 mm (0.076 to 0.085 inch) Service limit for the exhaust valve ... 2.5 mm (0.10 inch) (D) Standard width for the inlet valve ... 1.50 to 2.00 mm (0.059 to 0.079 inch) Service limit for the inlet valve ... 2.5 mm (0.10 inch) (16) Lifter

008 : Specifications

13

009

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Cylinder Head

Illustration 1

g00819698

(1) Dowel pins The dowel pins in the cylinder block hold the cylinder head gasket in the correct position when the cylinder head is installed., (2) Cylinder head gasket (3) The stamped marking on the cylinder head gasket must face upward. This ensures that the cylinder head gasket is installed correctly.

Illustration 2

g00819713

Put clean engine oil on the threads of the cylinder head bolts. Tighten all of the bolts finger tight.

Tighten the bolts in the number sequence in Illustration 2.

Tighten the cylinder head bolts to the following torque. ... 101 N¡m (75 lb ft), (4) Cylinder head Minimum distortion of the cylinder head ... 0.0 to 0.05 mm (0.000 to 0.002 inch) Maximum distortion of the cylinder head ... 0.12 mm (0.005 inch) Service limit ... 0.15 mm (0.006 inch) Refer to Testing and Adjusting, "Cylinder Head - Inspect" for the procedures for measuring the cylinder head.

009 : Specifications

14

Illustration 3

g00819738

(5) Piston height Table 1 Piston Height Below Cylinder Block Thickness of Cylinder Head Gasket -0.45 to -0.30 mm (-0.018 to -0.012 inch) -0.40 mm (-0.016 inch) -0.29 to -0.20 mm (-0.012 to -0.008 inch) -0.50 mm (-0.020 inch) Note: If the cylinder head has been machined, check the valve depth below the cylinder head face. See Specifications, "Cylinder Head Valves". Before any work is done on the valve seats, new valve guides must be installed.

009 : Specifications

15

010

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Exhaust Manifold

Illustration 1

g00826565

(1) Gasket (2) Exhaust manifold (3) Tighten the nuts for the exhaust manifold to the following torque. ... 25 N¡m (18 lb ft) (4) Tighten the bolts for the exhaust manifold to the following torque. ... 25 N¡m (18 lb ft)

010 : Specifications

16

011

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Camshaft

Illustration 1 Camshaft gear and bearings

g00459336

(1) Key for shaft and gear (2) Camshaft (3) Bearing (4) Spacers (5) Gear for tachometer (6) Spacer (7) Camshaft gear with governor (8) Hub Note: For information on the backlash of the camshaft gear, refer to Specifications, "Gear Group (Front)".

Lifters Diameter of the lifters ... 26.959 to 26.980 mm (1.0613 to 1.0622 inch) Diameter of the bore in the cylinder block for the lifters ... 27.000 to 27.021 mm (1.0631 to 1.0641 inch) Clearance between the lifters and the cylinder block ... 0.020 to 0.062 mm (0.0008 to 0.0024 inch)

Camshaft Lobe Lift

Illustration 2

g00295323

011 : Specifications

17

(A) Actual lobe lift (B) Height of the camshaft lobe (C) Base circle To determine the lobe lift, use the procedure that follows: 1. Measure the camshaft lobe height (B) .

2. Measure the base circle (C) .

3. Subtract the base circle that is found in Step 2 from the camshaft lobe height that is found in Step 1.

The difference is the actual camshaft lobe lift.

Illustration 3

g00819857

Camshaft lobe lift, (1) Camshaft lobe for inlet and exhaust valves Diameter of camshaft lobe for the inlet and exhaust valves ... 34.453 to 34.507 mm (1.3564 to 1.3585 inch) Maximum service limit of camshaft lobe for the inlet and exhaust valves ... 33.7 mm (1.33 inch) (2) Camshaft lobe for the fuel injection pump Diameter of camshaft lobe for the fuel injection pump ... 31.900 to 32.000 mm (1.2559 to 1.2598 inch) Maximum service limit of camshaft lobe for the fuel injection pump ... 30.0 mm (1.18 inch) (3) Camshaft eccentric for the fuel transfer pump Diameter of the camshaft eccentric for the fuel transfer pump ... 41.940 to 42.060 mm (1.6512 to 1.6559 inch) Maximum service limit of camshaft eccentric for the fuel transfer pump ... 41.8 mm (1.65 inch)

Retainer Plate for the Camshaft

Illustration 4

g00819901

(4) Tighten the setscrews for the retainer plate for the camshaft to the following torque. ... 11 N¡m (100 lb in) (5) Retainer plate for the camshaft (6) Camshaft gear

011 : Specifications

18

012

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Lines

Illustration 1

g01093847

(1) Engine oil line (2) Washers Note: The washers must be replaced with new washers when the engine oil line is removed., (3) Tighten the banjo bolts to the following torque. ... 12 N¡m (9 lb ft)

012 : Specifications

19

013

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Filter When the oil filter is installed, place a thin film of clean engine oil on the face of the gasket.

Tighten the oil filter firmly with your hand.

Illustration 1 Oil filter with bypass valve

g00459807

(1) Cylinder block (2) Oil filter (3) Bypass valve Pressure to open bypass valve ... 69 Âą 14 kPa (10 Âą 2 psi) (A) Engine oil flow from the oil pump to the oil filter (B) Engine oil flow from the oil filter (C) Engine oil flow around an open bypass valve

013 : Specifications

20

014

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Relief Valve

Illustration 1

g00820218

Note: When the engine oil relief valve is installed, ensure that all components are clean. Lightly lubricate all components with clean engine oil.

Pressure to open engine oil relief valve ... 352 to 448 kPa (51.1 to 65.0 psi), (1) O-ring A new O-ring should be used when the engine oil relief valve is installed., (2) Tighten the engine oil relief valve to the following torque. ... 64 N¡m (47 lb ft) Note: Always remove the engine oil relief valve before removing the crankshaft. Damage to the engine oil relief valve or damage to the crankshaft may occur.

014 : Specifications

21

015

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Pump NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

Illustration 1 g00458938 Idler gear and components of the engine oil pump

Type ... Gerotor pump, (1) C-clip (2) Collar (3) Spring (4) Shim (5) Oil pump cover (6) Inner rotor Number of lobes ... 4 (7) Spring (8) Outer rotor Number of lobes ... 5

Illustration 2

g00459701

(A) Clearance between the inner rotor and the outer rotor is the following value. ... 0.01 to 0.15 mm (0.0004 to 0.006 inch) Service Limit ... 0.25 mm (0.010 inch), (9) Bushing (10) Idler gear (11) Thrust washer

015 : Specifications

22

Illustration 3

g01290817

(1) C-clip (2) Collar (4) Shim (12) Feeler gauge (B) When the components of the oil pump are installed on the front housing, measurement (B) between C-clip (1) and collar (2) must not exceed the following distance. ... 0.10 to 0.15 mm (0.004 to 0.006 inch) Service limit ... 0.20 mm (0.008 inch) The distance between the faces is adjusted with shims (4) . The following sizes of shims are available: ยก 0.10 mm ยก 0.15 mm ยก 0.20 mm ยก 0.50 mm

015 : Specifications

23

016

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Pressure Minimum oil pressure at low idle with a temperature of 18째 to 20째C (64째 to 68째F) ... 62 kPa (9 psi) The engine oil pressure at the oil pressure switch that is located on the housing for the rocker shaft assembly is the following value. ... 29.4 kPa (4.26 psi) The engine oil pressure at the oil pressure switch that is located on the cylinder block is the following value. ... 98.0 kPa (14.21 psi) Maximum engine oil pressure at high idle and at normal operating temperature ... 352 to 448 kPa (51 to 65 psi)

016 : Specifications

24

017

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Pan

Illustration 1

g00820013

(1) Gasket (2) Engine oil pan (3) Washer (4) Tighten the bolts for the engine oil pan to the following torque. ... 11 N·m (8 lb ft) (5) Tighten the drain plugs of the engine oil pan to the following torque. ...

35 N·m (26 lb ft)

Oil Suction Tube and Oil Strainer

Illustration 2

g00820021

(1) O-ring (2) Oil suction tube (3) Tighten the bolts for the oil strainer to the following torque. ... 11 N·m (8 lb ft) (4) Strainer Note: Install a new O-ring in the hole of the cylinder block when the oil suction tube is removed or replaced.

017 : Specifications

25

018

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Water Temperature Regulator

Illustration 1

g00295521

Opening temperature of the water temperature regulator ... 80° to 84°C (176° to 151°F) Fully open temperature of the water temperature regulator ... 95 °C (203 °F) Minimum stroke of the water temperature regulator at the fully open temperature ... 8 mm (0.32 inch)

Water Temperature Regulator Housing

Illustration 2

g00820265

(1) Tighten the two bolts for the water temperature regulator housing to the following torque. ... 14 N·m (10 lb ft) (2) Cover (3) Water temperature regulator (4) Gasket

018 : Specifications

26

019

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Cylinder Block

Illustration 1

g00840601

(1) Cylinder block Diameter of the bore in the cylinder block ... 84.000 to 84.019 mm (3.3071 to 3.3078 inch) Service limit ... 84.200 mm (3.3150 inch) Flatness of the top of cylinder block ... Less than 0.05 mm (0.002 inch) Service limit ... 0.12 mm (0.005 inch), (2) Oil hole in the cylinder block Note: Ensure that oil hole (4) in front crankshaft bearing (6) is aligned with oil hole (2) in the cylinder block., (3) Chamfer Note: The chamfer of the bearing faces the front of the engine. A press should be used to press the bearing into the cylinder block from the front of the cylinder block., (4) Oil hole in the crankshaft bearing (A) The center of the oil hole in the bearing should be the following distance from the front face of the bearing. ... 15.0 ± 0.2 mm (0.59 ± 0.01 inch) Replace the bearing if the distance is not within the given tolerances., (B) The center of the oil hole in the bearing should be the following distance from the rear face of the bearing. ... 12.5 ± 0.2 mm (0.49 ± 0.01 inch) Replace the bearing if the distance is not within the given tolerances.

Refer to Specifications, "Crankshaft" for additional information about the main bearings and bearing caps.

Place engine oil on the bore of the front oil seal before installation in order to prevent damage to the oil seal., (5) Oil groove (6) Crankshaft bearing Note: The front face of crankshaft bearing (6) should be evenly aligned with the front face of cylinder block (7) ., (7) Front face of the cylinder block

019 : Specifications

27

020

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Crankshaft

Illustration 1

g00465053

(1) Chamfer The chamfer faces the front of the engine., (2) Upper half of the main bearing with the oil groove (3) Upper half of main bearing cap (4) Notch on the upper half of the main bearing The notch in this position on the bearing cap faces the rear of the engine., (5) Connecting rod journal Diameter of the connecting rod journal ... 51.964 to 51.975 mm (2.0458 to 2.0463 inch) Service limit ... 51.90 mm (2.043 inch) Note: If the service limit is exceeded, then the crankshaft must be replaced., (6) Main bearing journal Diameter of main bearing journal ... 67.957 to 67.970 mm (2.6755 to 2.6760 inch) Service limit ... 67.90 mm (2.673 inch) Note: If the service limit is exceeded, then the crankshaft must be replaced., (7) Thrust washers Standard thickness ... 2.95 to 3.00 mm (0.116 to 0.118 inch) Service limit ... 2.80 mm (0.110 inch) (8) Lower half of the main bearing The lower half of the main bearing does not have an oil groove.

020 : Specifications

28

Measure Wear on the Crankshaft

Illustration 2

g00464232

Measure the diameters of the crankshaft journals that are shown in Illustration 2. This procedure measures wear and eccentricity. Measure the diameters of the connecting rod journals (5) and main journals (6) in positions (1) and (2) . Measure the diameter (A) and (B) in each position., (1) (2) Taper The difference between positions (1) and (2) must not be more than the following value. ... 0.05 mm (0.002 inch) (A) (B) Eccentricity The eccentricity must be the following value or the eccentricity must be less than the following value. ... 0.03 mm (0.001 inch) Service limit ... 0.06 mm (0.002 inch)

Measure the Main Bearing Clearance

Illustration 3 Front main bearing

g00464228

Measure the bore of the main bearings in positions (1) and (2) . Measure the bore in the directions (A) and (B) in each position.

Refer to "Measure Wear on the Crankshaft". Subtract the smallest diameter of the crankshaft journal from the largest main bearing bore. The remainder is the clearance between the main bearing and the crankshaft journal.

020 : Specifications

29

Clearance Standard clearance ... 0.044 to 0.102 mm (0.0017 to 0.0040 inch) Service limit ... 0.20 mm (0.008 inch) If the measurements are outside of the tolerances, the main bearings or the crankshaft must be replaced.

The end play is measured on the front main bearing journal.

End play of the crankshaft ... 0.10 to 0.40 mm (0.004 to 0.016 inch) Service limit ... 0.50 mm (0.020 inch)

Crankshaft Main Bearing Cap

Illustration 4

g00463533

Refer to the Specifications Module, "Cylinder Block" topic for additional information about the front crankshaft bearing., (1) Tighten the crankshaft main bearing cap bolt to the following torque. ... 52 N·m (38 lb ft) (2) Upper half of bearing cap One of the halves of the crankshaft bearing has an oil groove. The half of the bearing with the oil groove is installed in the upper half of the bearing cap., (3) Lower half of the bearing cap (4) Dowel Two dowels are installed in each bearing cap in order to correctly align the two halves of the bearing cap.

Illustration 5

g00846004

(5) Tighten the retaining bolts for the crankshaft to the following torque. ... 27 N·m (20 lb ft) (6) Tighten the allen head screw to the following torque. ... 52 N·m (38 lb ft)

020 : Specifications

30

021

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Connecting Rod Bearing Journal

Illustration 1

g00820847

(1) Tighten the connecting rod nuts to the following torque. ... 52 N¡m (38 lb ft) (2) Connecting rod bearing cap (3) Connecting rod bearing Standard clearance ... 0.035 to 0.085 mm (0.0014 to 0.0034 inch) Service limit ... 0.20 mm (0.008 inch) Axial clearance between the crankshaft and the connecting rod Standard clearance ... 0.01 mm to 0.3 mm (0.004 to 0.01 inch) Service limit ... 0.7 mm (0.03 inch) (4) Connecting rod journal Table 1 Diameter of the Connecting Rod Journal Connecting rod Diameter of the connecting rod Service limit of the connecting rod bearings journal journal 51.964 to 51.975 mm (2.0458 to Standard 51.90 mm (2.043 inch) 2.0463 inch) If the clearance between the bearing and piston pin is not within the tolerance, one or both components must be replaced.

021 : Specifications

31

022

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Main Bearing Journal

Crankshaft main bearings Original Size Journal Undersize Journal 0.25 mm (0.010 inch) Undersize Journal 0.50 mm (0.020 inch)

Table 1 Main Bearing Journal Diameter of the crankshaft journal 67.957 to 67.970 mm (2.6755 to 2.6760 inch) 67.707 to 67.720 mm (2.6656 to 2.6661 inch) 67.457 to 67.470 mm (2.6558 to 2.6563 inch)

Service limit of the crankshaft journal 67.90 mm (2.673 inch) 67.65 mm (2.663 inch) 67.40 mm (2.654 inch)

Note: If the clearance between the main bearing and the crankshaft journal is not within the specified tolerance, the crankshaft must be replaced.

Clearance between the main bearing and the crankshaft journals ... 0.044 to 0.102 mm (0.0017 to 0.0040 inch) Service limit of the main bearing ... 0.20 mm (0.008 inch)

022 : Specifications

32

023

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Connecting Rod

Illustration 1

g00693257

(1) Connecting rod (2) Piston pin bearing Clearance between the connecting rod and the piston pin bearing ... 0.010 to 0.025 mm (0.0004 to 0.0010 inch) Service limit ... 0.10 mm (0.004 inch) (3) Bolt and nut for connecting rod cap Tighten the nut to the following torque. ... 52 N¡m (38 lb ft) (4) Connecting rod bearing Clearance between the connecting rod and the connecting rod bearing ... 0.035 to 0.085 mm (0.0014 to 0.0033 inch) Service limit ... 0.20 mm (0.008 inch)

Markings on the Connecting Rod

Illustration 2 Typical example

g00555416

The pistons and connecting rods are matched to each cylinder. Note the position of each connecting rod and piston for correct assembly.

Identification marks (1) on the connecting rod and on the connecting rod cap must align. When the connecting rod is installed correctly, the marks should face the right side of the engine.

023 : Specifications

33

Distortion of the Connecting Rod Distortion of the connecting rod For every 100 mm (3.94 inch) of length, the distortion should be less than the following value. ...

0.08 mm (0.003 inch) Service limit for 100 mm (3.94 inch) of length of distortion ... 0.20 mm (0.008 inch) Parallelism For every 100 mm (3.94 inch) of length, the connecting rod should be in parallel less than the following value. ... 0.05 mm (0.002 inch) Service limit for 100 mm (3.94 inch) of length of parallelism ... 0.15 mm (0.006 inch)

023 : Specifications

34

024

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Piston and Rings Markings on the Piston

Illustration 1

g00845975

(1) The chamber that is on the top of the piston must face the right side of the engine. (2) The Shibaura name that is forged on the inside of the piston must align with the marks that are on the connecting rod.

Piston Rings

Illustration 2 g00845969 The gaps in the piston rings must be spread apart by 90 degrees.

(1) Top piston ring Shape of top ring (A) ... Barrel face Note: Install the scribe mark on the piston ring toward the top of the piston., (2) Intermediate ring Shape of intermediate ring (B) ... Taper Note: Install the scribe mark on the ring toward the top of the piston., (3) Oil control ring Note: Install the scribe mark on the ring toward the top of the piston.

The oil control ring has two components. The two components of the oil control ring are installed in the following order: 1. Spring (D) 024 : Specifications

35

2. Oil control ring (C) Note: Use a piston to insert the piston ring square with respect to the cylinder bore. The top surface of the piston ring should be equally distant from the face of the cylinder block at all points before the piston ring end gap is measured., (4) Piston

Illustration 3

g00845991

(5) Feeler gauge (6) Piston ring Gap for No. 1 piston ring ... 0.20 to 0.35 mm (0.008 to 0.014 inch) Service limit for No. 1 piston ring ... 1.0 mm (0.04 inch) Gap for No. 2 piston ring ... 0.20 to 0.40 mm (0.008 to 0.016 inch) Service limit for No. 2 piston ring ... 1.0 mm (0.04 inch) Gap for oil control ring ... 0.20 to 0.40 mm (0.008 to 0.016 inch) Service limit for oil control ring ... 1.0 mm (0.04 inch) Measure the clearance between the piston ring groove and the piston ring. If the clearance exceeds the service limit, then replace the pistons and the rings.

Clearance for the No. 1 piston ring ... 0.07 to 0.11 mm (0.003 to 0.004 inch) Service limit for No. 1 piston ring ... 0.25 mm (0.010 inch) Clearance for No. 2 piston ring ... 0.04 to 0.08 mm (0.002 to 0.003 inch) Service limit for No. 2 piston ring ... 0.25 mm (0.010 inch) Clearance for the oil control ring ... 0.02 to 0.06 mm (0.001 to 0.002 inch) Service limit for the oil control ring ... 0.15 mm (0.006 inch)

Pistons Diameter of piston Standard piston ... 83.948 to 83.963 mm (3.3050 to 3.3056 inch) Service limit ... 83.7 mm (3.30 inch) Diameter of piston skirt ... 83.948 to 83.963 mm (3.3050 to 3.3056 inch) Clearance of the piston to the cylinder wall Standard clearance ... 0.038 to 0.072 mm (0.0015 to 0.0028 inch) Service limit ... 0.25 mm (0.010 inch) Piston pin Outside diameter ... 27.996 to 28.000 mm (1.1022 to 1.1024 inch) Service limit ... 27.98 mm (1.102 inch) Clearance between the hole for the piston pin and the piston pin Standard clearance ... -0.001 to +0.007 mm (-0.0004 to +0.0003 inch) Service limit ... 0.02 mm (0.001 inch) 024 : Specifications

36

025

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Housing (Front)

Illustration 1

g00827564

(1) Mechanical stop lever (2) Front housing (3) Locator hole (4) Locator pin (5) Tighten the bolts and nuts to the following torque. ... 10 N¡m (90 lb in) Note: Note the positions of the bolts when the bolts are removed. The bolts have different lengths., (6) Seal protector

025 : Specifications

37

026

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Gear Group (Front)

Engine C1.5/3013C Genset

C2.2/3024C Genset C2.2T Genset (1)

Table 1 Injection timing Maximum rated engine speed 1500 1800 3000 1500 1800 3000 1500 1800

Injection timing (BTDC) (1) 14° ± 1° 14° ± 1° 20° ± 1° 12° ± 1° 12° ± 1° 18° ± 1° 15° ± 1° 15° ± 1°

Before Top Dead Center

Illustration 1

g00836394

(1) Timing mark on the camshaft gear (2) Timing mark on the idler gear (3) Idler gear (4) Timing mark on the camshaft gear Minimum backlash for all gears ... 0.08 mm (0.003 inch) Maximum backlash for all gears ... 0.25 mm (0.010 inch) Note: If the backlash is greater than the maximum backlash, replace the camshaft gear, the idler gear and the crankshaft gear.

When the idler gear is installed on the shaft of the oil pump, align a timing mark on idler gear (4) with the timing mark on crankshaft gear (2) . Also, align the other timing mark on idler gear (4) with the timing mark on camshaft gear (3) .

026 : Specifications

38

027

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Flywheel

Illustration 1

g00820355

(1) Heat the flywheel ring gear to the following temperature. ... 120 ° to 150 ° C (248 ° to 302 ° F) Note: If excessive wear is not present, remove the ring gear and install the ring gear at 90 degrees from the original position. Heat the ring gear evenly., (2) Tighten the flywheel bolts to the following torque. ... 74 N·m (55 lb ft) Maximum flywheel runout ... 0.20 mm (0.008 inch)

027 : Specifications

39

028

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Flywheel Housing

Illustration 1

g00820369

(1) Backing Plate (2) Flywheel housing (3) Tighten the bolts for the backing plate to the engine block to the following torque. ... 25 N¡m (19 lb ft) (4) Crankshaft rear seal (5) Tighten the bolts for the backing plate to the flywheel housing to the following torque. ... 25 N¡m (19 lb ft)

028 : Specifications

40

029

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Crankshaft Pulley

Illustration 1

g00821185

(1) Woodruff key (2) Crankshaft pulley (3) Tighten the crankshaft pulley nut to the following torque. ...

304 N¡m (224 lb ft) (4) Puller

029 : Specifications

41

030 3024C Engine for Caterpillar Built Machines, SENR5004-02

Belt Tension Chart Table 1 Belt Tension Chart Gauge Reading Initial Belt Tension (1) Used Belt Tension (2) 400 to 489 N (90 to 110 lb) 267 to 356 N (60 to 80 lb) (1)

Initial Belt Tension refers to a new belt.

(2)

Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

Note: Use a 144-0235 Belt Tension Gauge to measure the tension of the belt.

030 : Specifications

Specifications

42

031

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fan Drive

Illustration 1

g00831690

(1) Tighten the bolts for the pulley to the fan to the following torque. ... 11 ± 1 N·m (8 ± 1 lb ft) (2) Adapter (3) Pulley (4) Water pump

031 : Specifications

43

032

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Lifting Bracket All engines are equipped with two engine lifting brackets.

Tighten the bolt on each engine lifting bracket to the following torque. ... 26 N¡m (20 lb ft)

032 : Specifications

44

033

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Alternator and Regulator

Illustration 1 Side view of the alternator

g00379653

Illustration 2 End view of the alternator

g00379659

The rotation of the alternator is clockwise when the alternator is viewed from the pulley.

Note: Test the battery with a carbon pile 4C-4911 Battery Load Tester in order to measure the maximum output from the alternator.

The regulator of the alternator is sealed. The regulator is a nonserviceable part.

Polarity ... Negative ground to the case Rotation ... Either direction Output voltage ... 14.0± 0.5 volts Rated voltage ... 12 volts Rated current output ... 50 or 90 amperes The capacity of the alternator depends on the options on the machine., (1) Tighten the pulley nut to the following torque. ... 60 N·m (44 lb ft) (2) Tighten terminal nut "B" to the following torque. ... 4.4 N·m (39 lb in) (3) Pins "D" for 3 wire connector Tighten the bolt (not shown) from the alternator to the front housing to the following torque. ... 24 N·m (18 lb ft) Tighten the bolt (not shown) from the adjustment lever to the alternator to the following torque. ... 12 N·m (9 lb ft) Alignment of the alternator pulley to the crankshaft pulley ... ±2.40 mm (0.095 inch) Rated capacity of alternator circuit breaker for alternator with a 55 ampere capacity ... 60 amperes Rated capacity of alternator circuit breaker for alternator with a 90 ampere capacity ... 100 amperes

033 : Specifications

45

034

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Electric Starting Motor Starting Motor

Illustration 1 g00379835 Starting motor and starting motor solenoid

No load conditions at 25°C (77°F) Rpm with no load ... 4000 to 6000 rpm Maximum current ... 540 amperes Current draw with no load ... 130 amperes Voltage ... 11.5 volts Rated voltage ... 12 volts Power rating ... 2.0 kilowatts Power rating C0.5, C0.7, C1.1/3011C and C1.6 Standard ... 1.1 kilowatts Option ... 1.4 kilowatts C1.5/3013C, C2.2/3024C and C2.2/3024CT ... 2.0 kilowatts Minimum average cranking rpm ... 130 Starting motor solenoid Pull-in current ... 54.5 amperes Hold-in current ... 10.5 amperes (1) Tighten the battery terminal nut to the following torque. ... 15 N·m (11 lb ft) (2) Tighten the two mounting bolts to the following torque. ... 50 ± 6 N·m (37 ± 4 lb ft) (3) Tighten the nut for the switch terminal to the following torque. ... 1.0 to 1.3 N·m (9 to 12 lb in) Maximum resistance of the starter cable at 20°C (68°F) and at 12 volts ... 0.04 ohms

034 : Specifications

46

Start Relays

Illustration 2 Schematic of the relays

g00381753

(4) When the ignition switch is in the OFF position or the RUN position, the relay switch is closed across the contact "30" and the contact "87a". (5) When the ignition switch is in the START position, the relay switch is closed across the contact "30" and the contact "87". Then, the starting motor is engaged.

Maximum voltage drop in closed position ... 0.150 to 0.250 volts, (6) Connector pins on the start relay Resistance between contact "85" and contact "86" ... 7.2 Âą 0.7 ohms

034 : Specifications

47

035 3024C Engine for Caterpillar Built Machines, SENR5004-02

Coolant Temperature Switch

Illustration 1 Coolant temperature switch

g01094334

Tighten the coolant temperature switch to the following torque. ... 27 N¡m (20 lb ft)

035 : Specifications

Specifications

48

036

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Engine Oil Pressure Switch

Illustration 1

g00904803

Tighten the engine oil pressure switch to the following torque.

C0.5 and C0.7 ... 18 N¡m (13.3 lb ft) C1.1/3011C, C1.5/3013C, C1.6, C2.2/3024C and C2.2/3024CT ... 10 N¡m (7 lb ft) Note: The engine oil pressure switch can be found in two positions., (1) Engine oil pressure switch that is located on the valve mechanism cover C1.1/3011C ... (Deutsch) Green sticker with a white dot Pressure rating ... 49.0 kPa (7.11 psi) C0.5, C0.7, C1.5/3013C, C1.6, C2.2/3024C and C2.2/3024CT ... (Amp) Brown connector Pressure rating ... 29.4 kPa (4.26 psi) (2) Engine oil pressure switch that is located on the cylinder block C1.1/3011C ... (Deutsch) Green sticker with a white dot Pressure rating ... 49.0 kPa (7.11 psi) C0.5, C0.7 and C1.6 ... (Deutsch) Green sticker with a red dot Pressure rating ... 68.9 kPa (10.0 psi) C1.5/3013C and C2.2/3024C and C2.2/3024CT ... (Amp) Blue connector Pressure rating ... 98 kPa (14.21 psi) C1.5/3013C and C2.2/3024C and C2.2/3024CT ... (Amp) Black connector Pressure rating ... 68.9 kPa (10.0 psi)

036 : Specifications

49

037

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Glow Plugs

Illustration 1

g00820321

(1) Tighten the nut on the connector for the electrical connectors to the following torque. ... 1.2 N¡m (11 lb in) (2) Washer (3) Connector (4) Tighten the glow plug to the following torque. ... 18 N¡m (159 lb in)

037 : Specifications

50

038

Specifications

3024C Engine for Caterpillar Built Machines, SENR5004-02

Fuel Shutoff Solenoid

Illustration 1

g00820306

(1) Tighten the fuel shutoff solenoid to the following torque. ... 17 N¡m (13 lb ft) (2) Washer Ensure that the washer is replaced with a new washer during the installation of the fuel shutoff solenoid (1).

038 : Specifications

51

INDEX

SENR5005-03

3024C Engine for Caterpillar Built Machines Systems Operation Engine Design

INDEX

1 5

3024C Engine General Information

6

Engine Description Lifting the Engine 3024C Engine Model Views Fuel System

8

General Operation of the Fuel System Governor Fuel Injection Pump Fuel Injection Nozzles Fuel Transfer Pump Glow Plugs Air Inlet and Exhaust System

13

Cylinder Head And Valves Lubrication System

15

Cooling System

17

Basic Engine

18

Cylinder Head and Block Pistons and Connecting Rods Timing Gear Case and Gears Electrical System

20

Engine Electrical System Automatic Shutdown System Automatic Shutdown Conditions Charging System Components Alternator Regulator Starting System Components Solenoid Electric Starting Motor Other Components Circuit Breaker 3024C Engine for Caterpillar Built Machines Testing and Adjusting Troubleshooting

25

Introduction Troubleshooting The Fuel Injection Nozzles On The Engine The engine is difficult to start or the engine runs rough.

SENR5005-03

52

The engine exhaust has too much black smoke.

The engine has lost power and the engine uses too much fuel.

The engine is misfiring, running rough, or running poorly.

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester Back leakage The fuel injection nozzle does not inject fuel in the correct quantity or in the correct pattern.

Troubleshooting the Engine The engine will not start.

The engine starts and the engine runs for a brief period of time and the engine stops.

The engine misfires or the engine runs rough.

The engine runs evenly, but the engine loses power.

The engine lacks power.

The engine has excessive vibration.

The engine has excessive combustion noise.

The engine has excessive valve compartment noise.

Engine oil is in the cooling system.

Engine knock occurs.

The rocker arm has insufficient movement and the valve lash exceeds the specification.

A cylinder head valve is loose.

Oil condenses at the exhaust.

The valve lash is less than the required specification.

Engine components have early wear.

Coolant is in the engine oil.

The engine exhaust has too much black smoke or too much gray smoke.

The engine exhaust has too much white smoke or too much blue smoke.

The engine has low oil pressure.

The engine oil pressure is too high.

The engine uses too much engine oil.

The engine overheats.

The exhaust temperature is too high.

The starting motor does not turn or the starting motor turns too slowly.

The starting motor turns, but the pinion gear does not engage the flywheel ring gear.

The engine does not crank or the engine rotates slowly when the keyswitch is in the start position.

The starting motor continues to run after the ignition switch is released.

The pinion gear does not disengage after the engine starts to run.

The alternator does not charge the battery or the alternator charge rate is slow or irregular.

The alternator charges the battery to a voltage that is too high.

The alternator is noisy.

Fuel System - Inspect

40

Air in Fuel - Test

41

Engine Speed - Check

43

Finding Top Center Position for No. 1 Piston

44

Fuel Injection Nozzle - Test

46

Inspection and Cleaning of the Fuel Injection Nozzles Leakage Test Pressure Test SENR5005-03

53

Test for the Nozzle Spray Pattern Fuel Injection Timing - Check

50

Fuel Quality - Test

51

Fuel System - Prime

52

Fuel System Pressure - Test

54

Gear Group (Front) - Time

56

Air Inlet and Exhaust System - Inspect

57

Exhaust Temperature - Test

58

Measure the Exhaust Temperature Engine Crankcase Pressure (Blowby) - Test

59

Compression - Test

60

Compression Engine Valve Lash - Inspect/Adjust

62

Valve Lash Check Valve Lash Adjustment Valve Depth - Inspect

65

Valve Guide - Inspect

66

Engine Oil Pressure - Test

67

Engine Oil Pump - Inspect

68

Excessive Bearing Wear - Inspect

70

Excessive Engine Oil Consumption - Inspect

71

Engine Oil Leaks on the Outside of the Engine Engine Oil Leaks into the Combustion Area of the Cylinders Cooling System - Check - Overheating

72

Cooling System - Inspect

74

Cooling System - Test

75

Test Tools For The Cooling System Making the Correct Antifreeze Mixtures Checking the Filler Cap Testing The Radiator And Cooling System For Leaks Cooling System Conditioner Water Temperature Regulator - Test

81

Water Pump - Inspect

82

Piston Ring Groove - Inspect

83

Inspect the Piston and the Piston Rings Inspect the Clearance of the Piston Ring Inspect the Piston Ring End Gap Connecting Rod - Inspect

85

Distortion of Connecting Rod Inspect the Bearings and Piston Pin for Wear Connecting Rod Bearings - Inspect

87

Main Bearings - Inspect

88

Cylinder Block - Inspect

89

Cylinder Head - Inspect

90

Piston Height - Inspect

92

Flywheel - Inspect

94 SENR5005-03

54

Alignment of the Flywheel Face Flywheel Runout Flywheel Housing - Inspect

95

Face Runout (Axial Eccentricity) of the Flywheel Housing Bore Runout (Radial Eccentricity) of the Flywheel Housing Gear Group - Inspect

97

Alternator - Test

98

Battery - Test

99

Charging System - Test

100

Alternator Regulator Coolant Temperature Switch - Test

101

Electric Starting System - Test

102

Engine Oil Pressure Switch - Test

103

Fuel Shutoff Solenoid - Test

104

Glow Plugs - Test

105

Continuity Test Glow Plug Circuit

SENR5005-03

55

001

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Design S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP

3024C Engine

Illustration 1 g00296424 Cylinder and valve location, (A) Exhaust valve (B) Inlet valve

Bore ... 84.0 mm (3.30 inch) Stroke ... 100.0 mm (3.94 inch) Displacement ... 2.2 L (135.23 in3) Cylinder arrangement ... In-line Type of combustion ... Indirect injection Compression ratio ... 23.3:1 Number of cylinders ... 4 Valves per cylinder ... 2 Valve lash Inlet valve ... 0.2 mm (0.008 inch) Exhaust valve ... 0.2 mm (0.008 inch) Firing order ... 1, 3, 4, 2 When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction. ... Clockwise When the camshaft is viewed from the front of the engine, the camshaft rotates in the following direction. ... Clockwise The front of the engine is opposite the flywheel end of the engine. The left side and the right side of the engine are determined from the flywheel end. Number 1 cylinder is the front cylinder of the engine.

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002

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

General Information , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP

Engine Description Note: When you are ordering new parts, refer to the engine identification number in order to receive the correct parts.The 3024C engine is a diesel engine that is controlled with a mechanically actuated fuel injection pump. The engine cylinders are arranged in-line.The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has a single valve spring. The pistons have two compression rings and an oil control ring.It is important to ensure the correct piston height so that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in order to conform to requirements for emissions.The crankshaft has five main journals. End play is controlled by thrust washers that are located on the rear main bearing.The timing gears are stamped with timing marks in order to ensure the correct alignment of the gears during assembly. When the No. 1 piston is at top center compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear.The crankshaft gear turns the idler gear which then turns the following gears: the camshaft gear and the gear for the lubricating oil pump.The fuel injection pump is mounted on the cylinder block. The fuel injection pump is operated by the camshaft lobes. The fuel transfer pump is located on the right hand side of the cylinder block. The fuel transfer pump is operated by the camshaft lobes.The fuel injection pump conforms to requirements for emissions. Adjustments to the fuel injection pump timing and high idle should only be made by trained personnel. The fuel injection pumps have mechanical governors that control the engine rpm.The engine oil pump is a gerotor type pump. The engine oil pump is located in the center of the idler gear. The engine oil pump sends lubricating oil to the main oil gallery through an oil relief valve. The oil relief valve is located on the right side of the cylinder block. The rocker arms receive pressurized oil through an externally located oil line. The oil line runs from the main oil gallery to the cylinder head.Coolant from the bottom of the radiator passes through the belt driven centrifugal water pump. The coolant is cooled by the radiator and the temperature is regulated by a water temperature regulator.

Lifting the Engine NOTICE Failure to follow recommended procedures for handling or transporting engines can lead to engine damage.

To avoid possible engine damage, use the following procedure.

When you are lifting or moving the engine, use the following procedures in order to prevent engine damage.

1. Do not tilt the engine to an extreme angle unless the lubricating oil is first drained from the oil pan.

2. Do not turn the engine onto a side or an end surface unless the lubricating oil is first drained from the oil pan.

3. If the oil is not drained prior to tilting the engine or turning the engine onto a side or an end surface, the lubricating oil from the oil pan can flow into the intake manifold and the cylinder bores. This situation could cause a hydraulic lock in the engine. Hydraulic lock can severely damage the engine.

4. The engine oil should be refilled to the correct level before the engine is started.

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3024C Engine Model Views

Illustration 1 g00822097 Left side view of the engine, (1) Engine oil filler cap (2) Crankcase breather (3) Water temperature regulator (4) Lifting eye (5) Engine oil pressure sensor (6) Inlet manifold (7) Fan drive pulley (8) Exhaust manifold (9) Water pump (10) Coolant temperature switch (11) Cover plate for the accessory drive (12) Starting motor solenoid (13) Crankshaft pulley (14) Electric starting motor (15) Engine oil pan (16) Alternator (17) Engine oil drain plug

Illustration 2

g00822094

Right side view of the engine, (18) Fuel injection nozzle (19) Lifting eye (20) Fuel return line (21) Fuel injector lines (22) Fuel shutoff solenoid (23) Mechanical fuel shutoff (24) Fuel transfer pump (25) Fuel injection pump (26) Flywheel housing (27) Fuel control lever (28) Engine oil level gauge (29) Flywheel (30) Engine oil filter

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003

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel System , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

General Operation of the Fuel System

Illustration 1 g00854612 Typical example, (1) Fuel tank (2) Water separator (3) Primary fuel filter (4) Fuel transfer pump (5) Mechanical governed fuel injection pump (6) Fuel injection nozzles (7) Fuel return line from the fuel injection nozzles (8) Fuel return line from the fuel injection pump

When the engine is cranking, the fuel is pulled from fuel tank (1) by fuel transfer pump (4). The fuel transfer pump forces the fuel through the water separator (2) and the primary fuel filter (3) to the fuel injection pump (5) .

When the fuel goes through the water separator, any water in the fuel will go to the bottom of the bowl.

The water can be drained through a valve which is located at the bottom of the bowl. If the engine does not have water separator (2), primary fuel filter (3) functions as a water separator. The primary fuel filter can be drained through a valve that is located at the bottom of the filter housing.

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The fuel flows from the water separator at low pressure to primary fuel filter (3). The fuel flows at low pressure from the fuel filter to fuel injection pump (5) .

The fuel injection pump sends fuel at high pressure to each fuel injection nozzle (6). The fuel injection nozzle sprays fuel into a precombustion chamber which slows the rate of combustion in the cylinder. The following items will result from reducing the rate of fuel combustion: prevention of engine knock, reduction of noise and reduction of emissions.

Illustration 2 g00468241 Phases of operation of the fuel injection nozzle, (A) Closed valve (B) Open valve (C) Fully open valve

The fuel injection nozzle injects fuel into the precombustion chamber at different angles during two phases. Most of the fuel is injected when the valve is fully open (C). This process is called indirect fuel injection. The results are more even combustion and complete combustion of the fuel at a reduced temperature. Improved fuel combustion will increase power output while reducing emissions and reducing fuel consumption.

Excess fuel from the fuel injection nozzles flows through fuel return line (7) to the inlet side of primary fuel filter (3) and back to the fuel tank (1). The excess fuel aids the cooling of the fuel injection nozzles.

Also, the fuel return line removes any air that is trapped in the fuel injection nozzles and the fuel injection pump.

Excess fuel from the fuel injection pump flows through fuel line (8) to the inlet side of primary fuel filter (3) and back to the fuel tank (1) .

The fuel injection pump needs fuel for lubrication. If the precision parts of the pump are not adequately lubricated, the components may be easily damaged. The engine must not be started until the fuel injection pump is full of fuel that is free of air.

The system must be primed when any part of the system is drained of fuel. The following list contains examples of both service and repairs when you must prime the system: ¡ The fuel filter is changed. ¡ The low pressure fuel line is removed. ¡ The fuel injection pump is removed. ¡ The fuel injection nozzles are removed. ¡ The fuel tank is drained. ¡ A leak exists in the low pressure side of the fuel system.

Refer to Systems Operation, Testing and Adjusting, "General Information" for locations of the components for the fuel system.

The fuel filter housing may be equipped with a priming button. When the priming button is moved up and down, pressure is applied in the fuel system. This will remove any air out of the fuel system.

In order to release air from the fuel injection pump and the fuel injection nozzles, the nuts for the fuel injection nozzles should be loosened. The priming button is operated until fuel, that is free from air, flows from each connection on the fuel injection nozzles. Refer to Testing and Adjusting, "Air In Fuel - Test".

Each cylinder has a glow plug. The glow plugs may be activated by one of two methods. The following methods are the two ways of activating the glow plugs: ¡ A starting aid switch ¡ An auxiliary position on the ignition switch When the switch is manually turned on, the glow plug becomes hot. The heat increases the vaporization of the fuel in the cylinder. This condition improves the ease of starting in cold weather. Power to the glow plugs is stopped when the switch is manually turned off.

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Governor The fuel rack is connected to the linkage, which controls the fuel injection pump. This linkage is located in the timing case.These engines have a mechanical governor in order to control engine rpm. The governor operates for all engine rpm. The governor weight assembly is installed on the front of the gear of the camshaft. The other components of the governor are installed in the timing gear case.

Illustration 3 g00822233 Governor control mechanism in the timing gear case, (1) Connection for the linkage to the fuel injection pump (2) Mechanical stop control (3) Lever return spring (4) Control lever (5) Start spring (6) Arm (7) Governor adjustment screw

The movement of the governor weight assembly is transferred to the fuel rack on the fuel injection pump by control lever (4), arm (6) and the linkage to the fuel injection pump. A spring connects the arm and the control lever. This spring controls the movement of the governor weight assembly on the camshaft. When the angle of the control lever changes, tension on the spring changes. This action controls the linkage to the fuel rack on the fuel injection pump, which controls the engine rpm.

The bolt for the maximum speed adjustment is mounted in the cylinder block. This adjustment limits the movement of arm (6). This adjustment should only be made by personnel with the correct training.

The bolt for the maximum fuel adjustment is mounted in the cylinder block. This adjustment regulates the fuel injection at high engine rpm. This adjustment should only be made by personnel with the correct training.

A spring connects the linkage to the fuel injection pump and mechanical stop control (2). When the engine is first started, the spring automatically increases the fuel flow to the cylinders.

The fuel injection pump timing, the low idle, and the high idle are preset at the factory. Adjustments to the pump timing and idle rpm should only be made by personnel which have had the correct training. The timing for the fuel injection pump should only change if the camshaft or the cylinder block are replaced.

The fuel injection pump timing should not change if the fuel injection pump is reinstalled with a shim that is the same size.

The fuel rack automatically returns to the excess fuel position when the engine is stopped. The excess fuel position aids the cold starting of the engine.

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Fuel Injection Pump

Illustration 4 g00746909 Fuel injection pump (typical example), (1) Fuel line to the fuel injection nozzles (2) Fuel delivery valve (3) Nuts and bolts for mounting the fuel injection pump to the cylinder block (4) Shim (5) Vent screw for the fuel injection pump (6) Fuel flow from the fuel transfer pump

The engines have the energized-to-run system for starting the engine and stopping the engine. The electric fuel shutoff solenoid must be energized in order for fuel to flow to the engine cylinders.

The fuel injection pump is a cassette type pump. The cassette type pump contains the following components: valves for the delivery of fuel, fuel rack and pushrods. The fuel injection pump is installed directly into the cylinder block.

The part number and code letters for the fuel injection pump are stamped on the front of the pump.

The fuel injection pump is a pressurized system that is totally enclosed. The pump sends the correct amount of fuel under high pressure at the correct time through the fuel injection nozzles to the individual cylinders. The fuel injection occurs near the end of the compression stroke. The fuel injection pump regulates the amount of fuel that is delivered to the fuel injection nozzles. This action controls the engine rpm by the governor setting or the position of the throttle control.

The camshaft is driven by the idler gear in the timing case. Lobes on the camshaft cause the pushrod for each cylinder to reciprocate. The reciprocating motion first draws the fuel. The reciprocating motion then pressurizes the fuel. A fuel delivery valve (2) for each cylinder acts as a check valve in order to prevent a loss of pressure to the fuel injection nozzle.

The correct operation of the fuel injection pump requires the pump to be completely full of fuel and empty of air. When vent screw (5) is loosened, air can escape from the fuel injection pump.

The fuel injection pump will lubricate the components during operation.

Fuel Injection Nozzles

Illustration 5 , (1) Fuel injection nozzle (2) Gasket

g00836660

Gasket (2) helps to prevent blowby. The gasket also sets the projection of the fuel injection nozzle (1) into

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62

the precombustion chamber. This projection affects the time that is required for combustion in the cylinder. If the projection is excessive, engine knock can occur at high rpm.

Note: When a fuel injection nozzle (1) is installed in the cylinder head, a new gasket (2) should be installed.

The operating pressure of the fuel injection nozzle is set and tested at the factory. Refer to Specifications, "Fuel Injection Nozzles" for the pressure settings of the fuel injection nozzle.

During operation, extra fuel is used as coolant and lubricant for components of the fuel injection nozzle.

Fuel Transfer Pump

Illustration 6 g00854760 Components of the fuel transfer pump (typical example), (IN) Fuel flow to the fuel transfer pump (OUT) Fuel flow out of the fuel transfer pump (1) Outlet valve (2) Inlet valve (3) Diaphragm (4) Diaphragm assembly (5) Arm

The fuel transfer pump creates a vacuum in order to force fuel from the fuel tank. Pressure is created in order to pump the fuel to the fuel injection pump. The diaphragm (3) prevents the leakage of the fuel into the cylinder block. The diaphragm creates part of the pumping action of the fuel transfer pump. Outlet valve (1) and inlet valve (2) operate as check valves.

A lobe on the camshaft causes arm (5) to move up and down. When the arm moves down, diaphragm assembly (4) moves down. This down movement increases the size of the chamber above the diaphragm assembly. This suction opens inlet valve (2) which draws fuel into the chamber above the diaphragm assembly (4) to the fuel transfer pump (IN).

When the arm moves up, the diaphragm assembly moves up. This up movement pressurizes the chamber above the diaphragm assembly. This pressure opens outlet valve (1) which allows fuel to flow out of the fuel transfer pump (OUT) toward the fuel injection pump.

Glow Plugs Each cylinder has a glow plug in order to aid the cold starting of the engine. The glow plugs may be energized by two different methods: ยก The ignition switch is moved to the auxiliary position (if equipped). ยก The starting aid switch (if equipped) is moved to the ON position.

Usually, energizing the glow plugs for six seconds will heat the cylinder sufficiently for easy starting of the engine. The glow plugs should not be activated for more than 15 seconds continuously.

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63

004

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Air Inlet and Exhaust System , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP Naturally aspirated engines pull outside air through an air cleaner directly into the inlet manifold. The air flows from the inlet manifold to the engine cylinders. The fuel is mixed with the air in the engine cylinders. After the fuel combustion occurs in the engine cylinder, the exhaust gases flow directly to the outside air through the exhaust manifold and the exhaust system.

Each piston makes four strokes: 1. Intake Air is drawn into the cylinder through the open inlet valve. Fuel is sprayed into the engine by the fuel injection nozzle.

2. Compression The mixture of air and fuel is compressed in the cylinder in order to heat the mixture to the temperature of combustion.

3. Power The mixture of air and fuel ignites at the top of the compression stroke. The expansion of gases from the combustion forces the piston downward. This force creates the power of the engine.

4. Exhaust The piston moves upward in order to force the gases of combustion from the cylinder through the open exhaust valve.

The sequence of the strokes by all of the pistons in all of the engine cylinders provides constant air flow from the air inlet system during the engine operation.

The exhaust stroke and the timing of the valve mechanism pushes combustion gases out of the open exhaust valve through the exhaust manifold. The exhaust gases flow from the exhaust manifold to the outside through a muffler.

The valve mechanism cover contains an open breather assembly. This device vents the gases, which are caused by blowby, from the valve mechanism cover to the outside air. The breather reduces emissions without reducing the power of the engine.

Cylinder Head And Valves

Illustration 1 g00468536 Cross section of the inlet valve and the exhaust valve in the cylinder head

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Illustration 2 g00458090 Cylinder head and valves (typical example), (1) Collet (2) Valve spring retainer (3) Valve spring (4) Valve guide seal (5) Recess for valve spring (6) Valve guide (7) Exhaust valve (8) Inlet valve (9) Valve face angle (10) Head of exhaust valve (11) Head of inlet valve (12) Cap (13) Valve guide seal (14) Cylinder head (15) Cylinder head gasket (16) Pushrod (17) Valve seat insert (18) Valve lifter

The valves and the valve mechanism control the flow of air into the cylinders during engine operation.

The valves and the valve mechanism control the flow of exhaust out of the cylinders during engine operation. The cylinder head assembly has two valves for each cylinder. Each valve has one valve spring (3). The ports for inlet valve (8) and exhaust valve (7) are on the left side of the cylinder. Steel valve seat inserts (17) are installed in cylinder head (14) for both inlet valve (8) and exhaust valve (7).

The seat face angle is equal to valve face angle (9). The valve seat inserts can be replaced.

The valve moves along a steel valve guide (6). The valve guides can be replaced.

The inlet valve and the exhaust valve are opened and closed by the rotation and movement of the following components: ¡ Crankshaft ¡ Idler gear ¡ Camshaft ¡ Valve lifters ¡ Pushrods ¡ Rocker arms ¡ Valve springs The camshaft gear is driven by the idler gear. The camshaft gear, the idler gear and the crankshaft gear are timed together. When the camshaft turns, the valve lifters are moved up and down. The pushrods move the rocker arms. The rocker arms make the inlet valves and the exhaust valves open and close.

This is in sequence with the firing order of the engine. The valve springs push the valves back to the closed position.

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65

005

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Lubrication System , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP The lubrication system contains the following components: ¡ Oil pump ¡ Engine oil relief valve ¡ Oil filter ¡ Oil pan ¡ Oil strainer and suction pipe ¡ Oil level gauge ¡ Oil pressure switch ¡ An oil supply line to the cylinder head The oil pump is contained within the idler gear. The engine oil relief valve is installed in the right side of the cylinder block.

The oil filter is a spin-on filter that is disposable.

Illustration 1 g01051663 Idler gear and components of the oil pump, (1) C-clip (2) Collar (3) Spring (4) Shim (5) Oil pump cover (6) Inner rotor (7) Spring (8) Outer rotor (9) Bushing (10) Idler gear (11) Thrust washer

Pressure for the lubrication system is supplied by an engine oil pump which uses rotors. The oil pump is part of idler gear (10) . The idler gear is driven by the crankshaft gear.

The oil pump has an inner rotor (6) and an outer rotor (8) . The axes of rotation of the rotors are offcenter relative to each other. There is a pin that is inserted through a hole in oil pump cover (5) into the outer rotor. The pin functions as a key in order to keep the outer rotor in a fixed position with the idler gear.

The outer rotor is pressed in bushing (9) . The bushing is pressed in idler gear (10) .

The inner rotor has four lobes which mesh with the five lobes of the outer rotor. When the outer lobe rotates, the distance increases between the lobes of the outer rotor and the lobes of the inner rotor in order to create suction. Then, the space between the lobes is filled with oil. When the distance decreases between the lobes, pressure is created. This pressure forces the oil into the chamber for the engine oil relief valve.

Lubricating oil from the oil pan flows through a strainer and a line to the suction side of the engine oil pump. The suction side is in the timing gear case. The lubricating oil flows from the outlet side of the pump to a relief valve. The relief valve is installed on the right side of the cylinder block. The lubricating oil, which flows around the relief valve, flows to the oil filter.

When the engine rpm increases, the flow rate of the oil pump increases. The increase in the flow rate

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66

from the oil pump causes the pressure to increase. The relief valve opens if the oil pressure is too high.

When the oil pressure on the plunger of the relief valve is greater than the force of the spring in the relief valve, the relief valve opens. The lubricating oil which flows through the relief valve is returned to the oil pan.

The oil filter is installed on the right side of the cylinder block. The oil flows through the oil filter into the main oil gallery. The main oil gallery is drilled through the total length of the right side of the cylinder block.

Oil flows from the main oil gallery through an externally mounted oil supply line to the cylinder head.

An oil pressure switch measures the oil pressure at this location. This oil lubricates the rocker arm assembly. The oil passes through the rocker shaft to the bore of each rocker lever. Then, the oil flows from the rocker levers through holes that are located in the top of the rocker levers. The valve stems, the valve springs, and the tappets are lubricated by the splash and the mist of the oil.

The lubricating oil flows through drilled holes in the main oil gallery to passages in the main journals of the crankshaft. Then, the oil flows to the main bearings of the crankshaft. Also, the oil flows through passages in the crankshaft to the large end bearings of the connecting rods. The piston bearings, the pistons, and the cylinder bores are lubricated by the splash and the mist of the oil.

A hole is located in the bore of each main bearing. This hole allows oil to flow through passages that lubricate the journals of the camshaft for the valves. The bearing for the front journal receives oil from the front main journal of the crankshaft. The camshaft is lubricated by the splash of the oil.

The timing gears are lubricated by the splash of the oil. Lubricating oil from the timing case returns to the oil pan.

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67

006

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Cooling System , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP The coolant system contains the following components: ¡ Radiator ¡ Pressure cap for the radiator ¡ Fan for the radiator ¡ Drive pulley (if equipped) for the fan ¡ Hydraulic drive (if equipped) for the fan ¡ Water pump ¡ Drive pulley for the water pump ¡ Water temperature regulator ¡ Housing for the water temperature regulator ¡ Coolant temperature switch The coolant flows from the bottom of the radiator to the centrifugal water pump. The water pump is installed on the cylinder block above the timing case. The water pump is driven by a pulley. The crankshaft pulley turns a belt which drives the pulley of the water pump.

The water pump forces the coolant to flow to the water temperature regulator. When the engine is cold, the water temperature regulator is closed. Then, the coolant flows directly into the cylinder head. When the engine warms, the water temperature regulator begins to open. Then, the regulator allows some of the coolant to flow to the top of the radiator.

The regulator opens fully when the engine reaches the normal operating temperature. When the regulator is fully open, the flow to the radiator is the maximum. However, the regulator does not close the flow of coolant into the cylinder head.

Coolant flows continuously through the cylinder head and the top of the cylinder block. This coolant flows into the back of the water pump from the cylinder block. This coolant then mixes with the coolant that is pumped from the radiator by the water pump.

The water temperature regulator maintains the correct engine temperature by adjusting the direct flow of coolant to the top of the radiator. The coolant is cooled by the radiator. Heat is removed from the coolant by cooler air which passes over the radiator fins. The fan causes a high volume of air to flow between the radiator fins in order to provide sufficient cooling. The coolant flows from the radiator through the bottom hose to the coolant pump.

The engine has a housing for the water temperature regulator. The housing is installed on the left side of the cylinder head.

Different machine models have different locations for the radiator, the fan, and the fan drive. These three components may be remotely mounted from the engine if the machine has a hydraulic drive for the fan.

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68

007

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Basic Engine , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Cylinder Head and Block The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each valve has a single valve spring and an oil seal. The valve and the valve spring are held in position by a valve spring cap and two collets. The oil seal fits over the top of the valve guide. The valve seat inserts and the valve guides can be replaced.The ports for the inlet and for the exhaust valves are on the left side of the cylinder head.The cylinder block does not have cylinder liners. The cylinder walls are honed.The valve mechanism cover is made from aluminum. The cover contains the following components: ¡ An open breather assembly ¡ An oil filler cap ¡ A seal for the face toward the cylinder head ¡ Holes for four cap nuts ¡ Holes for two bolts ¡ An air inlet manifold The cap nuts are threaded onto studs. The steel studs are threaded into the cylinder head.

The bolts are threaded onto the cover for the rocker shaft assembly.

The gases in the valve cover, which are caused by blowby, pass from the breather assembly to the outside air.

Pistons and Connecting Rods The pistons of the engine have a combustion chamber in the crown of the piston in order to provide an efficient mix of the fuel and the air.The piston pin is off-center in order to reduce the noise level.The pistons have two compression rings and an oil control ring.The correct piston height is important in order to ensure that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in order to conform to requirements for emissions.

The piston must not be machined in order to obtain the correct piston height.A piston and connecting rod are matched to each cylinder.One height of piston is available. The inside of the piston is marked "Shibaura". This reference mark faces the right side of the engine. Refer to Testing and Adjusting, "Basic Engine" for procedures to measure the piston height.Identification marks on the connecting rod and the connecting rod cap must align. The identification marks face the right side of the engine.The main bearing caps have a chamfered edge on one side. The chamfer faces the front of the engine.Two main bearing caps have notches on the face of the cap that is opposite the side with the chamfer. The bearing cap with the notch toward the outside edge of the bearing cap is for the number 3 bearing journal.

Timing Gear Case and Gears The timing gear case contains the following components: ¡ Front oil seal for the crankshaft pulley ¡ Bearing for the crankshaft gear ¡ Oil pump ¡ Adjustment screw for setting the maximum fuel position ¡ Adjustment screw for setting the maximum speed position

007 : Systems Operation

69 ¡ ¡ ¡ ¡

Mechanical stop control Linkage for the fuel injection pump Fuel Control lever for the governor Throttle

The crankshaft has a front bearing that is pressed in the cylinder block and three main journal bearings on three cylinder engines. The crankshaft has a front bearing that is pressed in the cylinder block and four main journal bearings on four cylinder engines.

The engine has three thrust washers. The thrust washers are hemispherical in shape. Two thrust washers are located on both sides of the bottom half of the rear main bearing. The third thrust washer is located on the rear side of the upper half of the main bearing.

The crankshaft has front oil seals and rear oil seals.

The timing case is made of aluminum. The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears.

The number one piston is at the top center position on the compression stroke when the following timing marks are aligned: ¡ Idler gear ¡ Crankshaft gear ¡ Camshaft gear ¡ Crankshaft pulley ¡ Timing case The crankshaft gear turns the idler gear which then turns the camshaft gear.

The idler gear contains the oil pump. The idler gear turns the gear for the tachometer.

The crankshaft pulley drives the pulley on the water pump and the pulley which drives the alternator.

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70

008

Systems Operation

3024C Engine for Caterpillar Built Machines, SENR5005-03

Electrical System , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Engine Electrical System

Illustration 1 Typical example

g00841218

The electrical system has two separate circuits. ¡ Charging circuit ¡ Starting circuit Some of the electrical system components are used in more than one circuit. The following items are common in each of the circuits: ¡ Battery ¡ Circuit breaker ¡ Cables ¡ Wires for the battery The charging circuit is in operation when the engine is running. An alternator converts mechanical energy to electrical energy for the charging circuit. A voltage regulator in the circuit controls the electrical output in order to keep the battery at full charge.

008 : Systems Operation

71

NOTICE The disconnect switch, if equipped, must be in the ON position in order to let the electrical system function. There will be damage to some of the charging circuit components if the engine is running with the disconnect switch in the OFF position.

If the engine has a disconnect switch, the starting circuit can operate only after the disconnect switch is put in the "ON" position.

The starting switch is in operation only when the start switch is activated.

The charging circuit is connected through the ammeter. The starting circuit is not connected through the ammeter.

Automatic Shutdown System

Illustration 2 Typical example

g00841303

Illustration 3 g00841411 Electrical connector for the automatic shutdown system (typical example), (1) Ignition switch (2) Ignition switch (3) Fuel shutoff solenoid (4) Engine oil pressure switch (5) Coolant temperature switch (6) Ground

008 : Systems Operation

72

Automatic Shutdown Conditions The engine will shut down if the following conditions continue for more than ten seconds while you start the engine or for two seconds while you operate the engine: ¡ Engine coolant temperature of 110° ± 3°C (230° ± 5°F) ¡ Engine oil pressure at the cylinder head of 29 kPa (4 psi) or less ¡ Engine oil pressure at the lower cylinder block 98 kPa (14 psi) or less Note: There is no automatic shutdown for low coolant level.

Note: The capacity of the diode must be 3 Amperes with a reverse voltage of 600 volts.

Note: The rated current draw of the engine oil pressure switch is 0.42 Amperes (5 watts maximum bulb).

Note: If necessary, a delay fuse should be used for replacement.

Charging System Components NOTICE Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.

Alternator

Illustration 4 g00292313 Alternator, (1) Regulator (2) Roller bearing (3) Stator winding (4) Ball bearing (5) Rectifier bridge (6) Field winding (7) Rotor assembly (8) Fan

The alternator is driven by the crankshaft pulley through a belt. When the engine is running, the pulley rotates the shaft inside the alternator. The rotor assembly is attached to the shaft. The rotor assembly has many magnetic poles. The magnetic poles are similar to fingers. An air space exists between each of the opposite poles. The poles have residual magnetism that produces a small amount of magnet-like lines of force (magnetic field). This magnetic field is produced between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings. The alternating current is produced from the small magnetic lines of force that are created by the residual magnetism of the poles. The AC is changed into direct current (DC) when the current passes through the diodes of the rectifier bridge. Most of this current provides the battery charge and the supply for the low amperage circuit. The remainder of the current is sent to the field windings. The DC current flow through the field windings (wires around an iron core) increases the strength of the magnetic lines of force. These stronger magnetic lines of force increase the amount of AC that is produced in the stator windings. The increased speed of the rotor assembly also increases the current output of the alternator and the voltage output of the alternator.

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73

Regulator

Illustration 5 Typical regulator assembly

g00360155

The voltage regulator is a solid-state electronic switch. The voltage regulator senses the voltage of the system. The regulator then uses switches to control the current to the field windings. This controls the voltage output in order to meet the electrical demand of the system.

Starting System Components Solenoid

Illustration 6 Typical solenoid schematic

g00292316

A solenoid is an electromagnetic switch that performs two basic functions: ยก The solenoid closes the high current starter motor circuit with a low current start switch circuit. ยก The solenoid engages the starter motor pinion with the ring gear.

The solenoid has windings (one set or two sets) around a hollow cylinder. A plunger with a spring load device is inside of the cylinder. The plunger can move forward and backward. When the start switch is closed and electricity is sent through the windings, a magnetic field is created. The magnetic field pulls the plunger forward in the cylinder. This moves the shift lever in order for the pinion drive gear to engage with the ring gear. The front end of the plunger then makes contact across the battery and across the motor terminals of the solenoid. The starter motor then begins to turn the flywheel of the engine.

When the start switch is opened, current no longer flows through the windings. The spring now returns the plunger to the original position. At the same time, the spring moves the pinion gear away from the flywheel.

When two sets of windings in the solenoid are used, the windings are called the hold-in winding and the pull-in winding. Both of the windings wind around the cylinder for an equal amount of times. The pull-in

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winding uses a wire with a larger diameter in order to produce a stronger magnetic field. When the start switch is closed, part of the current flows from the battery through the hold-in winding. The remainder of the current flows through the pull-in windings, to the motor terminal, and then to the ground. When the solenoid is fully activated, the current is shut off through the pull-in windings. Only the smaller hold-in windings are in operation for the extended period of time that is necessary for the engine to be started. The solenoid will now take a smaller amount of current from the battery. Heat that is created by the solenoid will be kept at an acceptable level.

Electric Starting Motor

Illustration 7 g00292330 Starter motor cross section (typical example), (1) Field (2) Solenoid (3) Clutch (4) Starter pinion (5) Commutator (6) Brush assembly (7) Armature

The starter motor rotates the engine flywheel at a rate that is fast enough to start the engine.

The starter motor has a solenoid (2). When the start switch is activated, solenoid (2) will move starter pinion (4) in order to engage starter pinion (4) to the ring gear on the engine flywheel. Starter pinion (4) and the ring gear will engage when the circuit between the battery and the starter motor is closed by the electric contacts in solenoid (2). When the circuit between the battery and the starter motor is complete, starter pinion (4) will rotate the engine flywheel. A clutch provides protection for the starter motor so that the engine cannot turn the starter motor too fast. When the switch is released, starter pinion (4) will move away from the ring gear.

Other Components Circuit Breaker

Illustration 8 g00281837 Circuit breaker schematic, (1) Reset button (2) Disc in open position (3) Contacts (4) Disc (5) Battery circuit terminals

The circuit breaker is a switch that opens the battery circuit if the current in the electrical system is higher than the rating of the circuit breaker. Metal disc (2) is activated by heat. As the current in the electrical system increases, the temperature of metal disc (2) will increase. The heat that is caused by the excessive current will cause a distortion in metal disc (2). When a distortion occurs in metal disc (2), contacts (3) open. A circuit breaker that is open can be reset when the metal disc becomes cooler. Push reset button (1) in order to close contacts (3) and reset the circuit breaker.

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001

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Troubleshooting , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Introduction Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and the corrective action. The most common problems are identified in this troubleshooting manual. The symptoms, causes, and guidance for solving the problems are given.The list of problems, causes and corrections will only give an indication of the location of a possible problem. There is also a list that shows some of the repairs that are required.Sometimes additional repair work is required beyond the repair which is recommended. Frequently, a problem does not exist in isolation. The problem can be a result of wear or of damage to several parts which operate together as part of a system.Service personnel may remember similar complaints which were corrected by a previous method of troubleshooting. A similar complaint can have a different cause.Get a good description of the problem from the operator and/or the person that owns the vehicle. Knowing the details of the problem can save time. This will make the repair job faster and easier.All possible problems and the probable causes cannot be listed. The technician must follow a logical process of eliminating possible causes and of identifying the specific causes of the problems.

Troubleshooting The Fuel Injection Nozzles On The Engine Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean.Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzle.Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.Refer to Specifications, "Fuel Injection Nozzles" for additional information.

The engine is difficult to start or the engine runs rough.

Probable Cause 1. The fuel injection nozzle does not seal correctly in the cylinder head.

Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.

2. There is debris on the mating surface of the cylinder head with the gaskets or the insert. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.

Remove any extra gaskets or debris.

3. The connections of the high pressure fuel line leak.

Tighten the fittings of the high pressure fuel line.

4. The fuel injection nozzle does not operate correctly.

Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.

5. The incorrect fuel injection nozzle is installed.

Make sure that all fuel injection nozzles are the correct replacement parts for the engine. Refer to the

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Parts Manual for the correct replacement part.

The engine exhaust has too much black smoke.

Probable Cause 1. Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the mating surface of the cylinder head with the gaskets or the insert.

Remove any extra gaskets or debris.

2. The fuel injection nozzle does not operate correctly.

Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.

3. The incorrect fuel injection nozzle is installed.

Make sure that all fuel injection nozzles are the correct replacement parts for the engine. Refer to the Parts Manual for the correct replacement part.

The engine has lost power and the engine uses too much fuel.

Probable Cause 1. The fuel injection nozzle does not seal in the cylinder head.

Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.

2. Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the sealing surface for the fuel injection nozzle.

Remove any extra gaskets or debris.

3. The connections of the high pressure fuel line leak.

Tighten the fittings of the high pressure fuel line.

4. The fuel injection nozzle does not operate correctly.

Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.

Test the fuel injection nozzle on a nozzle tester.

5. The incorrect fuel injection nozzle is installed.

Make sure that all fuel injection nozzles have the correct code for the engine.

6. A connection of the fuel return line leaks.

Inspect all connections of the low pressure fuel line for tightening to the correct torque.

The engine is misfiring, running rough, or running poorly.

Probable Cause 1. The fuel injection nozzle does not seal in the cylinder head.

Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.

2. Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the sealing surface for the fuel injection nozzle.

Remove any extra gaskets or debris.

3. The connections of the high pressure fuel line leak.

Tighten the fittings of the high pressure fuel line.

4. The fuel injection nozzle does not operate correctly.

Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle

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77

tester in order to measure the pressure setting.

Test the fuel injection nozzle on a nozzle tester.

5. The incorrect fuel injection nozzle is installed.

Make sure that all fuel injection nozzles have the correct code for the engine.

6. A restriction exists in the high pressure fuel line.

Inspect all high pressure fuel lines for damage.

7. A seat washer that is not the correct thickness is installed.

The correct seat washer is 2.0 mm (0.08 inch) thick.

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean.Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzles. Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Back leakage 1. Fuel leaks through the threaded connection of the body and the nozzle nut.

Make sure that the threads are clean. Tighten the body to the correct torque.

2. Debris or damage exists on the orifices.

Visually inspect the components of the valve for carbon pitting, for scoring, or for other damage.

Clean the surface of the orifices with solvent. Replace the fuel injection nozzles if corrosion exists.

The fuel injection nozzle does not inject fuel in the correct quantity or in the correct pattern.

Probable Cause 1. The setting of the opening pressure is incorrect.

Test the setting of the opening pressure. Adjust the setting to the correct pressure.

2. The fuel injection nozzle is stuck.

Debris or damage exists on the fuel injection nozzle.

3. The orifices are blocked.

Inspect the orifices for carbon buildup. The fuel injection nozzle must be cleaned or replaced.

4. The passage for the fuel return is obstructed.

Clean the passage in order to remove any carbon buildup or other debris.

Troubleshooting the Engine When you are troubleshooting the engine, refer to the Specifications Module and the Systems Operation, Testing and Adjusting Module for additional information.

The engine will not start.

Probable Cause 1. The engine starting procedure was incorrectly followed.

Ensure that the engine starting procedure is correctly followed.

2. The manual valve in the fuel line is closed.

Open the valve.

3. The fuel level is low in the fuel tank. Air is in the fuel system.

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Fill the fuel tank with fuel. Remove the air from the fuel system.

4. The fuel is contaminated.

The fuel contains water, dirt, ice, or wax. Replace the fuel filters. Replace the fuel in the fuel tank with clean fuel.

5. Engine cranking speed is too slow.

The engine oil is too thick. The connections of the battery cables to the starting motor are loose.

6. The glow plugs for the fuel injection pump do not operate correctly.

Inspect the cable connections and the electrical connections of the glow plugs and the electrical components of the starting aid circuit. Test the glow plugs for correct operation.

7. The fuel shutoff solenoid is not operating correctly.

Ensure that the fuel shutoff solenoid operates correctly. Replace a fuel shutoff solenoid that is suspect.

8. The fuel transfer pump is not operating correctly. The fuel transfer pump was installed when the lobe of the camshaft was at maximum lift.

Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information. Remove the fuel transfer pump if the fuel pressure is too low. The fuel transfer pump must be repaired or replaced.

Install the fuel transfer pump with the lobe of the camshaft on minimum lift. Tighten the mounting bolts evenly.

9. The fuel filter or the fuel lines are restricted. Excess water has built up in the fuel filter.

Check fuel lines and the fuel filter. Drain any water from the fuel filter.

10. The operation of the fuel injection pump is not correct.

Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump.

Refer to the Specifications Module, "Fuel Injection Pump" topic. Check the timing of the drive gear for the fuel injection pump with the idler gear. The fuel injection pump must be repaired or replaced.

Make sure that the linkage of the fuel rack operates correctly.

Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque.

Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

11. The governor and the fuel injection linkage are damaged. The governor and the fuel injection linkage are incorrectly assembled in the timing gear case.

Adjust the linkage. Replace suspect parts.

12. A fuel injection nozzle is not operating correctly.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

13. The cylinders have low compression.

Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: n Cylinder walls are worn or damaged. n Piston rings are worn or broken. n The piston height is incorrect. n The piston is damaged. n The fuel injection nozzles are not seated correctly. n The valve lash requires adjustment.

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The fuel injection pump timing is incorrect.

The engine timing is incorrect. n When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

14. The glow plugs do not operate correctly. The engine floods in cold weather.

Ensure that the glow plugs become hot when the ignition switch is in the START position. n n

The engine starts and the engine runs for a brief period of time and the engine stops.

Probable Cause 1. The fuel filter or the fuel lines are restricted. Excess water has built up in the fuel filter.

Check the fuel lines and the fuel filter. Replace the fuel filter. Drain any water from the fuel filter.

2. The operation of the fuel transfer pump is not correct.

Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information. Remove the fuel transfer pump if the fuel pressure is too low. The fuel transfer pump must be repaired or replaced.

3. The air inlet or the exhaust system is restricted.

Inspect the air inlet and the exhaust systems. Remove any restrictions.

4. Air is in the fuel system.

Find the air leak in the fuel system. Repair the fuel system.

The engine misfires or the engine runs rough.

Probable Cause 1. The fuel pressure is low.

Ensure that the fuel tank has enough fuel. Look for leaks or suspect bends in all of the fuel supply lines. Test the outlet pressure of the fuel transfer pump.

2. Air is in the fuel system.

Find the air leak in the fuel system. Repair the air leak.

3. The valve lash is not correct.

Adjust the valve lash.

4. The operation of the fuel injection pump is not correct.

Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump.

Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced.

Make sure that the linkage of the fuel rack operates correctly.

Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque.

Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

5. A fuel injection nozzle does not operate correctly.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

6. The engine mounts are not correctly tightened or the engine mounts are not mounted correctly. This 001 : Testing and Adjusting

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condition also causes vibration.

Check the engine mounts for correct positioning. Check the bolts of the engine mounts for correct tightening.

7. The fuel is contaminated with water, dirt, ice, or wax.

Drain any water from the fuel tank and from the fuel filter. If the fuel is contaminated by dirt, ice, or wax, replace the fuel.

8. The cylinders have low compression.

Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: n Cylinder walls are worn or damaged. n Piston rings are worn or broken. n The piston height is incorrect. n The piston is damaged. n The fuel injection nozzles are not seated correctly. n The valve lash requires adjustment. n The fuel injection pump timing is incorrect. n The engine timing is incorrect. n When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

The engine runs evenly, but the engine loses power.

Probable Cause 1. The cylinders have low compression.

Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: n Cylinder walls are worn or damaged. n Piston rings are worn or broken. n The piston height is incorrect. n The piston is damaged. n The fuel injection nozzles are not seated correctly. n The valve lash requires adjustment. n The fuel injection pump timing is incorrect. n The engine timing is incorrect. n When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

2. The operation of the fuel injection pump is not correct.

Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump.

Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced.

Make sure that the linkage of the fuel rack operates correctly.

Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque.

Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

3. The valve lash is not correct.

Adjust the valve lash.

4. The air cleaner is restricted.

The air cleaner must be repaired or the air cleaner must be replaced.

5. Air is in the fuel system.

Remove the air from the fuel system. Make sure that the fittings of the fuel lines are aligned. Make sure that the fittings of the fuel lines are tightened correctly.

6. The fuel transfer pump is not operating correctly. The fuel transfer pump was installed when the lobe of the camshaft was at maximum lift.

Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information. Remove the fuel transfer pump if the fuel pressure is too low. The fuel transfer pump must be repaired or replaced.

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Install the fuel transfer pump with the lobe of the camshaft on minimum lift. Tighten the mounting bolts evenly.

The engine lacks power.

Probable Cause 1. Fuel of poor quality is in the fuel system.

Remove the fuel from the fuel tank. Install a new fuel filter. Put a good grade of clean fuel in the fuel tank.

2. The fuel pressure is low.

Make sure that sufficient fuel is in the fuel tank. Look for leaks or suspect bends in the fuel line between the fuel tank and the fuel transfer pump. Remove any air in the fuel system. Check the outlet pressure of the fuel transfer pump.

3. The governor and the fuel injection linkage is damaged or the governor and the fuel injection linkage is incorrectly assembled in the timing gear case.

Adjust the linkage. Replace suspect parts.

4. The valve lash is not correct.

Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting.

5. The operation of the fuel injection pump is not correct.

Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump.

Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced.

Make sure that the linkage of the fuel rack operates correctly.

Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque.

Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

6. A fuel injection nozzle is not operating correctly.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

The engine has excessive vibration.

Probable Cause 1. The bolts for the pulleys are loose. Refer to the Specifications Module, "Crankshaft Pulley" topic for additional information.

Tighten the bolts.

2. A pulley is suspect.

Inspect the pulleys for wear or for damage. If the pulley is worn or damaged, use new parts for replacement.

3. The engine mounts are loose, worn, or suspect.

Tighten all mounting bolts. Inspect the engine mounts for wear or for damage. Use new parts for 001 : Testing and Adjusting

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replacement.

The engine has excessive combustion noise.

Probable Cause 1. Fuel of poor quality is in the fuel system.

Remove the fuel from the fuel tank. Install a new fuel filter. Put a good grade of clean fuel in the fuel tank.

2. A fuel injection nozzle is not operating correctly.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

3. The piston height is incorrect.

Measure the piston height. To obtain the correct piston height, the piston, the piston pin, the bearings, or the connecting rod should be replaced.

The engine has excessive valve compartment noise.

Probable Cause 1. Valve springs or locks are broken.

Install new parts. Broken locks can cause the valve to slide into the cylinder. Major damage to the engine can occur.

2. The bolts and nuts, which hold the rocker arm assembly, are loose.

Tighten the bolts or nuts. Refer to the Specifications Module, "Rocker Shaft" topic for additional information.

3. The valve lash exceeds the specification.

Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting.

Engine oil is in the cooling system.

Probable Cause 1. The cylinder head gasket is suspect.

Install a new cylinder head gasket.

Engine knock occurs.

Probable Cause 1. A main bearing is damaged.

Inspect the main bearings and the bearing surfaces of the crankshaft. Replace damaged parts.

2. The crankshaft is damaged.

Replace the crankshaft. Clean the engine thoroughly.

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3. The piston height is incorrect.

Check the piston height. Inspect the piston, the connecting rod, and the crankshaft for wear. Check for correct installation.

4. The projection of the fuel injection nozzle in the precombustion chamber is incorrect.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is suspect. Test the fuel injection nozzle for that cylinder. Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection line nuts are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

The rocker arm has insufficient movement and the valve lash exceeds the specification.

Probable Cause 1. Lubrication of internal engine components is inadequate.

Check lubrication of the valves. There must be a strong flow of oil at high rpm. There must be a small flow of oil at low rpm. Oil passages in the engine must be clean.

2. Rocker arm parts are worn.

If there is too much wear, install new parts or rocker arms. Adjust the valve lash.

3. The end of the valve stem is worn.

Install new valves. Adjust the valve lash.

4. The valve lash exceeds the specification.

Measure the valve lash. Adjust the valve lash.

5. The pushrods are worn.

If there is too much wear, install new pushrods. Adjust the valve lash.

6. The valve lifters are worn.

If there is too much wear, install new valve lifters. Adjust the valve lash.

7. The lobes of the camshaft are worn.

Measure the valve lash. Check for free movement of the valves. Check for bent valve stems. Check for wear on the valve lifters. Replace suspect parts. Adjust the valve lash.

8. The bolts and the nuts that hold the rocker arm assembly are loose.

Tighten the bolts and the nuts.

A cylinder head valve is loose.

Probable Cause 1. The valve keeper for the valve is broken.

Replace the valve keeper. Broken keepers can cause the valve to slide into the cylinder. Major engine damage can result.

2. The valve springs are broken or damaged.

Install new valve springs.

Oil condenses at the exhaust.

Probable Cause 1. The valve compartment contains too much oil.

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Look at both ends of the rocker arm shaft. Be sure that a plug is installed in each end.

2. The valve guides are worn.

Install new valve guides. Recondition the cylinder head.

3. The piston rings are worn.

Replace the piston rings.

The valve lash is less than the required specification.

Probable Cause 1. The valve seat or the face of the valve is worn.

Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting.

Engine components have early wear.

Probable Cause 1. Dirt is in the engine oil.

Remove the dirty engine oil. Install a new oil filter. Put clean oil in the engine.

2. Leaks exist in the air inlet system.

Inspect all gaskets and connections. The components must be repaired or replaced.

3. Fuel leaks into the engine oil. Fuel leaks will cause high fuel consumption and low engine oil pressure. n Fuel leaks into the crankcase from the fuel transfer pump. n Fuel leaks past the valve in a fuel injection nozzle. n The pressure setting of the fuel injection nozzles is too high. n The drive is broken on the fuel injection pump.

Adjust the component. Replace a damaged component.

Coolant is in the engine oil.

Probable Cause 1. The cylinder head gasket is damaged.

Install a new cylinder head gasket.

2. The cylinder head is cracked or damaged.

Install a new cylinder head.

3. The cylinder block is cracked or damaged.

Install a new cylinder block.

The engine exhaust has too much black smoke or too much gray smoke.

Probable Cause 1. The cylinders have low compression.

Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: n Cylinder walls are worn or damaged. n Piston rings are worn or broken. n The piston height is incorrect. n The piston is damaged. n The fuel injection nozzles are not seated correctly. n The valve lash requires adjustment. n The fuel injection pump timing is incorrect.

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The engine timing is incorrect.

When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

2. The operation of the fuel injection pump is not correct.

Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump.

Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced.

Make sure that the linkage of the fuel rack operates correctly.

Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque.

Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

3. A fuel injection nozzle is not operating correctly.

Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Replace the suspect fuel injection nozzle.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

4. The inlet air is restricted.

Check the air cleaner for restrictions. The air cleaner must be cleaned or replaced. n n

The engine exhaust has too much white smoke or too much blue smoke.

Probable Cause 1. The engine contains too much engine oil.

Drain the excess oil from the engine oil pan.

2. The engine misfires or the engine runs rough.

Refer to Problem 3.

3. The fuel injection timing is not correct.

Adjust the timing of the fuel injection pump. Refer to the Specifications Module or the Systems Operations, Testing and Adjusting Module, "Fuel Injection Pump" topic for additional information.

4. The valve guides are worn.

Replace the valve guides. Check the flatness of the cylinder head. Recondition the cylinder head if the flatness is out of tolerance.

5. The piston rings are worn. Refer to the Specifications Module, "Pistons and Rings" topic for additional information.

Replace the piston rings.

6. The engine consistently runs below the normal operating temperature. The water temperature regulator is suspect.

Replace the water temperature regulator.

7. The breather hose or the vent hole in the breather assembly is obstructed.

Clean the vent hole, the breather assembly, and the breather hose.

The engine has low oil pressure.

Probable Cause 1. The engine oil level is low.

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Add engine oil to the correct level.

2. The engine oil filter is restricted.

Install a new engine oil filter. Replace the oil in the engine with clean engine oil. Check the operation of the engine oil bypass valve for the engine oil filter.

3. Fuel leaks into the lubrication oil. Fuel leaks will cause high fuel consumption and low engine oil pressure. n Fuel leaks into the crankcase from the fuel transfer pump. n Fuel leaks past the valve in a fuel injection nozzle. n The pressure setting of the fuel injection nozzles is too high. n The drive is broken on the fuel injection pump.

4.

5.

6.

7.

8.

9.

Adjust the component. Replace a damaged component.

Too much clearance exists between the bore of the rocker arm and the rocker shaft.

Check for adequate lubrication of the rocker arm assembly. Replace parts which are worn. Refer to the Specifications Module, "Rocker Shaft" topic for additional information.

The suction pipe for the engine oil pump is suspect.

Replace the suction pipe.

The engine oil bypass valve does not operate correctly.

Clean the bypass valve. Replace the bypass valve if the spring is broken or the plunger is damaged.

The engine oil pump does not operate correctly.

Check the distance of the face of the cover of the oil pump above the face of the idler gear. Refer to the Specifications Module, "Engine Oil Pump" topic. Check the wear of the lobe on the oil pump.

The components of the idler gear and the oil pump must be repaired or replaced.

Too much clearance exists between the crankshaft and the crankshaft bearings.

Replace the crankshaft or the crankshaft bearings. Refer to the Specifications Module, "Crankshaft" topic for additional information.

Too much clearance exists between the camshaft and the camshaft bearings.

Replace the camshaft or the camshaft bearings.

The engine oil pressure is too high.

Probable Cause 1. The engine oil bypass valve does not open.

The bypass valve must be cleaned or replaced.

The engine uses too much engine oil.

Probable Cause 1. The engine contains too much engine oil.

Drain the excess engine oil from the engine oil pan.

2. Oil lines have leaks.

Find the source of the oil leaks. Repair the line or fitting.

3. The valve guides are worn.

Replace the valve guides.

4. The piston rings are worn. Refer to the Specifications Module, "Pistons and Rings" topic for additional information.

Replace worn parts.

The engine overheats.

Probable Cause 1. The air flow through the radiator is restricted.

Clean the exterior of the radiator in order to remove all restrictions.

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2. The coolant level in the engine is low.

Add coolant into the radiator to the correct level.

3. The pressure cap is suspect.

Test the operation of the pressure cap. Replace a faulty pressure cap.

4. Gases from combustion are in the coolant.

Find the source of the entry of the gases from combustion into the coolant system. Repair the source of the problem.

5. The water temperature regulator is suspect.

Test the water temperature regulator for correct operation. Refer to the Systems Operation, Testing and Adjusting Module or the Specifications Module for additional information. Replace a faulty water temperature regulator.

6. The water pump is suspect.

The water pump must be repaired or replaced.

7. The engine is operating with too much load.

Reduce the load.

8. The timing of fuel injection pump is incorrect.

Adjust the timing. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information.

The exhaust temperature is too high.

Probable Cause 1. A restriction exists in the air inlet or in the exhaust system.

Remove the restriction.

2. The timing of the fuel injection pump is incorrect.

Adjust the timing of the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information.

The starting motor does not turn or the starting motor turns too slowly.

Probable Cause 1. The battery is discharged.

Charge the battery. Replace a damaged battery. Clean all cable terminals and battery posts. Apply 1U-8267 Battery Saver and Cleaner on the cable clamps and the battery posts. Tighten the cable clamps on the battery posts.

2. The terminals or the brushes of the starting motor have a short circuit to ground.

Find the short circuit. Repair the short circuit.

3. The ignition switch, the starting motor solenoid, or the start relay is damaged.

Replace the ignition switch, the starting motor solenoid, or the start relay.

4. An excessive voltage drop exists in the cables or across the terminals in the circuits for the starting motor. The battery cables are loose at the terminals, corroded, or cracked. The battery terminals are corroded or broken.

Inspect the battery cables and the battery terminals for loose connections, corrosion or other damage.

The starting motor turns, but the pinion gear does not engage the flywheel ring gear.

Probable Cause 1. The pinion drive or the overrunning clutch is suspect.

Replace the pinion drive or the overrunning clutch.

2. The ring gear of the flywheel is damaged.

Replace the flywheel.

3. The shift lever or the linkage is damaged.

Replace the shift lever or the linkage.

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4. The starting motor solenoid is damaged.

Replace the starting motor solenoid.

5. The armature or idler gear of the starting motor is damaged.

Replace the starting motor.

The engine does not crank or the engine rotates slowly when the keyswitch is in the start position.

Probable Cause 1. The battery has a low charge.

Charge the battery. Replace a faulty battery. Clean all cable terminals and battery posts. Apply the 1U-8267 Battery Saver and Cleaner on the cable clamps and to battery posts. Tighten the cable clamps on the battery posts.

2. The start relay is suspect.

Replace the start relay.

3. An excessive voltage drop exists in the cables or across the terminals in the circuits for the starting motor. The battery cables are loose at the battery terminals, corroded, or cracked. The battery terminals are corroded or broken.

Inspect the battery cables and battery terminals for loose connections, corrosion or other damage.

Replace damaged parts.

Refer to "The Starting Motor does not turn or the Starting motor turns too slowly.".

4. The overrunning clutch for the pinion drive slips.

Replace the overrunning clutch.

The starting motor continues to run after the ignition switch is released.

Probable Cause 1. The ignition switch, the start relay, or the starting motor solenoid is suspect.

Replace the ignition switch, the start relay, or the starting motor solenoid.

The pinion gear does not disengage after the engine starts to run.

Probable Cause 1. The return spring of the pinion solenoid is damaged.

Replace the return spring of the pinion solenoid.

2. The shift lever or the linkage is damaged.

Replace the shift lever or the linkage.

3. The ignition switch or the start relay is suspect.

Replace the ignition switch or the start relay.

The alternator does not charge the battery or the alternator charge rate is slow or irregular.

Probable Cause 1. The drive belt for the alternator is loose.

Inspect the drive belt for wear and for damage. The drive belt must be adjusted or replaced.

2. The drive pulley for the alternator is loose or worn.

Inspect the pulley for wear or for damage. Tighten the nuts of the pulley to the correct torque.

Replace a damaged pulley.

3. The electrical cables and connections in the charging and starting circuits are loose or damaged.

4. Inspect all cables and connections. All connections must be clean and tight. Apply the 1U-8267 Battery Saver and Cleaner on the cable terminals and the connections. Replace suspect parts.

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5. The regulator or the field winding of the rotor in the alternator are suspect.

The alternator must be repaired or replaced.

6. The brushes of the alternator are worn or dirty.

The brushes must be cleaned or replaced.

7. The rectifier in the alternator is suspect.

Replace the rectifier or the alternator.

The alternator charges the battery to a voltage that is too high.

Probable Cause 1. The regulator is suspect.

Replace the alternator.

The alternator is noisy.

Probable Cause 1. The drive belt for the alternator is worn or damaged.

Replace the drive belt for the alternator.

2. The drive pulley for the alternator is loose or worn.

Inspect the pulley for wear and for damage. Tighten the nuts of the pulley to the correct torque.

Replace a damaged pulley.

3. The drive belt and the drive pulley are not in alignment.

Adjust the alignment.

4. The bearings of the alternator are worn or damaged.

Replace the alternator.

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002

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel System - Inspect A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance.

1. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt.

2. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends.

Verify that the fuel return line is not collapsed.

3. Install a new fuel filter.

4. Cut the old filter open with the 175-7546 Oil Filter Cutter Gp . Inspect the filter for excess contamination. Determine the source of the contamination. Make the necessary repairs.

5. Service the primary fuel filter (if equipped).

6. Operate the hand priming pump (if equipped). If excessive resistance is felt, inspect the fuel pressure regulating valve. If uneven resistance is felt, test for air in the fuel. Refer to Testing and Adjusting, "Air in Fuel - Test" for more information.

7. Remove any air that may be in the fuel system. Refer to Testing and Adjusting, "Fuel System Prime".

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003

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Air in Fuel - Test Table 1 Required Tools Part Number Part Description 2P-8278 Tube As (Sight Gauge)

Qty 1

This procedure checks for air in the fuel system. This procedure also assists in finding the source of the air.

1. Examine the fuel system for leaks. Ensure that the fuel line fittings are properly tightened. Check the fuel level in the fuel tank. Air can enter the fuel system on the suction side between the fuel transfer pump and the fuel tank.

Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury.

2. Install a 2P-8278 Tube As (Sight Gauge) in the fuel return line. When possible, install the sight gauge in a straight section of the fuel line that is at least 304.8 mm (12 inches) long. Do not install the sight gauge near the following devices that create turbulence: n Elbows n Relief valves n Check valves Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel that is present in the sight gauge, prime the fuel system. Refer to Testing and Adjusting, "Fuel System Prime" for more information. If the engine starts, check for air in the fuel at varying engine speeds.

When possible, operate the engine under the conditions which have been suspect.

Illustration 1 g00578151 2P-8278 Tube As (Sight Gauge), (1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable amount of air in the fuel. (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there is two seconds to three seconds intervals between bubbles. (3) Excessive air bubbles in the fuel are not acceptable.

3. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at the inlet to the fuel transfer pump. If a second sight gauge is not available, move the sight gauge from 003 : Testing and Adjusting

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the fuel return line and install the sight gauge at the inlet to the fuel transfer pump. Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel that is present in the sight gauge, prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for more information. If the engine starts, check for air in the fuel at varying engine speeds.

If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump. Refer to the Testing and Adjusting, "Fuel System - Prime".

If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of the fuel system.

To avoid personal injury, always wear eye and face protection when using pressurized air.

NOTICE To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the fuel tank.

4. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel transfer pump. Repair any leaks that are found. Check the fuel pressure in order to ensure that the fuel transfer pump is operating properly. For information about checking the fuel pressure, see Testing and Adjusting, "Fuel System Pressure - Test".

5. If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair the fuel tank or the stand pipe in the fuel tank.

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004

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Speed - Check

Part Number 9U-7400 9U-7401 6V-4950 (1)

Table 1 Tools Needed Part Name Multitach Tool Gp OR Multitach Tool Gp Speed Pickup

Quantity 1 (1)

1 1

Part of 9U-7400 Multitach Tool Gp

Illustration 1 9U-7400 Multitach Tool Gp

g00286276

The 9U-7400 Multitach Tool Gp can measure engine rpm from a magnetic pickup on the flywheel housing. The 9U-7400 Multitach Tool Gp also has the ability to measure engine rpm from visual engine parts in rotation.

Note: Refer to Special Instruction, NEHS0605 for the operating instructions of the 9U-7400 Multitach Tool Gp and the instructions for the test procedure.

The 6V-4950 Speed Pickup is another diagnostic tool accessory that can be used with the 9U-7401 Multitach Tool Gp . The 6V-4950 Speed Pickup can be used on single wall fuel injection lines that are 6 mm (0.25 inch). With these tools, engine speed can be measured quickly with an accuracy of Âą 1 rpm.

Note: Refer to Special Instruction, SEHS8029 for the operating instructions of the 6V-4950 Speed Pickup .

For the maximum engine operating speed (rpm), refer to Operation and Maintenance Manual, "Emissions Certification Film".

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005

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Finding Top Center Position for No. 1 Piston , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP Table 1 Required Tools Part Number Part Description Temporary Pointer

Qty 1

Illustration 1 g01241391 The engine that is shown may not reflect your application.

Setting top center position, (1) Temporary pointer

1. Fasten a temporary pointer (1) to the front of the front cover. Put the tip of the pointer close to the edge of the damper on the crankshaft or close to the edge of the pulley.

2. Remove the fuel injection nozzles and the valve mechanism cover. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove" and Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

3. Rotate the crankshaft clockwise when you face the front of the engine. Rotate the crankshaft until the pushrod for the inlet valve of the rear cylinder begins to tighten.

Note: Be careful when you rotate the crankshaft. The number one inlet valve will be held in position on top of the piston. If the crankshaft is not positioned properly, the valve may fall from the cylinder head.

4. Rotate the crankshaft further by 1/8 of a turn in a clockwise direction. Insert a suitable lever between the rocker lever and the valve spring cap of the number one inlet valve. Open the inlet valve. Insert a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker lever.

5. Slowly rotate the crankshaft in a counterclockwise direction until the piston makes contact with the open valve. Make a temporary mark on the damper or the pulley in order to align accurately with the tip of the pointer.

6. Rotate the crankshaft in a clockwise direction by one or two degrees. Remove the spacer that is between the valve stem and the rocker lever. Rotate the crankshaft by 1/4 of a turn in a counterclockwise direction. Insert a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker lever of the No. 1 inlet valve.

7. Slowly rotate the crankshaft clockwise until the piston makes contact with the open valve. Make another temporary mark on the damper or the pulley in order to align accurately with the tip of the 005 : Testing and Adjusting

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pointer.

8. Make a temporary mark at the center point between the two marks on the damper or the pulley.

Remove the other two marks. Rotate the crankshaft by 1/8 of a turn in a counterclockwise direction.

Remove the spacer between the valve stem and the rocker lever.

9. Slowly rotate the crankshaft in a clockwise direction until the mark on the damper or the pulley, which was made in Step 8, aligns with the tip of the pointer. The number one piston is now at the top center on the compression stroke.

10. After establishing the number one piston is at the top center on compression stroke. Carry out necessary procedures that are required.

11. Install the fuel injection nozzles and the valve mechanism cover. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - install" and Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

12. Remove the temporary pointer (1) from the front of the front cover.

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006

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel Injection Nozzle - Test , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP Perform the following procedures in order to determine if a fuel injection nozzle does not work correctly.

Table 1 Required Tools Part Number Part Name Qty 5P-4150 Tester Group 1 5P-7448 Adapter 1 6V-2170 Tube Assembly 1 8S-2270 Fuel Collector 1 1U-8857 Extension Tube 1 6V-6068 Calibration Fluid 1

Illustration 1 , (1) Fuel injection nozzle (2) Gasket

g00846800

1. Run the engine at low idle.

2. Loosen the nut for the fuel supply line at each fuel injection nozzle (1) . Listen for the low idle to decrease or become rough when the nuts are loosened at each cylinder.

The fuel injection nozzle may be faulty if the following items occur during the test: n Engine rpm does not decrease. n The engine continues to run properly.

3. If the fuel injection nozzle is worn or damaged, remove the fuel injection nozzle for additional testing.

Note: If leakage at the nut for the fuel supply line occurs, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injection nozzle.

Do not tighten the nut for the fuel supply line on the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.

Inspection and Cleaning of the Fuel Injection Nozzles Before a fuel injection nozzle is tested, remove any loose carbon from the tip of nozzle. Do not use abrasive material or a wire brush in order to clean the nozzle.Note: Extra care should be used in

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handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt in the orifices of the nozzle tip can damage engine components. The dirt can also distort the spray pattern of the nozzle.

Leakage Test

Illustration 2 g00470020 5P-4150 Nozzle Testing Group , (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter

This procedure tests for leakage around all components of the fuel injection nozzle.

1. Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 2.

Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension Tube (4) and 8S-2270 Fuel Collector (5) .

2. Pump the pressure to about 2030 kPa (294 psi) below the opening pressure of fuel injection nozzle (2) . Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately 0 kPa (0 psi). If fuel injection nozzle (2) is not faulty, the time will not be less than 5 seconds or more than 45 seconds.

If the time that is required for the pressure to decrease to 0 kPa (0 psi) is less than 5 seconds, too much fuel is leaking around the valve needle. Replace fuel injection nozzle (2) .

3. Look for any leakage in the connection from the adapter to fuel injection nozzle (2) . If leakage is visible, make sure that the components are tightened to the correct torque.

If leakage continues to occur, unscrew the body of fuel injection nozzle (2) from the nozzle nut.

Inspect the threaded surfaces for foreign particles and damage.

If the faces are damaged, replace fuel injection nozzle (2) .

If the faces are undamaged, clean the faces. Repeat Steps 1 and 2. If leakage continues to occur, replace the fuel injection nozzle.

4. Pump the pressure of the nozzle tester to approximately 2030 kPa (294 psi) below the opening pressure of fuel injection nozzle (2) . Fuel should not collect on the tip of fuel injection nozzle (2) in a sufficient quantity in order to drip from the tip for at least ten seconds. A light dampness is acceptable.

If the results of the tests are not acceptable, replace fuel injection nozzle (2) .

Pressure Test

Ensure that you wear eye protection at all times during testing. When 006 : Testing and Adjusting

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fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator.

Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

Illustration 3 g00470020 5P-4150 Nozzle Testing Group , (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter

NOTICE Do not use dirty test fluids when you test fuel injection nozzles. Also, do not test fuel injection nozzles unless you have the correct service tools.The use of dirty test fluids and the use of incorrect service tools will result in damage to fuel injection nozzles.

Note: This procedure is a test of the opening pressure of the fuel injection nozzle.

1. Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 3.

The spray from fuel injection nozzle (2) must be directed into 1U-8857 Extension Tube (4) and 8S2270 Fuel Collector (5) .

Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967 (ISO 4113) oil.

2. Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush fuel injection nozzle (2) by operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.

3. Open the gauge protector valve. Slowly increase the pressure until the valve in fuel injection nozzle (2) opens. Note the highest pressure indication on the dial indicator before the pointer moves to 0 kPa (0 psi). This highest pressure indication is the opening pressure of fuel injection nozzle (2) . The opening pressure occurs when the valve needle is lifted from the nozzle seat.

Refer to Specifications, "Fuel Injection Nozzles" for the correct pressure settings. If the opening pressure is not within the range of the setting which is given in the table, fuel injection nozzle (2) must be replaced.

Test for the Nozzle Spray Pattern

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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator.

Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

Illustration 4 g00470020 5P-4150 Nozzle Testing Group , (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter

The pressure adjustment must be correct before you test the spray pattern.

This procedure tests for the correct spray pattern for fuel injection nozzles.

1. Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 4.

Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension Tube (4) and 8S-2270 Fuel Collector (5) .

2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.

Illustration 5 g00468241 Phases of operation and spray pattern of the fuel injection nozzle The spray angle is 4 degrees from the vertical when the nozzle is fully open., (A) Closed nozzle (B) Open nozzle (C) Fully open nozzle

3. Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of fuel injection nozzle (2) .

The spray flows around the tip of the nozzle. A difference in the nozzle spray patterns indicates that fuel injection nozzle (2) is faulty. Refer to the correct spray pattern in Illustration 5.

Observe the following characteristics of the spray: n Drops of fuel should not be in the spray. n Fuel should be sprayed in the shape of a cone around the nozzle. n Fuel should be sprayed evenly in a 360 degree pattern around the nozzle.

Note: Be sure that the gauge protector valve is closed before fuel injection nozzle (2) is removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.

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007

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel Injection Timing - Check , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP Fuel injection timing is set in the factory. Fuel injection timing can not change during operation.

Note: If a fuel injection pump is removed, replace the old shims with new shims of the same thickness.

Old shims must not be reused.

Note: If the thickness of the shim is 0.5 mm (0.0197 inch) or the thickness of the shim is below 0.5 mm (0.0197 inch), install beaded shims. If the shim thickness is above 0.5 mm (0.0197 inch), install the non-beaded shim. Then install the beaded shim. Ensure that the beading on the beaded shim faces upward, toward the bottom of the fuel injection pump.

For the 3024C engine, select the correct combination of shims from table 2.

Table 1 Shim Thickness (mm) Part Number Beaded 0.2 154-3017 Yes 0.3 160-3555 Yes 0.4 160-3556 Yes 0.5 160-3557 Yes 0.5 160-3558 No If the original shim thickness can not be determined, contact the Dealer Solution Network. The user must provide the full engine number of the product that is serviced.

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008

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel Quality - Test

Part Number 5P-2712

Table 1 Required Tools Part Description Thermometer/Hydrometer

Qty 1

This test checks for problems regarding fuel quality. Refer to Diesel Fuels and Your Engine, SEBD0717 for additional details.

Use the following procedure to test for problems regarding fuel quality: 1. Determine if water and/or contaminants are present in the fuel. Check the water separator (if equipped). If a water separator is not present, proceed to Step 2. Drain the water separator, if necessary. A full fuel tank minimizes the potential for overnight condensation.

Note: A water separator can appear to be full of fuel when the water separator is actually full of water.

2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of the fuel tank. Visually inspect the fuel sample for contaminants. The color of the fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or similar to sludge can be an indication of the growth of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates that the fuel may not be suitable for operating conditions. The following methods can be used to prevent wax from clogging the fuel filter: n Fuel heaters n Blending fuel with additives n Utilizing fuel with a low cloud point such as kerosene Refer to Operation and Maintenance Manual, "Fuel Recommendations" for more information.

3. Check fuel API with a 5P-2712 Thermometer/Hydrometer for low power complaints. The acceptable range of the fuel API is 30 to 45 when the API is measured at 15 °C (60 °F), but there is a significant difference in energy within this range.

Table 2 Fuel Density (API) (1) Correction Factors API at Correction Factor 16 °C (60 °F) 32.0 0.987 35.0 1.000 40.0 1.022 45.0 1.044 (1)

The measured fuel API rating and the corresponding temperature must be corrected to 16 °C (60 °F) before selecting a fuel correction factor. Use the chart for the fuel density correction factor in order to determine the fuel API rating at 16 ° C (60 °F).

Note: A correction factor that is greater than 1.000 may be the cause of low power and/or poor fuel consumption.

4. If fuel quality is still suspected as a possible cause to problems regarding engine performance, disconnect the fuel inlet line, and temporarily operate the engine from a separate source of fuel that is known to be good. This will determine if the problem is caused by fuel quality. If fuel quality is determined to be the problem, drain the fuel system and replace the fuel filters. Engine performance can be affected by the following characteristics: n Cetane number of the fuel n Air in the fuel n Other fuel characteristics

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009

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel System - Prime , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.

NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

Illustration 1 g00730216 Fuel transfer pump, (A) Fuel inlet (B) Fuel outlet (1) Fuel transfer pump (2) O-ring seal

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Illustration 2 g00733551 Hand priming pump, (3) Priming button (4) Fuel filter base

Use the following procedures in order to remove air from the fuel system: 1. Loosen the nuts on the fuel lines to the fuel injection nozzles.

2. Operate priming button (3) of the fuel filter base until fuel that is free from air flows from the fuel injection nozzles. Then, tighten the nuts on the fuel lines for the fuel injection nozzles. Refer to Specifications, "Fuel Injection Lines" for the correct torque.

Illustration 3 g00751787 Typical example, (5) Vent screw (6) Fuel injection pump

3. Loosen vent screw (5) on fuel injection pump (6). Operate priming button (3) on the fuel filter base until fuel that is free from air flows from the vent screw. Tighten the vent screw to a torque of 6 ± 1 N·m (53 ± 9 lb in).

4. Start the engine. Check all the fuel lines and the components for leaks if the engine runs properly and the engine stops or the engine begins to run roughly. Air probably entered the fuel system in the low pressure side.

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010

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel System Pressure - Test

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.

NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

The fuel transfer pump is located on the right side of the engine.

The pressure test measures the output pressure of the fuel transfer pump.

Illustration 1 g00730216 Fuel transfer pump, (A) Fuel inlet (B) Fuel outlet (1) Fuel transfer pump (2) O-ring seal

Illustration 2

g00293196

1U-5470 Engine Pressure Group

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Refer to Special Instruction, SEHS8907, "Using The 1U-5470 Engine Pressure Group".

1. Disconnect outlet line (B) of the fuel transfer pump. Prime the fuel system in order to eliminate air from the fuel transfer pump. Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System - Prime" topic for the proper procedure. Connect 1U-5470 Engine Pressure Group to the outlet of the fuel transfer pump.

2. Disconnect the electrical wire to the fuel shutoff solenoid. Put the lever of the fuel shutoff valve in the closed position.

3. Crank the engine for ten seconds. Record the maximum pressure. The pressure indication on the gauge should be in the following ranges: Maximum pressure ... 42 to 70 kPa (6 to 10 psi) Minimum pressure ... 31 kPa (4.5 psi) 4. If the pressure is less than the minimum pressure or more than the maximum pressure, the fuel transfer pump must be repaired or replaced.

5. Observe the amount of time for the maximum pressure that was recorded during cranking to decrease by one-half. If the time is less than thirty seconds, the fuel transfer pump must be replaced or repaired.

6. Remove the pressure gauge from the fuel transfer pump. Connect the outlet line to the fuel transfer pump. Loosen the nuts for the fuel supply lines on the fuel injection nozzles. Operate the priming button (3) of the fuel filter base until fuel, which is free from air, flows from the connection. Tighten the nuts on the fuel injection nozzles. Refer to Specifications, "Fuel Injection Lines" for the proper torque.

7. Connect the wire of the fuel shutoff solenoid.

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011

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Gear Group (Front) - Time , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

Illustration 1

g00836394

1. Align timing mark (2) on idler gear (3) with the timing mark on crankshaft gear (4) and align timing mark (2) on idler gear (3) with the timing mark on camshaft gear (1) .

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012

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Air Inlet and Exhaust System - Inspect A general visual inspection should be made to the air inlet and exhaust system. Make sure that there are no signs of leaks in the system.

There will be a reduction in the performance of the engine if there is a restriction in the air inlet system or the exhaust system.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts and rotating parts.

1. Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not blocked or collapsed.

2. Inspect the engine air cleaner element. Replace a dirty engine air cleaner element with a clean engine air cleaner element.

3. Check for dirt tracks on the clean side of the engine air cleaner element. If dirt tracks are observed, contaminants are flowing past the engine air cleaner element and/or the seal for the engine air cleaner element.

4. For engines with plastic valve mechanism covers, if you experience excessive crankcase pressure, remove the valve mechanism cover and check the end of the shroud for a skin of plastic. If the end of the shroud has a skin of plastic, remove the skin of plastic. Ensure that all of the debris is removed.

5. If the breather tube is made of plastic, use low pressure air to check for a blockage in the breather tube. If a blockage is inside of the connector, the cover assembly must be replaced. A broken valve mechanism cover will result if you try to remove the connection.

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013

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Exhaust Temperature - Test Measure the Exhaust Temperature

Tool A

Table 1 Required Tools Part Number Part Name 164-3310 Laser Infrared Thermometer

Qty 1

When the engine runs at low idle, the temperature of an exhaust manifold port can indicate the condition of a fuel injection nozzle.

A low temperature indicates that no fuel is flowing to the cylinder. An inoperative fuel injection nozzle or a problem with the fuel injection pump could cause this low temperature.

A very high temperature can indicate that too much fuel is flowing to the cylinder. A malfunctioning fuel injection nozzle could cause this very high temperature.

Use Tooling (A) in order to check the exhaust temperature at the exhaust outlet for each cylinder.

Compare the temperature readings for each exhaust outlet. Investigate any difference in the temperature readings.

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014

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Crankcase Pressure (Blowby) - Test

Part Number 285-0910 285-0900 NETG5044

Table 1 Tools Needed Part Name Multi-Tool Gp Blowby Tool Group Software license

Quantity 1 1 1

Damaged pistons or rings can cause too much pressure in the crankcase. This condition will cause the engine to run rough. There will be more than the normal amount of fumes (blowby) rising from the crankcase breather. The breather can then become restricted in a very short time, causing oil leakage at gaskets and seals that would not normally have leakage. Blowby can also be caused by worn valve guides or by a failed turbocharger seal.

Illustration 1 285-0910 Multi-Tool Gp

g01311364

The 285-0910 Multi-Tool Gp is used to check the amount of blowby.

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015

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Compression - Test , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Compression

Part Number 9U-6274

Table 1 Tools Needed Part Name Compression Test Tool Gp

Qty 1

The following conditions can affect the results of the cylinder compression test: ยก Battery ยก Condition of the starter ยก Ambient conditions ยก Quality of the compression gauge

Illustration 1 Checking compression of engine

g00564993

1. Remove the fuel injection nozzle from the cylinder in order to measure the compression for that cylinder.

2. Connect a compression gauge to the cylinder.

3. Disconnect the fuel shutoff solenoid or hold the governor stop lever in the engine stop position.

4. Operate the starter and record the pressure on the compression gauge.

5. Repeat for each cylinder.

Note: Compression tests should only be used to compare pressures between cylinders of an engine.

If one or more cylinders vary more than 350 kPa (51 psi) then those cylinders may be damaged.

Note: The cylinder compression test should not be the only test for determining the condition of an engine.

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Compression Pressure (1)

(1)

Table 2 Standard at Assembly 2940 kPa (426 psi)

Repair Limit 2450 kPa (355 psi)

The compression pressure is taken at 250 rpm.

6. Repair procedures must be taken if the compression is lower than the repair limit.

NOTICE Be sure to measure the compression on all of the cylinders. If all of the cylinders are not checked an improper diagnosis may result. The compression pressure will vary with the change in engine rpm. It is necessary to keep the engine rpm constant for all cylinders when you are taking a compression reading.

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016

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Valve Lash - Inspect/Adjust , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP

To prevent possible injury, do not use the starter to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.

If the valve lash requires adjustment several times in a short period of time, excessive wear exists in a different part of the engine. Repair the problem in order to prevent more damage to the engine.

Not enough valve lash can be the cause of rapid wear of the camshaft and valve lifters. Not enough valve lash can indicate that the seats for the valves are worn.

Valves become worn due to the following causes: ¡ Incorrect operation of fuel injection nozzles ¡ Excessive dirt and oil are present on the filters for the inlet air. ¡ Incorrect fuel settings on the fuel injection pump. ¡ The load capacity of the engine is frequently exceeded.

Too much valve lash can cause broken valve stems, springs, and spring retainers. Too much valve lash can be an indication of the following problems: ¡ Worn camshaft and valve lifters ¡ Worn rocker arms ¡ Bent pushrods ¡ Broken socket on the upper end of a pushrod ¡ Loose adjustment screw for the valve lash If the camshaft and valve lifters show rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause.

Valve Lash Check An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable range.

Check the valve lash while the engine is stopped. The clearance is specified in Table 2.

Table 1 Valve Lash Valves Acceptable Clearance for Valve Lash Inlet 0.20 mm (0.008 inch) Exhaust 0.20 mm (0.008 inch) If the measurement is not within the acceptable clearance, adjustment is necessary. Refer to the Systems Operation, Testing and Adjusting Module, "Valve Lash Adjustment" topic.

Valve Lash Adjustment The valve lash is measured between the top of the valve stem and the rocker arm lever. Refer to the 016 : Testing and Adjusting

113

Specifications Module, "Engine Design" topic for the correct valve lash.Note: No. 1 cylinder is at the front of the engine.Note: When these procedures are performed, the front housing must be installed.Perform the following procedures in order to adjust the valve lash:

Illustration 1 g00396857 Sequence for setting the valve lash (typical example)

Illustration 2 , (9) Adjustment screw (10) Feeler gauge

g00473333

1. Rotate the crankshaft in the clockwise direction that is viewed from the front of the engine. When the inlet valve of the number 4 cylinder has opened and the exhaust valve of the number 4 cylinder has not completely closed, measure the valve lash of the inlet valve (1) and the exhaust valve (2) of the No. 1 cylinder. a. Loosen the valve adjustment screw locknut that is on the adjustment screw (9) . b. Place the appropriate feeler gauge (10) between the rocker arm and the valve. Turn the adjustment screw (9) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved. c. After each adjustment, tighten the valve adjustment screw locknut while the valve adjustment screw (9) is being held from turning.

2. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the number 2 cylinder has opened and the exhaust valve of the number 2 cylinder has not completely closed measure the valve lash of the inlet valve (5) and the exhaust valve (6) of the No. 3 cylinder. a. Loosen the valve adjustment screw locknut that is on the adjustment screw (9) . b. Place the appropriate feeler gauge (10) between the rocker arm and the valve. Turn the adjustment screw (9) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved. c. After each adjustment, tighten the valve adjustment screw locknut while the valve adjustment screw (9) is being held from turning.

3. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the number 1 cylinder has opened and the exhaust valve of the number 1 cylinder has not completely closed measure the valve lash of the inlet valve (7) and the exhaust valve (8) of the No. 4 cylinder. a. Loosen the valve adjustment screw locknut that is on the adjustment screw (9) . b. Place the appropriate feeler gauge (10) between the rocker arm and the valve. Turn the adjustment

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screw (9) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved. c. After each adjustment, tighten the valve adjustment screw locknut while the valve adjustment screw (9) is being held from turning.

4. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the number 3 cylinder has opened and the exhaust valve of the number 3 cylinder has not completely closed measure the valve lash of the inlet valve (3) and the exhaust valve (4) of the No. 2 cylinder. a. Loosen the valve adjustment screw locknut that is on the adjustment screw (9) . b. Place the appropriate feeler gauge (10) between the rocker arm and the valve. Turn the adjustment screw (9) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved. c. After each adjustment, tighten the valve adjustment screw locknut while the valve adjustment screw (9) is being held from turning.

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017

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Valve Depth - Inspect

Tool A

Table 1 Required Tools Part Number Part Name 8T-0455 Liner Projection Tool Group

Qty 1

Illustration 1 g00323908 8T-0455 Liner Projection Tool Group , (1) Dial indicator (2) Gauge body (3) Gauge block

1. Use Tooling (A) in order to check the depths of the inlet valves and the exhaust valves below the face of the cylinder head. Use gauge block (3) to zero dial indicator (1) .

Illustration 2 g00323909 Measurement of the valve depth, (1) Dial indicator (2) Gauge body

2. Position gauge body (2) and dial indicator (1) in order to measure the valve depth. Measure the depth of the inlet valve and the exhaust valve before the valve springs are removed.

Refer to Specifications, "Cylinder Head Valves" for the minimum, the maximum, and the service wear limits for the valve depth below the cylinder head face.

If the valve depth below the cylinder head face exceeds the service limit, use a new valve to check the valve depth. If the valve depth still exceeds the service limit, renew the cylinder head. If the valve depth is within the service limit, renew the valves.

3. Inspect the valves for cracks and other damage. Check the valve stems for wear. Check that the valve springs are the correct length under the test force. Refer to Specifications, "Cylinder Head Valves" for the dimensions and tolerances of the valves and valve springs.

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018

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Valve Guide - Inspect Table 1 Required Tools Part Number Part Name 8T-5096 Dial Indicator Group

Qty 1

Perform this test in order to determine if a valve guide should be replaced.

Illustration 1 g00314806 , (1) Valve guide (2) Radial movement of the valve in the valve guide (3) Valve stem (4) Dial indicator (5) Valve head

1.

2.

3.

4.

Place a new valve in the valve guide.

Place the dial indicator with the magnetic base on the face of the cylinder head.

Lift the edge of the valve head to a distance of 15.0 mm (0.60 inch).

Move the valve in a radial direction away from the dial indicator. Make sure that the valve moves away from the dial indicator as far as possible. Position the contact point of the dial indicator on the edge of the valve head. Set the position of the needle of the dial indicator to zero.

5. Move the valve in a radial direction toward the dial indicator as far as possible. Note the distance of movement which is indicated on the dial indicator. If the distance is greater than the maximum clearance of the valve in the valve guide, replace the valve guide. Refer to Specifications, "Cylinder Head Valves" for the maximum clearance of the valve in the valve guide.

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019

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Oil Pressure - Test , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP Table 1 Tools Needed Part Number Part Name 1U-5470 Engine Pressure Group

Qty 1

An oil pressure gauge that has a defect can indicate low oil pressure.

The 1U-5470 Engine Pressure Group can be used to check engine oil pressure.

Illustration 1 1U-5470 Engine Pressure Group

g00296486

The 1U-5470 Engine Pressure Group has a gauge that measures the oil pressure in the engine. Refer to Special Instruction, SEHS8907 for more information on using the 1U-5470 Engine Pressure Group .

The information is included in the tool group.

1. Ensure that the engine is filled to the correct oil level.

2. Connect the 1U-5470 Engine Pressure Group to a pressure tap location for engine oil.

3. Operate the engine. Allow the engine to obtain normal operating temperature.

4. Keep the oil temperature constant with the engine at the rated rpm. Read the pressure gauge.

5. Refer to Table 3 in order to determine if the engine oil pressure is in tolerance for 3024C engines.

Table 2 Oil Pressure Minimum engine oil pressure at low idle with a temperature of 18째 to 20째C 62 kPa (9 psi) (64째 to 68째F) Maximum engine oil pressure at high idle and at normal operating 352 to 448 kPa (51 to 65 temperature psi) Find the cause of the problem and correct the problem if the results of the test do not fall within the pressure range in Table 3. Engine failure or a reduction in engine life can be the result if engine operation is continued with oil pressure outside this range.

Note: A record of engine oil pressure at regular intervals can be used as an indication of possible problems of the engine. A record of engine oil pressure at regular intervals can also be used as an indication of possible damage to the engine. The engine should be inspected and the problem should be corrected if there is a sudden increase or a sudden decrease of 70 kPa (10 psi) in oil pressure.

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020

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Oil Pump - Inspect If any part of the engine oil pump is worn enough in order to affect the performance of the engine oil pump, the engine oil pump must be replaced.

Perform the following procedures in order to inspect the engine oil pump. Refer to Specifications, "Engine Oil Pump".

Illustration 1 g00458938 Idler gear and components of the engine oil pump, (1) C-clip (2) Collar (3) Spring (4) Shim (5) Oil pump cover (6) Inner rotor (7) Spring (8) Outer rotor (9) Bushing (10) Idler gear (11) Thrust washer

1. Remove the front housing. Remove C-clip (1) .

Note: If the front housing is removed, do not turn the crankshaft.

2. Disassemble the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump Remove" for additional information. Do not remove bushing (9) from idler gear (10) unless damage is observed.

3. Clean all of the parts and inspect the parts for cracks in the metal or other damage. Look for wear on the components. Ensure that bushing (9) is not loose in idler gear (10) .

Illustration 2 g00459701 Clearance between the inner rotor and the outer rotor

4. Install the idler gear and the inner rotor on the shaft. Measure clearance (A) between inner rotor (6) and outer rotor (8) .

Refer to Specifications, "Engine Oil Pump".

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Illustration 3 g01290817 Face of the cover for the oil pump above the face of the idler gear, (1) C-clip (2) Collar (4) Shim (12) Feeler gauge

5. Use feeler gauge (12) to measure the distance between C-clip (1) and collar (2) .

6. When the components of the engine oil pump are installed on the front housing, measurement (B) between C-clip (1) and collar (2) must be between 0.10 to 0.15 mm (0.004 to 0.006 inch)for new components. Dimension B must be not more than 0.20 mm (0.008 inch) for used parts.

The distance between the faces is adjusted with shims (4) . The thicknesses of the shims are given in Specifications, "Engine Oil Pump".

Illustration 4

g00826185

7. Install the components of the engine oil pump and the front housing on the cylinder block. Make sure that the two dowels align with the bushing, the outer rotor, and the holes in the idler gear.

Align the timing mark (15) on idler gear (10) with the timing mark on crankshaft gear (16) when you install the idler gear on the oil pump shaft. Also, align the other timing mark (15) on idler gear (10) with the timing mark on the camshaft gear (13) . The hole (14) in oil pump cover (5) should align with the locating pin in the front housing.

Note: When the front housing is not installed on the engine, do not rotate the crankshaft.

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021

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Excessive Bearing Wear - Inspect When some components of the engine show bearing wear in a short time, the cause can be a restriction in an oil passage.

An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for the oil supply to the component. A restriction in an oil supply passage will not allow enough lubrication to reach a component. This will result in early wear.

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022

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Excessive Engine Oil Consumption - Inspect Engine Oil Leaks on the Outside of the Engine Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the engine oil pan and all lubrication system connections. Look for any engine oil that may be leaking from the crankcase breather. This can be caused by combustion gas leakage around the pistons. A dirty crankcase breather will cause high pressure in the crankcase. A dirty crankcase breather will cause the gaskets and the seals to leak.

Engine Oil Leaks into the Combustion Area of the Cylinders Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke.

There are several possible ways for engine oil to leak into the combustion area of the cylinders: ¡ Leaks between worn valve guides and valve stems ¡ Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine oil) ¡ Incorrect installation of the compression ring and/or the intermediate ring ¡ Leaks past the seal rings in the turbocharger shaft ¡ Overfilling of the crankcase ¡ Wrong oil level gauge or guide tube ¡ Sustained operation at light loads Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used.

Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature.

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023

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Cooling System - Check - Overheating Above normal coolant temperatures can be caused by many conditions. Use the following procedure to determine the cause of above normal coolant temperatures:

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in order to relieve pressure before removing any hose from the radiator.

1. Check the coolant level in the cooling system. If the coolant level is too low, air will get into the cooling system. Air in the cooling system will cause a reduction in coolant flow and bubbles in the coolant. Air bubbles will keep coolant away from the engine parts, which will prevent the transfer of heat to the coolant. Low coolant level is caused by leaks or incorrectly filling the radiator.

2. Check the mixture of antifreeze and water. The mixture should be approximately 50 percent water and 50 percent antifreeze with 3 to 6 percent coolant conditioner. If the coolant mixture is incorrect, drain the system. Put the correct mixture of water, antifreeze and coolant conditioner in the cooling system.

3. Check for air in the cooling system. Air can enter the cooling system in different ways. The most common causes of air in the cooling system are not filling the cooling system correctly and combustion gas leakage into the cooling system. Combustion gas can get into the system through inside cracks, a damaged cylinder head, or a damaged cylinder head gasket. Air in the cooling system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles keep coolant away from the engine parts, which prevents the transfer of heat to the coolant.

4. Check the sending unit. In some conditions, the temperature sensor in the engine sends signals to a sending unit. The sending unit converts these signals to an electrical impulse which is used by a mounted gauge. If the sending unit malfunctions, the gauge can show an incorrect reading. Also if the electric wire breaks or if the electric wire shorts out, the gauge can show an incorrect reading.

5. Check the radiator. a. Check the radiator for a restriction to coolant flow. Check the radiator for debris, dirt, or deposits on the inside of the radiator core. Debris, dirt, or deposits will restrict the flow of coolant through the radiator. b. Check for debris or damage between the fins of the radiator core. Debris between the fins of the radiator core restricts air flow through the radiator core. Refer to Testing and Adjusting, "Cooling System - Inspect".

6. Check the filler cap. A pressure drop in the radiator can cause the boiling point to be lower. This can cause the cooling system to boil. Refer to Testing and Adjusting, "Cooling System - Test".

7. Check the fan and/or the fan shroud. The fan shroud must be the proper size and the fan shroud must be positioned correctly.

8. Check for loose drive belts. a. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the fan drive belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to the Testing and Adjusting Section, "Belt Tension Chart". b. A loose water pump drive belt will cause a reduction in coolant flow through the radiator. Check the water pump drive belt for proper belt tension. Adjust the water pump drive belt's tension, if necessary. Refer to the Testing and Adjusting Section, "Belt Tension Chart".

9. Check the cooling system hoses and clamps. Damaged hoses with leaks can normally be seen. Hoses that have no visual leaks can soften during operation. The soft areas of the hose can become kinked or crushed during operation. These areas of the hose can cause a restriction in the coolant flow.

Hoses become soft and/or get cracks after a period of time. The inside of a hose can deteriorate, and the loose particles of the hose can cause a restriction of the coolant flow.

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10. Check for a restriction in the air inlet system. A restriction of the air that is coming into the engine can cause high cylinder temperatures. High cylinder temperatures require higher than normal temperatures in the cooling system.

11. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine can cause high cylinder temperatures. a. Make a visual inspection of the exhaust system. b. Check for damage to exhaust piping or for a damaged muffler. If no damage is found, check the exhaust system for a restriction.

12. Check the shunt line. The shunt line must be submerged in the expansion tank. A restriction of the shunt line from the radiator top tank to the engine water pump inlet will cause a reduction in water pump efficiency. A reduction in water pump efficiency will result in low coolant flow and overheating.

13. Check the water temperature regulator. A water temperature regulator that does not open, or a water temperature regulator that only opens part of the way can cause overheating. Refer to Testing and Adjusting, "Water Temperature Regulator - Test".

14. Check the water pump. A water pump with a damaged impeller does not pump enough coolant for correct engine cooling. Remove the water pump and check for damage to the impeller.

15. Check the air flow through the engine compartment. The air flow through the radiator comes out of the engine compartment. Ensure that the filters, air conditioner, and similar items are not installed in a way that prevents the free flow of air through the engine compartment.

16. Consider high outside temperatures. When outside temperatures are too high for the rating of the cooling system, there is not enough of a temperature difference between the outside air and coolant temperatures.

17. Consider high altitude operation. The cooling capacity of the cooling system goes down as the engine is operated at higher altitudes. A pressurized cooling system that is large enough to keep the coolant from boiling must be used.

18. The engine may be running in the lug condition. When the load that is applied to the engine is too large, the engine will run in the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes a reduction in air flow through the radiator. This lower engine rpm also causes a reduction in coolant flow through the system. This combination of less air and less coolant flow during high input of fuel will cause above normal heating.

19. Timing of the engine which is incorrect may also cause overheating of the engine. Late timing creates more heat in the engine. Early timing creates less heat in the engine.

Note: If the timing of the engine is incorrect, the exhaust valves may be burned and damage to the exhaust manifold may occur.

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024

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Cooling System - Inspect Cooling systems that are not regularly inspected are the cause for increased engine temperatures. Make a visual inspection of the cooling system before any tests are performed.

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in order to relieve pressure before removing any hose from the radiator.

1. Check the coolant level in the cooling system.

2. Look for leaks in the system.

Note: A small amount of coolant leakage across the surface of the water pump seals is normal. This leakage is required in order to provide lubrication for this type of seal. A hole is provided in the water pump housing in order to allow this coolant/seal lubricant to drain from the pump housing.

Intermittent leakage of small amounts of coolant from this hole is not an indication of water pump seal failure.

3. Make sure that air flow through the radiator does not have a restriction. Look for bent core fins between the folded cores of the radiator. Also, look for debris between the folded cores of the radiator.

4. Inspect the drive belts for the fan.

5. Check for damage to the fan blades.

6. Look for air or combustion gas in the cooling system.

7. Inspect the filler cap, and check the surface that seals the filler cap. This surface must be clean.

8. Look for large amounts of dirt in the radiator core. Look for large amounts of dirt on the engine.

Remove the dirt from the radiator core and the engine.

9. Fan shrouds that are loose or missing cause poor air flow for cooling.

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025

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Cooling System - Test Remember that temperature and pressure work together. When a diagnosis is made of a cooling system problem, temperature and pressure must be checked. Cooling system pressure will have an effect on the cooling system temperature. For an example, refer to Illustration 1. This will show the effect of pressure on the boiling point (steam) of water. This will also show the effect of height above sea level.

Illustration 1 g00286266 Cooling system pressure at specific altitudes and boiling points of water

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

The coolant level must be to the correct level in order to check the coolant system. The engine must be cold and the engine must not be running.

After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling system.

Then remove the pressure cap.

The level of the coolant should not be more than 13 mm (0.5 inch) from the bottom of the filler pipe. If the cooling system is equipped with a sight glass, the coolant should be to the proper level in the sight glass.

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Test Tools For The Cooling System

Part Number 4C-6500 8T-2700 9U-7400 9S-8140 1U-7297 1U-7298

Table 1 Required Tools Part Name Digital Thermometer Blowby/Air Flow Indicator Multitach Tool Group Pressurizing Pump Coolant/Battery Tester Coolant/Battery Tester

Qty 1 1 1 1 1 1

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts and rotating parts.

Illustration 2 4C-6500 Digital Thermometer

g00876179

The 4C-6500 Digital Thermometer is used in the diagnosis of problems that cause overheating or overcooling in the engine. This tool can be used to check the temperature in several areas of the cooling system. The testing procedure is in Tool Operating Manual, NEHS0554.

Illustration 3 8T-2700 Blowby/Air Flow Indicator

g00313263

The 8T-2700 Blowby/Air Flow Indicator is used to check the air flow through the radiator core. Refer to Special Instruction, SEHS8712, "Using the 8T-2700 Blowby/Air Flow Indicator " for the test procedure for checking blowby and air flow.

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Illustration 4 9U-7400 Multitach Tool Group

g00286276

The 9U-7400 Multitach Tool Group is used to measure the fan speed. Refer to Operating Manual, NEHS0605, " 9U-7400 Multitach Tool Group " for the testing procedure.

Illustration 5 9S-8140 Pressurizing Pump

g00286369

The 9S-8140 Pressurizing Pump is used to test the filler caps. This pressurizing pump is also used to pressure test the cooling system for leaks.

Illustration 6 g00439083 1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery Tester

Check the coolant frequently in cold weather for the proper glycol concentration. Use either the 1U-7297 Coolant/Battery Tester or the 1U-7298 Coolant/Battery Tester in order to ensure adequate freeze protection. The testers are identical except for the temperature scale. The testers give immediate, accurate readings. The testers can be used for antifreeze/coolants that contain ethylene or propylene glycol.

Making the Correct Antifreeze Mixtures Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze. The pure antifreeze increases the concentration of antifreeze in the cooling system. The increased concentration increases the concentration of dissolved solids and undissolved chemical inhibitors in the

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cooling system. Add an antifreeze and water mixture in the concentration which provides the desired freeze protection. Use the following chart in order to determine the correct concentration of antifreeze in water to use.

Table 2 Antifreeze Concentrations For Freeze Protection Temperature Concentration Protection to 30% antifreeze and 70% water -15°C (5°F) Protection to 40% antifreeze and 60% water -23°C (-9°F) Protection to 50% antifreeze and 50% water -37°C (-35°F) Protection to 60% antifreeze and 40% water -51°C (-60°F)

Checking the Filler Cap Table 3 Required Tools Part Number Part Name 9S-8140 Pressurizing Pump

Qty 1

One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.

Illustration 7 g00296067 Typical schematic of filler cap, (1) Sealing surface between the pressure cap and the radiator

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

To check for the amount of pressure that opens the filler cap, use the following procedure: 1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the cooling system. Then, remove the filler cap.

2. Inspect the pressure cap carefully. Look for damage to the seal. Look for damage to the surface that seals. Remove any debris on the cap, the seal, or the sealing surface.

Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface. Inspect the

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following components for any foreign substances: n Filler cap n Seal n Surface for seal

3.

4.

5.

6.

Remove any deposits that are found on these items, and remove any material that is found on these items.

Install the pressure cap on the 9S-8140 Pressurizing Pump .

Observe the exact pressure that opens the filler cap.

Compare the pressure to the pressure rating that is found on the top of the filler cap.

If the filler cap is damaged, replace the filler cap.

Testing The Radiator And Cooling System For Leaks Table 4 Required Tools Part Number Part Name 9S-8140 Pressurizing Pump

Qty 1

Use the following procedure to test the radiator and the cooling system for leaks.

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

1. When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release from the cooling system. Then remove the filler cap.

2. Make sure that the coolant covers the top of the radiator core.

3. Put the 9S-8140 Pressurizing Pump onto the radiator.

4. Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the operating pressure of the filler cap.

5. Check the radiator for leakage on the outside.

6. Check all connections and hoses of the cooling system for leaks.

The radiator and the cooling system do not have leakage if all of the following conditions exist: n You do NOT observe any leakage after five minutes. n The dial indicator remains constant beyond five minutes.

The inside of the cooling system has leakage only if the following conditions exist: n The reading on the gauge goes down. n You do NOT observe any outside leakage.

Make any repairs, as required.

Cooling System Conditioner

Supplemental cooling system additive contains alkali. To prevent personal injury, do not drink, avoid contact with the skin and eyes.

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NOTICE All water is corrosive at engine operating temperature. The cooling system should be protected with a 3% to 6% concentration of cooling system conditioner at all times.

Caterpillar does not recommend the use of cooling system solutions that are intended to stop leaks.

Use of these products may result in excessive internal deposits that could reduce the engine's heat transfer characteristics.

Caterpillar Cooling System Conditioner can be used with an antifreeze or without an antifreeze of ethylene glycol base in the coolant.

When the conditioner is added to the coolant, the cooling system must be flushed and the cooling system must be cleaned.

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026

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3024C Engine for Caterpillar Built Machines, SENR5005-03

Water Temperature Regulator - Test

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in order to relieve pressure before removing any hose from the radiator.

1. Remove the water temperature regulator from the engine.

2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the fully open temperature of the water temperature regulator. Stir the water in the pan. This will distribute the temperature throughout the pan.

3. Hang the water temperature regulator in the pan of water. The water temperature regulator must be below the surface of the water. The water temperature regulator must be away from the sides and the bottom of the pan.

4. Keep the water at the correct temperature for ten minutes.

5. After ten minutes, remove the water temperature regulator. Immediately measure the opening of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the minimum opening distance of the water temperature regulator at the fully open temperature.

If the distance is less than the amount listed in the manual, replace the water temperature regulator.

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027

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Water Pump - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Illustration 1

g00825983

1. Start the engine. Inspect the water pump for excessive leaks at vent hole (1) .

Note: A small amount of coolant leakage across the surface of the seal for the jacket water pump is normal. This leakage is required to provide lubrication for this type of seal. A hole is provided in the water pump housing in order to allow this coolant/seal lubricant to drain from the water pump housing. Intermittent leakage of small amounts of coolant from this hole is not an indication of water pump seal failure.

2. Inspect the water pump shaft for unusual noise, excessive looseness and/or vibration of the bearings.

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028

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Piston Ring Groove - Inspect Table 1 Required Tools Part Number Part Name 8H-8581 Feeler Gauge

Qty 1

Inspect the Piston and the Piston Rings 1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in the grooves and that the rings are not broken.

Inspect the Clearance of the Piston Ring 1. Remove the piston rings and clean the grooves and the piston rings.

Illustration 1 g01284934 , (1) Feeler gauge (2) Piston ring (3) Piston grooves

2. Fit new piston rings (2) in the piston grooves (3) .

3. Check the clearance for the piston ring by placing the 8H-8581 Feeler Gauge (1) between piston groove (3) and the top of piston ring (2) . Refer to Specifications, "Piston and Rings" for the dimensions.

Note: Some pistons have a tapered top groove and the piston ring is wedged. The clearance for the top piston ring cannot be checked by the above method when this occurs.

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Inspect the Piston Ring End Gap

Illustration 2 g01358235 , (1) Piston ring (2) Cylinder ring ridge (3) Feeler gauge

1. Clean all carbon from the top of the cylinder bores.

2. Place each piston ring (1) in the cylinder bore just below the cylinder ring ridge (2) .

3. Use the 8H-8581 Feeler Gauge (3) to measure piston ring end gap. Refer to Specifications, "Piston and Rings" for the dimensions.

Note: The coil spring must be removed from the oil control ring before the gap of the oil control ring is measured.

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029

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Connecting Rod - Inspect These procedures determine the following characteristics of the connecting rod: ¡ The distortion of the connecting rod ¡ The parallel alignment of the bores of the connecting rod ¡ Conformance to specifications and clearances

Distortion of Connecting Rod

Illustration 1 g00690891 Measure the Connecting Rod for Distortion and Parallelism., (1) Measuring pins (2) Connecting rod (A) 100 mm (3.9 inch) (B) The distortion of the connecting rod should be less than 0.08 mm (0.003 inch). The connecting rod should be parallel within 0.05 mm (0.002 inch).

1. Use the following tools that are provided by the customer in order to measure distortion and parallelism for connecting rod (2) : n Appropriate gauges for measuring distance n Measuring pins (1) 2. Measure the length of the connecting rod between the centers of measuring pins (1) .

3. Measure the connecting rod for distortion between the bores.

The bores for the crankshaft bearing and the bearing for the piston pin must be square and parallel with each other within the required limits.

The limits are measured at a distance of 100 mm (3.9 inch) (A) from each side of connecting rod (2) .

When the bearings for the connecting rod are removed from the connecting rod, the limit for parallelism is ± 0.15 mm (± 0.006 inch).

The limit for distortion is ± 0.20 mm (± 0.008 inch).

Inspect the Bearings and Piston Pin for Wear 1. Inspect the piston pin and the bearing for the piston pin for wear. Measure the dimensions of the bearing and the piston pin.

If the bearing or the piston pin are not within tolerances, the component must be replaced.

Refer to the Specifications Module, "Piston and Rings" for dimensions.

2. Measure the clearance of the piston pin in the bearing for the piston pin.

If the clearance between the bearing and piston pin is not within the tolerance, one or both components must be replaced.

Refer to the Specifications Module, "Connecting Rod" for dimensions.

3. Measure the axial clearance between the connecting rod and the crankshaft.

If the axial clearance between the connecting rod and the crankshaft is not within the tolerance, one or both components must be replaced.

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Refer to the Specifications Module, "Crankshaft" for dimensions.

4. Measure the clearance between the connecting rod journal on the crankshaft and the connecting rod bearing. Use plastigage to measure the clearance.

If the clearance between the connecting rod and the crankshaft is not within the tolerance, one or both components must be replaced.

Refer to the Specifications Module, "Crankshaft" for appropriate clearances.

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030

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Connecting Rod Bearings - Inspect

Illustration 1

g00720890

Inspect the connecting rod bearings for peeling, melting, seizure or poor contact. If the connecting rod bearings are worn or if the connecting rod bearings are damaged, replace the connecting rod bearings.

1. Measure the clearance between the connecting rod bearing and the crankshaft journal.

2. Measure the connecting rod bearings at positions (1) and (2) in directions (A) and (B). Refer to the Specifications Module, "Connecting Rod" topic for information on the tolerances.

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031

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Main Bearings - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Illustration 1

g00720890

Inspect the main bearings for peeling, melting, seizure or poor contact. If the main bearings are worn or if the main bearings are damaged, replace the main bearings.

1. Measure the clearance between the main bearings and the crankshaft journal.

2. Measure the main bearings at positions (1) and (2) in directions (A) and (B). Refer to the Specifications Module, "Cylinder block" topic for information on the tolerances.

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032

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Cylinder Block - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP Table 1 Required Tools Part Number Part Name 1P-3537 Dial Bore Gauge Group 1U-7234 Feeler Gauge

Qty 1 1

Illustration 1

g00285686

Illustration 2

g00907375

Use a straight edge and a feeler gauge to check the six positions for flatness. Refer to Illustration 2.

Inspect the top of the cylinder block for cracks, damage, and warpage.

Inspect each cylinder bore. There should be no scoring, rust or corrosion. Use a 1P-3537 Dial Bore Gauge Group in order to measure each cylinder bore. Each cylinder bore should be measured at the top, middle and bottom.

If the cylinder bores exceed the service limit, the cylinder block must be renewed. Refer to Specifications, "Cylinder Block" for the bore diameters and tolerances.

Note: The flex-hone process must not be used on these engines.

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033

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Cylinder Head - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N - RLL1-UP , S/N SCH1-UP , S/N - SLK1-UP Table 1 Required Tools Part Number Part Name 8S-6691 Cylinder Head Stand Set

Illustration 1 Bolt tightening sequence

Qty 1

g00819713

1. Remove the bolts in the cylinder head in the reverse sequence that is shown in Illustration 1.

Remove the cylinder head from the engine.

2. Clean the cylinder head thoroughly. Make sure that the contact surface of the cylinder head and the contact surface of the cylinder block are clean, smooth and flat.

3. Inspect the bottom surface of the cylinder head for the following items: pitting, corrosion and cracks.

Inspect the area around the valve seat inserts and the holes for the fuel injection nozzles.

Illustration 2 Typical example

g00842292

4. Put the cylinder head (1) on the 8S-6691 Cylinder Head Stand Set (2) .

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Illustration 3 Typical example

g00841853

5. Measure the cylinder head (1) for flatness. Measure the flatness with a straight edge (3) and with a feeler gauge (4) . n Measure the cylinder block from point (A) to point (B) . n Measure the cylinder block from point (C) to point (D) . n Measure the cylinder block from point (A) to point (C) . n Measure the cylinder block from point (B) to point (D) . n Measure the cylinder block from point (A) to point (D) . n Measure the cylinder block from point (B) to point (C) .

Refer to Specifications, "Cylinder Head" for the requirements of flatness.

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034

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Piston Height - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Part Number 8T-0455

Table 1 Required Tools Part Name Liner Projection Tool Group

Qty 1

If the piston height above the top face of the cylinder block or below the top face of the cylinder block is not within the tolerance that is given in Specifications, "Cylinder Head", the gasket for the cylinder head may need to be replaced. If any of the following components are replaced or remachined, the piston height must be measured: ยก Crankshaft ยก Cylinder head ยก Connecting rod ยก Piston pin bearing ยก Piston The correct piston height must be maintained in order to ensure that the engine conforms to the standards for emissions.

Note: The top of the piston should not be machined. If the original piston is installed, be sure that the original piston is assembled to the correct connecting rod and installed in the original cylinder.

Illustration 1 g00323908 8T-0455 Liner Projection Tool Group , (1) Dial indicator (2) Gauge body (3) Gauge block

1. Use the 8T-0455 Liner Projection Tool Group in order to measure the piston height above the top face of the cylinder block or below the top face of the cylinder block. Use gauge block (3) to zero dial indicator (1) .

034 : Testing and Adjusting

143

Illustration 2 g00326383 Measurement of the piston height, (1) Dial indicator (2) Gauge body

2. Position gauge body (2) and dial indicator (1) in order to measure the piston height. Slowly rotate the crankshaft in order to determine when the piston is at the highest position. Record this dimension.

Compare this dimension with the dimensions that are given in Specifications, "Cylinder Head".

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144

035

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Flywheel - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Alignment of the Flywheel Face Table 1 Required Tools Part Number Part Name 8T-5096 Dial Indicator Group

Qty 1

Illustration 1

g00295952

1. Position the magnetic base of the dial indicator group on the flange of the flywheel housing. Position the plunger of the dial indicator on the face of the flywheel. Refer to Illustration 1.

2. Set the dial indicator to read 0.

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

Note: During the check, keep the crankshaft pressed toward the front of the engine in order to remove any end clearance.

4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference must not be greater than 0.20 mm (0.008 inch), which is the maximum permissible alignment of the flywheel face.

Flywheel Runout

Illustration 2

g00295954

1. Position the magnetic base of the dial indicator group on the flange of the flywheel housing. Position the plunger of the dial indicator on the inside diameter of the flywheel. Refer to Illustration 2.

2. Set the dial indicator to read 0.

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference must not be greater than 0.20 mm (0.008 inch), which is the maximum permissible flywheel runout.

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145

036

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Flywheel Housing - Inspect Table 1 Required Tools Part Number Part Name 8T-5096 Dial Indicator Gp

Qty 1

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 1 8T-5096 Dial Indicator Gp

g00285931

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

Illustration 2 g00285932 Checking face runout of the flywheel housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A) . Read the dial indicator at locations (B) , (C) and (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.20 mm (0.008 inch) for an "SAE 5" flywheel housing. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.23 mm (0.009 inch) for an "SAE 4" flywheel housing. These measurements are the maximum permissible face runout (axial eccentricity) of the flywheel housings.

036 : Testing and Adjusting

146

Bore Runout (Radial Eccentricity) of the Flywheel Housing

Illustration 3 8T-5096 Dial Indicator

g00285934

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing.

Illustration 4 g00285932 Checking bore runout of the flywheel housing

2. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A) . Read the dial indicator at locations (B) , (C) and (D) .

3. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.20 mm (0.008 inch) for an "SAE 5" flywheel housing. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.23 mm (0.009 inch) for an "SAE 4" flywheel housing. These measurements are the maximum permissible bore runout (radial eccentricity) of the flywheel housings.

036 : Testing and Adjusting

147

037

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Gear Group - Inspect , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Illustration 1

g00907566

1. Inspect the gears for wear or damage. If one or more of the gears are worn or damaged, use new parts for replacement.

2. Measure the backlash of the gears with a feeler gauge. Refer to Illustration 1. If the backlash measurement is greater than the maximum, install new gears.

Note: Refer to Specifications, "Gear Group (Front)" for the minimum and maximum backlash measurements.

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148

038

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Alternator - Test Table 1 Required Tools Part Number Part Name Qty 237-5130 Digital Multimeter 1 225-8266 Ammeter Tool Gp 1 1. Put the positive lead "+" of the multimeter on the "Bat" terminal of the alternator. Put the negative "" lead on the ground terminal or on the frame of the alternator. Put the ammeter around the positive output wire of the alternator.

2. Turn off all electrical accessories. Turn off the fuel to the engine. Crank the engine for 30 seconds.

Wait for two minutes in order to cool the starting motor. If the electrical system appears to operate correctly, crank the engine again for 30 seconds.

Note: Cranking the engine for 30 seconds partially discharges the batteries in order to do a charging test. If the battery has a low charge, do not perform this step. Jump start the engine or charge the battery before the engine is started.

3. Start the engine and run the engine at full throttle.

4. Check the output current of the alternator. The initial charging current should be equal to the minimum full load current or greater than the minimum full load current. Refer to Specifications, "Alternator and Regulator" for the correct minimum full load current.

Table 2 Fault Conditions And Possible Causes Current At Start- The Voltage Is Below The Voltage Is Within The Voltage Is up Specifications After 10 Specifications After 10 Above Minutes.

Minutes.

Specifications After 10 Minutes.

Less than the specifications

Replace the alternator.

Check the circuit of the ignition switch.

Turn on all accessories. If the voltage decreases below the specifications, replace the alternator.

Decreases after Replace the alternator.

The alternator and the battery Replace the matching match the specifications. Turn alternator. specifications on all accessories in order to verify that the voltage stays within specifications.

The voltage Follow the procedures that The alternator operates within Replace the consistently are in the Tool Operating the specifications. Follow the alternator. Inspect exceeds Manual, SEHS7633 in order procedures in the Tool the battery for specifications. to test the battery. Test the Operating Manual, SEHS7633 damage. alternator again. in order to test the battery.

5. After approximately ten minutes of operating the engine at full throttle, the output voltage of the alternator should be 14.0 Âą 0.5 volts. Refer to the Fault Conditions And Possible Causes in Table 3.

6. After ten minutes of engine operation, the charging current should decrease to approximately 10 amperes. The actual length of time for the charging current to decrease to 10 amperes depends on the following conditions: n The battery charge n The ambient temperature n The rpm of the engine Refer to the Fault Conditions And Possible Causes in Table 3.

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149

039

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Battery - Test Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in good condition. The wire and cable connections must be clean, and both components must be tight.

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.

The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery.

NOTICE The charging unit will be damaged if the connections between the battery and the charging unit are broken while the battery is being charged. Damage occurs because the load from the battery is lost and because there is an increase in charging voltage. High voltage will damage the charging unit, the regulator, and other electrical components.

See Special Instruction, SEHS7633, "Battery Test Procedure" for the correct procedures to use to test the battery. This publication also contains the specifications to use when you test the battery.

039 : Testing and Adjusting

150

040

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Charging System - Test The condition of charge in the battery at each regular inspection will show if the charging system is operating correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed. There are no adjustments on maintenance free batteries. A large amount of water would be more than one ounce of water per cell per week or per every 100 service hours.

When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a permanent part of the system. Off-engine testing or bench testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, perform a test in order to prove that the units have been repaired to the original condition of operation.

Alternator Regulator The charging rate of the alternator should be checked when an alternator is charging the battery too much or not charging the battery enough. Alternator output should be 28 Âą 1 volt on a 24 volt system and 14 Âą 0.5 volt on a 12 volt system. No adjustment can be made in order to change the rate of charge on the alternator regulators. If the rate of charge is not correct, a replacement of the regulator is necessary. For individual alternator output, refer to Specification, "Alternator and Regulator".See Special Instruction, REHS0354, "Charging System Troubleshooting" for the correct procedures to use to test the charging system. This publication also contains the specifications to use when you test the charging system.

040 : Testing and Adjusting

151

041

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Coolant Temperature Switch - Test This procedure tests the coolant temperature switch for correct operation. Perform this procedure when the engine is running.

1. Use the 6V-7070 Digital Multimeter to measure the resistance of the coolant temperature switch.

When the temperature of the coolant is 50 °C (122 °F) or less, disconnect the wire connector from the coolant temperature switch.

2. Place one lead of the multimeter on the connector of the coolant temperature switch. Place the other lead of the multimeter on a ground for the coolant temperature switch.

Measure the resistance. The resistance should be 54 ± 2 ohms.

3. Repeat the previous step when the temperature of the coolant is approximately 120 °C (248 °F). The resistance should not be less than 15 ohms.

4. If the resistance through the coolant temperature switch is not within the given resistances, replace the coolant temperature switch.

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152

042

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Electric Starting System - Test , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP

Part Number 237-5130

Table 1 Tools Needed Part Name Digital Multimeter

Quantity 1

Use the multimeter in the DCV range to find starting system components which do not function.

Move the start control switch in order to activate the starting solenoids. The starting solenoid's operation can be heard as the pinion of the starting motor is engaged with the ring gear on the engine flywheel.

If a solenoid for a starting motor will not operate, it is possible that the current from the battery did not reach the solenoid. Fasten one lead of the multimeter to the connection (terminal) for the battery cable on the solenoid. Connect the other lead to a good ground. A zero reading indicates that there is a broken circuit from the battery. More testing is necessary when there is a voltage reading on the multimeter.

The solenoid operation also closes the electric circuit to the motor. Connect one lead of the multimeter to the solenoid connection (terminal) that is fastened to the motor. Connect the other lead to a good ground. Activate the starting solenoid and look at the multimeter. A voltage reading of the battery shows that the problem is in the motor. The motor must be removed for further testing. A zero reading on the multimeter shows that the solenoid contacts do not close. A zero reading on the multimeter indicates the need for a repair to the solenoid, or for an adjustment to the clearance on the pinion for the starting motor.

Perform a test. Fasten one multimeter lead to the connection (terminal) for the small wire at the solenoid and fasten the other lead to the ground. Look at the multimeter and activate the starting solenoid. A voltage reading shows that the problem is in the solenoid. A zero reading indicates that the problem is in the start switch or the wires for the start switch.

Fasten one multimeter lead to the start switch at the connection (terminal) for the wire from the battery.

Fasten the other lead to a good ground. A zero reading indicates a broken circuit from the battery.

Check of the circuit breaker and wiring. If there is a voltage reading, the problem is in the start switch or in the wires for the start switch.

Starting motors that operate too slowly can have an overload because of too much friction in the engine that is being started. Slow operation of the starting motors can also be caused by a short circuit, loose connections, and/or dirt in the motor.

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153

043

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Engine Oil Pressure Switch - Test This procedure tests the engine oil pressure switch for correct operation.

1. Turn the ignition switch to the ON, but do not start the engine. The warning light for low engine oil pressure should turn on.

If the warning light does not turn on, check the electrical circuit to the warning light and the engine oil pressure switch for shorts or an open circuit. Check the bulb for the warning light for damage.

If the circuit is correct, replace the engine oil pressure switch. If the circuit is repaired or if the engine oil pressure switch or warning lamp are replaced, repeat this Step in order to ensure that the warning light turns on.

2. Remove the engine oil pressure switch from the cylinder block. Disconnect the wire connector on the wiring harness from the engine oil pressure switch. Use a 12 volt battery as a power source. Connect the terminals of the battery, the engine oil pressure switch and the leads of the 6V-7070 Digital Multimeter in series. Measure the current through the engine oil pressure switch.

3. The current should be 0.30 to 0.40 amperes. If the current through the engine oil pressure switch is greater than 0.42 amperes, replace the engine oil pressure switch.

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154

044

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Fuel Shutoff Solenoid - Test

Illustration 1 g00471071 , (1) Negative "-" lead (2) Body of the fuel shutoff solenoid (3) Plunger (4) Positive "+" lead (5) Electrical connector

This procedure tests the fuel shutoff solenoid for correct operation.

1. Remove the fuel shutoff solenoid from the engine. Refer to the Disassembly and Assembly Module, "Fuel Shutoff Solenoid - Remove and Install" topic.

2. Use a 12 volt battery as a power source. Connect the lead from battery positive terminal (4) to electrical connector (5) on the fuel shutoff solenoid. Connect the lead from battery negative terminal (1) to body (2) on the fuel shutoff solenoid.

Plunger (3) on the fuel shutoff solenoid will extend the maximum distance when the leads are connected.

If the plunger does not move or if the plunger does not extend the maximum distance, replace the fuel shutoff solenoid.

3. Use the 6V-7070 Digital Multimeter to measure the current through the fuel shutoff solenoid.

Connect the battery, the fuel shutoff solenoid, and the leads of the multimeter in series.

The current should be 1.0 Âą 0.1 amperes. If the current is not within this tolerance, replace the fuel shutoff solenoid.

4. Install the fuel shutoff solenoid on the engine. Refer to the Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install" topic.

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155

045

Testing and Adjusting

3024C Engine for Caterpillar Built Machines, SENR5005-03

Glow Plugs - Test , S/N - BXM1-UP , S/N - C3A1-UP , S/N - C3C1-UP , S/N - C3D1-UP , S/N - C4F1-UP , S/N - C4X1UP , S/N - C5F1-UP , S/N - CAB1-UP , S/N - DST1-UP , S/N - MJH1-UP , S/N - MTL1-UP , S/N RLL1-UP , S/N - SCH1-UP , S/N - SLK1-UP Table 1 Required Tools Part Number Part Name 6V-7070 Digital Multimeter 8T-0500 Test Light

Qty 1 1

Illustration 1 g00820321 , (1) Nut (2) Washer (3) Connector (4) Glow plug

Continuity Test 1. Connect the 8T-0500 Test Light between a ground and the terminal of the glow plug (4). Choose the glow plug that is farthest away from the battery. Turn the starting aid switch to the ON position.

If the circuit is correct, the test light should turn on.

If the test light does not turn on, inspect the circuit for loose connections, broken wires, and other damage.

2. Disconnect connector (3) from the glow plugs.

3. Use the 6V-7070 Digital Multimeter to measure the resistance between the electrical terminal of the glow plug (4) and ground. The point for the ground should be as close to the glow plug as possible.

Maximum resistance for the glow plugs. ... 0.0139 ohms 4. Connect the test light to the positive terminal of the battery and to the electrical terminal of glow plug (4). If the light turns on, the continuity in the glow plug is correct.

If the light does not turn on, replace the glow plug.

Repeat this step for each glow plug.

Glow Plug Circuit 1. Disconnect the cable for the power supply from connector (3). Remove the connector from the electrical terminal of the glow plug (4) .

2. Connect the leads of the 6V-7070 Digital Multimeter between the cable for the power supply and the terminal of a glow plug. Turn on the starting aid switch. Observe the amperage reading of the multimeter. Then, connect the leads of the multimeter between the terminal of the glow plug and a ground. Measure the voltage.

Maximum current through the glow plugs. ... 110 amperes 045 : Testing and Adjusting

156

The voltage should not drop more than 0.5 volts. Perform Step 2 for each glow plug.

3. If the multimeter reading is below the specified amperes, the glow plug should be replaced. If there is no reading, replace the glow plug.

If the voltage reading of the multimeter is zero, inspect the starting aid switch and the power supply for faulty components and loose connections.

4. When the tests are complete, install the connector to the terminals of the glow plugs. Connect the cable for the power supply to the glow plugs.

045 : Testing and Adjusting

157

INDEX

SENR5006-04

3024C Engine for Caterpillar Built Machines Disassembly and Assembly Fuel Transfer Pump - Remove

INDEX

1 5

Removal Procedure Fuel Transfer Pump - Install

6

Installation Procedure Fuel Injection Lines - Remove and Install

7

Removal Procedure Installation Procedure Fuel Injection Nozzles - Remove

10

Removal Procedure Fuel Injection Nozzles - Install

11

Installation Procedure Fuel Shutoff Solenoid - Remove and Install

12

Removal Procedure Installation Procedure Governor - Disassemble

14

Disassembly Procedure Removal of the Governor Weight Assembly Removal of the lever for the Engine Stop Remove the linkage for the fuel injection pump Remove the Speed Control Lever for the Engine Governor - Assemble

17

Assembly Procedure Install the Speed Control Lever for the Engine Install the Linkage for the Fuel Injection Pump Installation of the Lever for the Engine Stop Installation of the Governor Weight Assembly Fuel Injection Pump - Remove

20

Removal Procedure Fuel Injection Pump - Install

21

Installation Procedure Exhaust Manifold - Remove and Install

22

Removal Procedure Installation Procedure Inlet and Exhaust Valve Springs - Remove and Install

24

Removal Procedure Installation Procedure Inlet and Exhaust Valves - Remove and Install

27

Removal Procedure Removal Procedure (Alternate Method) Installation Procedure

SENR5006-04

158

Installation Procedure (Alternate Method) Engine Oil Line - Remove and Install

30

Removal Procedure Installation Procedure Engine Oil Relief Valve - Remove and Install

31

Removal Procedure Installation Procedure Engine Oil Pump - Remove

33

Removal Procedure Engine Oil Pump Idler Hub Engine Oil Pump - Install

36

Installation Procedure Idler Hub Engine Oil Pump Water Pump - Remove

39

Removal Procedure Water Pump - Install

41

Installation Procedure Water Temperature Regulator - Remove and Install

42

Removal Procedure Installation Procedure Flywheel - Remove

44

Removal Procedure Flywheel - Install

46

Installation Procedure Crankshaft Rear Seal - Remove

48

Removal Procedure Crankshaft Rear Seal - Install

49

Installation Procedure Flywheel Housing - Remove and Install

50

Removal Procedure (Engines with Flywheel Housing and Back plate) Removal Procedure (Engines with Flywheel Housing) Installation Procedure (Engines with Flywheel Housing and Back plate) Installation Procedure (Engines with Flywheel Housing) Crankshaft Pulley - Remove and Install

55

Removal Procedure Installation Procedure Crankshaft Front Seal - Remove

57

Removal Procedure Crankshaft Front Seal - Install

58

Installation Procedure Housing (Front) - Remove

59

Removal Procedure Housing (Front) - Install

61

Installation Procedure SENR5006-04

159

Crankcase Breather - Remove and Install

62

Removal Procedure Installation Procedure Valve Mechanism Cover - Remove and Install

64

Removal Procedure Installation Procedure Rocker Shaft and Pushrod - Remove

66

Removal Procedure Rocker Shaft - Disassemble

68

Disassembly Procedure Rocker Shaft - Assemble

69

Assembly Procedure Rocker Shaft and Pushrod - Install

70

Installation Procedure Cylinder Head - Remove

71

Removal Procedure Cylinder Head - Install

73

Installation Procedure Lifter Group - Remove and Install

75

Removal Procedure Installation Procedure Camshaft - Remove

77

Removal Procedure Camshaft - Install

79

Installation Procedure Engine Oil Pan - Remove and Install

81

Removal Procedure Installation Procedure Pistons and Connecting Rods - Remove

83

Removal Procedure Pistons and Connecting Rods - Disassemble

84

Disassembly Procedure Pistons and Connecting Rods - Assemble

86

Assembly Procedure Pistons and Connecting Rods - Install

88

Installation Procedure Connecting Rod Bearings - Remove

90

Removal Procedure Connecting Rod Bearings - Install

91

Installation Procedure Crankshaft Main Bearings - Remove

93

Removal Procedure Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft Main Bearings - Install

95

Installation Procedure SENR5006-04

160

Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft - Remove

97

Removal Procedure Crankshaft - Install

98

Installation Procedure Bearing Clearance - Check

99

Measurement Procedure Coolant Temperature Switch - Remove and Install

101

Removal Procedure Installation Procedure Engine Oil Pressure Switch - Remove and Install

103

Removal Procedure Installation Procedure Glow Plugs - Remove and Install

105

Removal Procedure Installation Procedure V-Belts - Remove and Install

107

Removal Procedure Installation Procedure Alternator - Remove and Install

109

Removal Procedure Installation Procedure Electric Starting Motor - Remove and Install

110

Removal Procedure Installation Procedure

SENR5006-04

161

001

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Transfer Pump - Remove Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00824616

1. Loosen hose clamps and remove the two fuel lines from fuel transfer pump (1) .

2. Remove two bolts (4) that fasten fuel transfer pump (1) to the cylinder block.

Note: Before removing the fuel transfer pump (1) from the cylinder block, note the position of the flange (2) of the fuel transfer pump (1) for assembly.

3. Remove fuel transfer pump (1) and O-ring (3). Replace the O-ring when you install the fuel transfer pump.

Note: In order to remove the fuel transfer pump from the engine, it may be necessary to rotate the crankshaft until the rocker arm of the fuel transfer pump is not under pressure.

001 : Disassembly and Assembly

162

002

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Transfer Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

1.

2.

3.

4.

g00824616

Note: Ensure that the camshaft lobe for the fuel transfer pump is at minimum lobe lift before the fuel transfer pump is installed.

Note: The flange of the fuel transfer pump has two sets of locating holes. This allows the fuel transfer pump to be mounted in four positions.

Put O-ring (3) and fuel transfer pump (1) in position on the engine. Ensure that the rocker lever is positioned correctly on the camshaft lobe.

Install two bolts (4) that fasten fuel transfer pump (1) to the cylinder block.

Connect the two fuel lines and hose clamps to the fuel transfer pump (1). Tighten the hose clamps.

Prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for additional information.

002 : Disassembly and Assembly

163

003

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Injection Lines - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Note: Put identification marks on all tube assemblies for installation purposes. Plug all tube assemblies.

This helps to prevent contaminants from entering the system.

Illustration 1

g00818680

NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened.

The nozzles will be damaged if the top of the nozzle turns in the body.

The engine will be damaged if a defective fuel injection nozzle is used because the shape of fuel (spray pattern) that comes out of the nozzles will not be correct.

003 : Disassembly and Assembly

164

1.

2.

3.

4.

Disconnect union nuts (1) for fuel injection lines (2) from fuel injection nozzles.

Disconnect union nuts (1) for fuel injection lines (2) from the fuel injection pump.

Remove fuel injection lines (2) from the engine as a unit.

Remove banjo bolt (4) from fuel return line (3) .

Illustration 2

g00824793

5. Remove washers (8) from fuel return line (3) .

6. Remove nut (5) from fuel injection nozzles (7).

7. Remove fuel return line (3) from the engine and remove washers (6) from fuel injection nozzles (7).

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

003 : Disassembly and Assembly

165

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 3

g00824793

Illustration 4

g00818680

1. Install new washers (6) to fuel injection nozzles (7) and install fuel return line (3) to the fuel injection nozzles.

2. Install nuts (5) to fuel injection nozzles (7) .

Tighten the nuts to a torque of 27 N路m (20 lb ft).

3. Install new washers (8) to fuel return line (3) and install banjo bolt (4) to the fuel injection pump.

Tighten banjo bolt (4) to a torque of 2.5 N路m (22 lb in).

4. Install fuel injection lines (2) on the engine as a unit.

NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened.

The nozzles will be damaged if the top of the nozzle turns in the body.

The engine will be damaged if a defective fuel injection nozzle is used because the shape of fuel (spray pattern) that comes out of the nozzles will not be correct.

5. Connect fuel injection lines (2) to the fuel injection pump.

Tighten union nuts (1) to a torque of 23 N路m (17 lb ft).

6. Connect fuel injection lines (2) to fuel injection nozzles (7) .

Tighten union nuts (1) to a torque of 23 N路m (17 lb ft).

7. Prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for more information.

003 : Disassembly and Assembly

166

004

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Injection Nozzles - Remove Removal Procedure Start By: A. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00854283

1. Remove fuel injection nozzle (1) from the cylinder head.

2. Remove seat washer (2) from the cylinder head. Cap all openings or plug all openings immediately after removal.

Note: Do not reuse seat washer (2) after removal. Replace the seat washer with a new part during installation.

004 : Disassembly and Assembly

167

005

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Injection Nozzles - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00854283

Note: Do not reuse seat washer (2) after removal. Replace the seat washer with a new part before installation.

1. Install seat washer (2) into the injector bore in the cylinder head.

2. Install fuel injection nozzle (1) into the cylinder head. Tighten the fuel injection nozzles to a torque of 64 N¡m (47 lb ft).

End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Remove and Install".

005 : Disassembly and Assembly

168

006

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Shutoff Solenoid - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00824952

1. Disconnect electrical connections (3) to the fuel shutoff solenoid (1). Mark all connections for later installation.

2. Remove fuel shutoff solenoid (1) from the fuel injection pump housing by rotating the fuel shutoff solenoid in a counterclockwise direction.

3. Remove the O-ring seal (2) from fuel shutoff solenoid (1) .

006 : Disassembly and Assembly

169

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00824952

1. Check the condition of O-ring seal (2). If the O-ring seal is worn or damaged use a new part for replacement.

2. Install fuel shutoff solenoid (1) into the fuel injection pump housing by rotating the fuel shutoff solenoid in a clockwise direction. Tighten the fuel shutoff solenoid to a torque of 17 N¡m (12 lb ft).

3. Reconnect electrical connection (3) to fuel shutoff solenoid (1) before you operate the engine.

006 : Disassembly and Assembly

170

007

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Governor - Disassemble Disassembly Procedure Start By: A. Remove the engine front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

Note: The components for the governor assembly are located in the engine front housing.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Removal of the Governor Weight Assembly

Illustration 1

g00837567

1. Remove slider (2) from the end of the camshaft gear.

2. Remove bolts (1) that secure governor weight assembly (4) to the end of camshaft gear (3) and then remove governor weight assembly (4) .

3. Check governor weight assembly (4) for any wear or damage. Replace any components that are worn or damaged.

007 : Disassembly and Assembly

171

Removal of the lever for the Engine Stop

Illustration 2

g00837587

Illustration 3

g00837825

1. Remove spring (5) from lever (6) for the engine stop.

2. Loosen bolt (9) and nut (11) that secures control arm (7) to the lever (6) for the engine stop.

Note: Do not remove nut (11) and washers (10) from bolt (9) .

3. Remove control arm (7) from lever (6) for the engine stop .

4. Remove lever (6) for the engine stop from the engine front housing (8).

Note: The bushing is secured to the engine front housing with a special adhesive. The bushing must not be removed. If the bushing is removed, the threads in the engine front cover will be damaged.

5. The lever for the engine stop consists of the following components: clip (12) and O-ring (13) .

6. Check the components for wear or damage. Replace the components that are worn or damaged.

Remove the linkage for the fuel injection pump Note: When the linkage for the fuel injection pump is removed or the engine front cover is replaced, the setting for the maximum fuel may be affected.

Illustration 4

g00837709

Illustration 5

1.

2.

3.

4.

Remove spring (14) from fuel control lever (15) .

Remove C-clip (21) from governor control lever (19) .

Remove governor control lever (19) and remove lever (16) from the engine front housing.

Perform the following procedure in order to disassemble the fuel control lever (15) . a. Remove spring (14) from the end of fuel control lever (15). b. Remove the Angleich unit (torque control) (17) from lever (16) .

007 : Disassembly and Assembly

g00837723

172

c. Remove pin (18) that connects fuel control lever (15) to lever (16) .

5. Check the components for wear or damage. Replace any components that are worn or damaged.

Remove the Speed Control Lever for the Engine

Illustration 6

g00837616

1. Remove nut (22) and remove washer (23) that secures lever (24) to the arm (30) for the engine speed control .

2. Remove lever (24) from the arm (29) for the engine speed control .

3. Remove nut (24) from arm (30) for the engine speed control. Remove washer (26) and remove spring (27) from arm (30) for the engine speed control .

4. Remove arm (30) for the engine speed control from the engine front housing (8) .

5. Remove C-clip (29) and O-ring (28) from arm (30) .

007 : Disassembly and Assembly

173

Disassembly and Assembly

008 3024C Engine for Caterpillar Built Machines, SENR5006-04

Governor - Assemble Assembly Procedure

Tool A

Table 1 Required Tools Part Number Part Description 9S-3263 Thread Lock Compound

Qty 1

Note: The components for the governor assembly are located in the engine front housing.

Install the Speed Control Lever for the Engine

Illustration 1

g00837616

1. Install C-clip (29) and install O-ring (28) to arm (30). Install arm assembly (30) into engine front housing (8) .

2. Place spring (27) and washer (26) onto arm (30). Install nut (25) onto arm (30) .

3. Install lever (24) onto arm (30) .

4. Install washer (23) and nut (22) onto arm (30) .

Install the Linkage for the Fuel Injection Pump 1. Perform the following procedure if the fuel control lever was disassembled:

Illustration 2

g00839203

Illustration 3

008 : Disassembly and Assembly

g00837709

174

a. Apply Tooling (A) to the first two threads of the Angleich unit (torque control) (17) . b. Install the Angleich unit (torque control) (17) to lever (16). Tighten the Angleich (torque control) to a torque of 5 N¡m (44 lb in).

Illustration 4

2.

3.

4.

5.

6.

g00837723

Install fuel control lever (15) to lever (16) with pin (18) .

Install spring (14) to fuel control lever (15) .

Install governor control lever (19) and lever (16) to the engine front housing.

Install washer (20) and C-clip (21) on governor control lever (19) .

Attach spring (14) to the notch on the engine front housing (8) .

Installation of the Lever for the Engine Stop

Illustration 5

g00837587

Illustration 6

g00837825

1. Check the components for wear or damage. Replace the components that are worn or damaged.

2. Install O-ring (13) and C-clip (12) to lever (6) for the engine stop.

3. Lubricate O-ring (13) and the shaft of lever (6) for the engine stop. Install lever (6) for the engine stop to the engine front housing (8) .

4. Install control arm (7) onto lever (6) for the engine stop. Tighten bolt (9) and nut (11) to secure control arm (7) to lever (6) for the engine stop.

5. Install spring (5) to lever (6) for the engine stop. Tighten bolt (9) and nut (11) for control arm (7) .

Note: If control arm (7) was disassembled, attach washers (10) and nut (11) to bolt (9) onto the control arm.

008 : Disassembly and Assembly

175

Installation of the Governor Weight Assembly

Illustration 7

g00837567

1. Place governor weight assembly (4) in position on the gear (3) of the camshaft for the fuel injection pump.

2. Install bolts (1) that secure governor weight assembly (4) in position.

3. Tighten bolts (1) to a torque of 7 N¡m (5 lb ft).

4. Install slider (2) onto the end of camshaft gear (3). Ensure that the flange of the slider is installed into the recess of each governor weight assembly.

End By: Install the engine front housing. Refer to Disassembly and Assembly, "Housing (Front) Install".

008 : Disassembly and Assembly

176

009

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Injection Pump - Remove Removal Procedure Start By: A. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Remove and Install".

B. Remove the engine speed actuator. Refer to Disassembly and Assembly, "Engine Speed Actuator Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00825132

Illustration 2

g00825137

1. Remove bolts (4) and nuts (2) that fasten the fuel injection pump to the cylinder block.

2. Carefully raise fuel injection pump (1) from the cylinder block and remove clip (7) that connects link (6) to fuel rack control (5) .

3. Remove fuel injection pump (1) from the cylinder block.

Note: Record the thickness of each shim and the number of shims for reassembly. The fuel injection timing is determined by the shim pack thickness that is between the fuel injection pump and the mounting face on the cylinder block. For more information on the fuel injection pump, refer to Specifications, "Fuel Injection Pump".

4. Remove shims (3) from the mounting plate.

009 : Disassembly and Assembly

177

010

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Fuel Injection Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1 Typical example

g00825132

Illustration 2 Typical example

g00825137

1. Position the correct number of shims (3) on the mounting face of the cylinder block. Refer to Specifications, "Fuel Injection Pump".

2. Position fuel injection pump (1) close to the mounting face of the cylinder block, and connect link (6) and fuel rack control (5) with clip (7) .

3. Put fuel injection pump (1) in position on the mounting face of the cylinder block.

4. Install bolts (4) and nuts (2) that fasten the fuel injection pump to the cylinder block.

For 3013C Engines and 3024C Engines, tighten bolts (4) and nuts (2) to a torque of 15 N¡m (11 lb ft).

For 3011C Engines, tighten bolts (4) and nuts (2) to a torque of 6 N¡m (53 lb in).

End By: a. Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid Remove and Install". b. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

010 : Disassembly and Assembly

178

011

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Exhaust Manifold - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 Typical example

g00825291

1.

2.

3.

4.

Remove exhaust manifold nuts (5) and bolts (6) .

Remove exhaust manifold (4) from the cylinder head (1) .

Remove gasket (3) from the cylinder head.

Remove any remaining gasket material and carbon from the cylinder head and the exhaust manifold.

Be careful not to damage the mating surface on the cylinder head for the exhaust manifold.

5. Remove studs (2) for exhaust manifold (4) from cylinder head (1) .

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00825291

Typical example

011 : Disassembly and Assembly

179

1. If studs (2) were removed during disassembly, install attaching studs (2) to cylinder head (1) .

2. Put a new exhaust manifold gasket (3) in position on cylinder head (1) .

Note: Do not use any sealant on the exhaust manifold gasket.

3. Put exhaust manifold (4) in position on cylinder head (1) .

4. Install exhaust manifold nuts (5) and bolts (6) .

For 3013C Engines and 3024C Engines, tighten nuts (5) and bolts (6) to a torque of 25 N¡m (18 lb ft).

For 3011C Engines, tighten nuts (5) and bolts (6) to a torque of 10 N¡m (89 lb in).

Note: Tighten the two inner bolts first on three cylinder engines. Tighten the four inner bolts first on four cylinder engines. Then tighten the two outer bolts and the two nuts. Ensure that the bolts with different lengths are installed in the correct holes.

011 : Disassembly and Assembly

180

Disassembly and Assembly

012 3024C Engine for Caterpillar Built Machines, SENR5006-04

Inlet and Exhaust Valve Springs - Remove and Install Removal Procedure

Tool A

Table 1 Required Tools Part Number Part Description 9U-6195 Valve Spring Compressor

Qty 1

Start By: A. Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Before you begin the removal of the valve springs, refer to Specifications, "Cylinder Head Valves" and Testing and Adjusting, "Cylinder Head - Inspect" for appropriate information on the valve springs.

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

1. Ensure that the piston is at the top center position.

Illustration 1

g00825744

Personal injury can result from parts and/or covers under spring pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

2. Use Tooling (A) to compress valve springs (1) . Remove valve keepers (2) .

012 : Disassembly and Assembly

181

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

3. Release the pressure on Tooling (A) . Remove valve spring retainer (3) and valve springs (1) from the cylinder head.

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

Installation Procedure

Tool A

Table 2 Required Tools Part Number Part Description 9U-6195 Valve Spring Compressor

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00825744

Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

1. Place new valve springs (1) into position on the cylinder head.

Note: Ensure that the closed damper coils are toward the cylinder head if double valve springs are used.

2. Install valve spring retainer (3) .

3. Use Tooling (A) to compress valve springs (1) .

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

012 : Disassembly and Assembly

182

4. Install valve keepers (2) in order to lock the valve springs in position.

5. Release the pressure slowly on Tooling (A) . Remove Tooling (A) . Strike the top of the valves with a soft faced hammer in order to ensure that the valve keepers are properly installed.

End By: Install the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".

012 : Disassembly and Assembly

183

013

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Inlet and Exhaust Valves - Remove and Install Removal Procedure

Tool A

Table 1 Required Tools Part Number Part Description 9U-6195 Valve Spring Compressor

Qty 1

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

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Clean the bottom face of the cylinder head. Use a dial indicator to check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to the Specifications, "Cylinder Head Valves" for the correct dimensions.

2. Place an index mark on the heads of the inlet valves and the exhaust valves for installation purposes.

Illustration 1

g00659252

Illustration 2

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

3.

4.

5.

6.

7.

8.

9.

10.

Use Tooling (A) to compress valve springs (3) .

Remove two valve keepers (1) .

Slowly release the pressure on Tooling (A) and remove Tooling (A) .

Remove valve spring retainers (2) .

Remove valve springs (3) .

Remove valve stem seals (4) .

Remove valve spring seat washers (5) .

Remove inlet valves (6) and exhaust valves (6) .

013 : Disassembly and Assembly

g00825746

184

Removal Procedure (Alternate Method)

Tool B

Table 2 Required Tools Part Number Part Description 5S-1330 Valve Spring Compressor

Qty 1

Follow the instructions above using Tooling (B) .

Installation Procedure

Tool A

Table 3 Required Tools Part Number Part Description 9U-6195 Valve Spring Compressor

Illustration 3

g00659252

Qty 1

Illustration 4

g00825746

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

Lubricate the stems of inlet valves (6) and the stems of exhaust valves (6) with clean engine oil.

Install inlet valves (6) and exhaust valves (6) in the respective positions.

Install valve spring seat washers (5) .

Install new valve stem seals (4) .

Install valve springs (3) .

Note: Install valve springs (3) on the valve spring seat washers. This is done with double valve springs.

Install valve spring retainers (2) .

Use Tooling (A) to compress valve springs (3) .

Install valve keepers (1) .

Slowly release the pressure on Tooling (A) and remove Tooling (A). Strike the top of the valves with

013 : Disassembly and Assembly

185

a soft hammer in order to ensure that the valve keepers are properly installed.

Note: Refer to Specifications, "Cylinder Head Valves" for more information on the inlet valves and the exhaust valves.

10. Use a dial indicator to check the depth of the new valves below the cylinder head. If the depth of the new valves is below the correct depth, the valve seat inserts must be replaced.

End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

Installation Procedure (Alternate Method)

Tool B

Table 4 Required Tools Part Number Part Description 5S-1330 Valve Spring Compressor

Qty 1

Follow the procedure above using Tooling (B).

013 : Disassembly and Assembly

186

014

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Line - Remove and Install Removal Procedure

Illustration 1 Typical example

1.

2.

3.

4.

g00827402

Loosen nut (4) that attaches oil line (1) to the cylinder block.

Remove banjo bolt (3) and remove washers (2) from the cylinder block.

Remove banjo bolt (3) and remove washers (2) from the cylinder head. Discard washers (2).

Remove oil line (1) from the engine.

Installation Procedure

Illustration 2 Typical example

1.

2.

3.

4.

5.

g00827402

Position oil line (1) on the engine.

Position banjo bolt (3) and new washers (2) on oil line (1). Install the oil line to the cylinder block.

Position banjo bolt (3) and washers (2) to oil line (1). Install the oil line to the cylinder head.

Tighten nut (4) that attaches oil line (1) to the cylinder block.

Tighten banjo bolts (3) to 12 N¡m (9 lb ft).

014 : Disassembly and Assembly

187

015

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Relief Valve - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00820218

1. Remove engine oil relief valve (2) from the cylinder block.

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

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

015 : Disassembly and Assembly

188

Illustration 2

g00820218

1. Install new O-ring seal (1) on engine oil relief valve (2) .

2. Lubricate engine oil relief valve (2) with clean engine oil.

3. Install engine oil relief valve (2) in the cylinder block. Tighten the engine oil relief valve to a torque of 64 N¡m (47 lb ft).

015 : Disassembly and Assembly

189

016

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Pump - Remove Removal Procedure Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

B. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

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

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

016 : Disassembly and Assembly

190

Engine Oil Pump

Illustration 1

g00825411

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

1. Remove retaining ring (9) that retains idler gear (3) on idler hub (1) .

2. Remove the following items from idler hub (1) : n Collar (8) n Spring (7) n Shim (6) n Oil pump cover (5) n Inner rotor (4) 3. Remove idler gear (3) from idler hub (1) .

4. Remove thrust washer (2) from idler hub (1) .

5. Inspect all the components for wear or damage. If components are worn or damaged, use new parts for replacement.

Note: Refer to Specifications, "Engine Oil Pump" for more information.

6. If the engine oil pump has excessive buildup of sludge, inspect the oil strainer. The oil strainer can be removed by using the following procedure: a. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Illustration 2

g00825406

b. Remove bolts (12) and oil strainer (13) from the cylinder block. Inspect the oil strainer for damage. If the oil strainer is damaged, use a new part for replacement. c. Remove tube assembly (11) from the cylinder block. d. Remove O-ring seal (10) from the tube assembly. Inspect the O-ring seal for wear or damage. If the O-ring seal is worn or damaged, use a new part for replacement.

016 : Disassembly and Assembly

191

Idler Hub

Tool A

Table 1 Required Tools Part Number Part Description 1P-0074 Slide Hammer Puller

Illustration 3

Qty 1

g01037604

1. Use Tooling (A) to remove idler hub (1) from the cylinder block.

016 : Disassembly and Assembly

192

Disassembly and Assembly

017 3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Pump - Install Installation Procedure

Tool B C (1) C (2) D E

Table 1 Required Tools Part Number Part Description 8T-5096 Dial Indicator Test Group 256-4864 Alignment Tool 241-4232 Alignment Tool 1S-0257 Ball Peen Hammer 1P-0808 Multipurpose Grease

(1)

3003 engines

(2)

3013, 3014 and 3024 engines

Qty 1 1 1 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

Idler Hub

Illustration 1

g01198501

Illustration 2

1. Use Tooling (C) and Tooling (D) to install idler hub (1) in the cylinder block.

017 : Disassembly and Assembly

g00825411

193

Engine Oil Pump

Illustration 3

g01037617

Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

1. Apply Tooling (E) to the faces of inner rotor (4) and to the vanes of idler gear (3) .

2. Align Timing Marks (A) and (B) that are on idler gear (3) with the respective timing marks on gears (14) and (15) . Install idler gear (3) on idler hub (1) .

3. Install inner rotor (4) in idler gear (3) .

Personal injury can result from the release of the spring force.

The drive shaft, the piston, and the drive gear are under spring force.

Use a press to slowly release the spring force before the components are removed.

4. Install the following items on idler hub (1) : n Oil pump cover (5) n Shim (6) n Spring (7) n Collar (8) 5. Install retaining ring (9) on idler hub (1) .

6. Use Tooling (B) in order to measure the end play of the engine oil pump. Refer to Specifications, "Engine Oil Pump".

7. If the oil strainer was removed, use the following procedure for installation:

017 : Disassembly and Assembly

194

Illustration 4

g01037619

a. Install O-ring seal (10) on tube assembly (11) . b. Install tube assembly (11) in the cylinder block. c. Install oil strainer (13) on the cylinder block and tighten bolts (12) to a torque of 11 N¡m (97 lb in).

End By: a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

017 : Disassembly and Assembly

195

018

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Water Pump - Remove Removal Procedure Start By: A. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

B. Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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

Illustration 2

Illustration 1

g00825842

g00831690

2. Remove set screws (1) that fasten adapter (2) and pulley (3) to water pump (4). Remove adapter (2) and pulley (3) from water pump (4) .

3. Remove bolt (5) and alternator bracket (6) from water pump (4) .

018 : Disassembly and Assembly

196

Illustration 3

g00825811

4. Loosen hose clamps (9) and remove hose (11) from water pump (4) .

5. Loosen the hose clamp for the lower hose (not shown) to water pump (4) and remove the lower hose (not shown) from the water pump.

6. Remove nut (10) and bolts (8) that fasten water pump (4) to the engine.

7. Remove water pump (4) and gasket (7) from the engine.

018 : Disassembly and Assembly

197

019

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Water Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Remove all debris and gasket material from the mating surfaces of the water pump and the cylinder head.

Illustration 1

g00825811

Illustration 2

g00825842

2. Install new gasket (7) in position on the engine.

3. Place water pump (4) in position on the engine and install bolts (8) and nut (10) . Tighten nut (10) and bolts (8) that fasten water pump (4) to the engine.

4. Install lower hose (not shown) and tighten the hose clamp. Install hose (11) on water pump (4) and tighten hose clamps (9) .

5. Place alternator bracket (6) into position on water pump (4) and install bolt (5) on water pump (4) .

Illustration 3

g00831690

6. Install pulley (3) and adapter (2) on water pump (4) . Install set screws (1) and tighten to a torque of 11 N¡m (8 lb ft).

7. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities".

End By: a. Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install". b. Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

019 : Disassembly and Assembly

198

020

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Water Temperature Regulator - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to the OEM for the approximate capacity of the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change" or Operation and Maintenance Manual, "Cooling System Extended Life Coolant - Change".

Illustration 1

g00825537

2.

3.

4.

5.

Remove two bolts (1) from water temperature regulator housing (5) .

Remove cover (2) and gasket (4) for the water temperature regulator (3) .

Remove water temperature regulator (3) from the water temperature regulator housing (5) .

Remove all debris and gasket material from the mating surfaces of cover (2) and water temperature regulator housing (5). Use a new gasket for assembly.

6. Inspect water temperature regulator (3) for wear or damage. If the water temperature regulator is worn or damaged, use a new part for replacement. Refer to Testing and Adjusting, "Water

020 : Disassembly and Assembly

199

Temperature Regulator - Test" for more information on testing the water temperature regulator.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00825537

1. Install water temperature regulator (3) to water temperature regulator housing (5) .

2. Position a new gasket (4) and cover (2) for water temperature regulator (3) on water temperature regulator housing (5) .

3. Install bolts (1) to cover (2). Tighten the two bolts for the cover to a torque of 14 N¡m (10 lb ft).

4. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities" for more information.

020 : Disassembly and Assembly

200

021

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Flywheel - Remove Removal Procedure

Tool A

Table 1 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

Start By: A. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The two cylinder, the three cylinder and the four cylinder engines have different flywheels. The removal procedure is similar for all models.

Illustration 1 Typical example

g00825636

1.

2.

3.

4.

5.

Install Tooling (A) and a suitable lifting device to the flywheel (2) .

Remove two setscrews (1) opposite each other from the flywheel.

Install two M10 x 1.25 mm guide studs in the place of the setscrews that were removed.

Remove the remaining setscrews (1) that fasten the flywheel to the crankshaft.

Remove the flywheel (2) from the rear of the crankshaft.

Note: On some three cylinder engines, a roll pin is located between the crankshaft and the flywheel.

6. Inspect the flywheel ring gear (3) and the flywheel (2) for wear or damage. If the flywheel ring gear or the flywheel is worn or damaged, use new parts for replacement.

021 : Disassembly and Assembly

201

Illustration 2 Typical example

g00825639

7. To remove the flywheel ring gear (3) from the flywheel (2), place the flywheel on a suitable support.

Use a suitable hammer (not shown) and a punch (4) in order to remove the ring gear from the flywheel.

021 : Disassembly and Assembly

202

022

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Flywheel - Install Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Illustration 1 Typical example

g01372138

Illustration 2 Typical example

g01126937

1. Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If there are any oil leaks refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".

2. If necessary, perform the following procedure to install the ring gear (2) to the flywheel (1) . a. Identify the orientation of the new ring gear in order to install the ring gear correctly onto the flywheel.

Note: The chamfered side of the gear teeth (3) must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement of the starting motor. b. Heat the flywheel ring gear (2) in an oven to a maximum temperature of 150°C (302°F) prior to installation.

Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of the ring gear (2) is correct and quickly install the ring gear onto the flywheel (1) .

3. Install a tooling (A) and a suitable lifting device to the flywheel (1) .

4. Install two M10 x 1.25 guide studs opposite each other in the end of the crankshaft.

5. Position the flywheel (1) onto the two guide studs.

On three cylinder engines that have a roll pin, ensure that the roll pin is installed to the crankshaft and that the roll pin is free from damage. Align the hole in the flywheel with the roll pin in the crankshaft.

022 : Disassembly and Assembly

203

6. Install the setscrews (4) that fasten the flywheel to the crankshaft.

7. Remove the two guide studs and install the two remaining setscrews (4) in the flywheel.

8. Use a suitable tool to prevent the flywheel (1) from rotating. Tighten the setscrews (4) to a torque of 73.5 N¡m (54.2 lb ft).

9. Remove tooling (A) and the lifting device from the flywheel.

022 : Disassembly and Assembly

204

023

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Rear Seal - Remove Removal Procedure Start By: A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00847841

1. Remove bolts (3) and backplate (2) from the rear of the cylinder block.

2. Remove crankshaft rear seal (1) from the cylinder block.

023 : Disassembly and Assembly

205

024

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Rear Seal - Install Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 4C-9612 Silicone Sealant

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Clean the back of the cylinder block and the mating surface of the backplate.

Illustration 1

2.

3.

4.

5.

g00847841

Install crankshaft rear seal (1) on the cylinder block.

Put a bead of Tooling (A) around the bolt holes and the face of the cylinder block.

Position backplate (2) on the rear of the cylinder block.

Install bolts (3) that fasten backplate (2) on the cylinder block. Tighten the bolts to a torque of 15 N¡m (11 lb ft).

End By: Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing Remove and Install".

024 : Disassembly and Assembly

206

025

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Flywheel Housing - Remove and Install Removal Procedure (Engines with Flywheel Housing and Back plate)

Tool A

Table 1 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

Start By: A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Support the engine with a suitable lifting device or support the engine on blocks that are positioned on a flat level surface.

2. Install tool (A) and a suitable lifting device to the flywheel housing. Support the weight of the housing (8) .

Illustration 1 Typical example

g00827061

3. Remove the setscrews (3) that fasten the flywheel housing (8) to the cylinder block.

4. Remove the setscrews (5) on each side of the cylinder block. These setscrews fasten the flywheel housing (8) to the cylinder block.

5. Remove the setscrews (1) that fasten the back plate (2) to the flywheel housing (8) .

6. Remove the nuts (7) and the bolts (not shown) that fasten the back plate (2) to the flywheel housing (8) .

025 : Disassembly and Assembly

207

Illustration 2 Typical example

g00826988

7. Use tool (A) and the lifting device to remove the flywheel housing (8) from the back plate.

Removal Procedure (Engines with Flywheel Housing)

Tool A

Table 2 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

Start By: A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The two cylinder, the three cylinder and the four cylinder engines have different flywheel housings. The removal procedure is similar for all models.

1. Support the engine with a suitable lifting device or support the engine on blocks that are positioned on a flat level surface.

2. Install tool (A) and a suitable lifting device to the flywheel housing. Support the weight of the housing (2) .

025 : Disassembly and Assembly

208

Illustration 3 Typical example

g01123577

Illustration 4

g01126979

3. Remove the setscrews (1) that fasten the flywheel housing (2) to the cylinder block.

4. Use the tool (A) and the lifting device to remove the flywheel housing (2) from the engine.

Installation Procedure (Engines with Flywheel Housing and Back plate)

Tool A

Table 3 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 5 Typical example

g00827061

Illustration 6

g00826988

1. Clean the rear face of the back plate (2) and the faces of the flywheel housing (8). Inspect the crankshaft rear seal (not shown) for leaks. Inspect the dowels (6) for damage. If the crankshaft rear seal or the dowels are damaged, use new parts for replacement. Refer to Disassembly and Assembly, 025 : Disassembly and Assembly

209

"Crankshaft Rear Seal - Remove" and Disassembly and Assembly, "Crankshaft Rear Seal - Install".

2. Use tool (A) and the lifting device to align the flywheel housing (8) to the dowels (6). Install the flywheel housing to the back plate.

3. Install the nuts (7) and the bolts (not shown) that fasten the back plate (2) to the flywheel housing (8) .

4. Install the setscrews (1) that fasten the back plate (2) to the flywheel housing (8) .

5. Install the setscrews (5) on each side of the cylinder block. These setscrews fasten the flywheel housing (8) to the cylinder block.

6. Remove the tool (A) and the lifting device from the flywheel housing.

7. Install the setscrews (3) that fasten the flywheel housing (8) to the cylinder block.

8. For C1.5/3013C, C2.2/3024C and C2.2/3024CT engines, tighten the fasteners to a torque of 25 N·m (19 lb ft).

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

Installation Procedure (Engines with Flywheel Housing)

Tool A

Table 4 Required Tools Part Number Part Description 138-7573 Link Bracket

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 7 Typical example

g01123556

Illustration 8 Typical example

g01126979

1. Clean the mating face of the flywheel housing (2). Inspect the crankshaft rear seal (4) for leaks.

Inspect the dowels (5) for damage. If the crankshaft rear seal or the dowels are damaged, use new parts for replacement. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove" and Disassembly and Assembly, "Crankshaft Rear Seal - Install".

2. Use tool (A) and the lifting device to align the flywheel housing (2) to the dowels (5). Install the flywheel housing to the engine.

3. Install the setscrews (1) that fasten the flywheel housing to the cylinder block.

For C0.5 and C0.7 engines, tighten the setscrews to a torque of 15 N·m (11 lb ft).

For C1.1/3011C and C1.6 engines, tighten the setscrews to a torque of 50 N·m (37 lb ft).

025 : Disassembly and Assembly

210

For C1.5/3013C engines, tighten the setscrews to a torque of 25 N¡m (19 lb ft).

4. Remove tool (A) and the lifting device from the flywheel housing.

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

025 : Disassembly and Assembly

211

026

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Pulley - Remove and Install Removal Procedure Table 1 Required Tools Tool Part Number Description Qty 8S-2264 Puller Group 1 A 6V-3668 Bolt 3 1. Loosen the bolts for the alternator and slide the alternator toward the engine.

2. Remove the fan drive belt.

Illustration 1

g00827213

Illustration 2

1. Remove nut (5) and washer (3) from crankshaft pulley (2) .

2. Use Tooling (A) in order to remove crankshaft pulley (2) from crankshaft (4) .

3. Remove woodruff key (1) from crankshaft (4) .

Installation Procedure

Illustration 3

g00827213

1. Install woodruff key (1) to crankshaft (4) .

2. Put crankshaft pulley (2) in position on crankshaft (4) .

3. Position washer (3) on crankshaft (4) .

026 : Disassembly and Assembly

g00827241

212

4. Lubricate nut (5) with clean engine oil and install the nut.

For 3011C Engines, tighten nut (5) to a torque of 123 N¡m (91 lb ft).

For 3013C Engines and 3024C Engines, tighten nut (5) to a torque of 304 N¡m (224 lb ft).

5. Put the V-belt in position on the engine.

6. Slide the alternator away from the engine and tighten the bolts for the alternator. Refer to Testing and Adjusting, "Belt Tension Chart" for more information on the proper belt tension.

026 : Disassembly and Assembly

213

Disassembly and Assembly

027 3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Front Seal - Remove Removal Procedure

Tool A B

Table 1 Required Tools Part Number Part Description 1U-8145 Drill Bit 1U-7600 Slide Hammer Puller Gp

Qty 1 1

Start By: A. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00827263

Illustration 2

g01037807

1. Use Tooling (A) and carefully drill three evenly spaced holes (1) in crankshaft front seal (2) .

2. Carefully remove the crankshaft front seal by alternating the position of Tooling (B) from one hole to another hole. This will allow you to evenly remove the crankshaft front seal from housing (3) .

Note: Do not damage the flange of the crankshaft during the removal process of the crankshaft front seal.

NOTICE Ensure that the main lip is used in order to remove the crankshaft front seal. Do not damage the edge of the housing for the crankshaft front seal.

027 : Disassembly and Assembly

214

028

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Front Seal - Install Installation Procedure

Tool C

Table 1 Required Tools Part Number Part Description 5P-3537 Seal Guide

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01037829

1. Clean housing (3) for crankshaft front seal (2) and inspect the housing for any damage.

2. Lubricate the lip of crankshaft front seal (2) with clean engine oil.

3. Position crankshaft front seal (2) in housing (3) for the crankshaft front seal.

NOTICE Ensure that the lip of the crankshaft front seal that is spring loaded is facing toward the inside of the front housing and that it is square with the bore of the housing for the crankshaft front seal.

4. Use Tooling (C) to install new crankshaft front seal (2) .

5. Apply clean engine oil on the area of the crankshaft pulley that will be in contact with crankshaft front seal (2) .

End By: Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley Remove and Install".

028 : Disassembly and Assembly

215

029

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Housing (Front) - Remove Removal Procedure

Tool A

Table 1 Required Tools Part Number Part Description 256-4866 or Seal Installer 256-4871

Qty 1

Start By: A. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump Remove".

B. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

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

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

029 : Disassembly and Assembly

216

Illustration 1

g01041799

1. Remove bolts (7) and nuts (6) from front housing (3) .

2. Install Tooling (A) before removing front housing (3) from cylinder block (1) .

3. Remove front housing (3) from the front of cylinder block (1) .

Note: Ensure that mechanical stop lever (2) is in the full clockwise position before removing the front housing from cylinder block (1) .

Note: Locating hole (4) and locating pin (5) must align for installation.

4. Remove gasket material from the cylinder block and remove gasket material from front housing (3) .

5. Inspect front housing (3) for wear or damage. If the front housing is damaged, use a new part for replacement.

029 : Disassembly and Assembly

217

030

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Housing (Front) - Install Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 256-4866 or Seal Installer 256-4871

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE If the front housing is not installed, do not turn the crankshaft.

Damage to the engine may occur.

1. Clean all surfaces thoroughly. Inspect the condition of the gasket. Replace the gasket, if necessary.

2. Install Tooling (A) on the crankshaft.

Illustration 1

g01041799

3. When front housing (3) is installed, rotate mechanical stop lever (2) in a clockwise direction for easier installation. Observe the position of the linkage (not shown) in the front housing. In order for the link to be connected during the fuel injection pump installation, correctly position the link for the fuel injection pump.

4. Align locating pin (5) with locating hole (4) on the oil pump cover.

5. Position front housing (3) on the front of cylinder block (1) .

6. Install bolts (7) and nuts (6) finger tight. Tighten bolts (7) and nuts (6) to a torque of 10 N¡m (89 lb in).

7. Remove Tooling (A) from the crankshaft.

Note: Do not adjust the maximum fuel adjustment screw if the front housing or the governor linkage have been replaced. You must check the high idle rpm after assembly of the front housing.

End By: a. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install". b. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".

030 : Disassembly and Assembly

218

031

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankcase Breather - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00827682

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

1. Loosen bolts (2) and remove breather cover (1) from the valve mechanism cover.

2. Remove spring (3). Remove the diaphragm and plate (4).

3. Clean vent hole (6). Clean cavity (5) for the breather assembly in the valve mechanism cover.

031 : Disassembly and Assembly

219

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE Make sure that the components of the breather assembly are installed correctly. Engine damage may occur if the breather assembly is not working properly.

Illustration 2

g00827682

Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

1. Install a new diaphragm and plate (4) for the breather assembly. Install a new spring (3). Install breather assembly into cavity (5) of the valve mechanism cover.

Note: Ensure that vent hole (6) is clean.

2. Install breather cover (1) and bolts (2). Tighten the bolts.

031 : Disassembly and Assembly

220

032

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Valve Mechanism Cover - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine.

Note: The inlet manifold is part of the valve mechanism cover.

Illustration 1 Typical example

g00819350

1. Remove the setscrews (2) from the connector (3) and remove the connector from the valve mechanism cover (6) . Remove the gasket (4) . Discard the gasket.

2. Remove the setscrews (1) and remove the cap nuts (5) that attach the valve mechanism cover (6) to the housing (7) for the rocker shaft assembly.

3. Remove the valve mechanism cover (6) from the housing (7) for the rocker shaft assembly. Remove the joint (8) from the valve mechanism cover (6) . Inspect the joint. If the joint is worn or damaged,

032 : Disassembly and Assembly

221

use a new part for replacement.

Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 266-9682 White Compound

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine.

1. Clean all surfaces thoroughly.

Illustration 2 Typical example

g00819350

2. Apply Tooling (A) to the joint (8) . Install the joint (8) to the valve mechanism cover (6) .

Note: Ensure that the new joint is fully seated into the grooves of the valve mechanism cover.

3. Install the valve mechanism cover (6) to the housing (7) for the rocker shaft assembly.

4. Install the setscrews (1) and install the cap nuts (5) .

5. For C0.5 and C0.7 engines, tighten the setscrews and cap nuts to a torque of 10 N路m (7.5 lb ft).

For C1.1/3011C and C1.6 engines, tighten the setscrews and cap nuts to a torque of 11 N路m (8.1 lb ft).

For C1.5/3013C, C2.2/3024C and C2.2/3024CT engines, tighten the setscrews and the cap nuts to a torque of 14 N路m (10 lb ft).

6. Install a new gasket (4) to the valve mechanism cover (6) . Install the connector (3) to the valve mechanism cover (6) with setscrews (2) . Tighten the setscrews to a torque of 14 N路m (10 lb ft).

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033

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Rocker Shaft and Pushrod - Remove Removal Procedure Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00827968

1. Loosen adjusting screws (3) in order to release tension off the rocker shaft assembly.

2. Remove nuts (2) and bolt (1) from each end of rocker shaft assembly (4) .

3. Remove rocker shaft assembly (4) and the base for the valve mechanism cover from cylinder head (7) .

4. Inspect rocker shaft assembly (4) for wear or for damage. If the rocker shaft assembly is worn or damaged, use new parts for replacement.

5. Remove pushrods (6) from the cylinder head. Mark the pushrods or identify the pushrods for

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223

installation. Inspect the pushrods for wear or for damage. If the pushrods are damaged, use new parts for replacement.

6. Remove caps (5) from the top of the valve stems. Inspect the caps for wear or for damage. If the caps are worn or damaged, use new parts for replacement.

7. Remove O-ring seal (9) from base (8) .

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224

034

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Rocker Shaft - Disassemble Disassembly Procedure Start By: A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00842949

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

1. In order to remove rocker arms (1), rocker arms (2), washers (3), and springs (4) slide rocker shaft (7) from the end of base (9) .

Note: Place an identification mark on each of the components for installation.

2. Remove adjusting screws (6) and nut (5) from rocker arms (1) and rocker arms (2) .

3. Inspect all of the components from base (9) for wear or for damage. If any of the components are worn or damaged, use new parts for replacement.

4. Inspect O-ring seal (8) for wear or for damage. If the O-ring seal is worn or damaged, use a new part for replacement.

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225

035

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Rocker Shaft - Assemble Assembly Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Lubricate all of the components with clean engine oil.

Note: Inspect O-ring seal (8) for wear or for damage. If the O-ring seal is worn or damaged, use a new part for replacement.

Illustration 1

g00842949

Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

2.

3.

4.

5.

6.

7.

Install adjusting screw (6) and nut (5) to rocker arms (1) and rocker arms (2) .

Position rocker shaft (7) in the end of base (9) .

Gradually insert rocker shaft (7) and install rocker arm (1) .

Insert rocker shaft (7) and install rocker arm (2) .

Slide rocker shaft (7) through washer (3) and spring (4) .

Repeat Steps 2 through 6 in order to install the remaining components.

End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

035 : Disassembly and Assembly

226

036

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Rocker Shaft and Pushrod - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 Typical example

g00827968

1. Lubricate pushrods (6) with clean engine oil. Install pushrods (6) in the cylinder head.

Note: Ensure that the pushrods are installed correctly in the socket of the valve lifters.

2. Install caps (5) on the top of the valve stems.

3. Install rocker shaft assembly (4) and base (8) for the valve mechanism cover on cylinder head (7) .

4.

5.

6.

7.

Note: Lubricate nuts (2) with clean engine oil before installation.

Install bolts (1) and nuts (2) finger tight.

Note: Ensure that the ends of the adjusting screws on each rocker arm are properly seated in the ends of pushrods (6) .

Tighten bolts (1) on each end of the base (8) for the valve mechanism cover.

The nut tightening sequence moves from the center of the rocker shaft outward.

For 3011C engines, tighten nuts (1) to a torque of 23 N路m (17 lb ft) and bolts (2) to a torque of 10 N路m (89 lb in).

For 3013C engines and 3024C Engines, tighten nuts (1) to a torque of 33 N路m (24 lb ft) and bolts (2) to a torque of 10 N路m (89 lb in).

Adjust the valve lash. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for the correct procedure to adjust the valve lash.

End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

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227

037

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Cylinder Head - Remove Removal Procedure Start By: A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".

B. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold- Remove and Install".

C. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

D. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".

E. Remove fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

F. Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles Remove".

G. Remove the oil line. Refer to Disassembly and Assembly, "Engine Oil Line - Remove and Install".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00828137

Illustration 2

g00828140

1. Gradually loosen cylinder head bolts (1) in the reverse order that is shown above. This will help prevent distortion of cylinder head (2) .

Note: Do not use a pry bar to separate cylinder head (2) from cylinder block (3). Use a rubber mallet 037 : Disassembly and Assembly

228

to loosen the cylinder head from the cylinder block.

2. Attach a suitable lifting device to cylinder head (2). Carefully lift cylinder head (2) off cylinder block (3) .

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

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229

038

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Cylinder Head - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00828137

Illustration 2

g00828396

1. Thoroughly clean the top of cylinder block (3) and the bottom of cylinder head (2) . Ensure that there is no debris in the cylinder bores.

2.

3.

4.

5.

Note: A number at location (5) with four digits is stamped on cylinder head gasket (4) in order to ensure the correct positioning of the cylinder head gasket. This number faces the cylinder head.

Make sure that cylinder head gasket (4) for cylinder head (2) is the correct thickness as the original cylinder head gasket before installation.

Note: Refer to Specifications, "Cylinder Head" in order to determine the thickness of the original cylinder head gasket.

Note: The correct piston height must be maintained in order to prevent damage to the pistons and the valves. Refer to Testing and Adjusting, "Piston Height - Inspect". The correct piston height must be maintained in order to ensure that the engine conforms to the exhaust emission standards.

Place cylinder head gasket (4) on the dowels (6) on the top of the cylinder block (3) . Do not use any gasket sealant or compound on the cylinder head gasket.

Attach a suitable lifting device to cylinder head (2) .

Place cylinder head (2) on cylinder block (3) . Ensure that cylinder head (2) is positioned on dowels (6) . Verify that cylinder head gasket (4) is positioned correctly.

Lubricate cylinder head bolts (1) with clean engine oil.

Illustration 3

g00828140

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230

6. Install cylinder head bolts (1) and gradually tighten the cylinder head bolts in a numerical sequence.

The numerical sequence is shown in Illustration 3. Tighten the cylinder head bolts to a torque of 101 N¡m (74 lb ft).

End By: a. Install the oil line. Refer to Disassembly and Assembly, "Engine Oil Line - Remove and Install". b. Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles Install". c. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection lines - Remove and Install". d. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install". e. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install". f. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install". g. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

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039

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Lifter Group - Remove and Install Removal Procedure Table 1 Required Tools Tool Part Number A 1U-7262

Part Description Telescoping Magnet

Qty 1

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

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Mark the original location of the lifters for later installation.

Illustration 1

g00828101

1. Use Tooling (A) to remove lifter (1) from the cylinder block.

2. Inspect lifter (1) for wear or damage. If the lifters are worn or damaged, use new parts for replacement.

3. Repeat Steps 1 and 2 for the remaining lifters.

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232

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00692979

1. Ensure that lifter (1) is clean and that the oil hole in the lifter is not restricted. Lubricate the lifter with clean engine oil and install the lifter in the cylinder block.

Note: Ensure that the lifters are installed in the original location.

2. Repeat Step 1 for the remaining lifters.

End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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233

040

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Camshaft - Remove Removal Procedure Start By: A. Remove the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

B. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump Remove".

C. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump Remove".

D. Remove the engine front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00828467

1. Remove slider (1) from camshaft gear (4) .

2. Rotate the crankshaft until timing marks (2) on the following components are aligned.

Note: The No. 1 cylinder is at the top center position when these marks are in alignment. Refer to Illustration 1. n Camshaft gear (4) n Idler gear (5) n Crankshaft gear (3) 3. Remove idler gear (5). Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

040 : Disassembly and Assembly

234

Illustration 2

g00828468

Illustration 3

g01003180

4. Rotate camshaft gear (4) in order to align access hole (8) in the camshaft gear with bolt (6). Remove bolt (6) and remove bolt (7) from camshaft retainer (9) .

5. Carefully remove camshaft gear (4) and camshaft (10) from cylinder block (11). Be careful not to damage the lobes of the camshaft or the camshaft bearings.

6. Inspect the components for wear or damage. Replace the components that are worn or damaged.

040 : Disassembly and Assembly

235

041

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Camshaft - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft is clean. Lubricate the camshaft with clean engine oil.

Illustration 2

Illustration 1

g00828468

g01003212

2. Carefully install camshaft (10) and camshaft gear (4) in cylinder block (11). Be careful not to damage the lobes of the camshaft or the camshaft bearings.

3. Align the bolt holes in camshaft retainer (9) with the bolt holes in cylinder block (11). Rotate camshaft gear (4) in order to align access hole (8) in the camshaft gear with the hole for bolt (6).

Install bolt (6) and bolt (7) that secures camshaft retainer (9) in position on cylinder block (11).

Tighten bolt (6) and bolt (7) to a torque of 11 N¡m (95 lb in).

Illustration 3

g00828467

4. Install idler gear (5). Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

Note: When you install the idler gear, ensure that timing marks (2) are aligned on the following components. n Camshaft gear (4) n Idler gear (5) 041 : Disassembly and Assembly

236 n Crankshaft gear (3) 5. Install slider (1) to camshaft gear (4) .

End By: a. Install the engine front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". b. Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Install". c. Install the fuel injection pump. Refer to Disassembly and assembly, "Fuel Injection Pump - Install". d. Install the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

041 : Disassembly and Assembly

237

042

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Pan - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

g00820013

1. Remove drain plugs (5) and washers (3) from engine oil pan (2). Drain the engine oil into a suitable container for storage or disposal.

2. Remove bolts (4) for engine oil pan (2) .

3. Remove engine oil pan (2) from the engine.

4. Remove the remaining gasket material (1) from engine oil pan (2) and the cylinder block.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

042 : Disassembly and Assembly

238

Illustration 2

g00820013

1. Clean all surfaces thoroughly. Inspect the condition of gasket (1). Replace the gasket, if necessary.

2. Position gasket (1) and engine oil pan (2) on the engine.

3. Install bolts (4) for engine oil pan (2) .

For 3011C Engines, tighten the bolts for the engine oil pan to a torque of 6 N¡m (53 lb in).

For 3013C Engines and 3024C Engines, tighten the bolts for the engine oil pan to a torque of 11 N¡m (97 lb in).

4. Install drain plugs (5) and washers (3) to oil pan (2). Tighten the drain plugs for the engine oil pan to a torque of 35 N¡m (26 lb ft).

Note: When a drain plug is removed, install a new O-ring.

5. Fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Refer to Operation and Maintenance Manual, "Refill Capacities" for more information.

042 : Disassembly and Assembly

239

043

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Pistons and Connecting Rods - Remove Removal Procedure

Tool A

Table 1 Required Tools Part Number Part Description 8S-2269 Ridge Reamer

Qty 1

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

B. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

C. Remove the oil suction tube. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (A) to remove the wear ridge from the inner surface of the cylinder bore.

Illustration 1

g01047932

2. Rotate the crankshaft until the piston is at the bottom center. Remove connecting rod nuts (5) from the connecting rod. Remove connecting rod cap (4).

Note: Identification marks (X) are on the connecting rod and the connecting rod cap. The identification marks ensure that the pistons are installed into the correct cylinder in the cylinder block.

3.

4.

5.

6.

Note: Use tape or rubber tubing on connecting rod bolts (2) to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.

Push the piston and connecting rod (1) away from the crankshaft until the piston rings are out of the cylinder bore. Remove the piston from the cylinder block.

Remove connecting rod bearings (3) from connecting rod (1) and connecting rod cap (4) .

Keep connecting rods (1) and connecting rod caps (4) together. Ensure that the identification marks are on the connecting rod and on the connecting rod cap. This will ensure that the piston is installed into the correct cylinder in the cylinder block.

Repeat Steps 1 through 5 for removing the remaining pistons and connecting rods.

043 : Disassembly and Assembly

240

Disassembly and Assembly

044 3024C Engine for Caterpillar Built Machines, SENR5006-04

Pistons and Connecting Rods - Disassemble Disassembly Procedure

Tool A B C

Table 1 Required Tools Part Number Part Description 1P-1857 Retaining Ring Pliers 1U-6683 Ring Expander 1P-0510 Driver Group

Qty 1 1 1

Start By: A. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00835996

Illustration 2

g00836010

1. Use Tooling (A) to remove retaining rings (4) from piston (2) .

2. Remove piston pin (3) and connecting rod (1) from piston (2) .

Note: Check the condition of the following parts: retaining rings (4), piston pin (3) and piston (2). If these items are worn or damaged, use new parts for replacement.

3. Use Tooling (B) to remove the following items from piston (2) : top piston ring (5), intermediate piston ring (6) and oil control piston ring (7) .

Note: Check the condition of the piston rings. If the piston rings are worn or damaged, use new parts for replacement.

044 : Disassembly and Assembly

241

Illustration 3

g01038026

Illustration 4

g01047985

4. Use Tooling (C) and a suitable press to remove piston pin bushing (8) from connecting rod (1) .

Note: Check the condition of the following items: piston pin bushing (8) and connecting rod (1) .

044 : Disassembly and Assembly

242

Disassembly and Assembly

045 3024C Engine for Caterpillar Built Machines, SENR5006-04

Pistons and Connecting Rods - Assemble Assembly Procedure

Tool A B C

Table 1 Required Tools Part Number Part Description 1P-1857 Retaining Ring Pliers 1U-6683 Ring Expander 1P-0510 Driver Gp

Qty 1 1 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g01038026

Illustration 2

g01038122

1. If the piston pin bushing was removed, use a suitable press and Tooling (C) to install a new piston pin bushing into connecting rod (1) .

2. Lubricate all components with clean engine oil.

Note: Align Hole (X) in piston pin bushing (8) with the hole in connecting rod (1) .

3. Install piston pin bushing (8) in connecting rod (1) .

4. Use a pin boring machine in order to obtain the proper diameter of the bushing after installation. The clearance between the bushing and the piston pin is -0.001 to 0.007 mm (-0.0001 to 0.0003 inch).

045 : Disassembly and Assembly

243

Illustration 3

g00836010

Illustration 4

g01038127

Illustration 5

g01038129

Illustration 6

g01038130

5. Use the following procedure with Tooling (B) to install the piston rings on piston (2) . a. Install oil control piston ring (7) in the groove that is lowest on the piston. Latch pin (9) that is on oil control ring (7) must be inside the ends of spring (10) .

Note: Ensure that the latch pin that is on the oil control ring is 180 degrees from the oil control ring gap. b. Install intermediate piston ring (6) with the tapered face into the second groove on the piston. The scribe mark and Notch (Y) must be toward the top of the piston. c. Position the piston ring gaps at 90 degrees away from each other. d. Install top piston ring (5) with the barrel face and the molybdenum insert into the top groove on the piston. The scribe mark must be toward the top of the piston.

6. Align Identification Marks (Z) on connecting rod (1) and piston (2) .

Note: The Shibaura name inside the piston must align with the stamped number on the connecting rod.

7. Install piston pin (3) into piston (2) and connecting rod (1) .

Note: If the piston pin cannot be installed by hand, raise the temperature of the piston in order to install the piston pin.

8. Use Tooling (A) to install retaining rings (4) .

End By: Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".

045 : Disassembly and Assembly

244

046

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Pistons and Connecting Rods - Install Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 1U-6684 Piston Ring Compressor

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the inspection procedure of the connecting rod bearings and the crankshaft connecting rod journals.

1. Put clean engine oil on the following components: n Crankshaft journals n Inside of the cylinder bores n Piston rings n Connecting rod bearings 2. Rotate the crankshaft until the bearing journals are at the bottom center. The bearing journals that are at the bottom center are for the piston installation.

Illustration 1

g00829711

Illustration 2

g00829724

3. Put the piston and connecting rod in the cylinder bore. Align the identification marks on the top of the piston to the front of the cylinder block. Align identification marks (2) on the side of the connecting rod to the right side of the cylinder block. Put Tooling (A) in position on the cylinder block and compress the piston rings.

Note: Move the piston rings on the pistons until the ring openings are separated by approximately 90 degrees. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Assemble".

Note: Use tape or rubber tubing on the connecting rod bolts to protect the crankshaft journals.

4. Align the piston and the connecting rod with the crankshaft. Use a soft faced hammer (1) to tap the piston into the cylinder bore until Tooling (A) comes off the piston.

Note: Ensure that Tooling (A) is installed correctly in order to allow the piston and the connecting rod to easily slip into the cylinder block.

046 : Disassembly and Assembly

245

Illustration 3

g00829733

5. Before the connecting rod contacts the crankshaft, install the upper half of rod bearing (4) in the respective connecting rod (3). Make sure that the bearing tab properly engages with the slot in the connecting rod.

6. Place clean engine oil on the surface of the upper half of the connecting rod bearing. Guide the connecting rod into position on the crankshaft.

7. Install the lower half of connecting rod bearing (5) in the correspondingly marked connecting rod cap (6). Put clean engine oil on the surface of the lower half of the connecting rod bearing and on the connecting rod bolts.

8. Install connecting rod cap (6) and connecting rod nuts (7) .

For 3011C Engines, tighten the nuts for the connecting rod cap to a torque of 32 N¡m (24 lb ft).

For 3013C Engines and 3024C Engines, tighten the nuts for the connecting rod cap to a torque of 52 N¡m (38 lb ft).

9. Repeat Steps 1 through 8 for the remainder of the pistons and connecting rods.

10. Rotate the crankshaft in order to ensure that no binding occurs.

End By: a. Install the oil suction screen. Refer to Disassembly and Assembly, "Crankshaft - Install". b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install". c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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047

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Connecting Rod Bearings - Remove Removal Procedure Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

B. Remove the oil supply tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pump Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

The connecting rod caps and the connecting rods are matched to each cylinder. Note the markings on each connecting rod cap and on each connecting rod for later installation.

Note: The left side and the right side of the engine are determined from the flywheel end.

Illustration 1

g01047932

1. Rotate the crankshaft until the piston is at the bottom center. Remove connecting rod nuts (5) from connecting rod bolts (2). Remove connecting rod cap (4) from connecting rod (1) .

2. Remove the lower half of connecting rod bearing (3) from connecting rod cap (4) .

3. Remove the upper half of connecting rod bearing (3) from connecting rod (1). Push the connecting rod away from the crankshaft, if necessary.

Note: Use tape or rubber tubing on connecting rod bolts to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.

Note: Ensure that identification mark (X) on the connecting rod matches the identification mark on the connecting rod cap. The identification marks must be on the right side for installation purposes.

4. Repeat Steps 1 through 3 for the remaining connecting rod bearings.

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247

048

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Connecting Rod Bearings - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE When the connecting rod caps are installed, ensure that the identification marks are aligned.

Illustration 1

g01047932

1. Check the clearance between the connecting rod bearing and the connecting rod bearing journal of the crankshaft. Install the connecting rod bearings dry when the clearance checks are made. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for information on bearing clearance checks.

2. Clean the bearing surface of connecting rod (1) and connecting rod cap (4). Ensure that the number on connecting rod cap (4) matches the number on connecting rod (1) .

3. Clean upper connecting rod bearing (3) and lubricate the bearing face with clean engine oil.

4. Clean lower connecting rod bearing (3) and lubricate the bearing face with clean engine oil.

Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in connecting rod (1) .

5. Install upper connecting rod bearing (3) to connecting rod (1) .

6. Pull connecting rod (1) into position against the crankshaft.

7. Install lower connecting rod bearing (3) in connecting rod cap (4) .

8. Install connecting rod cap (4) in position on connecting rod (1) and install connecting rod nuts (5) to connecting rod bolts (2). Refer to Disassembly and Assembly, "Pistons and Connecting Rods Install" for the correct torque of connecting rod nuts (5) .

Note: Ensure that identification mark (X) on the connecting rod matches the identification mark on the connecting rod cap. The identification marks must face the right side of the engine for correct installation.

9. Repeat Steps 2 through 8 for the installation of the remaining connecting rod bearings.

End By: a. Install the oil supply tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pump Install". b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

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248

048 : Disassembly and Assembly

249

049

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Main Bearings - Remove Removal Procedure Start By: A. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Crankshaft Main Bearings

Illustration 1

g00830378

1. Remove two bolts (1) that secure the upper half of main bearing cap (2) to the lower half of main bearing cap (7) .

Note: Mark the halves of the main bearing carriers for later installation.

2. Separate the upper half of main bearing cap (2) from the lower half of main bearing cap (7) .

Note: Dowels (5) are installed in each bearing cap in order to align the two halves of the main bearing carrier.

3. Remove thrust washers (3) and thrust washer (6) .

4. Remove the main bearings (4) from the main bearing caps.

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250

Crankshaft Bearing (Front)

Tool A

Table 1 Required Tools Part Number Part Description 1P-0510 Driver Gp

Illustration 2

Qty 1

g00847649

1. Remove crankshaft bearing (1). Use tool (A) and a hammer to drive out the crankshaft bearing (1) from the inside of the cylinder block (2) .

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251

050

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft Main Bearings - Install Installation Procedure Crankshaft Main Bearings

Illustration 1

g00830378

1. Install the main bearings (4) into the halves of the main bearing caps.

2. Position the upper half of main bearing cap (2) in position on the crankshaft. Position the lower half of main bearing cap (7) in position on the crankshaft.

Note: Refer to the identification marks that have been made on the main bearing carriers for correct alignment.

Note: Ensure that dowels (5) are in the correct position. This will ensure that the two halves of the main bearing caps are aligned.

Note: Ensure that the lubricating oil holes align with the oil feed holes in the cylinder block.

3. Install thrust washers (3) and thrust washer (6) .

Note: Ensure that the thrust washers are aligned correctly and that the oil grooves are facing the crankshaft.

4. Install two bolts (1). Tighten the bolts to a torque of 52 N¡m (38 lb ft).

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252

Crankshaft Bearing (Front)

Tool C

Table 1 Required Tools Part Number Part Description 1P-0510 Driver Gp

Illustration 2

Qty 1

g00830789

1. Install crankshaft bearing (1). Use Tool (A) and a hammer to drive crankshaft bearing (1) from the outside of the cylinder block (4) .

Note: Ensure that the oil supply hole (5) is aligned with the oil gallery in the cylinder block (4).

Note: Ensure that the chamfered side (3) of bearing (1) is facing toward cylinder block (4) and that joint (2) of bearing (1) is facing toward the top of cylinder block (4) .

End By: Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".

050 : Disassembly and Assembly

253

051

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft - Remove Removal Procedure Start By: A. Remove the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief Valve Remove and Install".

B. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove and Install".

C. Remove the housing for the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".

D. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

E. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 Typical example

g00830444

1. Remove bolts (3) from the crankcase cross member.

2. Remove two allen head screws (2) that are recessed. The screws are located at the rear of the engine.

3. Place the engine in an upward position. Attach a suitable lifting device (1) to the crankshaft and main bearing assembly (5) .

4. Lift crankshaft (5) and the main bearing assembly from cylinder block (6). Do not scratch any of the finished surfaces on the crankshaft.

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254

052

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Crankshaft - Install Installation Procedure

Illustration 1 Typical example

g00830444

1. Lower crankshaft and the main bearing assembly (5) into cylinder block (6). Do not scratch any of the finished surfaces on the crankshaft.

Note: Ensure that the oil passages in the main bearings align with the oil passages in the cylinder block.

2. Align the two bolt holes at the lower part of the cylinder block with the threaded holes that are on the crankcase cross member (4) .

3. Install two allen head screws (2) that are recessed. The screws are located at the rear of the engine.

For 3011C Engines, tighten screws (2) to a torque of 27 N路m (20 lb ft).

For 3013C Engines and 3024C Engines, tighten screws (2) to a torque of 52 N路m (38 lb ft).

4. Install bolts (3) on the crankcase cross member (4).

For 3011C Engines, tighten bolts (3) to a torque of 27 N路m (20 lb ft).

For 3013C Engines and 3024C Engines, tighten bolts (3) to a torque of 52 N路m (38 lb ft).

End By: a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install". b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". c. Install the housing for the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Install". d. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install". e. Install the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief Valve Remove and Install".

052 : Disassembly and Assembly

255

053

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Bearing Clearance - Check Measurement Procedure

Tool

A

Table 1 Required Tools Part Number Part Description Qty Plastic Gauge (Green) 198-9142 0.025 to 0.076 mm 1 (0.001 to 0.003 inch) Plastic Gauge (Red) 198-9143 1 0.051 to 0.152 mm (0.002 to 0.006 inch) Plastic Gauge (Blue) 198-9144 1 0.102 to 0.229 mm (0.004 to 0.009 inch) Plastic Gauge (Yellow) 198-9145 0.230 to 0.510 mm 1 (0.009 to 0.020 inch)

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

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

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

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered: ยก Ensure that the backs of the bearings and the bores are clean and dry. ยก Ensure that the bearing locking tabs are properly seated in the tab grooves. ยก The crankshaft must be free of oil at the contact points of Tooling (A) .

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

053 : Disassembly and Assembly

256

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1 Typical Example

g01152855

4. Remove all of Tooling (A) before you install the bearing cap.

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

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257

054

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Coolant Temperature Switch - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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

2. Disconnect the harness assembly for the coolant temperature switch.

Illustration 1

g00830643

3. Remove coolant temperature switch (1) from water temperature regulator housing (2) .

4. Inspect coolant temperature switch (1) for damage. If the coolant temperature switch is damaged, use a new part for replacement. For information on testing the coolant temperature switch for correct operation, refer to Testing and Adjusting, "Coolant Temperature Switch - Test".

054 : Disassembly and Assembly

258

Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 5P-3413 Pipe Sealant

Qty 1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00830643

Note: Apply Tooling (A) to the threads of coolant temperature switch (1) .

1. Install coolant temperature switch (1) into the water temperature regulator housing. Tighten coolant temperature switch (1) to a torque of 27 N¡m (20 lb ft).

2. Connect the harness assembly for the coolant temperature switch.

3. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities" for additional information.

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259

055

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Engine Oil Pressure Switch - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Note: The engine oil pressure switch can be located in one of two positions, in the valve mechanism cover (1) or in the cylinder block (2). Refer to Specifications Manual, "Engine Oil Pressure Switch" for the correct location.

Illustration 1 Typical example

g01108876

1. Disconnect the harness assembly for the oil pressure switch.

2. If the engine oil pressure switch is located in the valve mechanism cover (1), remove the engine oil pressure switch.

055 : Disassembly and Assembly

260

If the oil pressure switch is located in the cylinder block (2), remove the engine oil pressure switch and adapter assembly. Remove the engine oil pressure switch from the adapter.

3. Clean the engine oil pressure switch.

Installation Procedure

Tool A

Table 1 Required Tools Part Number Part Description 5P-3413 Pipe Sealant

Qty 1

Note: The engine oil pressure switch can be located in one of two positions, in the valve mechanism cover (1) or in the cylinder block (2). Refer to Specifications Manual, "Engine Oil Pressure Switch" for the correct location.

Illustration 2 Typical example

g01109206

1. If a used engine oil pressure switch is installed, apply a thin layer of Tooling (A) to the threads of engine oil pressure switch.

2. If the engine oil pressure switch is located in the valve mechanism cover, Install the engine oil pressure switch (1). Tighten to a torque of 11 N·m (8.1 lb ft).

If the engine oil pressure switch is located in the cylinder block, install the adapter to the cylinder block and tighten to a torque of 11 N·m (8.1 lb ft). Install the engine oil pressure switch (2) to the adapter and tighten the engine oil pressure switch (2) to a torque of 23 N·m (16.9 lb ft).

3. Connect the harness assembly to the engine oil pressure switch.

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261

056

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Glow Plugs - Remove and Install Removal Procedure Start By: A. Remove the fuel injection lines, if necessary. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Disconnect batteries before performance of any service work.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 Typical example

g00820321

1. Remove nuts (1) and washers (2) from bus bar (3) on glow plugs (4) .

2. Remove bus bar (3) from glow plugs (4) .

3. Remove glow plugs (4) from the cylinder head.

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262

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 Typical example

g00820321

1. Install glow plugs (4) in the cylinder head.

For the C0.5, C0.7, C1.1/3011C and C1.6 engines, tighten the glow plugs to a torque of 11.5 N·m (8.5 lb ft).

For the C1.5/3013C, C2.2/3024C and C2.2/3024CT engines, tighten the glow plugs to a torque of 17.5 N·m (13 lb ft).

2. Install bus bar (3) on the glow plugs (4) .

3. Install the washers (2) and the nuts (1) on the glow plugs (4). Tighten the nuts (1) to a torque of 1.2 N·m (10.6 lb in).

End By: Install the fuel injection lines, if necessary. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

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263

057

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

V-Belts - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g00830925

1. Loosen bolts (1) and (3) on alternator (2) .

2. Push alternator (2) toward the engine and remove V-belt (4) .

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264

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2

g00830925

1. Check the condition of V-belt (4). If the V-belt is worn or damaged, use a new V-belt for replacement.

2. Put V-belt (4) in position on the engine.

3. Slide the alternator away from the engine and tighten bolts (1) and (3) for alternator (2). Refer to Testing and Adjusting, "Belt Tension Chart" for more information on the proper belt tension.

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265

058

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Alternator - Remove and Install Removal Procedure Start By: A. Remove the V-belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

1. Disconnect the battery.

Illustration 1

g00830949

2. Disconnect all harness assemblies from alternator (3) before proceeding. Mark the connections or identify the connections for later installation.

3. Remove bolt (1) and washer (2) from alternator (3) .

4. Remove bolts (5) , washers (4) , and nuts (6) that fasten alternator (3) to the engine.

5. Remove alternator (3) from the engine.

Installation Procedure

Illustration 2

g00830949

1.

2.

3.

4.

Position alternator (3) on the engine.

Install bolts (5) , washers (4) , and nuts (6) .

Install bolt (1) and washer (2) on alternator (3) .

Hand tighten bolts (5) and bolt (1) on alternator (3) .

Note: When you install the alternator, ensure that the alternator pulley is in alignment with the crankshaft pulley within 2.40 mm (0.095 inch).

5. Reconnect all harness assemblies to alternator (3) .

6. Connect the battery.

End By: Install the V-belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

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266

059

Disassembly and Assembly

3024C Engine for Caterpillar Built Machines, SENR5006-04

Electric Starting Motor - Remove and Install Removal Procedure 1. Disconnect the battery.

Illustration 1

g00831018

2. Disconnect all harness assemblies from electric starting motor (3) before proceeding. Mark all connections or identify all connections for later installation.

3. Remove bolts (1) and washers (2) that fasten electric starting motor (3) to the engine.

4. Remove electric starting motor (3) from the engine.

Installation Procedure

Illustration 2

g00831018

1. Position electric starting motor (3) on the engine.

2. Install bolts (1) and washers (2) that fasten electric starting motor (3) to the engine. Tighten the bolts to a torque of 50 ¹ 6 N¡m (37 ¹ 4 lb ft).

3. Reconnect all harness assemblies to electric starting motor (3) .

4. Connect the battery.

059 : Disassembly and Assembly