Caterpillar 3204 Vehicular Engine Manual – PDF DOWNLOAD

IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Air Cleaner

(1) Torque for wing nuts that hold the element assemblies ... 33 ± 3 lb. in.(3.7 ± 0.3 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Exhaust Manifold

(1) At assembly, put 5P3931 Anti-Seize Compound on manifold mounting bolts.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Exhaust Manifold SMCS - 1059-011; 1059-012

Remove Exhaust Manifold START BY: a. remove turbocharger

1. Remove eight bolts (2), exhaust manifold (1) and the gasket from the cylinder head assembly.

2. Inspect studs (3). Remove them if they are loose or damaged.

Install Exhaust Manifold

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1. If the exhaust manifold studs were removed, put 5P3931 Anti-Seize Compound on the threads of the studs, and tighten them to a torque of 30 ± 5 N·m (22 ± 4 lb.ft.).

2. Put gasket (1) and manifold (2) in position on the cylinder head assembly.

3. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the bolts that hold the manifold in place.

END BY: a. install turbocharger Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:57:41 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Muffler SMCS - 1059-011; 1059-012

(1) Muffler outlet.

NOTE: Do not tighten clamp bolts (2) until head is installed and muffler outlet is positioned in center of opening in hood.

(2) Tighten to a torque of ... 18 ± 5 lb. ft.(24 ± 7 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Muffler SMCS - 1059-011; 1059-012

(1) Muffler outlet.

NOTE: Do not tighten clamp bolts (2) until head is installed and muffler outlet is positioned in center of opening in hood.

(2) Tighten to a torque of ... 18 ± 5 lb. ft.(24 ± 7 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Muffler SMCS - 1062-010

Remove And Install Muffler 1. Remove the hood from the engine compartment.

2. Remove the bolts and strap (3).

3. Loosen bolts (4), and move clamp (1) away from the muffler.

4. Remove muffler (2) from the engine.

NOTE: The following steps are for installation of the muffler.

5. Put muffler (2) in position, and install clamp (1). Tighten bolts (4) to a torque of 25 ± 7 N·m (18 ± 5 lb.ft.).

6. Install strap (3) to hold the muffler in position on the support assembly.

7. Install the hood over the engine compartment.

Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 11

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Turbocharger SMCS - 1052-015; 1052-016

Disassemble Turbocharger

START BY: a. remove turbocharger

1. Put the turbocharger in position on tooling (A).

NOTE: Put alignment marks on the compressor and exhaust housings as to their location on the cartridge so they can be installed in the same position.

2. Bend the tabs on the locks away from the bolts.

3. Remove bolts (2), locks (1) and compressor housing (3).

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4. Bend the tabs on the locks away from the bolts. Remove bolts (5), the locks and cartridge assembly (4) from exhaust housing (6).

5. Put the cartridge assembly in position on tooling (B).

NOTICE Do not put a bending force on the shaft and wheel assembly when the nut is loosened.

6. Remove nut (7) from the shaft.

NOTICE

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 11

Do not let shaft assembly (9) fall when it is pushed out of the cartridge assembly.

7. Use a press to push shaft assembly (9) out of the cartridge assembly.

8. Remove wheel (8) from the cartridge.

9. Remove seal ring (11) from shaft assembly (9).

10. Remove shroud (10) from the shaft assembly.

NOTE: Put alignment marks on the cartridge and backplate assembly (14) as to the location of the backplate on the cartridge so it can be installed in its original position.

11. Bend the tabs on the locks away from the bolts.

12. Remove bolts (13) and locks (12).

13. Remove the cartridge from backplate assembly (14).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 11

14. Remove bearing (15) and collar (16) as a unit from the backplate assembly.

15. Remove bearing (15) from collar (16).

16. Remove seal ring (17) from collar (16).

17. Remove spring (18) from the backplate assembly.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 5 of 11

18. Remove seal ring (19) from the cartridge housing.

19. Remove snap ring (21), bearing (20) and snap ring (22) from the cartridge housing.

20. Turn the cartridge housing over, and remove snap ring (24), bearing (23) and snap ring (25).

NOTE: For more information on turbochargers, see Analyzing Turbocharger Failures, Form No. FEG45138, Guideline For Reusable Parts-Turbochargers, Form No. SEBF8018 and Guideline For Reusable Parts-Specifications For Reusable Turbocharger Components, Form No. SEBF8019.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 6 of 11

Assemble Turbocharger

1. Clean all parts of the turbocharger thoroughly before they are assembled.

2. Install snap ring (2), bearing (3) and snap ring (1) in the cartridge housing. Put clean engine oil on the bearing.

3. Turn the cartridge housing over, and install snap ring (5), bearing (6) and snap ring (4). Put clean engine oil on the bearing.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 7 of 11

4. Put seal ring (7) in position on the cartridge housing.

5. Put seal ring (8) in position on collar (9).

NOTICE Bearing (10) must be installed on the collar with the side that has a groove up as shown.

6. Put bearing (10) in position on collar (9).

7. Put bearing (10) and the collar in position on the cartridge housing as a unit. Make an alignment of the holes in the bearing with dowels (11).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 8 of 11

8. Put spring (12) in position in backplate (13).

9. Put shaft assembly (14) in position on tooling (A).

10. Fill the groove in the shaft with 6V2055 High Vacuum Grease.

11. Put seal ring (16) in position on the shaft assembly.

12. Install shroud (15) as shown.

13. Put the cartridge housing in position on shaft assembly (14).

14. Put the backplate in its original position. Install locks (18) and bolts (17). Tighten the bolts to a torque of 8.5 to 10.2 N·m (75 to 90 lb.in.).

15. Bend the tabs on locks (18) up against the bolts.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 9 of 11

16. Put compressor wheel (19) in position on shaft assembly (14).

17. Use the procedure which follows to install and tighten the nut which holds the compressor wheel in position.

NOTICE Do not put a bending force on the shaft and wheel assembly when the nut is loosened or tightened.

a. Put a small amount of clean engine oil on the threads and impeller face surface that makes contact with the nut. Install the nut. b. Tighten the nut to a torque of 2.25 N·m (20 lb.in.) plus 100° more. c. Remove the nut from the shaft. d. Put 6V1541 Quick Cure Primer on the threads of the shaft and nut. e. Put 9S3265 Retaining Compound on the threads of the shaft and nut. f. Install the nut on the shaft, and tighten the nut to a torque of 2.25 N·m (20 lb.in.) plus 100° more.

18. Put cartridge assembly (20) in a vise as shown. Make sure soft (brass) jaws are used.

19. Install tooling (C) on the cartridge assembly to check end play. The end play must be 0.03 to 0.10 mm (.001 to .004 in.).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 10 of 11

20. Put cartridge assembly (20) in its original position in turbine housing (21).

21. Put 5P3931 Anti-Seize Compound on bolts (23).

22. Put locks (22) in position, and install the bolts. Tighten the bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the tabs on the locks against the bolts.

23. Put compressor housing (24) in its original position on the cartridge assembly.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 11 of 11

24. Put locks (25) in position, and install bolts (26). Tighten the bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the tabs on the locks against the bolts.

25. Remove the turbocharger from tooling (B).

END BY: a. install turbocharger Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

V-Belt Tension Chart SMCS - 1052-015; 1052-016

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Camshaft SMCS - 1052-015; 1052-016

(1) Diameter of the bearing surface (journal) of camshaft ... 2.5000 ± .0005 in.(63.500 ± 0.013 mm) Clearance between bearings and bearing surfaces (journals) ... .0035 ± .0020 in.(0.089 ± 0.051 mm) Maximum permissible clearance between bearings and bearing surfaces (journals) ... .010 in.(0.25 mm) (2) End play for the camshaft ... .007 ± .003 in.(0.18 ± 0.08 mm) Maximum permissible end play ... .025 in.(0.64 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

(3) Tight fit between the gear and camshaft ... .0012 to .0028 in.(0.030 to 0.071 mm) Maximum permissible temperature of the gear for installation on the camshaft (do not use a torch) ...

600° F(315° C) NOTE: When gear is installed, timing mark must be to the outside (away from camshaft).

(4) Tighten stud to a torque of ... 11 ± 2 lb. ft.(15 ± 3 N·m)

(5) Height of camshaft lobes.

To find lobe lift, use the procedure that follows: A. Measure camshaft lobe height (5).

B. Measure base circle (7).

C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).

D. Specified camshaft lobe lift (6) is: a. Exhaust lobe ... .3071 in.(7.800 mm) b. Intake lobe ... .3077 in.(7.816 mm) Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is .010 in. (0.25 mm).

NOTE: For installation of camshaft, the timing mark on the camshaft gear tooth space must be in alignment with the timing mark on the tooth of the crankshaft gear.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 4

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Camshaft SMCS - 1210-011; 1210-012

Remove Camshaft

START BY: a. remove valve lifters b. remove timing gear cover

1. Put the engine in position on tooling (A) as shown.

NOTE: To keep the engine timing correct during removal and installation of the camshaft, put a mark on the teeth of the idler gear and camshaft drive gear at location (X). Put a mark on the teeth of the camshaft drive gear and crankshaft drive gear at location (Y).

2. Remove bolts (2) and gear (1) from the camshaft.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 4

3. Bend the tabs of lock (3) away from bolts (5). Remove bolts (5), lock (3) and washer (4) that hold the camshaft in place.

NOTICE Use extra care not to damage the camshaft bearings as the camshaft is removed.

4. Carefully remove camshaft (6) from the cylinder block.

Install Camshaft

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 4

1. Put the engine in position on tooling (A).

2. Put clean engine oil on the bearing journals and 2P2506 Thread Lubricant on the cam lobes of the camshaft.

3. Carefully install camshaft (1) in the cylinder block. Hold the camshaft up during installation so the camshaft bearings will not be damaged.

4. Install washer (3), lock (2) and the bolts that hold the camshaft in place. Bend the tabs of the lock against one of the flats of each bolt head.

5. Install two 3/8"-16 NC guide bolts (4) in the end of the camshaft.

6. Put camshaft drive gear (5) in position on the guide bolts. Make sure the marks on the idler gear and the crankshaft drive gear are in alignment with the marks on the camshaft drive gear.

7. Turn the camshaft, and make sure the "C" mark on the camshaft drive gear is in alignment with the "C" mark on the crankshaft drive gear.

NOTE: If a new gear has been installed, it will be necessary to check the engine timing to make sure the timing is correct. See Remove And Install Fuel Injection Pump Housing And Governor.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 4

8. Install two bolts in the camshaft gear, and remove the guide bolts. Install the remaining bolts in the camshaft drive gear. Tighten the bolts to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).

END BY: a. install timing gear cover b. install valve lifters Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Camshaft Bearings SMCS - 1211-011; 1211-012

Remove Camshaft Bearings

START BY: a. remove camshaft b. remove timing gears and plate c. remove flywheel housing

NOTE: The camshaft bearings may be pulled toward the inside or the outside of the cylinder block for removal.

1. Use tooling (A), and remove the rear camshaft bearing.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

2. Remove the remainder of the camshaft bearings with tool (A).

Install Camshaft Bearings

NOTICE Install the camshaft bearings with the oil hole in the bearing in alignment with the oil hole in the block and with the joint of the bearing above a horizontal center line through the bore of the bearing.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

1. Install the camshaft bearings in the cylinder block with tools (A) and (B) as follows: a. Install the center bearing to a depth of 287.5 ± 0.8 mm (11.32 ± .03 in.) [Dimension (A)] from the front surface of the block. b. Install the rear bearing to a depth of 556.8 ± 0.08 mm (21.92 ± .03 in.) [Dimension (B)] from the front surface of the block. c. Install the front bearing even (flush) with the front surface of the block and no more than 0.5 mm (.02 in.) [Dimension (C)] deep.

END BY: a. install flywheel housing b. install timing gears and plate c. install camshaft Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Crankshaft SMCS - 1211-011; 1211-012

Heat gear to install. Do not heat to a temperature of more than 600°F (315°C).

(1) End play for the crankshaft ... .0025 to .0190 in.(0.064 to 0.483 mm) Maximum permissible end play for the crankshaft ... .025 in.(0.64 mm) Thickness of thrust plates (new): Without tabs 6N8940 ... .1850 ± .0015 in.(4.699 ± 0.038 mm) With tabs 7N9342 ... .2150 ± .0015 in.(5.461 ± 0.038 mm) (2) Diameter of the surfaces (journals) for the connecting rod bearings:

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Standard, original size (new) ... 2.7497 ± .0008 in.(69.842 ± 0.020 mm) For bearings .010 in. (0.25 mm) smaller than original size ... 2.7397 ± .0008 in.(69.588 ± 0.020 mm) For bearings .020 in. (0.51 mm) smaller than original size ... 2.7297 ± .0008 in.(69.334 ± 0.020 mm) Make reference to GUIDELINES FOR REUSABLE PARTS: MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.

(3) Diameter of the surfaces (journals) for the main bearings: Standard, original size (new) ... 3.4992 ± .0008 in.(88.880 ± 0.020 mm) For bearings .010 in. (0.25 mm) smaller than original size ... 3.4892 ± .0008 in.(88.626 ± 0.020 mm) For bearings .020 in. (0.51 mm) smaller than original size ... 3.4792 ± .0008 in.(88.372 ± 0.020 mm) Clearance between main bearings and crankshaft (new) ... .0034 to .0073 in.(0.086 to 0.185 mm) Maximum permissible clearance between main bearings and crankshaft ... .008 in.(0.20 mm) Make reference to Special Instruction Form No. SEHS6713 for specifications for crankshaft reconditioning, and Guideline for Reusable Parts Form No. SEBF8030 for procedure to measure bent crankshafts.

(4) Rear wear sleeve: Remove wear sleeve with 5P7318 Distorter Group.

Install rear wear sleeve as follows: a. Clean the inner surface of the sleeve and the outer surface of the crankshaft with 8M8060 Quick Cure Primer. b. Put 9S3265 Retaining Compound on the cleaned surfaces. c. Install the sleeve on the crankshaft, with the chamfer on the outside.

NOTE: See Special Instruction Form SMHS7100 for the necessary tools and complete procedure for installation of rear wear sleeve and both front and rear seals.

Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:26 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Bearing Surface (Journal) For Connecting Rods SMCS - 1211-011; 1211-012

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:31 UTC+0400 2019

All Rights Reserved.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Bearing Surface (Journal) For Main Bearings SMCS - 1211-011; 1211-012

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:36 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Front Seal SMCS - 1160-011; 1160-012

Remove Crankshaft Front Seal

START BY: a. remove crankshaft pulley

1. Use tooling (A) to remove crankshaft front seal (1) from the timing gear cover.

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Install Crankshaft Front Seal

NOTE: If the crankshaft front pulley has been worn by the seal, use the 9S6012 Spacer [part of tooling (A)] to push the seal farther into the timing gear cover. This will locate the seal on the seal surface of the crankshaft pulley where there is no wear. Put the spacer from tooling (A) between the seal and the flange of the 9S6030 Installer. If there is no wear on the crankshaft pulley, do not use the 9S6012 Spacer.

1. Put 7F2770 Cement on the outer metal surface of the front seal. Put the seal in position on the short end of the 9S6030 Installer. The lip of the seal must be toward the inside of the engine.

2. Put the seal and the 9S6030 Installer in position on the end of the crankshaft. Install washer (1) that is used to hold the crankshaft pulley and the 6S5310 Bolt. Tighten the bolt until the installer makes contact with the crankshaft gear. Remove tooling (A) and washer (1).

END BY: a. install crankshaft pulley Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:43 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Main Bearings SMCS - 1203-010

Remove And Install Crankshaft Main Bearings

START BY: a. remove oil pan 1. Put the engine on tooling (A).

2. Remove the bolts that hold main bearing cap (1). Remove main bearing cap (1) and the lower half of the main bearing.

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3. Remove the bearing from the cap.

NOTICE If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.

NOTE: The center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the cylinder block. Remove the upper half of the main bearing.

4. Remove the upper half of the other main bearings as follows: a. Turn the crankshaft until tool (B) can be installed in the crankshaft journal. Install tool (B). b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first. c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009.)

5. Remove crankshaft thrust bearings (2) from each side of the No. 3 main bearing saddle.

NOTE: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.

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6. Clean the surfaces in the cylinder block for the main bearings. Use tool (B), and install new upper halves of main bearings (bearings with the oil hole) in the cylinder block. Do not put oil on the bearing.

7. Clean the surfaces of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps without oil.

Typical Example

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can

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give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

8. Check the main bearing clearance with Plastigage (C) as follows: a. Put a piece of Plastigage (C) on the crown of the bearing half that is in the cap or on the crankshaft journal as shown.

NOTICE Make sure the part number on the main bearing caps is toward the front of the engine and the number on the main bearing caps is the same as the number on the outside (camshaft side) of the cylinder block.

b. Put main bearing caps (1) in position on the cylinder block. Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads, and install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (1), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

9. Put clean engine oil on thrust bearings (2) from the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

10. Install main bearing caps (1), and tighten the bolts as in Steps 8b and 8c.

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11. Check the end play of the crankshaft with tool (D). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing. The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install oil pan Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:48 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Rear Seal and Wear Sleeve SMCS - 1161-011; 1161-012

Remove Crankshaft Rear Seal And Wear Sleeve

START BY: a. remove flywheel NOTE: Whenever the crankshaft seal is removed from the wear sleeve, a new Wear Sleeve and Seal Group must be installed as a set. If the seal is put back on the wear sleeve, the seal can be damaged.

1. Remove the crankshaft rear seal with tool (A).

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2. Install tool (C) in the rear seal bore.

3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.

4. Remove tool (C) and the wear sleeve by hand.

Install Crankshaft Rear Seal And Wear Sleeve

NOTICE If the crankshaft rear seal and wear sleeve come apart during installation, the seal and wear sleeve become scrap. A new seal and wear sleeve must be installed as a set.

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NOTE: The correct lubricant is on the new wear sleeve and seal group and no additional lubricant is necessary.

1. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows: a. Clean and prepare the crankshaft outside diameter with 6V1541 Quick Cure Primer. Apply 9S3265 Retaining Compound to the crankshaft outside diameter. b. Install locator (3) and the bolts on the rear of the crankshaft. c. Put wear sleeve (2) and seal (1) as a unit on locator (3) with the lip of the seal toward the front of the engine. d. Put installer (5) in position on the locator. e. Put clean engine oil on the face of nut (4), and install it on the locator. Tighten the nut until installer (5) makes contact with locator (3). Remove tooling (A).

END BY: a. install flywheel

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:53 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft And Gear SMCS - 1202; 1204-012; 1204-011

Remove Crankshaft And Gear

START BY: a. remove timing gear cover b. remove flywheel housing c. remove pistons and connecting rods

1. Turn the crankshaft until the "C" mark on the crankshaft drive gear is in alignment with the "C" mark on the camshaft drive gear as shown.

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2. Remove the three center main bearing caps (1).

3. Remove thrust bearings (2) from each side of the center crankshaft journal.

4. Remove bolt (3). Remove the oil pickup tube support strip and the clip from the cylinder block as a unit.

5. Install one of the flywheel bolts in the end of the crankshaft.

6. Fasten a nylon strap and a hoist on crankshaft (4) as shown.

7. Remove the two end caps.

NOTICE Be careful not to damage the crankshaft journals when the crankshaft is removed.

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8. Remove crankshaft (4) from the cylinder block. The weight of the crankshaft is 52 kg (115 lb.).

NOTICE If new main bearings are not to be installed during crankshaft installation, put identification marks on the original bearings as to their location in the engine.

9. Remove the crankshaft main bearings from the cylinder block and from the main bearing cap.

10. Check the condition of the main bearings and crankshaft. Make reference to Guideline For Reusable Parts: Main And Connecting Rod Bearings, Form No. SEBF8009 and Visual Inspection Of Crankshafts, Form No. SEBF8043.

11. Use tooling (A), and remove the drive gear from the crankshaft.

Install Crankshaft And Gear

1. Heat the crankshaft drive gear to a maximum temperature of 315° (600°F). Install drive gear (1) on the crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.

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If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

NOTE: For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

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NOTICE Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.

2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block for the main bearings. Install the upper main bearing halves (bearings with the oil hole) in the cylinder block.

3. Fasten a nylon strap and a hoist on crankshaft (2), and put it in position in the cylinder block with the "C" marks on the camshaft drive gear and crankshaft drive gear in alignment.

NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on all of the bearings for final assembly.

4. Check the main bearing clearances with Plastigage (A) as follows: a. Put a piece of Plastigage (A) between the crankshaft and the main bearing.

NOTICE Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.

NOTE: Do not turn the crankshaft when Plastigage (A) is in position. b. Install main bearing cap (3). Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads. Install the bolts. Tighten the bolts on the side where the main bearing tabs are located, to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.).

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c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (3), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

5. Put clean engine oil on thrust bearings (5) for the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

6. Install main bearing caps (3), and tighten the bolts as in steps 4b and 4c.

7. Put the clip and oil pickup tube support strip in position on the cylinder block as a unit, and install bolt (4) that holds them in place.

8. Check the end play of the crankshaft with tool (B). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing.

The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install pistons and connecting rods b. install flywheel housing c. install timing gear cover

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 16:59:58 UTC+0400 2019

All Rights Reserved.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Crankshaft Front Pulley SMCS - 1205-010

Remove and Install Crankshaft Front Pulley START BY: a. remove radiator and guard

1. Remove bolt (3) and washer (2) that holds pulley (1) to the crankshaft. Remove pulley (1) from the crankshaft.

2. Remove the key from the end of the crankshaft.

NOTE: The following steps are for installation of the crankshaft front pulley.

3. Install the key in the groove in the end of the crankshaft.

4. Align the groove in pulley (1) with the key, and install the pulley.

5. Install washer (2) and bolt (3). Tighten the bolt to a torque of 360 ± 47 N·m (265 ± 35 lb.ft.).

END BY: a. install radiator and guard

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:00:04 UTC+0400 2019

All Rights Reserved.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Block SMCS - 1205-010

EARLIER CYLINDER BLOCK SHOWN

NOTE: This engine does not use piston cooling jets. If a replacement engine has piston cooling jets, remove the jets and install four 7M4593 Plugs.

(1) Bore in the camshaft bearings (new) ... 2.5035 ± .0015 in.(63.589 ± 0.038 mm) (2) NOTE: See numbers 7 and 8 before installing camshaft bearings.

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Install bearings to the following positions from front face of block: A ... .03 ± .03 in.(0.8 ± 0.8 mm) B ... 1.12 ± .03 in.(28.4 ± 0.8 mm) C ... 11.32 ± .03 in.(288.6 ± 0.8 mm) D ... 21.92 ± .03 in.(557.8 ± 0.8 mm) NOTE: If only one camshaft bearing is used at the front, install the bearing flush with the front face of the cylinder block, but not deeper than 0.5 mm (.02 in.).

(3) Bore in block for camshaft bearings ... 2.6525 ± .0005 in.(67.373 ± 0.013 mm) (4) Torque for stud for oil filter ... 50 ± 10 lb. ft.(70 ± 14 N·m) (5) Distance from centerline of crankshaft to top of block (new) ... 12.7030 ± .0065 in.(322.656 ± 0.165 mm) (6) Measure wear of the cylinder bore at the top and bottom of piston ring travel.

Cylinder bore [standard, original size] ... 4.5005 + .0010 - .0005 in.(114.313 + 0.025 - 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.506 in.(114.45 mm) Cylinder bore must be made the next size larger when the size of the bore is ... 4.508 in.(114.50 mm) Cylinder bore [.020 in. (0.51 mm) larger than the original size] ... 4.5210 + .0010 - .0005 in.(114.833 + 0.025 - 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.526 in.(114.96 mm)

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Cylinder bore must be made the next size larger when the size of the bore is ... 4.528 in.(115.01 mm) Cylinder bore [.040 in. (1.02 mm) larger than the original size] ... 4.5410 + .0010 - .0005 in.(115.341 + 0.025 - 0.013 mm) Maximum permissible wear of cylinder bores ... 4.548 in.(115.52 mm) NOTE: A steel sleeve can be installed in the cylinder block.

(7) Bearing junction.

(8) Oil hole in camshaft bearing. Bearings must be positioned as shown with bearing junction above horizontal and oil hole to the left and 30° below horizontal centerline.

(9) Bore in the block for the main bearings: Standard, original size (new) ... 3.7075 ± .0005 in.(94.171 ± 0.013 mm) .010 in. (0.25 mm) larger than original size ... 3.7175 ± .0005 in.(94.424 ± 0.013 mm) (10) Distance from centerline of crankshaft to pan rails (new) ... 3.750 ± .004 in.(95.25 ± 0.10 mm) (11) Clearance between main bearing caps and cylinder block ... .0008 in.(0.020 mm) tight to ... .0012 in.(0.030 mm) loose (12) Torque for bolts holding caps for main bearings:

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Install the main bearings caps with the part numbers toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number on the cylinder block. a. Put 2P2506 Thread Lubricant on the threads of the bolts. b. Tighten the bolts first on the tab side of the cap to ... 45 ± 4 lb. ft.(61 ± 6 N·m) c. Tighten the bolts on the opposite side to ... 45 ± 4 lb. ft.(61 ± 6 N·m) d. Put a mark on each bolt and cap as shown. e. Tighten the bolts on the opposite side, from the mark ... 60° ± 5° f. Tighten the bolts on the tab side of the cap, from the mark ... 60° ± 5° Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:26 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Bearing Surface (Journal) For Main Bearings SMCS - 1205-010

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:32 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Camshaft Bearings SMCS - 1211-011; 1211-012

Remove Camshaft Bearings

START BY: a. remove camshaft b. remove timing gears and plate c. remove flywheel housing

NOTE: The camshaft bearings may be pulled toward the inside or the outside of the cylinder block for removal.

1. Use tooling (A), and remove the rear camshaft bearing.

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2. Remove the remainder of the camshaft bearings with tool (A).

Install Camshaft Bearings

NOTICE Install the camshaft bearings with the oil hole in the bearing in alignment with the oil hole in the block and with the joint of the bearing above a horizontal center line through the bore of the bearing.

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1. Install the camshaft bearings in the cylinder block with tools (A) and (B) as follows: a. Install the center bearing to a depth of 287.5 ± 0.8 mm (11.32 ± .03 in.) [Dimension (A)] from the front surface of the block. b. Install the rear bearing to a depth of 556.8 ± 0.08 mm (21.92 ± .03 in.) [Dimension (B)] from the front surface of the block. c. Install the front bearing even (flush) with the front surface of the block and no more than 0.5 mm (.02 in.) [Dimension (C)] deep.

END BY: a. install flywheel housing b. install timing gears and plate c. install camshaft Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:38 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Main Bearings SMCS - 1203-010

Remove And Install Crankshaft Main Bearings

START BY: a. remove oil pan 1. Put the engine on tooling (A).

2. Remove the bolts that hold main bearing cap (1). Remove main bearing cap (1) and the lower half of the main bearing.

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3. Remove the bearing from the cap.

NOTICE If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.

NOTE: The center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the cylinder block. Remove the upper half of the main bearing.

4. Remove the upper half of the other main bearings as follows: a. Turn the crankshaft until tool (B) can be installed in the crankshaft journal. Install tool (B). b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first. c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009.)

5. Remove crankshaft thrust bearings (2) from each side of the No. 3 main bearing saddle.

NOTE: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.

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6. Clean the surfaces in the cylinder block for the main bearings. Use tool (B), and install new upper halves of main bearings (bearings with the oil hole) in the cylinder block. Do not put oil on the bearing.

7. Clean the surfaces of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps without oil.

Typical Example

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can

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give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

8. Check the main bearing clearance with Plastigage (C) as follows: a. Put a piece of Plastigage (C) on the crown of the bearing half that is in the cap or on the crankshaft journal as shown.

NOTICE Make sure the part number on the main bearing caps is toward the front of the engine and the number on the main bearing caps is the same as the number on the outside (camshaft side) of the cylinder block.

b. Put main bearing caps (1) in position on the cylinder block. Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads, and install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (1), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

9. Put clean engine oil on thrust bearings (2) from the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

10. Install main bearing caps (1), and tighten the bolts as in Steps 8b and 8c.

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11. Check the end play of the crankshaft with tool (D). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing. The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install oil pan Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:42 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft And Gear SMCS - 1202; 1204-012; 1204-011

Remove Crankshaft And Gear

START BY: a. remove timing gear cover b. remove flywheel housing c. remove pistons and connecting rods

1. Turn the crankshaft until the "C" mark on the crankshaft drive gear is in alignment with the "C" mark on the camshaft drive gear as shown.

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2. Remove the three center main bearing caps (1).

3. Remove thrust bearings (2) from each side of the center crankshaft journal.

4. Remove bolt (3). Remove the oil pickup tube support strip and the clip from the cylinder block as a unit.

5. Install one of the flywheel bolts in the end of the crankshaft.

6. Fasten a nylon strap and a hoist on crankshaft (4) as shown.

7. Remove the two end caps.

NOTICE Be careful not to damage the crankshaft journals when the crankshaft is removed.

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8. Remove crankshaft (4) from the cylinder block. The weight of the crankshaft is 52 kg (115 lb.).

NOTICE If new main bearings are not to be installed during crankshaft installation, put identification marks on the original bearings as to their location in the engine.

9. Remove the crankshaft main bearings from the cylinder block and from the main bearing cap.

10. Check the condition of the main bearings and crankshaft. Make reference to Guideline For Reusable Parts: Main And Connecting Rod Bearings, Form No. SEBF8009 and Visual Inspection Of Crankshafts, Form No. SEBF8043.

11. Use tooling (A), and remove the drive gear from the crankshaft.

Install Crankshaft And Gear

1. Heat the crankshaft drive gear to a maximum temperature of 315° (600°F). Install drive gear (1) on the crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.

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If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

NOTE: For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

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NOTICE Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.

2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block for the main bearings. Install the upper main bearing halves (bearings with the oil hole) in the cylinder block.

3. Fasten a nylon strap and a hoist on crankshaft (2), and put it in position in the cylinder block with the "C" marks on the camshaft drive gear and crankshaft drive gear in alignment.

NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on all of the bearings for final assembly.

4. Check the main bearing clearances with Plastigage (A) as follows: a. Put a piece of Plastigage (A) between the crankshaft and the main bearing.

NOTICE Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.

NOTE: Do not turn the crankshaft when Plastigage (A) is in position. b. Install main bearing cap (3). Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads. Install the bolts. Tighten the bolts on the side where the main bearing tabs are located, to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.).

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c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (3), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

5. Put clean engine oil on thrust bearings (5) for the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

6. Install main bearing caps (3), and tighten the bolts as in steps 4b and 4c.

7. Put the clip and oil pickup tube support strip in position on the cylinder block as a unit, and install bolt (4) that holds them in place.

8. Check the end play of the crankshaft with tool (B). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing.

The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install pistons and connecting rods b. install flywheel housing c. install timing gear cover

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:48 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Piston Cooling Orifices SMCS - 1307-010

Remove And Install Piston Cooling Orifices

START BY: a. remove crankshaft and gear NOTE: The piston cooling orifices are installed in the No. 2 and 4 main bearing bosses in the cylinder block. See illustration B18488P1 on Page 90. A replacement is necessary only if they are damaged. Normally it will only be necessary to be sure the orifices are clean.

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1. Use a soft punch to remove four orifices (1) from the cylinder block.

2. Use tool (A) to install the orifices in main bearing bosses No. 2 and 4 until they are against the counterbore. Be sure the orifices are open after they are installed.

END BY: a. install crankshaft and gear Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:01:52 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Seats And Inserts (For PC Engines) SMCS - 1307-010

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Exhaust Valve

(1) Distance from the end of the valve to the valve spring washer seat ... 2.147 ± .020 in.(54.53 ± 0.51 mm) (2) Depth of bore in head for valve seat insert ... .3420 ± .0035 in.(8.686 ± 0.088 mm) (3) Diameter of valve seat insert ... 1.9120 ± .0005 in.(48.565 ± 0.013 mm) Bore in head for valve seat insert ... 1.9090 ± .0005 in.(48.489 ± 0.013 mm) (4) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm) (5) Angle of the face of the valve seat insert ... 451/2° ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 1.735 in.(44.07 mm)

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Maximum permissible ... 1.760 in.(44.70 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15° (8) Distance from head of the valve to cylinder head face ... .040 in.(1.02 mm) Maximum permissible (valve closed) ... .050 in.(1.27 mm) Minimum permissible (valve closed) ... .015 in.(0.38 mm)

Intake Valve

(1) Distance from the end of the valve to the valve spring washer seat ... 2.147 ± .020 in.(54.53 ± 0.51 mm) (2) Maximum permissible width of the face of the valve seat ... .120 in.(3.05 mm) (3) Angle of the face of the valve seat ... 301/2° ± 1/2°

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(4) Outside diameter of the valve seat ... 1.858 in.(47.19 mm) Maximum permissible ... 1.878 in.(47.70 mm) (5) Diameter of the bore ... 2.00 in.(50.8 mm) (6) Distance from head of valve to cylinder head face ... .050 in.(1.27 mm) Maximum permissible (valve closed) ... .060 in.(1.52 mm) Minimum permissible (valve closed) ... .025 in.(0.64 mm) (7) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .062 in.(1.57 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Seats And Inserts (For DI Engines) SMCS - 1307-010

Intake Valve (without valve seat insert)

(1) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)

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Minimum permissible (valve closed) ... .036 in.(0.91 mm) (2) Maximum permissible width of the face of the valve seat ... 120 in.(3.05 mm) (3) Outside diameter of the valve seat ... 2.045 ± .005 in.(52.23 ± 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm) (4) Angle of the face of the valve seat ... 301/2 ± 1/2° (5) Diameter of the bore ... 2.150 in.(54.61 mm) (6) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .170 in.(4.32 mm)

Intake Valve (with valve seat insert)

(1) Diameter of the valve seat insert ... 2.1500 ± .0005 in.(54.610 ± 0.013 mm) (2) Bore in head for valve seat insert ... 2.1470 ± .0005 in.(54.534 ± 0.013 mm) Depth of bore in head for valve seat insert ... .442 ± .002 in.(11.23 ± 0.05 mm) (3) Maximum permissible width of the face of the valve seat insert ... .120 in.(3.05 mm)

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(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm) Minimum permissible (valve closed) ... .036 in.(0.91 mm) (5) Angle of the face of the valve seat insert ... 301/2 ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 2.045 ± .005 in.(52.23 ± 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°

Exhaust Valve

(1) Depth of bore in head for valve seat insert ... .442 ± .005 in.(11.23 ± 0.13 mm) (2) Diameter of valve seat insert ... 1.9120 ± .0005 in.(48.565 ± 0.013 mm) (3) Bore in head for valve seat insert ... 1.9090 ± .0005 in.(48.489 ± 0.013 mm) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm) (4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .085 in.(2.16 mm) Minimum permissible (valve closed) ... .050 in.(1.27 mm)

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(5) Angle of the face of the valve seat insert ... 451/2 ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 1.735 ± .005 in.(44.07 ± 0.13 mm) Maximum permissible ... 1.760 in.(44.70 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15° Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Cover SMCS - 1307-010

TIGHTENING SEQUENCE FOR DI ENGINE

TIGHTENING SEQUENCE FOR PC ENGINE

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Tighten bolts in sequence shown to a torque of ... 10 ± 2 lb. ft.(14 ± 3 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Head (PC Engine) SMCS - 1307-010

HEAD BOLT TIGHTENING SEQUENCE

(1) Put 5P3931 Anti-Seize Compound on bolt threads and tighten bolts according to the HEAD BOLT CHART that follows:

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BOLT HEAD IDENTIFICATION

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SECTION A-A

(2) Seat for valve spring.

(3) Thickness of cylinder head from bottom of valve spring seat (2): New ... 3.740 ± .005 in.(94.30 ± 0.13 mm) Minimum permissible thickness ... 3.724 in.(94.59 mm) Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in.

(0.08 mm) for any 6 in. (152.4 mm) span.

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Sat Dec 14 17:02:13 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Head (DI Engine) SMCS - 1307-010

HEAD BOLT LOCATION AND TIGHTENING SEQUENCE

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(1) Put 5P3931 Anti-Seize Compound on bolt threads and tighten bolts according to the procedure that follows: 1. Tighten bolts 1 thru 18 in number sequence to ... 60 ± 10 lb. ft.(80 ± 14 N·m) 2. Tighten bolts 1 thru 18 in number sequence to ... 110 ± 5 lb. ft.(150 ± 7 N·m) 3. Again tighten bolts 1 thru 18 in number sequence to ... 110 ± 5 lb. ft.(150 ± 7 N·m) 4. Tighten bolts 19 thru 22 in number sequence to ... 32 ± 5 lb. ft.(43 ± 7 N·m)

SECTION A-A

(2) Holes for fuel injection nozzles.

(3) Thickness of cylinder head [measure through the fuel injection nozzle holes at each end of the cylinder head].

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New ... 3.785 ± .006 in.(96.14 ± 0.15 mm) Minimum permissible thickness ... 3.774 in.(95.86 mm) Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in.

(0.08 mm) for any 6 in. (152.4 mm) span.

Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:02:17 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 9

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Cylinder Head Assembly SMCS - 1100-011; 1100-012; 1100-015; 1100-016

Remove Cylinder Head Assembly

START BY: a. remove exhaust manifold b. remove rocker shaft assembly and push rods c. remove fuel injection nozzles *

1. Loosen hose clamp (2), and remove tube assembly (1) between the cylinder head assembly and the timing gear cover.

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2. Remove 22 bolts (3) that hold the cylinder head assembly to the cylinder block.

3. Fasten tool (A) and a hoist to the cylinder head assembly. Remove the cylinder head assembly from the cylinder block. Weight of the cylinder head assembly is 57 kg (125 lb.).

4. Remove the cylinder head gasket, water ferrule and seal from the cylinder block. *

The fuel injection nozzles do not have to be removed from the cylinder head assembly when the cylinder head assembly is removed from the cylinder block. If the fuel injection nozzles are not removed, do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection nozzles.

Install Cylinder Head Assembly

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NOTE: Check the cylinder head and block for top deck flatness. The flatness of the cylinder head and block should be within 0.15 mm (.006") total, and a maximum of 0.08 mm (.003") for any 152.4 mm (6.00") span.

1. Check the condition of the water ferrule and seal (4). Make a replacement if needed. Put the water ferrule and seal (4) in position with the adjusting screw of hose clamp (2) toward the top and approximately 45° to the right of vertical line as seen from the front of the engine. Make sure the seal is installed all the way into the counterbore.

2. Clean the surfaces of the cylinder head assembly and the cylinder block that make contact with each other. Make sure the surfaces are clean and dry. Install a new, dry cylinder head gasket (3) on the cylinder block.

NOTE: If the plugs in the oil passages in the cylinder head were removed, put 5P3413 Pipe Sealant with Teflon on the threads, and install the plugs in the head.

3. Fasten tool (A) and a hoist to the cylinder head assembly. Put cylinder head assembly (1) in position on the cylinder block.

4. Put 5P960 Multipurpose Type Grease on the threads of all the cylinder head bolts.

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5. Install the cylinder head bolts, and tighten them as follows: a. Tighten bolts 1 through 18 in the number sequence shown to a torque of 81.5 ± 13 N·m (60 ± 10 lb.ft.). b. Tighten bolts 1 through 18 in number sequence to a torque of 149 ± 6.5 N·m (110 ± 5 lb.ft.). c. Tighten bolts 1 through 18 again in number sequence to a torque of 149 ± 6.5 N·m (110 ± 5 lb.ft.). d. Tighten bolts 19 through 22 in number sequence to a torque of 43.5 ± 6.5 N·m (32 ± 5 lb.ft.).

6. Install tube assembly (5) between the cylinder head assembly and the timing gear cover. Tighten hose clamp (6).

END BY: a. install fuel injection nozzles b. install rocker shaft assembly and push rods c. install exhaust manifold

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 5 of 9

Disassemble Cylinder Head Assembly

START BY: a. remove cylinder head assembly

1. If necessary, remove plugs (1) with a punch and hammer.

2. Fasten a hoist to the cylinder head, and put it in position on tooling (A). Use adapter plates (2) from tooling (A) to hold the head in place.

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3. Put the valve springs under compression with tool (C).

4. Remove the locks from the valves.

5. Remove tool (C), the retainer, spring, washer and valve from the cylinder head. Put identification marks on the valve as to its location in the cylinder head.

6. Check the valve spring force with tool (B). The spring force must be 222 ± 22 N (50 ± 5 lb.) when the length of the spring is 42.04 mm (1.655 in.). For additional information, see Guidelines For Reusable Parts - Valve And Valve Springs Form Nos. SEBF8034 and SEBF8002.

7. Do Steps 2 through 5 for the remainder of the valves.

8. Remove the valve seat inserts with tooling (D).

9. Clean and remove any burrs from the valve seat bores.

NOTE: The valve guides are part of the cylinder head. Meaure the bore diameter of the guides at a location which is 19.0 mm (.75 in.) in from both ends of each valve guide. The bore must be a diameter of 9.512 ± 0.013 mm (.3745 ± .0005 in.). The maximum permissible bore diameter must not be more than 9.550 mm (.3760 in.). Valve guides worn more than the maximum specification can be

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made to the original size by knurling. Use the 4.5" Bore V8 DI Engine Reconditioning Procedures, Form No. SENR2031 as guide for knurling valve guides. For reconditioning information of the cylinder head, see Service Training Meeting Guide, Form No. SESV1202.

Assemble Cylinder Head Assembly

1. Clean and remove burrs and all foreign material from the valve seat bores.

2. Lower the temperature of the valve seat inserts, and install them with tooling (A).

3. Grind the valve inserts according to specifications given in Specifications.

4. Put clean engine oil on the valve stem. Install the valve, washer (3), spring (2) and retainer (1) in the cylinder head.

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5. Put the valve spring under compression with tool (C).

6. Install the locks on the valve stem with tool (B).

The locks can be thrown from the valve when the spring compressor is released if they are not in their correct position on the valve stem. To prevent possible personal injury, be sure to stay away from in front of the valve retainer and springs.

7. Remove tool (C), and hit the valve with a rubber hammer to be sure the locks are in their correct position.

8. Do Steps 4 through 7 for the remainder of the valves.

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9. If plugs (5) were removed from the cylinder head assembly, install them with tool (A) until they are 1.0 ± 0.5 mm (0.04 ± 0.02) from the bottom of the chamfer.

END BY: a. install cylinder head assembly Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Valve Cover SMCS - 1107-010

Remove And Install Valve Cover

1. Remove the muffler to gain better access to the valve cover.

2. Disconnect breather tube (1) from the breather boot.

3. Remove bolts (2) and valve cover (3) from the valve cover base.

NOTE: The following steps are for installation of the valve cover.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

4. If necessary, install a new gasket. Put cover (3) in position, and tighten bolts (2) in the sequence shown to a torque of 13.5 ± 2.7 N·m (120 ± 25 lb.in.).

5. Connect breather (1) to the boot, and install the muffler if removed.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Valve Cover Base SMCS - 1120-010

Remove And Install Valve Cover Base START BY: a. remove valve cover b. remove fuel injection lines

1. Disconnect fuel injection line nuts (1) from adapters (4). Remove adapters (4) from valve cover base (2). Remove the O-ring seals from the adapters.

2. Remove bolts (3), and remove valve cover base (2) and the gasket from the engine.

NOTE: The following steps are for installation of the valve cover base.

3. Inspect the condition of the valve cover base gasket, and replace it if necessary.

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4. Put valve cover base (2) in position, and install bolts (3). Tighten bolts (3) in the sequence shown to a torque of 13.5 ± 2.7 N·m (120 ± 24 lb.in.).

5. Lubricate the seals on adapters (4) with glycerine, and install the adapters in the valve cover base.

Connect the fuel injection lines, and tighten nuts (1) to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).

END BY: a. install fuel injection lines b. install valve cover Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Accessory Drive Gear SMCS - 1120-010

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

ACCESSORY DRIVE GEAR FOR DI ENGINE

(1) Torque for the bolt that holds the accessory drive gear: PC [with two washers (2) and sleeve (4)] ... 75 ± 10 lb. ft.(100 ± 14 N·m) DI (with one washer (2) and no sleeve) ... 110 ± 5 lb. ft.(149 ± 7 N·m) (2) Washer PC ... two DI ... one (3) Bore in the bearing for the idler gear (new) ... 1.0059 ± .0019 in.(25.550 ± 0.048 mm) Diameter of the shaft for the idler gear ... 1.0019 ± .0005 in.(25.448 ± 0.013 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

ACCESSORY DRIVE GEAR FOR PC ENGINE

(4) Sleeve (PC only).

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Accessory Drive Gear SMCS - 1120-010

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ACCESSORY DRIVE GEAR FOR DI ENGINE

(1) Torque for the bolt that holds the accessory drive gear: PC [with two washers (2) and sleeve (4)] ... 75 ± 10 lb. ft.(100 ± 14 N·m) DI (with one washer (2) and no sleeve) ... 110 ± 5 lb. ft.(149 ± 7 N·m) (2) Washer PC ... two DI ... one (3) Bore in the bearing for the idler gear (new) ... 1.0059 ± .0019 in.(25.550 ± 0.048 mm) Diameter of the shaft for the idler gear ... 1.0019 ± .0005 in.(25.448 ± 0.013 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

ACCESSORY DRIVE GEAR FOR PC ENGINE

(4) Sleeve (PC only).

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

V-Belt Tension Chart SMCS - 1120-010

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Water Pump SMCS - 1361-011; 1361-012; 1361-015; 1361-016

Remove Water Pump 1. Drain the coolant from the cooling system.

2. Remove the V-belts from the engine.

3. Remove bolts (1) and pulley (2) from the water pump.

4. Remove bolts (3), water pump (4) and the gasket from the timing gear cover.

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Install Water Pump

NOTE: Make sure the word "TOP" on the water pump housing is toward the top of the engine when installed.

1. Put gasket (1) and water pump (2) in position on the timing gear cover.

2. Install the bolts that hold the water pump in place.

3. Put pulley (3) in position on the water pump, and install the bolts that hold it in place.

4. Put the V-belts in position on the engine.

5. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

6. Use belt tension gauge such as a Borroughs Tool Company Part No. BT-33-72C or equivalent, and make an adjustment to the belt tension. Tighten a new belt until the gauge indication is 535 ± 22 N (120 ± 5 lb.). Tighten a used belt until the gauge indication is 400 ± 44 N (90 ± 10 lb.). Used belt tension is for a belt which has more than 30 minutes of operation at rated speed of the engine.

Disassemble Water Pump

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START BY: a. remove water pump

1. Hold the impeller shaft with a wrench, and use an impact wrench to remove nut (1) from the shaft.

Remove pump adapter (2).

2. Use tool group (A) and a press to remove shaft (3), the seal assembly and the impeller from the water pump housing.

3. Remove spacer (4) and seal (5) from the water pump housing.

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4. Remove snap ring (6) from the housing with tool (B).

5. Remove spacer (7) and bearing assembly (8) from the housing.

6. Remove the seal from the water pump housing with tool group (A).

7. Remove impeller (9) from shaft (10) with tool group (A).

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8. Remove water seal assembly (11) from the impeller shaft.

Assemble Water Pump

1. Put a small amount of 2S3230 Bearing Lubricant on the seal lip, and install the seal in the pump housing with tool group (A). Install the seal with the lip toward the bearing assembly as shown.

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2. Put 2S3230 Bearing Lubricant between the bearings. Put spacer (2) between bearing assembly (3), and then put bearing assembly (3) in position on a press.

3. Put impeller shaft (1) in position, and push it into the bearing assembly.

4. Install tool (B) on the impeller shaft, and then put the shaft and bearing assembly in position in the pump housing.

5. Install tool (C) on the bearing assembly.

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6. Install a suitable plate from tool group (A) on tool (C) as shown. Press the shaft and bearing assembly into the housing.

NOTE: Make an inspection of the seal at the impeller end of pump to see if the lip of the seal was pushed out or damaged. If so, make a replacement of the seal, and do Steps 3 through 6 again.

7. Install spacer (4) in the water pump housing.

8. Install snap ring (5) with tool (D).

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9. Remove tool (B) from the water pump housing.

10. Put a small amount of clean engine oil on the seal, and install it in the housing with tool (C) and a suitable plate from tool group (A). Install the seal with the lip toward the bearing assembly as shown.

11. Install spacer (7) in the pump housing. Install pump adapter (6) on the impeller shaft.

12. Put 9S3263 Thread Lock on the threads of the nut; then install the nut on the impeller shaft.

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13. Put the pump housing in a soft-jawed vise, and use a wrench to hold the impeller shaft while the nut is tightened to a torque of 170 ± 15 N·m (125 ± 11 lb.ft.).

14. Put water seal (8) in position on the impeller shaft. Put a small amount of clean engine oil on the seal. Install tool (E) on the seal; then push the seal into housing with a press.

NOTICE Do not use a hammer or similar tool to hit or drive the seal in place.

This will damage the seal.

NOTE: If the impeller does not have two holes drilled in it near the center, see the article "Use FT1783 Fixture To Drill Vent Holes In Impeller" in Service Magazine dated February 28, 1983, Form No. SEBD1306.

15. Install 5P7350 and 5P7352 Spacers (11) on the pump housing. Put impeller (10) in position on the shaft. Use the 5P7353 Spacer (9) and a press to push impeller (10) on the shaft until it just makes contact with the two spacers. Remove the spacers from between the pump housing and back face of the impeller. The 5P7350, 5P7352 and 5P7353 Spacers are all part of tool group (F).

NOTICE During the installation of the water pump on the front housing, make sure the clearance between the vanes (impeller) and the front housing

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is .35 to 1.14 mm (.014 to .045 in.). If this clearance is not correct, it will effect the performance of the pump.

END BY: a. install water pump Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:02:53 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel (4N184 and 7N6937) SMCS - 1361-011; 1361-012; 1361-015; 1361-016

Maximum temperature of ring gear, for installation ... 400° F(204° C) Install gear with part number to outside.

(1) Maximum permissible "eccentricity" (change in distance from center of bore) during one rotation (total indicator reading) ... .006 in.(0.15 mm) (2) Torque for the bolts that hold the flywheel to the crankshaft ... 55 ± 5 lb.ft.(75 ± 7 N·m)

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(3) Maximum permissible "eccentricity" (change in distance from center of bore) during one rotation (total indicator reading) ... .005 in.(0.13 mm) (4) Maximum permissible face "run out" (change from an exact vertical face) during one rotation (total indicator reading) ... .006 in.(0.15 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing SMCS - 1361-011; 1361-012; 1361-015; 1361-016

4N183 Housing

(1) Torque for bolts: 4N183 Housing 10 bolts ... 41 ± 4 lb.ft.(55 ± 5 N·m) 7N6344 Housing 12 bolts ... 65 ± 11 lb.ft.(90 ± 15 N·m)

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7N6344 Housing

(2) Maximum permissible face "run out" (change from an exact vertical face) at 4 points (total indicator reading) ... .012 in.(0.30 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing Bore SMCS - 1361-011; 1361-012; 1361-015; 1361-016

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs). This notation is necessary for making the calculations in the chart correctly.

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1. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push the crankshaft up against the top bearing. Write the measurement for bearing clearance on line 1 in column (C).

2. Divide the measurement from Step 1 by 2. Write this number on line 1 in columns (B) & (D).

3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).

4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the chart.

5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the chart.

6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurement in the chart.

7. Add lines I & II by columns.

8. Subtract the smaller number from the larger number in line III in columns (B) & (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.

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9. On the graph for total eccentricity find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

10. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of intersection is in the range marked "Not Acceptable" the flywheel housing must be changed.

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:03:09 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing Runout SMCS - 1361-011; 1361-012; 1361-015; 1361-016

Face Runout (axial eccentricity) of the Flywheel Housing:

8S2328 DIAL INDICATOR GROUP INSTALLED

1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before reading the indicator at each point.

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3. With dial indicator set at .000 in. (0.00 mm) at location (A), turn the crankshaft and read the indicator at locations (B), (C) and (D).

4. The difference between lower and higher measurements taken at all four points must not be more than .008 in. (0.20 mm), which is the maximum permissible face run out (axial eccentricity) of the flywheel housing.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Runout SMCS - 1361-011; 1361-012; 1361-015; 1361-016

Face Runout (axial eccentricity) of the Flywheel:

CHECKING FACE RUNOUT OF THE FLYWHEEL

1. Install the dial indicator as shown. Put a force on the flywheel toward the rear.

2. Set the dial indicator to read .000 in. (0.00 mm).

3. Turn the flywheel and read the indicator every 90°. Put a force on the flywheel to the rear before each reading.

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4. The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible face runout (axial eccentricity) of the flywheel.

Bore Runout (radial eccentricity) of the Flywheel:

CHECKING FLYWHEEL BORE

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CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE

1. Install the dial indicator (3) and make an adjustment of the universal attachment (4) so it makes contact as shown.

2. Set the dial indicator to read .000 in. (0.00 mm).

3. Turn the flywheel and read the indicator every 90°.

4. The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible bore runout (radial eccentricity) of the flywheel.

5. Runout (eccentricity) of the bore for the pilot bearing for the flywheel clutch, must not exceed .005 in. (0.13 mm).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Flywheel SMCS - 1156-011; 1156-012

Remove Flywheel

START BY: a. remove engine

1. Put tooling (A) in position on the flywheel with the end of the tool engaged in the groove of the flywheel as shown.

2. Remove two of the bolts, opposite each other, that hold the flywheel to the crankshaft. Install two 7/16"-20 NF × 7 in. (178 mm) long guide bolts (1) in the crankshaft.

3. Remove the remainder of the bolts, and remove flywheel (2) from the crankshaft. The weight of the flywheel is 27 kg (60 lb.).

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4. Remove ring gear (3) from flywheel (2) with a punch and hammer.

Install Flywheel

1. Heat ring gear (2) to a maximum temperature of 204°C (400°F). Install the ring gear on flywheel (1) with the part number toward the engine when the flywheel is installed.

2. Install two 7/16"-20 NF × 7 in. (178 mm) guide bolts opposite each other in the end of the crankshaft.

NOTICE

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When a new flywheel is installed, check the thickness of the new flywheel at the bolt holes in relation to the thickness of the old flywheel.

Install the correct length bolts so they will be fully engaged in the crankshaft flange. Bolts that are too long will make contact with the block on the back side of the crankshaft flange and pull the crankshaft back. This will cause the crankshaft thrust bearing to fail.

3. Put tooling (A) in position on the flywheel with the end of lifting bracket engaged in the groove of the flywheel as shown. Put flywheel (1) in position on the guide bolts, and make sure offset hole (4) in the flywheel (identified by dash mark) and the mark on the end of the crankshaft are in alignment.

NOTICE Make sure the correct sealant is put on the bolt threads. The holes for the bolts in the crankshaft flange are drilled through so the holes are open to the oil in the engine. Leakage along the bolt threads can be the result if the correct sealant is not used.

4. Put 9S3263 Thread Lock on the bolt threads, and install all but two of the bolts in the flywheel.

Remove tooling (A) and the guide bolts. Install the remainder of bolts (3) in the flywheel. Tighten the bolts to a torque of 75 ± 8 N·m (55 ± 6 lb.ft.).

5. Use tooling (B) to measure the face runout and bore runout of the flywheel. The face runout and bore runout must not be greater than 0.15 mm (.006 in.) total indicator reading. See Specifications for the correct procedure to measure the face runout and bore runout of the flywheel.

END BY: a. install engine Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Flywheel Housing SMCS - 1157-011; 1157-012

Remove Flywheel Housing

START BY: a. remove flywheel b. remove oil pan

1. Remove the starter from the engine.

2. Fasten tooling (A) and a hoist to the flywheel housing as shown.

NOTICE

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Be careful not to damage the crankshaft rear seal when flywheel housing (1) is removed.

3. Remove bolts (2) and the washers that hold the flywheel housing to the cylinder block.

4. Remove flywheel housing (1) and the gasket. The weight of the flywheel housing is 39 kg (85 lb.).

Install Flywheel Housing 1. Clean the old gasket from the surfaces of the cylinder block and flywheel housing that make contact with each other. Install a new gasket on the cylinder block.

2. Install two 7/16"-14 NC × 7 in. (178 mm) long guide bolts (1) in the cylinder block as shown.

3. Put clean engine oil on the crankshaft rear wear sleeve and on the lip of the seal.

NOTICE Be careful not to damage the crankshaft rear seal when flywheel housing (2) is installed.

4. Fasten tooling (A) and a hoist to flywheel housing (2) as shown. Put the flywheel housing in position on the cylinder block, and install the bolts that hold it. Tighten the bolts to a torque of 90 ± 15 N·m (65 ± 11 lb.ft.).

5. Cut the bottom of the gasket even with the flywheel housing and cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the oil pan gasket.

6. Install the starter on the engine.

END BY: a. install oil pan

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b. install flywheel Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft And Gear SMCS - 1202; 1204-012; 1204-011

Remove Crankshaft And Gear

START BY: a. remove timing gear cover b. remove flywheel housing c. remove pistons and connecting rods

1. Turn the crankshaft until the "C" mark on the crankshaft drive gear is in alignment with the "C" mark on the camshaft drive gear as shown.

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2. Remove the three center main bearing caps (1).

3. Remove thrust bearings (2) from each side of the center crankshaft journal.

4. Remove bolt (3). Remove the oil pickup tube support strip and the clip from the cylinder block as a unit.

5. Install one of the flywheel bolts in the end of the crankshaft.

6. Fasten a nylon strap and a hoist on crankshaft (4) as shown.

7. Remove the two end caps.

NOTICE Be careful not to damage the crankshaft journals when the crankshaft is removed.

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8. Remove crankshaft (4) from the cylinder block. The weight of the crankshaft is 52 kg (115 lb.).

NOTICE If new main bearings are not to be installed during crankshaft installation, put identification marks on the original bearings as to their location in the engine.

9. Remove the crankshaft main bearings from the cylinder block and from the main bearing cap.

10. Check the condition of the main bearings and crankshaft. Make reference to Guideline For Reusable Parts: Main And Connecting Rod Bearings, Form No. SEBF8009 and Visual Inspection Of Crankshafts, Form No. SEBF8043.

11. Use tooling (A), and remove the drive gear from the crankshaft.

Install Crankshaft And Gear

1. Heat the crankshaft drive gear to a maximum temperature of 315° (600°F). Install drive gear (1) on the crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.

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If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

NOTE: For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

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NOTICE Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.

2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block for the main bearings. Install the upper main bearing halves (bearings with the oil hole) in the cylinder block.

3. Fasten a nylon strap and a hoist on crankshaft (2), and put it in position in the cylinder block with the "C" marks on the camshaft drive gear and crankshaft drive gear in alignment.

NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on all of the bearings for final assembly.

4. Check the main bearing clearances with Plastigage (A) as follows: a. Put a piece of Plastigage (A) between the crankshaft and the main bearing.

NOTICE Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.

NOTE: Do not turn the crankshaft when Plastigage (A) is in position. b. Install main bearing cap (3). Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads. Install the bolts. Tighten the bolts on the side where the main bearing tabs are located, to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.).

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c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (3), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

5. Put clean engine oil on thrust bearings (5) for the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

6. Install main bearing caps (3), and tighten the bolts as in steps 4b and 4c.

7. Put the clip and oil pickup tube support strip in position on the cylinder block as a unit, and install bolt (4) that holds them in place.

8. Check the end play of the crankshaft with tool (B). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing.

The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install pistons and connecting rods b. install flywheel housing c. install timing gear cover

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:03:33 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Timing Gears SMCS - 1202; 1204-012; 1204-011

(1) Fuel pump drive gear.

(2) With the timing pin and timing bolt correctly installed, put a clockwise force of 50 lb. ft. (70 N·m) on the drive gear for the fuel pump and tighten bolt (1) to ... 130 ± 5 lb. ft.(175 ± 7 N·m) (3) Idler gear.

(4) Crankshaft gear.

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(5) Camshaft gear.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Accessory Drive Gear SMCS - 1202; 1204-012; 1204-011

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ACCESSORY DRIVE GEAR FOR DI ENGINE

(1) Torque for the bolt that holds the accessory drive gear: PC [with two washers (2) and sleeve (4)] ... 75 ± 10 lb. ft.(100 ± 14 N·m) DI (with one washer (2) and no sleeve) ... 110 ± 5 lb. ft.(149 ± 7 N·m) (2) Washer PC ... two DI ... one (3) Bore in the bearing for the idler gear (new) ... 1.0059 ± .0019 in.(25.550 ± 0.048 mm) Diameter of the shaft for the idler gear ... 1.0019 ± .0005 in.(25.448 ± 0.013 mm)

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ACCESSORY DRIVE GEAR FOR PC ENGINE

(4) Sleeve (PC only).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Timing Gears SMCS - 1202; 1204-012; 1204-011

(1) Accessory drive gear.

(2) Torque for bolt. See the Subject ACCESSORY DRIVE GEAR. (3) Idler gear.

(4) Crankshaft gear.

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(5) Camshaft gear.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Front Seal SMCS - 1160-011; 1160-012

Remove Crankshaft Front Seal

START BY: a. remove crankshaft pulley

1. Use tooling (A) to remove crankshaft front seal (1) from the timing gear cover.

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Install Crankshaft Front Seal

NOTE: If the crankshaft front pulley has been worn by the seal, use the 9S6012 Spacer [part of tooling (A)] to push the seal farther into the timing gear cover. This will locate the seal on the seal surface of the crankshaft pulley where there is no wear. Put the spacer from tooling (A) between the seal and the flange of the 9S6030 Installer. If there is no wear on the crankshaft pulley, do not use the 9S6012 Spacer.

1. Put 7F2770 Cement on the outer metal surface of the front seal. Put the seal in position on the short end of the 9S6030 Installer. The lip of the seal must be toward the inside of the engine.

2. Put the seal and the 9S6030 Installer in position on the end of the crankshaft. Install washer (1) that is used to hold the crankshaft pulley and the 6S5310 Bolt. Tighten the bolt until the installer makes contact with the crankshaft gear. Remove tooling (A) and washer (1).

END BY: a. install crankshaft pulley Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 5

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Timing Gears And Plate SMCS - 1162-011; 1162-012; 1206

Remove Timing Gears And Plate

START BY: a. remove timing gear cover

1. Loosen bolt and washer (1) that hold fuel injection pump drive gear (2) to the fuel injection pump camshaft until the washer is approximately 3.20 mm (.125 in.) from the gear. Do not remove the bolt and washer at this time.

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2. Install tooling (A) on the drive gear. Tighten the screw in tooling (A) until the drive gear is loose.

Remove tooling (A), bolt and washer (1) and drive gear (2).

3. Remove bolt (3), the lock and washer and idler gear (4).

4. Remove bearing (5) from the idler gear with tooling (B).

5. Turn the crankshaft until "C" marks (7) on crankshaft drive gear (8) and camshaft drive gear (6) are in alignment with each other.

NOTICE Do not turn the crankshaft after the camshaft drive gear has been removed. Damage to pistons or valves or both can result.

6. Remove bolts (9) and camshaft drive gear (6) from the camshaft.

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7. Remove three nuts (10) from the studs that hold the fuel injection pump housing to the timing gear plate.

8. Remove bolts (12) and timing gear plate (11) from the cylinder block.

Install Timing Gears And Plate

1. Clean the old gasket from the contact surfaces of the timing gear plate and the cylinder block.

Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan.

2. Be sure O-ring seals (1) are in position on the end of the fuel injection pump housing.

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3. Put timing gear plate (2) in position on the cylinder block. Install the four bolts that hold the plate in place. Install the three nuts that hold the fuel injection pump housing to the back of the timing gear plate.

4. Install camshaft drive gear (4) on the camshaft so the "C" marks on both camshaft drive gear (4) and crankshaft drive gear (3) are in alignment. Install the bolts that hold camshaft gear drive (4) on the camshaft. Tighten them to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).

5. Install the bearing in idler gear (5) with tooling (A). The end of the bearing must be 1.5 ± 0.5 mm (.06 ± .02 in.) below the surface of the gear hub.

6. Be sure the oil hole in shaft (6) for idler gear (7) is open. Put idler gear (7) in position on the shaft, and install the washer, lock and bolt that hold the gear on the shaft.

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7. Put fuel injection pump drive gear (8) in position on the fuel injection pump camshaft. Install the washer and bolt that hold the gear in place, but do not tighten the bolt at this time. The flat side of the washer must face away from the gear. For correct installation of the fuel injection pump drive gear and timing of the engine, see Install Fuel Injection Pump Housing And Governor.

END BY: a. install timing gear cover Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:04:00 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 7

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft And Gear SMCS - 1202; 1204-012; 1204-011

Remove Crankshaft And Gear

START BY: a. remove timing gear cover b. remove flywheel housing c. remove pistons and connecting rods

1. Turn the crankshaft until the "C" mark on the crankshaft drive gear is in alignment with the "C" mark on the camshaft drive gear as shown.

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2. Remove the three center main bearing caps (1).

3. Remove thrust bearings (2) from each side of the center crankshaft journal.

4. Remove bolt (3). Remove the oil pickup tube support strip and the clip from the cylinder block as a unit.

5. Install one of the flywheel bolts in the end of the crankshaft.

6. Fasten a nylon strap and a hoist on crankshaft (4) as shown.

7. Remove the two end caps.

NOTICE Be careful not to damage the crankshaft journals when the crankshaft is removed.

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8. Remove crankshaft (4) from the cylinder block. The weight of the crankshaft is 52 kg (115 lb.).

NOTICE If new main bearings are not to be installed during crankshaft installation, put identification marks on the original bearings as to their location in the engine.

9. Remove the crankshaft main bearings from the cylinder block and from the main bearing cap.

10. Check the condition of the main bearings and crankshaft. Make reference to Guideline For Reusable Parts: Main And Connecting Rod Bearings, Form No. SEBF8009 and Visual Inspection Of Crankshafts, Form No. SEBF8043.

11. Use tooling (A), and remove the drive gear from the crankshaft.

Install Crankshaft And Gear

1. Heat the crankshaft drive gear to a maximum temperature of 315° (600°F). Install drive gear (1) on the crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.

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If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...If the main bearing clearances are checked with the engine upright or on its side, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

NOTE: For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

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NOTICE Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.

2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block for the main bearings. Install the upper main bearing halves (bearings with the oil hole) in the cylinder block.

3. Fasten a nylon strap and a hoist on crankshaft (2), and put it in position in the cylinder block with the "C" marks on the camshaft drive gear and crankshaft drive gear in alignment.

NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on all of the bearings for final assembly.

4. Check the main bearing clearances with Plastigage (A) as follows: a. Put a piece of Plastigage (A) between the crankshaft and the main bearing.

NOTICE Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.

NOTE: Do not turn the crankshaft when Plastigage (A) is in position. b. Install main bearing cap (3). Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads. Install the bolts. Tighten the bolts on the side where the main bearing tabs are located, to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N*m (45 ± 4 lb.ft.).

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c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. d. Remove main bearing caps (3), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).

5. Put clean engine oil on thrust bearings (5) for the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.

6. Install main bearing caps (3), and tighten the bolts as in steps 4b and 4c.

7. Put the clip and oil pickup tube support strip in position on the cylinder block as a unit, and install bolt (4) that holds them in place.

8. Check the end play of the crankshaft with tool (B). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing.

The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.

END BY: a. install pistons and connecting rods b. install flywheel housing c. install timing gear cover

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 7 of 7

Copyright 1993 - 2019 Caterpillar Inc.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing SMCS - 1202; 1204-012; 1204-011

4N183 Housing

(1) Torque for bolts: 4N183 Housing 10 bolts ... 41 ± 4 lb.ft.(55 ± 5 N·m) 7N6344 Housing 12 bolts ... 65 ± 11 lb.ft.(90 ± 15 N·m)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

7N6344 Housing

(2) Maximum permissible face "run out" (change from an exact vertical face) at 4 points (total indicator reading) ... .012 in.(0.30 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing Bore SMCS - 1202; 1204-012; 1204-011

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs). This notation is necessary for making the calculations in the chart correctly.

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1. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push the crankshaft up against the top bearing. Write the measurement for bearing clearance on line 1 in column (C).

2. Divide the measurement from Step 1 by 2. Write this number on line 1 in columns (B) & (D).

3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).

4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the chart.

5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the chart.

6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurement in the chart.

7. Add lines I & II by columns.

8. Subtract the smaller number from the larger number in line III in columns (B) & (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.

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9. On the graph for total eccentricity find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

10. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of intersection is in the range marked "Not Acceptable" the flywheel housing must be changed.

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:04:15 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Flywheel Housing Runout SMCS - 1202; 1204-012; 1204-011

Face Runout (axial eccentricity) of the Flywheel Housing:

8S2328 DIAL INDICATOR GROUP INSTALLED

1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before reading the indicator at each point.

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3. With dial indicator set at .000 in. (0.00 mm) at location (A), turn the crankshaft and read the indicator at locations (B), (C) and (D).

4. The difference between lower and higher measurements taken at all four points must not be more than .008 in. (0.20 mm), which is the maximum permissible face run out (axial eccentricity) of the flywheel housing.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Flywheel Housing SMCS - 1157-011; 1157-012

Remove Flywheel Housing

START BY: a. remove flywheel b. remove oil pan

1. Remove the starter from the engine.

2. Fasten tooling (A) and a hoist to the flywheel housing as shown.

NOTICE

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Be careful not to damage the crankshaft rear seal when flywheel housing (1) is removed.

3. Remove bolts (2) and the washers that hold the flywheel housing to the cylinder block.

4. Remove flywheel housing (1) and the gasket. The weight of the flywheel housing is 39 kg (85 lb.).

Install Flywheel Housing 1. Clean the old gasket from the surfaces of the cylinder block and flywheel housing that make contact with each other. Install a new gasket on the cylinder block.

2. Install two 7/16"-14 NC × 7 in. (178 mm) long guide bolts (1) in the cylinder block as shown.

3. Put clean engine oil on the crankshaft rear wear sleeve and on the lip of the seal.

NOTICE Be careful not to damage the crankshaft rear seal when flywheel housing (2) is installed.

4. Fasten tooling (A) and a hoist to flywheel housing (2) as shown. Put the flywheel housing in position on the cylinder block, and install the bolts that hold it. Tighten the bolts to a torque of 90 ± 15 N·m (65 ± 11 lb.ft.).

5. Cut the bottom of the gasket even with the flywheel housing and cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the oil pan gasket.

6. Install the starter on the engine.

END BY: a. install oil pan

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b. install flywheel Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Rear Seal and Wear Sleeve SMCS - 1161-011; 1161-012

Remove Crankshaft Rear Seal And Wear Sleeve

START BY: a. remove flywheel NOTE: Whenever the crankshaft seal is removed from the wear sleeve, a new Wear Sleeve and Seal Group must be installed as a set. If the seal is put back on the wear sleeve, the seal can be damaged.

1. Remove the crankshaft rear seal with tool (A).

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2. Install tool (C) in the rear seal bore.

3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.

4. Remove tool (C) and the wear sleeve by hand.

Install Crankshaft Rear Seal And Wear Sleeve

NOTICE If the crankshaft rear seal and wear sleeve come apart during installation, the seal and wear sleeve become scrap. A new seal and wear sleeve must be installed as a set.

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NOTE: The correct lubricant is on the new wear sleeve and seal group and no additional lubricant is necessary.

1. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows: a. Clean and prepare the crankshaft outside diameter with 6V1541 Quick Cure Primer. Apply 9S3265 Retaining Compound to the crankshaft outside diameter. b. Install locator (3) and the bolts on the rear of the crankshaft. c. Put wear sleeve (2) and seal (1) as a unit on locator (3) with the lip of the seal toward the front of the engine. d. Put installer (5) in position on the locator. e. Put clean engine oil on the face of nut (4), and install it on the locator. Tighten the nut until installer (5) makes contact with locator (3). Remove tooling (A).

END BY: a. install flywheel

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:04:31 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Crankshaft Front Seal SMCS - 1160-011; 1160-012

Remove Crankshaft Front Seal

START BY: a. remove crankshaft pulley

1. Use tooling (A) to remove crankshaft front seal (1) from the timing gear cover.

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Install Crankshaft Front Seal

NOTE: If the crankshaft front pulley has been worn by the seal, use the 9S6012 Spacer [part of tooling (A)] to push the seal farther into the timing gear cover. This will locate the seal on the seal surface of the crankshaft pulley where there is no wear. Put the spacer from tooling (A) between the seal and the flange of the 9S6030 Installer. If there is no wear on the crankshaft pulley, do not use the 9S6012 Spacer.

1. Put 7F2770 Cement on the outer metal surface of the front seal. Put the seal in position on the short end of the 9S6030 Installer. The lip of the seal must be toward the inside of the engine.

2. Put the seal and the 9S6030 Installer in position on the end of the crankshaft. Install washer (1) that is used to hold the crankshaft pulley and the 6S5310 Bolt. Tighten the bolt until the installer makes contact with the crankshaft gear. Remove tooling (A) and washer (1).

END BY: a. install crankshaft pulley Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Timing Gears And Plate SMCS - 1162-011; 1162-012; 1206

Remove Timing Gears And Plate

START BY: a. remove timing gear cover

1. Loosen bolt and washer (1) that hold fuel injection pump drive gear (2) to the fuel injection pump camshaft until the washer is approximately 3.20 mm (.125 in.) from the gear. Do not remove the bolt and washer at this time.

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2. Install tooling (A) on the drive gear. Tighten the screw in tooling (A) until the drive gear is loose.

Remove tooling (A), bolt and washer (1) and drive gear (2).

3. Remove bolt (3), the lock and washer and idler gear (4).

4. Remove bearing (5) from the idler gear with tooling (B).

5. Turn the crankshaft until "C" marks (7) on crankshaft drive gear (8) and camshaft drive gear (6) are in alignment with each other.

NOTICE Do not turn the crankshaft after the camshaft drive gear has been removed. Damage to pistons or valves or both can result.

6. Remove bolts (9) and camshaft drive gear (6) from the camshaft.

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7. Remove three nuts (10) from the studs that hold the fuel injection pump housing to the timing gear plate.

8. Remove bolts (12) and timing gear plate (11) from the cylinder block.

Install Timing Gears And Plate

1. Clean the old gasket from the contact surfaces of the timing gear plate and the cylinder block.

Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan.

2. Be sure O-ring seals (1) are in position on the end of the fuel injection pump housing.

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3. Put timing gear plate (2) in position on the cylinder block. Install the four bolts that hold the plate in place. Install the three nuts that hold the fuel injection pump housing to the back of the timing gear plate.

4. Install camshaft drive gear (4) on the camshaft so the "C" marks on both camshaft drive gear (4) and crankshaft drive gear (3) are in alignment. Install the bolts that hold camshaft gear drive (4) on the camshaft. Tighten them to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).

5. Install the bearing in idler gear (5) with tooling (A). The end of the bearing must be 1.5 ± 0.5 mm (.06 ± .02 in.) below the surface of the gear hub.

6. Be sure the oil hole in shaft (6) for idler gear (7) is open. Put idler gear (7) in position on the shaft, and install the washer, lock and bolt that hold the gear on the shaft.

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7. Put fuel injection pump drive gear (8) in position on the fuel injection pump camshaft. Install the washer and bolt that hold the gear in place, but do not tighten the bolt at this time. The flat side of the washer must face away from the gear. For correct installation of the fuel injection pump drive gear and timing of the engine, see Install Fuel Injection Pump Housing And Governor.

END BY: a. install timing gear cover Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Timing Gear Cover SMCS - 1166-010

Remove And Install Timing Gear Cover

START BY: a. remove crankshaft front pulley b. remove alternator c. remove fan d. remove oil pan 1. Remove the alternator mounting bracket from the timing gear cover.

2. Remove two bolts (1) and bolt (2), and remove tube assembly (3) and the gasket from the oil pump.

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3. Disconnect hose (7) from the valve.

4. Disconnect water temperature sending unit (4) from the timing gear cover.

5. Loosen hose clamp (5).

6. Remove the tube assembly between the cylinder head and the timing gear cover.

7. Disconnect tube assemblies (6) and (9) from the hydraulic pump.

8. Remove two bolts (8) that hold the hydraulic pump in position on the timing gear plate.

9. Loosen hose clamp (10). Disconnect the hose from the oil cooler.

10. Loosen hose clamp (11), and disconnect hose (12) from the valve.

11. Remove clamp (13) that holds tube assemblies (6) and (9) together. Move the tube assemblies away from the timing gear cover.

12. Fasten a hoist and tooling (A) to timing gear cover (14). Remove the bolts that hold the timing gear cover in position, and remove the timing gear cover. The weight of the timing gear cover is 43 kg (95 lb.).

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13. Remove the gasket for the timing gear cover.

14. Remove the water ferrule, seal and the clamp from the top of the timing gear cover.

NOTE: The following steps are for installation of the timing gear cover.

15. Fasten a hoist and tooling (A) to timing gear cover (14) as shown.

16. Put the water ferrule, seal and hose clamp in position on the rear of the timing gear cover with the adjusting screw of the hose clamp toward the top and approximately 45° to the right of the vertical centerline as seen from the front of the engine. Make sure the seal is installed all the way into the counterbore.

17. Put the gasket and timing gear cover (14) in position, and install the bolts that hold them in place.

Cut the gasket even with the surface of the cylinder block.

18. Connect tube assemblies (6) and (9) to the hydraulic pump. Install clamp (13) to hold the tube assemblies in position.

19. Connect the hose to the oil cooler, and tighten clamp (10) to hold it in place.

20. Put hose (12) in position, and tighten clamp (11).

21. Tighten hose clamp (5).

22. Connect water temperature sending unit (4) to the timing gear cover.

23. Install two bolts (8) to hold the hydraulic pump in position.

24. Connect hose (7) to the heater valve, and tighten the clamp that holds it in place.

25. Put the gasket and tube assembly (3) in position on the oil pump, and install bolts (1) and (2).

26. Install the alternator mounting bracket on the timing gear cover.

END BY: a. install oil pan b. install fan c. install alternator d. install crankshaft front pulley Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Timing Gears SMCS - 1166-010

(1) Fuel pump drive gear.

(2) With the timing pin and timing bolt correctly installed, put a clockwise force of 50 lb. ft. (70 N·m) on the drive gear for the fuel pump and tighten bolt (1) to ... 130 ± 5 lb. ft.(175 ± 7 N·m) (3) Idler gear.

(4) Crankshaft gear.

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(5) Camshaft gear.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Accessory Drive Gear SMCS - 1166-010

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ACCESSORY DRIVE GEAR FOR DI ENGINE

(1) Torque for the bolt that holds the accessory drive gear: PC [with two washers (2) and sleeve (4)] ... 75 ± 10 lb. ft.(100 ± 14 N·m) DI (with one washer (2) and no sleeve) ... 110 ± 5 lb. ft.(149 ± 7 N·m) (2) Washer PC ... two DI ... one (3) Bore in the bearing for the idler gear (new) ... 1.0059 ± .0019 in.(25.550 ± 0.048 mm) Diameter of the shaft for the idler gear ... 1.0019 ± .0005 in.(25.448 ± 0.013 mm)

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ACCESSORY DRIVE GEAR FOR PC ENGINE

(4) Sleeve (PC only).

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Timing Gears SMCS - 1166-010

(1) Accessory drive gear.

(2) Torque for bolt. See the Subject ACCESSORY DRIVE GEAR. (3) Idler gear.

(4) Crankshaft gear.

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(5) Camshaft gear.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Camshaft SMCS - 1166-010

(1) Diameter of the bearing surface (journal) of camshaft ... 2.5000 ± .0005 in.(63.500 ± 0.013 mm) Clearance between bearings and bearing surfaces (journals) ... .0035 ± .0020 in.(0.089 ± 0.051 mm) Maximum permissible clearance between bearings and bearing surfaces (journals) ... .010 in.(0.25 mm) (2) End play for the camshaft ... .007 ± .003 in.(0.18 ± 0.08 mm) Maximum permissible end play ... .025 in.(0.64 mm)

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(3) Tight fit between the gear and camshaft ... .0012 to .0028 in.(0.030 to 0.071 mm) Maximum permissible temperature of the gear for installation on the camshaft (do not use a torch) ...

600° F(315° C) NOTE: When gear is installed, timing mark must be to the outside (away from camshaft).

(4) Tighten stud to a torque of ... 11 ± 2 lb. ft.(15 ± 3 N·m)

(5) Height of camshaft lobes.

To find lobe lift, use the procedure that follows: A. Measure camshaft lobe height (5).

B. Measure base circle (7).

C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).

D. Specified camshaft lobe lift (6) is: a. Exhaust lobe ... .3071 in.(7.800 mm) b. Intake lobe ... .3077 in.(7.816 mm) Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is .010 in. (0.25 mm).

NOTE: For installation of camshaft, the timing mark on the camshaft gear tooth space must be in alignment with the timing mark on the tooth of the crankshaft gear.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Rocker Arms And Lifters SMCS - 1166-010

(1) Valve clearance setting with engine stopped: Intake valve ... .015 in.(0.38 mm) Exhaust valve ... .025 in.(0.64 mm) (2) Torque for locknut on valve adjustment screw ... 24 ± 5 lb. ft.(30 ± 7 N·m) (3) Bore in rocker arm (new) ... .8603 ± .0008 in.(21.851 ± 0.020 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Shaft diameter (new) ... .8584 ± .0004 in.(21.803 ± 0.010 mm) Maximum permissible clearance between bearing and shaft (worn) ... .005 in.(0.13 mm) (4) Diameter of valve lifter ... 1.1589 ± .0004 in.(29.436 ± 0.010 mm) Bore in cylinder block for valve lifter ... 1.1624 ± .0006 in.(29.524 ± 0.015 mm) Maximum permissible clearance between valve lifter and cylinder block ... .008 in.(0.20 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Seats And Inserts (For PC Engines) SMCS - 1166-010

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 4

Exhaust Valve

(1) Distance from the end of the valve to the valve spring washer seat ... 2.147 ± .020 in.(54.53 ± 0.51 mm) (2) Depth of bore in head for valve seat insert ... .3420 ± .0035 in.(8.686 ± 0.088 mm) (3) Diameter of valve seat insert ... 1.9120 ± .0005 in.(48.565 ± 0.013 mm) Bore in head for valve seat insert ... 1.9090 ± .0005 in.(48.489 ± 0.013 mm) (4) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm) (5) Angle of the face of the valve seat insert ... 451/2° ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 1.735 in.(44.07 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 4

Maximum permissible ... 1.760 in.(44.70 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15° (8) Distance from head of the valve to cylinder head face ... .040 in.(1.02 mm) Maximum permissible (valve closed) ... .050 in.(1.27 mm) Minimum permissible (valve closed) ... .015 in.(0.38 mm)

Intake Valve

(1) Distance from the end of the valve to the valve spring washer seat ... 2.147 ± .020 in.(54.53 ± 0.51 mm) (2) Maximum permissible width of the face of the valve seat ... .120 in.(3.05 mm) (3) Angle of the face of the valve seat ... 301/2° ± 1/2°

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 4

(4) Outside diameter of the valve seat ... 1.858 in.(47.19 mm) Maximum permissible ... 1.878 in.(47.70 mm) (5) Diameter of the bore ... 2.00 in.(50.8 mm) (6) Distance from head of valve to cylinder head face ... .050 in.(1.27 mm) Maximum permissible (valve closed) ... .060 in.(1.52 mm) Minimum permissible (valve closed) ... .025 in.(0.64 mm) (7) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .062 in.(1.57 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Seats And Inserts (For DI Engines) SMCS - 1166-010

Intake Valve (without valve seat insert)

(1) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 4

Minimum permissible (valve closed) ... .036 in.(0.91 mm) (2) Maximum permissible width of the face of the valve seat ... 120 in.(3.05 mm) (3) Outside diameter of the valve seat ... 2.045 ± .005 in.(52.23 ± 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm) (4) Angle of the face of the valve seat ... 301/2 ± 1/2° (5) Diameter of the bore ... 2.150 in.(54.61 mm) (6) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .170 in.(4.32 mm)

Intake Valve (with valve seat insert)

(1) Diameter of the valve seat insert ... 2.1500 ± .0005 in.(54.610 ± 0.013 mm) (2) Bore in head for valve seat insert ... 2.1470 ± .0005 in.(54.534 ± 0.013 mm) Depth of bore in head for valve seat insert ... .442 ± .002 in.(11.23 ± 0.05 mm) (3) Maximum permissible width of the face of the valve seat insert ... .120 in.(3.05 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 4

(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm) Minimum permissible (valve closed) ... .036 in.(0.91 mm) (5) Angle of the face of the valve seat insert ... 301/2 ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 2.045 ± .005 in.(52.23 ± 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°

Exhaust Valve

(1) Depth of bore in head for valve seat insert ... .442 ± .005 in.(11.23 ± 0.13 mm) (2) Diameter of valve seat insert ... 1.9120 ± .0005 in.(48.565 ± 0.013 mm) (3) Bore in head for valve seat insert ... 1.9090 ± .0005 in.(48.489 ± 0.013 mm) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm) (4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .085 in.(2.16 mm) Minimum permissible (valve closed) ... .050 in.(1.27 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 4

(5) Angle of the face of the valve seat insert ... 451/2 ± 1/2° (6) Outside diameter of the face of the valve seat insert ... 1.735 ± .005 in.(44.07 ± 0.13 mm) Maximum permissible ... 1.760 in.(44.70 mm) (7) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15° Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Cover SMCS - 1166-010

TIGHTENING SEQUENCE FOR DI ENGINE

TIGHTENING SEQUENCE FOR PC ENGINE

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Tighten bolts in sequence shown to a torque of ... 10 ± 2 lb. ft.(14 ± 3 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Head (PC Engine) SMCS - 1166-010

HEAD BOLT TIGHTENING SEQUENCE

(1) Put 5P3931 Anti-Seize Compound on bolt threads and tighten bolts according to the HEAD BOLT CHART that follows:

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

BOLT HEAD IDENTIFICATION

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

SECTION A-A

(2) Seat for valve spring.

(3) Thickness of cylinder head from bottom of valve spring seat (2): New ... 3.740 ± .005 in.(94.30 ± 0.13 mm) Minimum permissible thickness ... 3.724 in.(94.59 mm) Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in.

(0.08 mm) for any 6 in. (152.4 mm) span.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Head (DI Engine) SMCS - 1166-010

HEAD BOLT LOCATION AND TIGHTENING SEQUENCE

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

(1) Put 5P3931 Anti-Seize Compound on bolt threads and tighten bolts according to the procedure that follows: 1. Tighten bolts 1 thru 18 in number sequence to ... 60 ± 10 lb. ft.(80 ± 14 N·m) 2. Tighten bolts 1 thru 18 in number sequence to ... 110 ± 5 lb. ft.(150 ± 7 N·m) 3. Again tighten bolts 1 thru 18 in number sequence to ... 110 ± 5 lb. ft.(150 ± 7 N·m) 4. Tighten bolts 19 thru 22 in number sequence to ... 32 ± 5 lb. ft.(43 ± 7 N·m)

SECTION A-A

(2) Holes for fuel injection nozzles.

(3) Thickness of cylinder head [measure through the fuel injection nozzle holes at each end of the cylinder head].

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

New ... 3.785 ± .006 in.(96.14 ± 0.15 mm) Minimum permissible thickness ... 3.774 in.(95.86 mm) Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in.

(0.08 mm) for any 6 in. (152.4 mm) span.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cylinder Block SMCS - 1166-010

EARLIER CYLINDER BLOCK SHOWN

NOTE: This engine does not use piston cooling jets. If a replacement engine has piston cooling jets, remove the jets and install four 7M4593 Plugs.

(1) Bore in the camshaft bearings (new) ... 2.5035 ± .0015 in.(63.589 ± 0.038 mm) (2) NOTE: See numbers 7 and 8 before installing camshaft bearings.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 4

Install bearings to the following positions from front face of block: A ... .03 ± .03 in.(0.8 ± 0.8 mm) B ... 1.12 ± .03 in.(28.4 ± 0.8 mm) C ... 11.32 ± .03 in.(288.6 ± 0.8 mm) D ... 21.92 ± .03 in.(557.8 ± 0.8 mm) NOTE: If only one camshaft bearing is used at the front, install the bearing flush with the front face of the cylinder block, but not deeper than 0.5 mm (.02 in.).

(3) Bore in block for camshaft bearings ... 2.6525 ± .0005 in.(67.373 ± 0.013 mm) (4) Torque for stud for oil filter ... 50 ± 10 lb. ft.(70 ± 14 N·m) (5) Distance from centerline of crankshaft to top of block (new) ... 12.7030 ± .0065 in.(322.656 ± 0.165 mm) (6) Measure wear of the cylinder bore at the top and bottom of piston ring travel.

Cylinder bore [standard, original size] ... 4.5005 + .0010 - .0005 in.(114.313 + 0.025 - 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.506 in.(114.45 mm) Cylinder bore must be made the next size larger when the size of the bore is ... 4.508 in.(114.50 mm) Cylinder bore [.020 in. (0.51 mm) larger than the original size] ... 4.5210 + .0010 - .0005 in.(114.833 + 0.025 - 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.526 in.(114.96 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 4

Cylinder bore must be made the next size larger when the size of the bore is ... 4.528 in.(115.01 mm) Cylinder bore [.040 in. (1.02 mm) larger than the original size] ... 4.5410 + .0010 - .0005 in.(115.341 + 0.025 - 0.013 mm) Maximum permissible wear of cylinder bores ... 4.548 in.(115.52 mm) NOTE: A steel sleeve can be installed in the cylinder block.

(7) Bearing junction.

(8) Oil hole in camshaft bearing. Bearings must be positioned as shown with bearing junction above horizontal and oil hole to the left and 30° below horizontal centerline.

(9) Bore in the block for the main bearings: Standard, original size (new) ... 3.7075 ± .0005 in.(94.171 ± 0.013 mm) .010 in. (0.25 mm) larger than original size ... 3.7175 ± .0005 in.(94.424 ± 0.013 mm) (10) Distance from centerline of crankshaft to pan rails (new) ... 3.750 ± .004 in.(95.25 ± 0.10 mm) (11) Clearance between main bearing caps and cylinder block ... .0008 in.(0.020 mm) tight to ... .0012 in.(0.030 mm) loose (12) Torque for bolts holding caps for main bearings:

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 4

Install the main bearings caps with the part numbers toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number on the cylinder block. a. Put 2P2506 Thread Lubricant on the threads of the bolts. b. Tighten the bolts first on the tab side of the cap to ... 45 ± 4 lb. ft.(61 ± 6 N·m) c. Tighten the bolts on the opposite side to ... 45 ± 4 lb. ft.(61 ± 6 N·m) d. Put a mark on each bolt and cap as shown. e. Tighten the bolts on the opposite side, from the mark ... 60° ± 5° f. Tighten the bolts on the tab side of the cap, from the mark ... 60° ± 5° Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Connecting Rod SMCS - 1166-010

DI CONNECTING ROD WITH TAPERED PIN END

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

PC CONNECTING ROD WITH STRAIGHT PIN END

(1) Bore in connecting rod for piston pin bearing ... 1.6255 ± .0005 in.(41.288 ± 0.013 mm) Tight fit between connecting rod eye and piston pin bearing ... .0025 to .0045 in.(0.064 to 0.114 mm) NOTE: Connecting rod must be heated for installation of piston pin bearing. Do not use a torch.

Heat connecting rod to temperature of (maximum) ... 400° F(215° C)

NOTE: Piston pin bearing junction and locating notch must be assembled in the top half of rod eye.

Bearing junction can be located at either position "A" above centerline.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

Make reference to Special Instruction Form SMHS7295 for use of pin bearing removal and installation tools and procedure.

(2) Bore in connecting rod for bearing with nuts tightened to specifications (6) ... 2.9418 ± .0005 in.

(74.721 ± 0.013 mm) (3) Distance between center of bearings ... 7.900 ± .001 in.(200.66 ± 0.03 mm) (4) Bore in bearing for piston pin (new) ... 1.5010 ± .0003 in.(38.125 ± 0.007 mm) Diameter of piston pin (new) ... 1.4999 ± .0002 in.(38.097 ± 0.005 mm) Maximum permissible clearance between bearing and piston pin (worn) ... .003 in.(0.08 mm) (5) Bore in bearing for crankshaft bearing surface (journal) ... 2.753 ± .001 in.(69.97 ± 0.03 mm) Clearance between bearing and crankshaft bearing surface (journal) ... .0017 to .0055 in.(0.043 to 0.140 mm) Maximum permissible clearance between bearing and crankshaft bearing surface (journal) ... .007 in.

(0.18 mm) (6) Tightening procedure for connecting rod bolts: a. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of nut and cap. b. Tighten both nuts to ... 30 ± 3 lb. ft.(40 ± 4 N·m) c. Put a mark on each nut and end of bolt. d. Tighten each nut from mark ... 60° ± 5° Make reference to Special Instruction Form Nos. GMG02394 & GMG02395 for information about checking and reconditioning connecting rods.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Crankshaft SMCS - 1166-010

Heat gear to install. Do not heat to a temperature of more than 600°F (315°C).

(1) End play for the crankshaft ... .0025 to .0190 in.(0.064 to 0.483 mm) Maximum permissible end play for the crankshaft ... .025 in.(0.64 mm) Thickness of thrust plates (new): Without tabs 6N8940 ... .1850 ± .0015 in.(4.699 ± 0.038 mm) With tabs 7N9342 ... .2150 ± .0015 in.(5.461 ± 0.038 mm) (2) Diameter of the surfaces (journals) for the connecting rod bearings:

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Standard, original size (new) ... 2.7497 ± .0008 in.(69.842 ± 0.020 mm) For bearings .010 in. (0.25 mm) smaller than original size ... 2.7397 ± .0008 in.(69.588 ± 0.020 mm) For bearings .020 in. (0.51 mm) smaller than original size ... 2.7297 ± .0008 in.(69.334 ± 0.020 mm) Make reference to GUIDELINES FOR REUSABLE PARTS: MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.

(3) Diameter of the surfaces (journals) for the main bearings: Standard, original size (new) ... 3.4992 ± .0008 in.(88.880 ± 0.020 mm) For bearings .010 in. (0.25 mm) smaller than original size ... 3.4892 ± .0008 in.(88.626 ± 0.020 mm) For bearings .020 in. (0.51 mm) smaller than original size ... 3.4792 ± .0008 in.(88.372 ± 0.020 mm) Clearance between main bearings and crankshaft (new) ... .0034 to .0073 in.(0.086 to 0.185 mm) Maximum permissible clearance between main bearings and crankshaft ... .008 in.(0.20 mm) Make reference to Special Instruction Form No. SEHS6713 for specifications for crankshaft reconditioning, and Guideline for Reusable Parts Form No. SEBF8030 for procedure to measure bent crankshafts.

(4) Rear wear sleeve: Remove wear sleeve with 5P7318 Distorter Group.

Install rear wear sleeve as follows: a. Clean the inner surface of the sleeve and the outer surface of the crankshaft with 8M8060 Quick Cure Primer. b. Put 9S3265 Retaining Compound on the cleaned surfaces. c. Install the sleeve on the crankshaft, with the chamfer on the outside.

NOTE: See Special Instruction Form SMHS7100 for the necessary tools and complete procedure for installation of rear wear sleeve and both front and rear seals.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Bearing Surface (Journal) For Connecting Rods SMCS - 1166-010

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:05:57 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Engine Supports SMCS - 1166-010

(1) Torque for three bolts in each support ... 90 ± 10 lb.ft.(120 ± 14 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

V-Belt Tension Chart SMCS - 1166-010

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Sat Dec 14 17:06:08 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Crankshaft Front Pulley SMCS - 1205-010

Remove and Install Crankshaft Front Pulley START BY: a. remove radiator and guard

1. Remove bolt (3) and washer (2) that holds pulley (1) to the crankshaft. Remove pulley (1) from the crankshaft.

2. Remove the key from the end of the crankshaft.

NOTE: The following steps are for installation of the crankshaft front pulley.

3. Install the key in the groove in the end of the crankshaft.

4. Align the groove in pulley (1) with the key, and install the pulley.

5. Install washer (2) and bolt (3). Tighten the bolt to a torque of 360 ± 47 N·m (265 ± 35 lb.ft.).

END BY: a. install radiator and guard

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:06:13 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Engine Supports SMCS - 1205-010

(1) Torque for three bolts in each support ... 90 ± 10 lb.ft.(120 ± 14 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Oil Pan SMCS - 1205-010

(1) Torque for plug ... 50 ± 10 lb. ft.(70 ± 14 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Oil Pan SMCS - 1302-010

Remove And Install Oil Pan 1. Remove the rear bottom guard. The weight of the rear bottom guard is 28 kg (62 lb.).

2. Remove plug (3), and drain the oil from the oil pan.

3. Remove the oil level gauge from the engine.

4. Remove bolts (1). Remove oil pan (2) and the gasket from the engine.

NOTE: The following steps are for installation of the oil pan.

5. Put the gasket and oil pan (2) in position, and install bolts (1).

6. Install plug (3) in the bottom of the oil pan. Tighten the plug to a torque of 68 ± 14 N·m (50 ± 10 lb.ft.).

7. Install the oil level gauge.

8. Fill the engine with oil to the correct level.

9. Install the rear bottom guard.

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:06:29 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Connecting Rod SMCS - 1302-010

DI CONNECTING ROD WITH TAPERED PIN END

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PC CONNECTING ROD WITH STRAIGHT PIN END

(1) Bore in connecting rod for piston pin bearing ... 1.6255 ± .0005 in.(41.288 ± 0.013 mm) Tight fit between connecting rod eye and piston pin bearing ... .0025 to .0045 in.(0.064 to 0.114 mm) NOTE: Connecting rod must be heated for installation of piston pin bearing. Do not use a torch.

Heat connecting rod to temperature of (maximum) ... 400° F(215° C)

NOTE: Piston pin bearing junction and locating notch must be assembled in the top half of rod eye.

Bearing junction can be located at either position "A" above centerline.

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Make reference to Special Instruction Form SMHS7295 for use of pin bearing removal and installation tools and procedure.

(2) Bore in connecting rod for bearing with nuts tightened to specifications (6) ... 2.9418 ± .0005 in.

(74.721 ± 0.013 mm) (3) Distance between center of bearings ... 7.900 ± .001 in.(200.66 ± 0.03 mm) (4) Bore in bearing for piston pin (new) ... 1.5010 ± .0003 in.(38.125 ± 0.007 mm) Diameter of piston pin (new) ... 1.4999 ± .0002 in.(38.097 ± 0.005 mm) Maximum permissible clearance between bearing and piston pin (worn) ... .003 in.(0.08 mm) (5) Bore in bearing for crankshaft bearing surface (journal) ... 2.753 ± .001 in.(69.97 ± 0.03 mm) Clearance between bearing and crankshaft bearing surface (journal) ... .0017 to .0055 in.(0.043 to 0.140 mm) Maximum permissible clearance between bearing and crankshaft bearing surface (journal) ... .007 in.

(0.18 mm) (6) Tightening procedure for connecting rod bolts: a. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of nut and cap. b. Tighten both nuts to ... 30 ± 3 lb. ft.(40 ± 4 N·m) c. Put a mark on each nut and end of bolt. d. Tighten each nut from mark ... 60° ± 5° Make reference to Special Instruction Form Nos. GMG02394 & GMG02395 for information about checking and reconditioning connecting rods.

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Sat Dec 14 17:06:34 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Pistons And Rings SMCS - 1302-010

(1) Clearance between top ring and groove ... .0030 to .0055 in.(0.076 to 0.140 mm) Replacement needed at ... .011 in.(0.28 mm) Maximum permissible clearance ... .014 in.(0.36 mm) (2) Clearance between oil ring and groove ... .0015 to .0035 in.(0.038 to 0.089 mm) Replacement needed at ... .006 in(0.15 mm) Maximum permissible clearance ... .008 in.(0.20 mm)

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(3) Bore in piston for pin ... 1.5005 to 1.5009 in.(38.113 to 38.123 mm) Maximum permissible clearance between piston pin and bore in piston ... .003 in.(0.08 mm) (4) Top ring: Clearance between ends of piston ring ... .0225 ± .0075 in.(0.572 ± 0.191 mm) Ring needs replacement when clearance is ... .045 in.(1.14 mm) Maximum permissible clearance (replacement of ring necessary) ... .055 in.(1.40 mm) NOTE: Clearance is measured between ends of piston ring while piston ring is installed in the part of the cylinder bore that has no wear.

(5) Oil ring: Clearance between ends of piston ring ... .020 ± .010 in.(0.51 ± 0.25 mm) Ring needs replacement when clearance is ... .038 in.(0.97 mm) Maximum permissible clearance (replacement of ring necessary) ... .045 in.(1.14 mm)

TOP VIEW OF PISTON (DI ENGINE)

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TOP VIEW OF PISTON (PC ENGINE)

(6) Installation of piston to connecting rod: DI Engine: Bearing tab slots (6) of connecting rod must be on same side as piston crater (7).

PC Engine: Bearing tab slots (6) of connecting rod must be on same side as piston valve pockets (8).

(7) Installation of piston and connecting rod group in engine: DI Engine: Craters (7) of pistons must be installed toward camshaft side of engine.

PC Engine: Valve pockets (8) of pistons must be installed toward camshaft side of engine.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Bearing Surface (Journal) For Connecting Rods SMCS - 1302-010

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:06:43 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Connecting Rod Bearings SMCS - 1219-010

Remove And Install Connecting Rod Bearings

START BY: a. remove oil pan

1. Turn the crankshaft until two pistons are at the bottom center. Remove connecting rod caps (2) from the two connecting rods. Remove the lower half of the rod bearing from the rod bearing cap.

NOTICE The connecting rod bolts are loose on the connecting rods and can fall out when the nuts are removed.

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2. Push connecting rods (1) away from the crankshaft. Remove the upper half of the rod bearing from the connecting rod.

NOTE: Install the connecting rod bearings dry when the clearance checks are made. Put clean engine oil on the connecting rod bearings for final assembly.

NOTICE Be sure the tabs in the back of the connecting rod bearings are in the tab grooves of the connecting rod and cap.

3. Install the upper half of the rod bearing in the connecting rod, and put the connecting rod in position on the crankshaft.

4. Install the lower half of the rod bearing in the connecting rod cap.

The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: ...Make sure that the backs of the bearings and the bores are clean and dry. ...Make sure that the bearing locking tabs are properly seated in their slots. ...The crankshaft must be free of oil where the Plastigage touches it. ...Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ...Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. ...Do not turn the crankshaft with the Plastigage installed. ...Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements. ...Remove the Plastigage before installing the cap.

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When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.

For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.

5. Use Plastigage (A) to check the connecting rod bearing clearance.

6. Put Plastigage (A) on the connecting rod bearing.

7. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.

NOTICE When connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.

8. Install connecting rod cap (2). Install the nuts. Tighten the nuts to a torque of 41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60° ± 5° more.

9. Remove the connecting rod caps. Measure the thickness of the Plastigage. The connecting rod bearing clearance must be 0.043 ± 0.140 mm (.0017 to .0055 in.) for new bearings. The maximum clearance with used bearings is 0.15 mm (.006 in.).

10. Install the connecting rod caps, and tighten the nuts as in Step 8.

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11. Do Steps 1 through 9 for the remainder of the connecting rod bearings.

END BY: a. install oil pan Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Pistons And Connecting Rods SMCS - 1225-011; 1225-012; 1225-015; 1225-016

Remove Pistons And Connecting Rods

START BY: a. remove cylinder head assembly b. remove oil pan

1. Put the engine in position on tooling (A) as shown.

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2. Remove the carbon ridge from the top inside surface of the cylinders with tool (B).

3. Turn the crankshaft until the two center pistons are in the down position.

4. Remove nuts (1) and rod cap (2). Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft.

NOTICE Do not let the connecting rods hit the crankshaft or the bottom edge of the cylinder bore when the pistons are removed.

5. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder block. Remove piston (3) and connecting rod (4) as a unit.

6. Keep each connecting rod cap with its respective connecting rod and piston. Put identification marks on each piston as to its location in the cylinder block.

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NOTICE Do not turn the crankshaft while any of the connecting rods are in the engine without the connecting rod caps installed.

7. Repeat Steps 3 through 6 for the remainder of the pistons.

Install Pistons And Connecting Rods

1. Put the engine in position on tooling (A).

2. Put clean engine oil on the piston rings, connecting rod bearings, cylinder walls and crankshaft journals.

3. Make sure the piston ring gaps are at least 120° apart on the piston.

4. Use tool (B), and install the piston and connecting rod in the same cylinder bore of the engine from which it was removed. The hole (crater) in the top of the piston must be toward the camshaft side of the engine.

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NOTE: For more detail concerning the installation of connecting rod bearings, see Remove And Install Connecting Rod Bearings.

5. Check the bearing clearances with tool (C). For complete details concerning measuring bearing clearances, see Engine Bearing And Crankshafts, Form No. SEBD0531.

6. Put clean engine oil on the threads of the bolts and contact surfaces of the nuts for the connecting rod caps.

NOTICE

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When the connecting rod caps are installed, make sure that the number on the side of cap (1) is next to and respective with the number on the side of connecting rod (2).

7. Put cap (1) in position on the connecting rod, and install the nuts. Tighten the nuts to a torque of 41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 ± 5° more.

8. Repeat Steps 1 through 7 for the remainder of the pistons.

END BY: a. install cylinder head assembly b. install oil pan

Disassemble Pistons And Connecting Rods

START BY: a. remove pistons and connecting rods

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1. Remove the rings from the piston with tool (A).

2. Remove the bearings from the connecting rod and connecting rod cap.

3. Remove snap rings (3), pin (1) and connecting rod (2) from the piston.

4. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295 for more information concerning removal and installation of piston pin bearings.

5. Heat the connecting rod to a temperature of 176° to 260°C (350° to 500°F). Put 5P8654 Spacer (11) in the base plate. Put the connecting rod on the base plate of tooling (B).

6. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B).

Install pin (6) in the center of the bore for the connecting rod bearings.

7. Install 5P8653 Adapter (9). Put the hole in the adapter in alignment with the hole in the base plate of tooling (B).

8. Install clamp bar (10) and clamp pin (7).

9. Install new piston bearing (5) on adapter (9).

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NOTE: The old bearing is pushed out by tooling (B) as the new bearing is installed.

10. Put 5P8645 Adapter (8) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (9) and the base plate of tooling (B).

11. Put pusher (4) on adapter (8).

12. Use tooling (B) to push the new piston pin bearing into the connecting rod until adapter (8) of tooling (B) makes full contact with the connecting rod surface.

13. Remove the connecting rod and the old piston pin bearing from tooling (B).

14. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension is 38.125 ± 0.008 mm (1.5010 ± .0003 in.).

Assemble Pistons And Connecting Rods

1. Install connecting rod (1) in the piston with the bearing tab groove (slot) on the same side as the hole (crater) in the top of the piston.

2. Install piston pin (2) and snap ring (3).

3. When old pistons are to be used again, clean and measure the pistons according to Guideline For Reusable Parts Pistons And Liners, Form No. SEBF8001.

4. Install the spring for the oil ring. Install the oil ring with tool (A). The gap in the ring must be approximately 180° from the oil ring spring connections.

5. Install the compression ring with tool (A). The side of the ring that has the identification "TOP" must be toward the top of the piston. The gaps in the rings must be approximately 120° apart.

NOTE: Compression rings that do not have identification must be installed with the edge that has the bevel toward the top of the pistons.

6. Install connecting rod bearings.

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END BY: a. install pistons and connecting rods Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Crankshaft Front Pulley SMCS - 1205-010

Remove and Install Crankshaft Front Pulley START BY: a. remove radiator and guard

1. Remove bolt (3) and washer (2) that holds pulley (1) to the crankshaft. Remove pulley (1) from the crankshaft.

2. Remove the key from the end of the crankshaft.

NOTE: The following steps are for installation of the crankshaft front pulley.

3. Install the key in the groove in the end of the crankshaft.

4. Align the groove in pulley (1) with the key, and install the pulley.

5. Install washer (2) and bolt (3). Tighten the bolt to a torque of 360 ± 47 N·m (265 ± 35 lb.ft.).

END BY: a. install radiator and guard

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:06:58 UTC+0400 2019

All Rights Reserved.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Rocker Arms And Lifters SMCS - 1205-010

(1) Valve clearance setting with engine stopped: Intake valve ... .015 in.(0.38 mm) Exhaust valve ... .025 in.(0.64 mm) (2) Torque for locknut on valve adjustment screw ... 24 ± 5 lb. ft.(30 ± 7 N·m) (3) Bore in rocker arm (new) ... .8603 ± .0008 in.(21.851 ± 0.020 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Shaft diameter (new) ... .8584 ± .0004 in.(21.803 ± 0.010 mm) Maximum permissible clearance between bearing and shaft (worn) ... .005 in.(0.13 mm) (4) Diameter of valve lifter ... 1.1589 ± .0004 in.(29.436 ± 0.010 mm) Bore in cylinder block for valve lifter ... 1.1624 ± .0006 in.(29.524 ± 0.015 mm) Maximum permissible clearance between valve lifter and cylinder block ... .008 in.(0.20 mm) Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:03 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valves And Valve Springs SMCS - 1205-010

NOTE: GUIDELINE FOR REUSABLE PARTS; VALVES AND VALVE SPRINGS, Form SEBF8002 and SEBF8034 have the procedure and specifications necessary for checking used valves and valve springs.

(1) Springs for valves (new):

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9L9190, 9N3617, 9N3387 Length under test force ... 1.655 in.(42.04 mm) Test force ... 50 ± 5 lb.(220 ± 22 N) Use again minimum load at length under test force ... 35 lb.(155 N) Length of spring at valve open position ... 1.167 in.(29.64 mm) Use again minimum load at valve open position ... 154.5 lb.(687 N) Free length after test ... 1.854 in.(47.09 mm) Outside diameter ... 1.440 in.(36.58 mm) Spring must not be bent more than ... .065 in.(1.65 mm)

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Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:08 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Valve Cover SMCS - 1205-010

TIGHTENING SEQUENCE FOR DI ENGINE

TIGHTENING SEQUENCE FOR PC ENGINE

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Tighten bolts in sequence shown to a torque of ... 10 ± 2 lb. ft.(14 ± 3 N·m) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Rocker Shaft Assembly And Push Rods SMCS - 1102; 1208-011; 1208-012

Remove Rocker Shaft Assembly And Push Rods START BY: a. remove valve cover base

1. Remove four bolts (2) and rocker shaft assembly (1) from the cylinder head.

2. Remove push rods (3) from the engine. Put identification marks on the push rods as to their location in the engine.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Install Rocker Shaft And Push Rods

1. Install push rods (2) in their original location in the engine.

2. Loosen adjustment screws (3) used to set the valve clearance. Put rocker shaft assembly (1) in position on the cylinder head assembly, and install the four bolts that hold it in place.

3. Make an adjustment to the valves until the intake valve clearance is 0.38 ± 0.08 mm (.015 ± 0.003 in.), and the exhaust valve clearance is 0.64 ± 0.08 mm (.025 ± 0.003 in.). Tighten the nuts on adjustment screws (3) to a torque of 32.5 ± 6.8 N·m (24.00 ± 5.00 lb.ft.). For the complete valve adjustment procedure, see Testing And Adjusting.

END BY: a. install valve cover base Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:18 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Rocker Shaft Assembly SMCS - 1102-015; 1102-016

Disassemble Rocker Shaft Assembly START BY: a. remove rocker shaft assembly and push rods

1. Remove bolt and washer (1) and washer (2) from the bracket.

2. Remove shaft assembly (3) from the bracket.

3. Remove washers (6) and rocker arm assemblies (7) from shaft (3).

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4. Remove adjustment screws (4) and nuts (5) from the rocker arm assemblies.

5. Inspect the ball end of the adjusting screw and valve contact surface of the rocker arm for wear, and make a replacement if needed.

Assemble Rocker Shaft Assembly 1. Make sure the oil holes in the rocker arm assemblies, rocker shaft and bracket are clean and free of all dirt and foreign material. Be sure the plugs are installed in both ends of the rocker shaft.

2. Measure the bore of the bushing in each of the rocker arms. The bore must be 21.852 ± 0.020 mm (.8603 ± .0008 in.) (new). The maximum permissible bore must not be more than 21.920 mm (.8630 in.) (worn).

NOTE: Make a replacement of the arm and bushing as a unit if the bore is not correct. The arms and bushings can not be ordered separately.

3. Measure the diameter of the shaft at each of the rocker arm locations. The diameter must be 21.793 to 21.814 mm (.8580 to .8588 in.) (new). The maximum permissible diameter must not be more than 21.768 mm (.8570 in.) (worn).

4. The maximum permissible clearance between the bearing and shaft must not be more than 0.13 mm (.005 in.) (worn).

5. Install screws (2) and nuts (1) into rocker arm assemblies (4). Turn the screws until they are 11.2 mm (.44 in.) below the bottom of the rocker arm assemblies.

6. Install rocker arm assemblies (4) and washers (3) on shaft (5) as shown.

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7. Put shaft (5) and the rocker arm assemblies in position on bracket (6). Be sure the adjustment screws are on the opposite side as the oil hole on the bottom of the bracket.

8. Make sure the flat surfaces on shaft (5) are turned up. Install washers (7), the washers and bolts.

END BY: a. install rocker shaft assembly and push rods Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:23 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Valve Lifters SMCS - 1209-010

Remove And Install Valve Lifters START BY: a. remove cylinder head assembly

NOTICE Put identification marks on the lifters as to their location in the cylinder block.

1. Remove valve lifters (1) from the cylinder block with a magnet. Put identification marks on the lifters for installation purposes if the old lifters are to be used again.

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2. Check the diameter of the valve lifter. The diameter of the valve lifter (new) must be 29.436 ± 0.010 mm (1.1589 ± .0004 in.). The bore in the block for new valve lifters must be 29.525 ± 0.025 mm (1.1624 ± .0010 in.). The maximum permissible clearance between the lifter and the bore for the valve lifter (worn) is 0.20 mm (.008 in.).

NOTICE Install the lifters in their respective bores in the cylinder block. Failure to do this can result in an increased rate of wear or failure.

3. Put 2P2506 Thread Lubricant on the lifter face that makes contact with the camshaft.

4. Install valve lifters (1) in their original positions in the cylinder block.

END BY: a. install cylinder head assembly Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:30 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Valve Cover SMCS - 1107-010

Remove And Install Valve Cover

1. Remove the muffler to gain better access to the valve cover.

2. Disconnect breather tube (1) from the breather boot.

3. Remove bolts (2) and valve cover (3) from the valve cover base.

NOTE: The following steps are for installation of the valve cover.

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4. If necessary, install a new gasket. Put cover (3) in position, and tighten bolts (2) in the sequence shown to a torque of 13.5 ± 2.7 N·m (120 ± 25 lb.in.).

5. Connect breather (1) to the boot, and install the muffler if removed.

Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:35 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC01559 Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Valve Cover Base SMCS - 1120-010

Remove And Install Valve Cover Base START BY: a. remove valve cover b. remove fuel injection lines

1. Disconnect fuel injection line nuts (1) from adapters (4). Remove adapters (4) from valve cover base (2). Remove the O-ring seals from the adapters.

2. Remove bolts (3), and remove valve cover base (2) and the gasket from the engine.

NOTE: The following steps are for installation of the valve cover base.

3. Inspect the condition of the valve cover base gasket, and replace it if necessary.

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4. Put valve cover base (2) in position, and install bolts (3). Tighten bolts (3) in the sequence shown to a torque of 13.5 ± 2.7 N·m (120 ± 24 lb.in.).

5. Lubricate the seals on adapters (4) with glycerine, and install the adapters in the valve cover base.

Connect the fuel injection lines, and tighten nuts (1) to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).

END BY: a. install fuel injection lines b. install valve cover Copyright 1993 - 2019 Caterpillar Inc.

Sat Dec 14 17:07:40 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Oil Filter (1N3224)

(1) 1N4425 Spring for bypass valve: Length under test force ... 1.9 in.(48.3 mm) Test force ... 4.6 ± .4 lb.(20.4 ± 2 N) Free length after test ... 2.20 in.(55.9 mm) Outside diameter ... .457 in.(11.61 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Engine Oil Cooler SMCS - 1378-010

Remove And Install Engine Oil Cooler 1. Drain the coolant from the cooling system.

2. Loosen hose clamps (1) and (4), and disconnect the hoses from the engine.

3. Remove two bolts (2), and remove oil cooler (3) from the engine.

4. Remove the two O-ring seals from the oil cooler.

NOTE: The following steps are for installation of the engine oil cooler.

5. Install the two O-ring seals in the oil cooler. Put clean engine oil on the seals.

6. Put oil cooler (3) in position on the engine, and install two bolts (2).

7. Connect the two hoses to the engine, and tighten hose clamps (1) and (4).

8. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

9. Check the oil level in the engine. See the Maintenance Guide.

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:45:29 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Fan SMCS - 1356-010

Remove And Install Fan START BY: a. remove alternator

1. Remove the bolts that hold guard assemblies (1) in position. Remove the guard assemblies from the radiator.

2. Remove the bolts that hold shield assembly (2) to the radiator. Move the shield assembly away from the radiator.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

3. Remove four bolts (4) and fan (3) from the water pump.

4. Remove shield assembly (2).

5. Remove the pulley and V-belt from the water pump.

NOTE: The following steps are for installation of the fan.

6. Put the pulley and V-belt in position on the water pump.

7. Put shield assembly (2) in position as shown.

8. Put fan (3) in position on the water pump, and install four bolts (4).

9. Move shield assembly (2) into position on the radiator, and install the bolts that hold it in place.

10. Put guard assemblies (1) in position on the radiator, and install the bolts that hold them in place.

END BY: a. install alternator Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Temperature Regulator And Water Lines SMCS - 1356-010

(1) 4N236 Water Temperature Regulator (Thermostat): Temperature when completely open ... 192° F(89° C)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Minimum opening distance ... .260 in.(6.60 mm) NOTE: Install regulator with vent hole at top.

(2) Torque for clamp ... 52 ± 5 lb. in.(5.9 ± 0.6 N·m) NOTE: Install clamp with adjusting screw toward the top and approximately 45° to the right of vertical (as seen from the front of the engine).

NOTE: Seal must be installed all the way into the counterbore before clamp is tightened.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Water Temperature Regulator SMCS - 1355-011; 1355-012

Remove Water Temperature Regulator 1. Drain the coolant in the cooling system to a level below the water temperature regulator.

2. Loosen the clamp, and disconnect the radiator hose from elbow (1).

3. Remove bolts (2), elbow (1), the water temperature regulator and gasket.

4. Remove gasket (3) and water temperature regulator (4) from elbow (1).

Install Water Temperature Regulator 1. Clean all gasket material and rust from the contact surfaces of the elbow and timing gear cover.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

NOTICE The engine will run hot if the water temperature regulator is installed wrong.

2. Install water temperature regulator (1) down in the counterbore of elbow (2) with the vent hole up.

NOTICE Make sure the vent hole is open, and do not use liquid gasket material on the gasket. The cylinder head can be damaged if the vent hole is not open.

3. Put gasket (3) and elbow (2) in position, and install the bolts that hold it.

4. Put the radiator hose in position on the elbow, and tighten the clamp.

5. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Temperature Regulator And Water Lines SMCS - 1355-011; 1355-012

(1) 4N236 Water Temperature Regulator (Thermostat): Temperature when completely open ... 192° F(89° C)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Minimum opening distance ... .260 in.(6.60 mm) NOTE: Install regulator with vent hole at top.

(2) Torque for clamp ... 52 ± 5 lb. in.(5.9 ± 0.6 N·m) NOTE: Install clamp with adjusting screw toward the top and approximately 45° to the right of vertical (as seen from the front of the engine).

NOTE: Seal must be installed all the way into the counterbore before clamp is tightened.

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Sun Dec 15 11:46:16 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Water Temperature Regulator SMCS - 1355-011; 1355-012

Remove Water Temperature Regulator 1. Drain the coolant in the cooling system to a level below the water temperature regulator.

2. Loosen the clamp, and disconnect the radiator hose from elbow (1).

3. Remove bolts (2), elbow (1), the water temperature regulator and gasket.

4. Remove gasket (3) and water temperature regulator (4) from elbow (1).

Install Water Temperature Regulator 1. Clean all gasket material and rust from the contact surfaces of the elbow and timing gear cover.

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NOTICE The engine will run hot if the water temperature regulator is installed wrong.

2. Install water temperature regulator (1) down in the counterbore of elbow (2) with the vent hole up.

NOTICE Make sure the vent hole is open, and do not use liquid gasket material on the gasket. The cylinder head can be damaged if the vent hole is not open.

3. Put gasket (3) and elbow (2) in position, and install the bolts that hold it.

4. Put the radiator hose in position on the elbow, and tighten the clamp.

5. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Pump (2W1223) SMCS - 1355-011; 1355-012

(1) Clearance between front housing and impeller face vanes ... .011 to .033 in.(0.28 to 0.84 mm) (2) Torque for nut with 9S3263 compound on threads ... 125 ± 11 lb. ft.(170 ± 15 N·m) (3) Distance from mounting face of the water pump to gage diameter (A) on impeller vanes ... 1.990 ± .005 in.(50.55 ± 0.13 mm)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Gage diameter (A) ... 3.000 in.(76.20 mm) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Pump (7N9001 and 8N8270) SMCS - 1355-011; 1355-012

(1) Clearance between front housing and impeller face vanes ... .011 to .033 in.(0.28 to 0.84 mm) (2) Distance from end of housing to end of seal (working height) ... .505 ± .005 in.(12.83 ± 0.13 mm) (3) Torque for bolt ... 55 ± 5 lb. ft.(75 ± 7 N·m) (4) Distance from mounting face of the water pump to gage diameter (A) on impeller vanes ... 1.990 ± .005 in.(50.55 ± 0.13 mm) Gage diameter (A) ... 3.000 in.(76.20 mm)

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:46:32 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Pump (4N455) SMCS - 1355-011; 1355-012

(1) Clearance between front housing and impeller face vanes ... .011 to .035 in.(0.28 to 0.89 mm) (2) Distance from mounting face of the water pump to gage diameter (A) on impeller vanes ... 1.990 ± .010 in.(50.55 ± 0.25 mm) Gage diameter (A) ... 3.000 in.(76.20 mm) NOTE: See Special Instruction Form SMHS7090 for water pump reconditioning procedures.

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:46:36 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Water Pump SMCS - 1361-015; 1361-016; 1361-011; 1361-012

Remove Water Pump 1. Drain the coolant from the cooling system.

2. Remove the V-belts from the engine.

3. Remove bolts (1) and pulley (2) from the water pump.

4. Remove bolts (3), water pump (4) and the gasket from the timing gear cover.

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Install Water Pump

NOTE: Make sure the word "TOP" on the water pump housing is toward the top of the engine when installed.

1. Put gasket (1) and water pump (2) in position on the timing gear cover.

2. Install the bolts that hold the water pump in place.

3. Put pulley (3) in position on the water pump, and install the bolts that hold it in place.

4. Put the V-belts in position on the engine.

5. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

6. Use belt tension gauge such as a Borroughs Tool Company Part No. BT-33-72C or equivalent, and make an adjustment to the belt tension. Tighten a new belt until the gauge indication is 535 ± 22 N (120 ± 5 lb.). Tighten a used belt until the gauge indication is 400 ± 44 N (90 ± 10 lb.). Used belt tension is for a belt which has more than 30 minutes of operation at rated speed of the engine.

Disassemble Water Pump

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START BY: a. remove water pump

1. Hold the impeller shaft with a wrench, and use an impact wrench to remove nut (1) from the shaft.

Remove pump adapter (2).

2. Use tool group (A) and a press to remove shaft (3), the seal assembly and the impeller from the water pump housing.

3. Remove spacer (4) and seal (5) from the water pump housing.

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4. Remove snap ring (6) from the housing with tool (B).

5. Remove spacer (7) and bearing assembly (8) from the housing.

6. Remove the seal from the water pump housing with tool group (A).

7. Remove impeller (9) from shaft (10) with tool group (A).

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8. Remove water seal assembly (11) from the impeller shaft.

Assemble Water Pump

1. Put a small amount of 2S3230 Bearing Lubricant on the seal lip, and install the seal in the pump housing with tool group (A). Install the seal with the lip toward the bearing assembly as shown.

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2. Put 2S3230 Bearing Lubricant between the bearings. Put spacer (2) between bearing assembly (3), and then put bearing assembly (3) in position on a press.

3. Put impeller shaft (1) in position, and push it into the bearing assembly.

4. Install tool (B) on the impeller shaft, and then put the shaft and bearing assembly in position in the pump housing.

5. Install tool (C) on the bearing assembly.

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6. Install a suitable plate from tool group (A) on tool (C) as shown. Press the shaft and bearing assembly into the housing.

NOTE: Make an inspection of the seal at the impeller end of pump to see if the lip of the seal was pushed out or damaged. If so, make a replacement of the seal, and do Steps 3 through 6 again.

7. Install spacer (4) in the water pump housing.

8. Install snap ring (5) with tool (D).

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9. Remove tool (B) from the water pump housing.

10. Put a small amount of clean engine oil on the seal, and install it in the housing with tool (C) and a suitable plate from tool group (A). Install the seal with the lip toward the bearing assembly as shown.

11. Install spacer (7) in the pump housing. Install pump adapter (6) on the impeller shaft.

12. Put 9S3263 Thread Lock on the threads of the nut; then install the nut on the impeller shaft.

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13. Put the pump housing in a soft-jawed vise, and use a wrench to hold the impeller shaft while the nut is tightened to a torque of 170 ± 15 N·m (125 ± 11 lb.ft.).

14. Put water seal (8) in position on the impeller shaft. Put a small amount of clean engine oil on the seal. Install tool (E) on the seal; then push the seal into housing with a press.

NOTICE Do not use a hammer or similar tool to hit or drive the seal in place.

This will damage the seal.

NOTE: If the impeller does not have two holes drilled in it near the center, see the article "Use FT1783 Fixture To Drill Vent Holes In Impeller" in Service Magazine dated February 28, 1983, Form No. SEBD1306.

15. Install 5P7350 and 5P7352 Spacers (11) on the pump housing. Put impeller (10) in position on the shaft. Use the 5P7353 Spacer (9) and a press to push impeller (10) on the shaft until it just makes contact with the two spacers. Remove the spacers from between the pump housing and back face of the impeller. The 5P7350, 5P7352 and 5P7353 Spacers are all part of tool group (F).

NOTICE During the installation of the water pump on the front housing, make sure the clearance between the vanes (impeller) and the front housing

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 10 of 10

is .35 to 1.14 mm (.014 to .045 in.). If this clearance is not correct, it will effect the performance of the pump.

END BY: a. install water pump Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Cooling System Pressure Cap SMCS - 1361-015; 1361-016; 1361-011; 1361-012

Cap must not leak at ... 6.5 psi(45 kPa) Cap must be open at ... 8 psi(55 kPa) Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Radiator And Radiator Guard SMCS - 1381-010

Remove And Install Radiator And Radiator Guard 1. Remove the hood from the engine compartment.

2. Drain the coolant from the cooling system.

3. Drain the oil from the transfer gear case.

4. Disconnect oil lines (1) and (5) from the oil cooler.

5. Remove bolts (2) and (7) that hold the radiator guard to the frame.

6. Disconnect hoses (3) and (6) from the radiator.

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7. Remove the bolts that hold two guard assemblies (4) in position, and remove the guard assemblies.

8. Remove four bolts (9), and move bracket (8) away from the radiator.

9. Disconnect wires (10) from the lights. Remove the lights and bracket (8) as an assembly.

10. Remove the bolts that hold back-up alarm (11) and ground wires (12) in place. Disconnect the wire from the back-up alarm and remove it.

11. Remove the bolts that hold door assemblies (14) to the radiator guard, and remove the door assemblies.

12. Fasten a hoist to radiator guard (13). Remove two bolts (15), and remove the radiator and radiator guard. The weight of the radiator and radiator guard is 136 kg (300 lb.).

NOTE: The following steps are for installation of the radiator and radiator guard.

13. Fasten a hoist to radiator guard (13). Put the radiator and radiator guard in position, and install bolts (2), (7) and (15).

14. Install door assemblies (14) on the radiator guard.

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15. Put back-up alarm (11) and two ground wires (12) in position, and install the bolts that hold them in place.

16. Connect the wire to the back-up alarm.

17. Put bracket (8) and the lights in position. Connect wires (10) to the lights.

18. Install four bolts (9) to hold bracket (8) in position on the frame.

19. Connect oil lines (1) and (5) to the oil cooler.

20. Put guard assemblies (4) in position, and install the bolts that hold them in place.

21. Connect hose assemblies (3) and (6) to the radiator.

22. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

23. Fill the transmission with oil to the correct level. See the Maintenance Guide.

24. Install the hood over the engine compartment.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Radiator Core SMCS - 1353-010

Remove And Install Radiator Core

START BY: a. remove radiator and radiator guard

1. Disconnect clips (3) from the radiator core. Remove tube (1).

2. Remove bolts (2) and shield assembly (4) from the radiator core.

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3. Fasten a hoist and tooling (A) to radiator core (5).

4. Remove four bolts (6) and radiator core from the radiator guard. The weight of the radiator core is 54 kg (120 lb.).

NOTE: The following steps are for installation of the radiator core.

5. Fasten a hoist and tooling (A) to radiator core (5). Put the radiator core in position in the radiator guard, and install four bolts (6).

6. Put shield assembly (4) in position, and install bolts (2).

7. Install tube (1). Connect two clips (3).

END BY: a. install radiator and radiator guard Copyright 1993 - 2019 Caterpillar Inc.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Water Temperature Regulator And Water Lines SMCS - 1353-010

(1) 4N236 Water Temperature Regulator (Thermostat): Temperature when completely open ... 192° F(89° C)

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Minimum opening distance ... .260 in.(6.60 mm) NOTE: Install regulator with vent hole at top.

(2) Torque for clamp ... 52 ± 5 lb. in.(5.9 ± 0.6 N·m) NOTE: Install clamp with adjusting screw toward the top and approximately 45° to the right of vertical (as seen from the front of the engine).

NOTE: Seal must be installed all the way into the counterbore before clamp is tightened.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Water Temperature Regulator SMCS - 1355-011; 1355-012

Remove Water Temperature Regulator 1. Drain the coolant in the cooling system to a level below the water temperature regulator.

2. Loosen the clamp, and disconnect the radiator hose from elbow (1).

3. Remove bolts (2), elbow (1), the water temperature regulator and gasket.

4. Remove gasket (3) and water temperature regulator (4) from elbow (1).

Install Water Temperature Regulator 1. Clean all gasket material and rust from the contact surfaces of the elbow and timing gear cover.

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NOTICE The engine will run hot if the water temperature regulator is installed wrong.

2. Install water temperature regulator (1) down in the counterbore of elbow (2) with the vent hole up.

NOTICE Make sure the vent hole is open, and do not use liquid gasket material on the gasket. The cylinder head can be damaged if the vent hole is not open.

3. Put gasket (3) and elbow (2) in position, and install the bolts that hold it.

4. Put the radiator hose in position on the elbow, and tighten the clamp.

5. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Systems Operation 3204 VEHICULAR ENGINE Media Number -REG01222-05

Publication Date -01/03/1984

Date Updated -10/10/2001

Systems Operation SMCS - 1419-010; 3181

Introduction NOTE: For Specifications with illustrations, make reference to SPECIFICATIONS for 3204 VEHICULAR ENGINE, Form No. REG01254. If the Specifications in Form REG01254 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

Engine Design

DI ENGINE

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PC ENGINE CYLINDER AND VALVE LOCATION

Bore ... 4.50 in.(114.3 mm) Stroke ... 5.00 in.(127.0 mm) Number and Arrangement of Cylinders ... 4, in line Firing Order (Injection Sequence) ... 1, 3, 4, 2 Rotation of Crankshaft (when seen from flywheel end) ... counterclockwise Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... counterclockwise NOTE: Front end of engine is opposite to flywheel end. Left side and right side of engine are as seen from flywheel end. No. 1 cylinder is the front cylinder on the engine.

Fuel System

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Fuel Flow

FUEL SYSTEM SCHEMATIC 1. Fuel tank. 2. Fuel return line. 3. Fuel injection nozzle. 4. Fuel injection line. 5. Fuel injection pump. 6. Primary fuel filter. 7. Fuel transfer pump. 8. Secondary fuel filter. 9. Constant bleed valve. 10. Fuel injection pump housing.

Fuel is pulled from fuel tank (1) through primary fuel filter (6) by fuel transfer pump (7). From the fuel transfer pump the fuel is pushed through secondary fuel filter (8) and to the fuel manifold in fuel injection pump housing (10). A bypass valve in the fuel transfer pump keeps the fuel pressure in the system at 20 to 40 psi (140 to 280 kPa). Constant bleed valve (9) lets a constant flow of fuel go through fuel return line (2) back to fuel tank (1). The constant bleed valve returns approximately 9 gal. (34 liters) per hour of fuel and air to the fuel tank. This helps keep the fuel cool and free of air.

Fuel injection pump (5) gets fuel from the fuel manifold and pushes fuel at very high pressure through fuel line (4) to fuel injection nozzle (3). The fuel injection nozzle has very small holes in the tip that change the flow of fuel to a very fine spray that gives good fuel combustion in the cylinder.

Fuel Injection Pump The fuel injection pump increases the pressure of the fuel and sends an exact amount of fuel to the fuel injection nozzle. There is one fuel injection pump for each cylinder in the engine.

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The fuel injection pump is moved by cam (14) of the fuel pump camshaft. When the camshaft turns, the cam raises lifter (11) and pump plunger (6) to the top of the stroke. The pump plunger always makes a full stroke. As the camshaft turns farther, spring (8) returns the pump plunger and lifter to the bottom of the stroke.

When the pump plunger is at the bottom of the stroke, fuel at transfer pump pressure goes into inlet passage (2), around pump barrel (4) and to bypass closed port (5). Fuel fills the area above the pump plunger.

After the pump plunger begins the up stroke, fuel will be pushed out the bypass closed port until the top of the pump plunger closes the port. As the pump plunger travels farther up, the pressure of fuel increases. At approximately 100 psi (690 kPa), check valve (1) opens and lets fuel flow into the fuel injection line to the fuel injection nozzle. When the pump plunger travels farther up, scroll (9) uncovers spill port (10). The fuel above the pump plunger goes through slot (7), along the edge of scroll (9) and out spill port (10) back to fuel manifold (3). This is the end of the injection stroke. The pump plunger can have more travel up, but no more fuel will be sent to the fuel injection nozzle.

FUEL INJECTION PUMP 1. Check valve. 2. Inlet passage. 3. Fuel manifold. 4. Pump barrel. 5. Bypass closed port. 6. Pump plunger. 7. Slot. 8.

Spring. 9. Scroll. 10. Spill port. 11. Lifter. 12. Fuel rack. 13. Gear. 14. Cam.

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When the pump plunger travels down and uncovers bypass closed port (5), fuel begins to fill the area above the pump plunger again, and the pump is ready to begin another stroke.

The amount of fuel the injection pump sends to the injection nozzle is changed by the rotation of the pump plunger. Gear (13) is attached to the pump plunger and is in mesh with fuel rack (12). The governor moves the fuel rack according to the fuel needs of the engine. When the governor moves the fuel rack, and the fuel rack turns the pump plunger, scroll (9) changes the distance the pump plunger pushes fuel between bypass closed port (5) and spill port (10) opening. The longer the distance from the top of the pump plunger to the point where scroll (9) uncovers spill port (10), the more fuel will be injected.

To stop the engine, the pump plunger is rotated so that slot (7) on the pump plunger is in line with spill port (10). The fuel will now go out the spill port and not to the injection nozzle.

Fuel Injection Nozzle The fuel injection nozzle goes through the cylinder head into the combustion chamber. The fuel injection pump sends fuel with high pressure to the fuel injection nozzle where the fuel is made into a fine spray for good combustion.

FUEL INJECTION NOZZLE 1. Carbon dam. 2. Seal. 3. Spring. 4. Passage. 5. Inlet passage. 6. Orifice. 7. Valve. 8. Diameter.

Seal (2) goes against the cylinder head and prevents leakage of compression from the cylinder.

Carbon dam (1) keeps carbon out of the bore in the cylinder head for the nozzle.

Fuel with high pressure from the fuel injection pump goes into inlet passage (5). Fuel then goes into passage (4) to the area below diameter (8) of valve (7). When the pressure of the fuel that pushes

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against diameter (8) becomes greater than the force of spring (3), valve (7) lifts up. When valve (7) lifts, the tip of the valve comes off of the nozzle seat and the fuel will go through the four .012 in.

(0.31 mm) orifices (6) into the combustion chamber.

The injection of fuel continues until the pressure of fuel against diameter (8) becomes less than the force of spring (3). With less pressure against diameter (8), spring (3) pushes valve (7) against the nozzle seat and stops the flow of fuel to the combustion chamber.

Fuel Transfer Pump The fuel transfer pump is a single piston pump that is moved by a cam lobe on the camshaft for the fuel injection pump.

When the camshaft turns, the cam lobe moves tappet (1) into the pump body. The tappet pushes piston (3) against the force of pumping spring (6). Outlet check valve (2) closes and inlet check valve (4) in the piston opens. Fuel in fuel inlet chamber (5) flows through the inlet check valve to the outlet side of the piston.

As the camshaft continues to turn, the cam lobe lets the tappet move out of the pump body. Pumping spring (6) pushes piston (3) towards the tappet. Inlet check valve (4) in the piston closes and outlet check valve (2) opens. The force of the pumping spring pushes fuel through the outlet check valve and into the fuel system.

The force of pumping spring (6) limits the pressure of the fuel in the system so that a bypass valve is not needed.

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FUEL TRANSFER PUMP 1. Tappet. 2. Outlet check valve. 3. Piston. 4. Inlet check valve. 5. Fuel inlet chamber. 6. Pumping spring.

Governor The governor controls the amount of fuel needed by the engine to maintain a desired rpm.

The governor flyweights (8) are driven directly by the fuel pump camshaft. Riser (10) is moved by flyweights (8) and governor spring (1). Lever (7) connects the riser with sleeve (2) which is fastened to valve (3). Valve (3) is a part of governor servo (5) and moves piston (4) and fuel rack (6). The fuel rack moves toward the front of the fuel pump housing (to the right in the illustration) when moved in the FUEL OFF direction.

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GOVERNOR 1. Governor spring. 2. Sleeve. 3. Valve. 4. Piston. 5. Governor servo. 6. Fuel rack. 7. Lever. 8. Flyweights. 9. Over fueling spring. 10. Riser. 11. Spring seat. 12. Stop bolt. 13. Torque spring. 14. Power setting screw. 15. Torque rise setting screw.

16. Stop collar. 17. Stop bar.

The force of governor spring (1) always pushes to give more fuel to the engine. The centrifugal (rotating) force of flyweights (8) always push to get a reduction of fuel to the engine. When these two forces are in balance (equal), the engine runs at a constant rpm.

When the engine is started and the governor is at the low idle position, over fueling spring (9) moves the riser forward and gives an extra amount of fuel to the engine. When the engine has started and begins to run, the flyweight force becomes greater than the force of the over fueling spring. The riser moves to the rear and reduces the amount of fuel to the low idle requirement of the engine.

When the governor control lever is moved to the high idle position, governor spring (1) is put in compression and pushes riser (10) toward the flyweights. When the riser moves forward, lever (7) moves sleeve (2) and valve (3) toward the rear. Valve (3) stops oil flow through governor servo (5) and the oil pressure moves piston (4) and the fuel rack to the rear. This increases the amount of fuel to the engine. As engine speed increases, the flyweight force increases and moves the riser toward the governor spring. When the riser moves to the rear, lever (7) moves sleeve (2) and valve (3) forward.

Valve (3) now directs oil pressure to the rear of piston (4) and moves the piston and fuel rack forward.

This decreases the amount of fuel to the engine.

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When the flyweight force and the governor spring force become equal, the engine speed is constant and the engine runs at high idle rpm. High idle rpm is adjusted by the high idle adjustment screw. The adjustment screw limits the amount of compression of the governor spring.

With the engine at high idle, when the load is increased, engine speed will decrease. Flyweights (8) move in and governor spring (1) pushes riser (10) forward and increases the amount of fuel to the engine. As the load is increased more, governor spring (1) pushes riser (10) farther forward. Spring seat (11) pulls on stop bolt (12). Stop collar (16) on the opposite end has power setting screw (14) and torque rise setting screw (15) that control the maximum amount of fuel rack travel. The power setting screw moves forward and makes contact with torque spring (13). This is the set point (balance point).

If more load is added to the engine, engine speed will decrease and push riser (10) forward more. This will cause power setting screw (14) to bend (deflect) torque spring (13) until torque rise setting screw (15) makes contact with stop bar (17). This is the point of maximum fuel to the engine.

Governor Servo The governor servo gives hydraulic assistance to the mechanical governor force to move the fuel rack.

The governor servo has cylinder (3), cylinder sleeve (4), piston (2) and valve (1).

GOVERNOR SERVO (Fuel on position) 1. Valve. 2. Piston. 3. Cylinder. 4. Cylinder sleeve. 5. Fuel rack. A. Oil inlet. B. Oil outlet. C. Oil passage. D. Oil passage.

When the governor moves in the FUEL ON direction, valve (1) moves to the left. The valve opens oil outlet (B) and closes oil passage (D). Pressure oil from oil inlet (A) pushes piston (2) and fuel rack (5) to the left. Oil behind the piston goes through oil passage (C), along valve (1) and out oil outlet (B).

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GOVERNOR SERVO (Balanced position) 1. Valve. 2. Piston. 3. Cylinder. 4. Cylinder sleeve. 5. Fuel rack. A. Oil inlet. B. Oil outlet. C. Oil passage. D. Oil passage.

When the governor spring and flyweight forces are balanced and the engine speed is constant, valve (1) stops moving. Pressure oil from oil inlet (A) pushes piston (2) until oil passages (C and D) are opened. Oil now flows through oil passage (D) along valve (1) and out through oil outlet (B). With no oil pressure on the piston, the piston and fuel rack (5) stop moving.

GOVERNOR SERVO (Fuel Off Position) 1. Valve. 2. Piston. 3. Cylinder. 4. Cylinder sleeve. 5. Fuel rack. A. Oil inlet. B. Oil outlet. C. Oil passage. D. Oil passage.

When the governor moves in the FUEL OFF direction, valve (1) moves to the right. The valve closes oil outlet (B) and opens oil passage (D). Pressure oil from oil inlet (A) is now on both sides of piston (2). The area of the piston is greater on the left side than on the right side of the piston. The force of the oil is also greater on the left side of the piston and moves the piston and fuel rack (5) to the right.

Dashpot The dashpot helps give the governor better speed control when there are sudden speed and load changes. The dashpot has cylinder (1), piston (2), dashpot spring (3), needle valve (5) and check valve (6). Piston (2) and spring seat (4) are fastened to dashpot spring (3).

DASHPOT (Governor Moving to Fuel On) 1. Cylinder. 2. Piston. 3. Dashpot spring. 4. Spring seat. 5. Needle valve. 6. Check valve. 7. Oil reservoir.

When the governor moves toward FUEL ON, spring seat (4) and piston (2) move to the right. This movement pulls oil from oil reservoir (7) through check valve (6) and into cylinder (1).

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DASHPOT (Governor Moving to Fuel Off) 1. Cylinder. 2. Piston. 3. Dashpot spring. 4. Spring seat. 5. Needle valve. 6. Check valve. 7. Oil reservoir.

When the governor moves toward FUEL OFF, spring seat (4) and piston (2) move to the left. This movement pushes oil out of cylinder (1), through needle valve (5) and into oil reservoir (7).

If the governor movement is slow, the oil gives no restriction to the movement of the piston and spring seat. If the governor movement is fast in the FUEL OFF direction, the needle valve gives a restriction to the oil and the piston and spring seat will move slowly.

Oil Flow For Fuel Pump And Governor Oil from the side of the cylinder block goes to support (9) and into the bottom of front governor housing (4). The flow of oil now goes in three different directions.

A part of the oil goes to the rear camshaft bearing in fuel pump housing (5). The bearing has a groove around the inside diameter. Oil goes through the groove and into the oil passage in the bearing surface (journal) of camshaft (7). A drilled passage through the center of the camshaft gives oil to the front camshaft bearing and to the thrust face of the camshaft drive gear. Drain hole (6) in the front of fuel pump housing (5) keeps the level of the oil in the housing even with the center of the camshaft. The oil returns to the oil pan through the timing gear housing.

Oil also goes from the bottom of the front governor housing through a passage to the fuel pump housing and to governor servo (2). The governor servo gives hydraulic assistance to move the fuel rack.

The remainder of the oil goes through passages to the rear of rear governor housing (3), through cover (1) and back into another passage in the rear governor housing. Now the oil goes into the compartment for the governor controls. Drain hole (8) keeps the oil at the correct level. The oil in this compartment is used for lubrication of the governor control components and the oil is the supply for the dashpot.

The internal parts of the governor are lubricated by oil leakage from the servo and the oil is thrown by parts in rotation. The flyweight carrier thrust bearing gets oil from the passage at the rear of the camshaft.

Oil from the governor returns to the oil pan through a hole in the bottom of the front governor housing and through passages in the support and cylinder block.

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FUEL PUMP AND GOVERNOR 1. Cover. 2. Servo. 3. Rear governor housing. 4. Front governor housing. 5. Fuel pump housing. 6. Drain hole. 7.

Camshaft. 8. Drain hole. 9. Support.

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Fuel System

Schematic Of The Fuel System 1. Fuel injection line (under valve cover). 2. Fuel injection line. 3. Housing for fuel injection pumps. 4. Glow plug. 5. Fuel injection valve (PC) or nozzle (DI). 6. Governor. 7. Precombustion chamber. 8. Fuel filter. 9. Fuel priming pump. 10. Fuel transfer pump. 11. Fuel tank.

This engine has a pressure type fuel system. There is one injection pump and one injection valve for each cylinder. The injection pumps are in injection pump housing (3) on the top of the engine. The injection valves for the PC engine are in the precombustion chambers (7). For the DI engine, the injection valves go through the cylinder head directly into the cylinder. Both types are found under the valve covers.

Fuel is pulled from fuel tank (11) through a filter screen in the inlet valve of fuel transfer pump (10).

The fuel transfer pump sends fuel through fuel filter (8) to fuel manifold in injection pump housing.

Fuel in the manifold of the injection pump housing is the supply for the injection pumps.

The injection pumps are in time with the engine and send fuel to the injection valves under high pressure. When the fuel pressure at the injection valves is high enough the valve opens and sends fuel into the precombustion chamber or directly into the cylinder.

Fuel transfer pump (10) has a pressure relief spring that controls the maximum fuel pressure output of the pump. As the fuel pressure increases, the pump piston will not return to its former position since

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the force of the spring on one side and the fuel pressure on the other side are equal. In this position the cam of the pump continues to move but can not reach the piston. Without piston movement, no more fuel can be pumped. When the pressure decreases, the spring rate again pushes the piston back toward the cam and the piston starts to pump fuel again.

When there is air on the inlet side of the fuel system, fuel priming pump (9) is used. Operation of the priming pump fills the system with fuel. This forces the air back into the tank, or to the point where a fuel line has been loosened.

Fuel Injection Pump Injection pump plungers (4) and lifters (8) are lifted by cams on camshaft (9) and always make a full stroke. The force of springs (5) hold the lifters (8) against the cams of the camshaft.

When the pump plunger is down, fuel from fuel manifold (1) goes through inlet passage (2) and fills the chamber above pump plunger (4). As the plunger moves up, it closes the inlet passage.

The pressure of the fuel in the chamber above the plunger increases until it is high enough to cause check valve (3) to open. Fuel under high pressure flows out of the check valve through the fuel line to the injection valve until the inlet passage opens into pressure relief passage in plunger (4). The pressure in the chamber then decreases and check valve (3) closes.

CROSS SECTION OF THE HOUSING FOR THE FUEL INJECTION PUMPS

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1. Fuel manifold. 2. Inlet passage in pump barrel. 3. Check valve. 4. Pump plunger. 5. Spring. 6. Gear. 7. Fuel rack. 8.

Lifter. 9. Camshaft.

The longer period that the inlet passage is closed, the larger the amount of fuel which will be forced through check valve (3). The period for which the inlet passage is closed is controlled by the pressure relief passage. The design of the passage makes it possible to change the inlet passage closed time by rotation of the plunger. When the governor moves fuel rack (7), it moves gears (6) that are fastened to plungers (4). This causes a rotation of the plungers.

Fuel Injection Valves Direct Injection Nozzle Fuel inlet (6) and nozzle tip (13) are parts of nozzle body (11). Valve (8) is held in position by spring force. The force of the spring is controlled by pressure adjustment screw (3). Locknut (4) holds pressure adjustment screw (3) in position. The lift of valve (8) is controlled by lift adjustment screw (2). Locknut (10) holds lift adjustment screw (2) in position. Compression seal (7) goes on nozzle body (11).

The compression seal goes against fuel inlet (6) and prevents the leakage of compression from the cylinder. Carbon dam (12), at the lower end of nozzle body (11) prevents the deposit of carbon in the bore in the cylinder head.

FUEL INJECTION NOZZLE 1. Cap. 2. Lift adjustment screw. 3. Pressure adjustment screw. 4. Locknut for pressure adjustment screw. 5. O-ring seal.

6. Fuel inlet. 7. Compression seal. 8. Valve. 9. Orifices (four). 10. Locknut for lift adjustment screw. 11. Nozzle body. 12.

Carbon dam. 13. Nozzle tip.

Fuel, under high pressure from the fuel injection pump goes through the hole in fuel inlet (6). The fuel then goes around valve (8), fills the inside of nozzle body (11) and pushes against the valve guide.

When the force made by the pressure of the fuel is more than the force of the spring, valve (8) will lift. When valve (8) lifts, fuel under high pressure will go through the four .0128 in. (0.325 mm) orifices (9) into the cylinder. When the fuel is sent to the cylinder, the force made by the pressure of

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the fuel in the nozzle body will become less. The force of the spring will then be more than the force of the pressure of the fuel in the nozzle body. Valve (8) will move to the closed position.

Valve (8) is a close fit with the inside of nozzle tip (13), and this makes a positive seal for the valve.

When the fuel is sent to the cylinder, a very small quantity of fuel will leak by the valve guide. This fuel gives lubrication to the moving parts of the fuel injection nozzle.

PC Type Nozzle Fuel, under high pressure from the injection pumps, is sent through the injection valves into the precombustion chambers. One precombustion chamber is located above each cylinder.

The injection valves have a large single orifice. The action of the fuel flowing through this orifice causes the fuel to atomize (change to very small drops). This makes it possible for the fuel to burn with a high level of efficiency.

Hydra-Mechanical Governor The accelerator pedal, or governor control, is connected to the control lever on the engine governor.

The governor controls the amount of fuel needed to keep the desired engine rpm.

The governor has governor weights (12), driven by the engine, governor spring (5), valve (14) and piston (15). The valve and piston are connected to fuel rack (18). The pressure oil for the governor comes from the engine oil pump. Pressure oil goes through oil passage (17) and around sleeve (16).

The accelerator pedal, or governor control, controls only the compression of governor spring (5).

Compression of the spring pushes to give more fuel to the engine. The centrifugal force (rotation) of governor weights (12) pulls to get a reduction of fuel to the engine. When these two forces are in balance, the engine runs at the desired rpm (governed rpm).

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HYDRA-MECHANICAL GOVERNOR (Typical Example) 1. Collar. 2. Speed limiter plunger. 3. Lever assembly. 4. Seat. 5. Governor spring. 6. Thrust bearing. 7. Oil passage. 8.

Drive gear (weight assembly). 9. Cylinder. 10. Bolt. 11. Spring seat. 12. Governor weights. 13. Spring. 14. Valve. 15.

Piston. 16. Sleeve. 17. Oil passage. 18. Fuel rack.

Valve (14) is shown in the position when the force of the governor weights and the force of the governor spring are in balance.

When there is an increase in engine load, there will be a decrease in engine rpm and the rotation of governor weights (12) will get slower. (The governor weights will move toward each other.)

Governor spring (5) moves valve (14) forward (toward the right in picture shown). When valve (14) moves forward, an oil passage around valve (14) opens to pressure oil. Oil now flows through oil passage (7) and fills the chamber behind piston (15) (the rear end of the valve stops oil flow through the rear of the cylinder, around the valve). This pressure oil pushes the piston and rack forward to give more fuel to the engine. Engine rpm goes up until the rotation of the governor weights is fast enough to be in balance with the force of governor spring (5).

When there is a reduction in engine load, there will be an increase in engine rpm and the rotation of governor weights (12) will get faster. This will move valve (14) backwards (toward the left in picture shown). This movement stops oil flow from the forward passage through piston (15) and allows the oil behind the piston to go out through a passage at the rear of the piston, around valve (14). Now, the pressure oil between sleeve (16) and piston (15) pushes the piston and fuel rack backwards. There is now a reduction in the amount of fuel to the engine. Engine rpm goes down until the centrifugal force (rotation) of the governor weights is in balance with the force of the governor spring. When these two forces are in balance, the engine will run at the desired rpm (governed rpm).

When engine rpm is at LOW IDLE, a spring-loaded plunger in lever assembly (3) comes in contact with a shoulder on the adjustment screw for low idle. To stop the engine, pull back on the governor control. This will let the spring-loaded plunger move over the shoulder on the low idle adjustment

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screw and move the fuel rack to the fuel closed position. With no fuel to the engine cylinders, the engine will stop.

After the engine has stopped, spring (13) moves valve (14) and piston (15) to the full load position.

This moves the rack to full travel position and gives full fuel flow through the fuel injection pump to start the engine.

Oil from the engine gives lubrication to the governor weight bearing. The other parts of the governor get lubrication from "splash-lubrication" (oil thrown by other parts). Oil from the governor runs back into the housing for the fuel injection pumps.

In earlier engines, when the governor control is moved to fuel-on position to start the engine, plunger (2) of the speed limiter puts a restriction on the movement of lever assembly (3). After oil pressure of the engine gets to a safe level, plunger (2) of the speed limiter moves back (out of the way) and the governor control can be moved to increase engine rpm. Later engines do not have a speed limiter.

A small force from spring (13) moves fuel rack (18) to give a little more fuel for engine start. With the engine running, the rotation of governor weights (12) will put spring (13) in compression and cause fuel rack (18) to move back. (Spring (13) is extended only when the engine is stopped or at start.) When the engine is running, spring (13) is in compression.

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Air Inlet And Exhaust System

AIR FLOW SCHEMATIC OF THE AIR INLET AND EXHAUST SYSTEM (PC TYPE SHOWN) 1. Inlet manifold. 2. Cylinder head. 3. Air inlet passage. 4. Exhaust valve location. 5. Intake valve location. 6. Exhaust manifold.

The air inlet and exhaust system components are: air precleaner, air cleaner, intake manifold, cylinder head, valve mechanism, exhaust manifold and muffler.

The precleaner and air cleaner filter the air before it gets into the inlet manifold and the passage in the cylinder head. This clean air passes through the inlet manifold and fills the inlet ports in the cylinder heads. Air flow from the inlet port into the cylinder is controlled by the intake valves.

There is one intake and one exhaust valve for each cylinder. Make reference to Valves And Valve System Components. Intake valve (5) will open when the piston moves down on the inlet stroke.

When the intake valve opens, air from the inlet port is pulled into the cylinder. The intake valve closes and the piston begins to move up on the compression stroke. The air in the cylinder is compressed.

When the piston is near the top of the compression stroke, fuel is injected into the precombustion chamber above the cylinder on the PC engine, and directly into the cylinder on the DI engine. The fuel mixes with the air and combustion starts. The force of combustion pushes the piston down on the power stroke. When the piston moves up again, it is on the exhaust stroke. Exhaust valve (4) opens,

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and the exhaust gases are pushed through the exhaust port into exhaust manifold (5). Exhaust gases then pass through the exhaust outlet pipe, the muffler and the exhaust stack. After the piston makes the exhaust stroke, the exhaust valve closes and the cycle (inlet, compression, power, exhaust) starts again.

Valves And Valve System Components The valve system components control the flow of inlet air into and exhaust gases out of the cylinders during engine operation.

The crankshaft gear drives the camshaft gear. The camshaft gear must be timed to the crankshaft gear to get the correct relation between piston and valve movement.

The camshaft has two cams for each cylinder. One cam controls the exhaust valve the other controls the intake valve.

As the camshaft turns, the lobes of camshaft (6) cause lifters (5) to go up and down. This movement makes push rods (3) move rocker arms (2). Movement of the rocker arms open and close valves (4) (intake or exhaust) according to the firing order (injection sequence) of the engine. There is one intake and one exhaust valve for each cylinder, and one rocker arm for each valve.

Valve springs (1) cause the valves to close when the lifters move down.

VALVE SYSTEM COMPONENTS 1. Valve spring. 2. Rocker arm. 3. Push rod. 4. Valve. 5. Lifter. 6. Camshaft.

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Lubrication System Lubrication System (Engines With New Scroll Fuel System)

SCHEMATIC OF THE LUBRICATION SYSTEM 1. Vertical oil passage at rear of cylinder block. 2. Oil passage in cylinder head. 3. Rocker arms. 4. Shaft for the rocker arms. 5. Oil supply passage for camshaft bearings. 6. Oil supply passage for bearings of the crankshaft and connecting rods. 7. Shaft for the idler gear. 8. Piston cooling jets. 9. Main oil passage. 10. Bypass valve for oil filter. 11. Oil passage from oil cooler to oil filter. 12. Oil passage from oil pump to oil cooler. 13. Oil passage in shaft for idler gear. 14. Bypass valve for oil pump. 15. Oil filter. 16. Oil cooler. 17. Bypass valve for oil cooler. 18. Suction pipe for oil pump. 19. Oil pump.

The lubrication system of this engine has the parts that follow: oil pan, oil pump, oil cooler, oil filter, bypass valve for oil cooler and oil filter and oil passages in the cylinder block.

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Oil from the oil pan is sent by oil pump (19) to an oil passage (12) at the right front of the cylinder block. Oil from this passage goes through oil cooler (16) from front to rear. From the oil cooler, the oil goes through oil filter (15) and then into main oil passage (9). The main oil passage is located in the right side of the cylinder block, just above the oil passage for the oil cooler.

From main oil passage (9), oil goes through oil passages (5 and 6) to camshaft bearings and crankshaft bearings and through oil passage (13) to idler gear shaft (7). Oil in passages (6) also goes to piston cooling jets (8) in numbers 2 and 4 main bearing supports. Piston cooling jets (8) are pressed into drilled holes in the supports for the main bearings.

Oil for the rocker arms (3) comes from passage (1) at the left rear of the cylinder block. It then goes into the cylinder head through a hollow dowel in the top, left side of the cylinder block. Passage (2) in the cylinder head sends oil into an oil hole in the bottom of the rear bracket that holds shaft (4) for the rocker arms. The oil then goes into the center of the shaft for the rocker arms, where it is pushed out through small holes for lubrication of each rocker arm. Some of the oil is also sent for lubrication of the valves, push rods and valve lifters (camshaft followers).

There is an oil line connected from main oil passage (9) to an elbow on the bottom of the fuel injection pump. Oil is sent from this elbow for operation and lubrication of the governor, and also for lubrication of the parts in the fuel injection pump housing. Some of the oil also gives lubrication to the bearing on the shaft of the fuel pump drive gear. After the oil has done its work, it will return to the engine oil pan.

There is a bypass valve (14) in the cover of the oil pump (19). This bypass valve controls the pressure of the oil from the oil pump (19). The oil pump output capacity is normally larger than the system will need. When there is more oil available than needed, the oil pressure will increase and bypass valve (14) will open. The oil that goes through the bypass valve is not needed, and this extra oil is returned to the inlet oil passage of oil pump (19).

With the engine cold (starting conditions), bypass valves (10 and 17) will open and give immediate lubrication to all components when cold oil with high viscosity causes a restriction to the oil flow through oil cooler (16) and oil filter (15). Oil pump (19) sends the cold oil through the bypass valves around the oil cooler and oil filter to oil manifold (9) in the cylinder block.

When the oil gets warm, the pressure difference in the bypass valves decreases and the bypass valves close. Now there is a normal flow of oil through the oil cooler and oil filter.

The bypass valves will also open when there is a restriction in the oil cooler or oil filter. This action does not let an oil cooler or oil filter with a restriction prevent lubrication of the engine.

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Engines with Serial Numbers 45V1 through 45V32893

SCHEMATIC OF THE LUBRICATION SYSTEM 1. Vertical oil passage at rear of cylinder block. 2. Oil passage in cylinder head. 3. Rocker arms. 4. Shaft for the rocker arms. 5. Oil supply passage for camshaft bearings. 6. Oil supply passage for bearings of the crankshaft and connecting rods. 7. Shaft for the idler gear. 8. Main oil passage. 9. Oil passage in shaft for idler gear. 10. Oil passage from oil cooler to oil filter. 11. Oil passage from oil pump to oil cooler. 12. Bypass valve for the oil pump. 13. Oil filter. 14. Oil cooler.

15. Suction pipe for the oil pump. 16. Oil pump.

The lubrication system of this engine has the parts that follow: oil pan, oil pump, oil cooler, oil filter and oil passages in the cylinder block.

Oil from the oil pan is sent by oil pump (16) to an oil passage (11) at the right front of the cylinder block. Oil from this passage goes through oil cooler (14), from front to rear. From the oil cooler, the oil goes through oil filter (13) and then into main oil passage (8). The main oil passage is located in the right side of the cylinder block, just above the oil passage for the oil cooler.

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From the main oil passage, oil is sent through passages (5), (6) and (9) to the main bearings, connecting rods, camshaft bearings and the idler gear of the accessory drive.

Oil for rocker arms (3) comes from passage (1) at the left rear of the cylinder block. It then goes into the cylinder head through a hollow dowel pin in the top, left side of the cylinder block. Passage (2) in the cylinder head sends oil into an oil hole in the bottom of the rear bracket that holds shaft (4) for the rocker arms. The oil then goes into the center of the shaft for the rocker arms, where it is pushed out through small holes for lubrication of each rocker arm. Some of the oil is also sent for lubrication of the valves, push rods, and valve lifters (camshaft followers).

There is an oil line connected from main oil passage (8) to an elbow on the bottom of the fuel injection pump. Oil is sent from this elbow for operation and lubrication of the governor, and also for lubrication of the parts in the fuel injection pump housing. Some of the oil also gives lubrication to the bearing on the shaft of the accessory drive gear. After the oil has done its work, it will return to the engine oil pan.

There is a bypass valve in the cover of the oil pump. This bypass valve controls the pressure of the oil from the oil pump. The oil pump output capacity is normally larger than the system will need. When there is more oil available than needed, the oil pressure will increase and the bypass valve will open.

The oil that goes through the bypass valve is not needed, and this extra oil is returned to the inlet oil passage of the oil pump.

This system permits a constant controlled oil pressure for engine operation.

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Engines with Serial Numbers 45V32894-Up

SCHEMATIC OF THE LUBRICATION SYSTEM 1. Vertical oil passage at rear of cylinder block. 2. Oil passage in cylinder head. 3. Rocker arms. 4. Shaft for the rocker arms. 5. Oil supply passage for camshaft bearings. 6. Oil supply passage for bearings of the crankshaft and connecting rods. 7. Shaft for the idler gear. 8. Main oil passage. 9. Oil passage in shaft for idler gear. 10. Bypass valve for oil filter.

11. Oil passage from oil cooler to oil filter. 12. Oil passage from oil pump to oil cooler. 13. Bypass valve for the oil pump.

14. Oil filter. 15. Oil cooler. 16. Suction pipe for the oil pump. 17. Oil pump.

The lubrication system of this engine has the parts that follow: oil pan, oil pump, oil cooler, oil filter and oil passages in the cylinder block.

Oil from the oil pan is sent by oil pump (17) to an oil passage (12) at the right front of the cylinder block. Oil from this passage goes through oil cooler (15), from front to rear. From the oil cooler, the oil goes through oil filter (14) and then into main oil passage (8). The main oil passage is located in the right side of the cylinder block, just above the oil passage for the oil cooler.

From the main oil passage, oil is sent through passages (5), (6) and (9) to the main bearings, connecting rods, camshaft bearings and the idler gear of the accessory drive.

Oil for rocker arms (3) comes from passage (1) at the left rear of the cylinder block. It then goes into the cylinder head through a hollow dowel pin in the top, left side of the cylinder block. Passage (2) in

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the cylinder head sends oil into an oil hole in the bottom of the rear bracket that holds shaft (4) for the rocker arms. The oil then goes into the center of the shaft for the rocker arms, where it is pushed out through small holes for lubrication of each rocker arm. Some of the oil is sent for lubrication of the valves, push rods, and valve lifters (camshaft followers).

There is an oil line connected from main oil passage (8) to an elbow on the bottom of the fuel injection pump. Oil is sent from this elbow for operation and lubrication of the governor, and also for lubrication of the parts in the fuel injection pump housing. Some of the oil also gives lubrication to the bearing on the shaft of the accessory drive gear. After the oil has done its work, it will return to the engine oil pan.

There is a bypass valve (13) in the cover of the oil pump (17). This bypass valve controls the pressure of the oil from the oil pump (17). The oil pump output capacity is normally larger than the system will need. When there is more oil available than needed, the oil pressure will increase and bypass valve (13) will open. The oil that goes through the bypass valve is not needed, and this extra oil is returned to the inlet oil passage of oil pump (17).

With the engine cold (starting conditions), bypass valve (10) will open and give immediate lubrication to all components when cold oil with high viscosity causes a restriction to the oil flow through oil filter (14). Oil pump (17) sends the cold oil through the bypass valve around the oil filter to main oil passage (8) in the cylinder block.

When the oil gets warm, the pressure difference in the bypass valve decreases and the bypass valve closes. Now there is a normal flow of oil through the oil filter.

The bypass valve will also open when there is a restriction in the oil filter. This action does not let an oil filter with a restriction prevent lubrication of the engine.

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Oil Filter Base

FLOW OF OIL (Bypass Valve (10) Closed)

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FLOW OF OIL (Bypass Valve (10) Open)

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Cooling System

SCHEMATIC OF THE COOLING SYSTEM 1. Cylinder head. 2. Elbow. 3. Radiator cap. 4. Coolant line. 5. Cylinder block. 6. Water pump. 7. Coolant line. 8. Engine oil cooler. 9. Coolant line. 10. Radiator.

Water pump (6) is driven from the crankshaft pulley by a V type belt. The water pump gets coolant from the bottom of radiator (10) and sends it into water passages of cylinder block (5). These passages send coolant around the cylinders to take away the heat of combustion.

Some of the coolant in the cylinder block is sent through coolant line (7) into oil cooler (8) to cool the oil for lubrication of the engine. The coolant then goes through line (9) to the inlet side of the water pump. The remainder of the coolant in cylinder block (5) goes up into cylinder head (1).

Coolant moves through the cylinder head to a thermostat under elbow (2) at the front of the engine. If the coolant is cold (cool), the thermostat will be closed. The coolant will go through a passage in the front cover to the water pump. If the coolant is warm, the thermostat will be open and coolant will go through line (4) and into the top tank of radiator (10). Coolant then goes through the core of the radiator to the bottom tank, where it is again sent through the cooling system.

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Radiator cap (3) is used to keep the correct pressure in the cooling system. This pressure keeps a constant supply of coolant to the water pump. If this pressure goes too high, a valve in the radiator cap moves (opens) to get a reduction of pressure. When the correct pressure is in the cooling system, the valve in the radiator cap moves down (closed).

NOTE: The thermostat is an important part of the cooling system. If the thermostat is not installed in the system most of the coolant from the cylinder head will go to the radiator. This will result in high flow through the radiator, reducing the amount of heat rejection from the coolant, causing boiling to take place at the water pump inlet. This results in water pump cavitation which reduces the flow of coolant to the engine. Both conditions results in overheating. In cold weather the coolant that flows to the radiator will also be too much. The engine will not get to normal temperature for operation.

Basic Block Crankshaft The crankshaft rotation changes the combustion forces in the cylinder into usable torque that powers the machine. There is a gear at the front of the crankshaft to drive the accessory drive gear, camshaft gear and the oil pump gear.

The crankshaft is supported by five main bearings. Pressure oil is supplied to all connecting rod bearing surfaces through drilled holes in the crankshaft.

Lip seals are used at both ends and a wear sleeve is used at the rear of the crankshaft for easy replacement and a reduction of maintenance cost.

Camshaft This engine uses a single, forged camshaft that is driven at the front end and is supported by four bearings. Each lobe on the camshaft moves a valve lifter, which in turn moves a push rod, rocker arm, and a valve (either exhaust or intake). There are two lobes for each cylinder.

Pistons And Rings The cast aluminum piston has two rings; one compression ring and one oil ring. The rings are located above the piston pin bore. The compression ring is a standard (conventional) type.

The oil ring is a standard (conventional) type and is spring loaded. Holes in the oil ring groove provide for the return of oil to the crankcase.

The direct injection piston has a special shape (cardioid design) of the top surface to help combustion efficiency. This piston also has a tapered pin bearing design. This provides a larger surface area at the top of the pin bearing to take the load of the power stroke more evenly.

The prechamber piston has a steel heat plug assembled in the pocket (crater) on top of the piston. This plug protects the top of the piston from erosion (distortion by heat).

The piston pin is retained by two snap rings which fit in grooves in the pin bore.

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Connecting Rods The DI connecting rod eye end has the tapered design with the larger bearing surface at the bottom of the eye. This provides more surface area for the increased load of the power stroke.

The PC connecting rod eye has the standard (conventional) type bearing.

Electrical System The electrical system has three separate circuits: the charging circuit, the starting circuit and the lighting circuit. Some of the electrical system components are used in more than one circuit. The battery (batteries), disconnect switch, circuit breaker, ammeter, cables and wires from the battery are all common in each of the circuits.

NOTICE The disconnect switch, if so equipped, must be in the ON position 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.

The charging circuit is in operation when the engine is running. An alternator makes electricity for the charging circuit. A voltage regulator in the circuit controls the electrical output to keep the battery at full charge.

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

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

The starting circuit of a "PC" engine can have a glow plug for each cylinder. Glow plugs are small heating units in the precombustion chambers. Glow plugs make ignition of the fuel easier when the engine is started in cold temperature.

The low amperage circuit and the charging circuit are both connected through the ammeter. The starting circuit is not connected through the ammeter.

Charging System Components Alternator The alternator is driven by a V-type belt from the crankshaft pulley. It is a 12 volt, 40 ampere unit with a regulator which has no moving parts (solid state). The only part in the alternator which has movement is rotor assembly (9). Rotor assembly (9) is held in position by a ball bearing at each end of rotor shaft (8).

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The alternator is made up of a frame (3) on the drive end, rotor assembly (9), stator assembly (5), rectifier assembly (11), brushes (7) and holder assembly, slip rings (13), rear end frame (12) and regulator (6). Drive pulley (1) has a fan (2) for heat removal by the movement of air thru the alternator.

ALTERNATOR SCHEMATIC (WITH REGULATOR ATTACHED) 1. Pulley. 2. Fan. 3. Drive end frame. 4. Stator coils. 5. Stator assembly. 6. Regulator. 7. Brushes. 8. Rotor shaft. 9. Rotor assembly. 10. Field windings. 11. Rectifier assembly. 12. Rear end frame. 13. Slip rings.

Rotor assembly (9) has field windings (10) (wires around an iron core) which make magnetic lines of force when direct current (DC) flows through them. As the rotor turns, the magnetic lines of force are broken by stator assembly (5). This makes an alternating current (AC) in the stator. Rectifier assembly (11) has diodes which change the alternating current (AC) from the stator to direct current (DC). Most of the direct current (DC) goes to charge the battery and make a supply of direct current (DC) for the low amperage circuit. The remainder of the direct current (DC) is sent to field windings (10) through brushes (7).

Alternator Regulator The regulator is fastened to the alternator by two different methods. One method fastens the regulator to the top, rear of alternator. With the other method the regulator is fastened separately by use of a wire and a connector that goes into the alternator.

The voltage regulator is a solid state (transistor, no moving parts) electronic switch. It feels the voltage in the system and gives the necessary field current (current to the field windings of the alternator) for the alternator to make the needed voltage. The voltage regulator controls the field current to the alternator by switching on and off many times a second. There is no voltage adjustment for this regulator.

Starting Circuit Components

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Solenoid A solenoid is a magnetic switch that does two basic operations: a. Closes the high current starter motor circuit with a low current start switch circuit. b. Engages the starter motor pinion with the ring gear.

SOLENOID SCHEMATIC

The solenoid switch is made of an electromagnet (two sets of windings) around a hollow cylinder.

There is a plunger (core) with a spring load inside the cylinder that can move forward and backward.

When electricity is sent thru the windings, a magnetic field is made that pulls the plunger forward in the cylinder. This moves the shift lever (connected to the rear of the plunger) to engage the pinion drive gear with the ring gear. The front end of the plunger then makes contact across the battery and motor terminals of the solenoid, and the starter motor begins to turn the flywheel of the engine.

The two windings in the solenoid are the hold-in winding and the pull-in winding. Both have the same number of turns around the cylinder, but the pull-in winding uses a larger diameter wire to produce a greater magnetic field. When the start switch is closed, part of the current flows from the battery thru the hold-in winding, and the rest flows thru the pull-in windings to motor terminal, then thru the motor to ground. When the solenoid is fully activated (connection across battery and motor terminal is complete), current is shut off thru the pull-in windings. Now only the smaller hold-in windings are in operation for the extended period of time it takes to start the engine. The solenoid will now take less current from the battery, and heat made by the solenoid will be kept at an acceptable level.

When the start switch is opened, current no longer flows thru hold-in windings. The spring now pushes the plunger back to the original position, and, at the same time, moves the pinion gear away from the flywheel.

Other Components Circuit Breaker The circuit breaker is a switch that opens the battery circuit if the current in the electrical system goes higher than the rating of the circuit breaker.

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CIRCUIT BREAKER SCHEMATIC 1. Reset button. 2. Disc in open position. 3. Contacts. 4. Disc. 5. Battery circuit terminals.

A heat activated metal disc with a contact point completes the electric circuit through the circuit breaker. If the current in the electrical system gets too high, it causes the metal disc to get hot. This heat causes a distortion of the metal disc which opens the contacts and breaks the circuit. A circuit breaker that is open can be reset after it cools. Push the reset button to close the contacts and reset the circuit breaker.

Wiring Diagrams

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WIRING DIAGRAM FOR D3 TRACTORS AND 931 TRACK-TYPE LOADERS WITH DI ENGINE

WIRING DIAGRAM FOR 910 WHEEL LOADERS WITH DI ENGINE

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WIRING DIAGRAM FOR D3 TRACTORS AND 931 TRACK-TYPE LOADERS WITH PC ENGINES

WIRING DIAGRAM FOR 910 WHEEL LOADERS WITH PC ENGINE (FROM 80U998-UP THERE IS NO DISCONNECT SWITCH)

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:59:22 UTC+0400 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Introduction SMCS - 1419-010; 3181 The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F. When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description, the specification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

NOTE: For Systems Operation and Testing and Adjusting, make reference to the 3204 Vehicular Engine, Form No. REG01222.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:59:48 UTC+0400 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Introduction SMCS - 1419-010; 3181 The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F. When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description, the specification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

NOTE: For Systems Operation and Testing and Adjusting, make reference to the 3204 Vehicular Engine, Form No. REG01222.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:59:53 UTC+0400 2019

All Rights Reserved.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Engine Design SMCS - 1419-010; 3181 Bore ... 4.5 in.(114.3 mm) Stroke ... 5.0 in.(127.0 mm) Number and Arrangement of Cylinders ... 4, in line Firing Order (Injection Sequence) ... 1, 3, 4, 2 Rotation of Crankshaft (when seen from flywheel end) ... Counterclockwise Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... Counterclockwise NOTE: Front end of engine is opposite to flywheel end. No. 1 cylinder is the front cylinder.

CYLINDER AND VALVE LOCATION (DI ENGINE)

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CYLINDER AND VALVE LOCATION (PC ENGINE)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320...Page 1 of 177

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Testing and Adjusting 3204 VEHICULAR ENGINE Media Number -REG01222-05

Publication Date -01/03/1984

Date Updated -10/10/2001

Testing And Adjusting SMCS - 1419-010; 3181

Introduction NOTE: For Specifications with illustrations, make reference to SPECIFICATIONS for 3204 VEHICULAR ENGINE, Form No. REG01254. If the Specifications in Form REG01254 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specification given in the book with the latest date.

Troubleshooting Troubleshooting can be difficult. The TROUBLESHOOTING INDEX gives a list of possible problems. To make a repair to a problem, make reference to the cause and correction on the pages that follow.

This list of problems, causes, and corrections will only give an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in the list.

Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. This list is only a guide and can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.

Troubleshooting Index 1. Engine Will Not Turn When Start Switch Is On. 2. Engine Will Not Start.

3. Engine Misfires or Runs Rough.

4. Stall at Low rpm.

5. Sudden Changes In Engine rpm.

6. Not Enough Power.

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7. Too Much Vibration.

8. Loud Combustion Noise.

9. Valve Train Noise (Clicking).

10. Oil In Cooling System.

11. Mechanical Noise (Knock) In Engine.

12. Fuel Consumption Too High.

13. Loud Valve Train Noise.

14. Too Much Valve Lash.

15. Valve Rotocoil or Spring Lock is Free.

16. Oil at the Exhaust.

17. Little or No Valve Clearance.

18. Engine Has Early Wear.

19. Coolant In Lubrication Oil. 20. Too Much Black or Gray Smoke.

21. Too Much White or Blue Smoke.

22. Engine Has Low Oil Pressure.

23. Engine Uses Too Much Lubrication Oil. 24. Engine Coolant Is Too Hot. 25. Starter Motor Does Not Turn.

26. Alternator Gives No Charge.

27. Alternator Charge Rate Is Low or Not Regular.

28. Alternator Charge Is Too High.

29. Alterntor Has Noise.

30. Exhaust Temperature Is Too High.

Engine Crankshaft Will Not Turn When Start Switch Is On

Engine Will Not Start

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Engine Misfires Or Runs Rough

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Stall At Low RPM

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Sudden Changes In Engine Speed (rpm)

Not Enough Power

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Too Much Vibration

Loud Combustion Noise (Sound)

Valve Train Noise (Clicking)

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Oil In Cooling System

Mechanical Noise (Knock) In Engine

Fuel Consumption Too High

Loud Valve Train Noise

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Too Much Valve Lash

Valve Rotocoil Or Spring Lock Is Free

Oil At The Exhaust

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Little Or No Valve Clearance

Engine Has Early Wear

Coolant In Lubrication Oil

Too Much Black Or Gray Smoke

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Too Much White Or Blue Smoke

Engine Has Low Oil Pressure

Engine Uses Too Much Lubrication Oil

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Engine Coolant Is Too Hot

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Starter Motor Does Not Turn

Alternator Gives No Charge

Alternator Charge Rate Is Low Or Not Regular

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Alternator Charge Too High

Alternator Has Noise

Exhaust Temperature Is Too High

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Fuel System Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system.

Many times work is done on the fuel system when the problem is really with some other part of the engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust.

Smoke that comes from the exhaust can be caused by a bad fuel injection valve, but it can also be caused by one or more of the reasons that follow: a. Not enough air for good combustion. b. An overload at high altitude. c. Oil leakage into combustion chamber. d. Not enough compression. e. Fuel injection timing retarded.

Fuel System Inspection To check for low fuel pressure, remove the fuel pressure switch or the pipe plug from the fuel filter base. Connect the 8M2743 Gauge from the 5P6225 Hydraulic Test Box to the hole where the switch or plug was removed. Run the engine at high idle and check the fuel pressure reading. The fuel pressure must be a minimum of 15 psi (105 kPa).

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. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.

2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a bad bend.

3. Install a new fuel filter. Clean the primary fuel filter.

4. Remove any air that may be in the fuel system. Use the priming pump to push the air through the return line to the fuel tank.

To remove air from the fuel injection lines, loosen the fuel line nuts 1/2 turn. Move the governor lever to the low idle position. Crank engine with the starter motor until fuel without air comes from the fuel line connections. Tighten the fuel line nuts.

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Checking Engine Cylinders Separately An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.

Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the injection pump and fuel injection nozzle for that cylinder.

Temperature of an exhaust manifold port, when a engine runs at low idle speed, can also be an indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of a nozzle with a defect.

Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by a nozzle with a defect.

The most common defects found with the fuel injection nozzles are: 1. Carbon on tip of the nozzle or in the nozzle orifice.

2. Orifice wear.

NOTICE Do not test nozzles unless you have the correct service tools.

Testing Fuel Injection Nozzles *

5P4150 Nozzle Testing Group.5P4244 Adapter.8S2270 Fuel Collector.FT1384 Extension.8S2245 Cleaning Tool Group.

8S2258 Brass Wire Brush.6V4979 Carbon Seal Installation Tool.

1F1153 Needle Nose Pliers.5P4721 Tube Assembly.7/64" Hex Wrench.

*

Special Instruction Form No. SEHS7292.

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5P4150 NOZZLE TESTING GROUP 1. Nozzle assembly. A. 5P4244 Adapter. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). C. 5P4721 Tube Assembly. D. 2P2324 Gauge, 0 to 5000 psi (0 to 34500 kPa). E. Gauge protector valve for 2P2324 Gauge. F. FT1384 Extension. G. Gauge protector valve for 5P4146 Gauge. H. On-off valve. J. 8S2270 Fuel Collector. K. Pump isolator valve.

EXTRA VALVE L. Gauge protector valve (must be in open position at all times).

NOTICE Be sure to use clean SAEJ967 Calibration Fluid when tests are made.

Dirty test fluid will damage components of fuel injection nozzles. The temperature of the test fluid must be 65 to 75°F (18 to 24°C) for good test results.

Order calibration fluid by part number, in the quantities needed, according to the information that follows: 6V6068 Calibration Fluid,5 U.S. gal. (18.9 liter).6V6067 Calibration Fluid,55 U.S. gal. (208.2 liter).

The fuel injection nozzle can not be disassembled for cleaning or adjustment. Do the tests that follow to determine if the nozzle performance is acceptable.

I. Valve Opening Pressure Test.

II. Flush the Nozzle.

III. Tip Leakage Test.

IV. Orifice Restriction Test.

V. Bleedscrew Leakage Test.

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Nozzle Preparation for Test Before fuel injection nozzle (1) can be tested, all loose carbon around the tip of the nozzle must be removed with the 8S2258 Brass Wire Brush (M).

REMOVING CARBON DAM 1. Fuel injection nozzle. 2. Carbon dam. 3. Seal. Remove carbon dam (2) with needle nose pliers and remove seal (3) from the nozzle.

NOTICE Do not use a steel brush or a wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. To much use of the 8S2258 Brass Wire Brush will also remove the coating that is on the nozzle for protection.

8S2245 CLEANING KIT M. 8S2258 Brass Wire Brush. N. 6V4979 Carbon Seal Tool. P. 8S2250 Nozzle Holding Tool.

Clean the groove for carbon seal dam (2) and the body of the nozzle below the groove with the 8S2258 Brass Wire Brush (M). Remove the carbon, but be sure not to use the brush enough to cause damage to the body of the nozzle.

NOTE: A change in color in the area below the groove is normal and does not effect the body of the nozzle.

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FUEL INJECTION NOZZLE 4. Bleed screw and seal.

Remove bleed screw and seal (4) from the nozzle.

NOTE: The bleed screw and seal must be removed for all tests except test V; Bleed Screw Leakage Test.

I. Valve Opening Pressure Test (VOP) 1. Install 5P4721 Tube Assembly (C) to the tester.

2. Install the fuel injection nozzle with 5P4244 Adapter (A) on tube assembly (C). Be sure the nozzle tip is down and extends into FT1384 Extension (F) and 8S2270 Fuel Collector (J).

When fuel injection nozzles are tested, be sure to wear eye protection.

Fuel comes from the orifices in the nozzle tip with high pressure. The fuel can pierce (go thru) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the 8S2270 Fuel Collector and FT1384 Extension.

NOTICE Put a shop towel around the upper part of the nozzle to take in any fuel leakage.

3. Close on-off valve (H). Open pump isolator valve (K).

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NOZZLE READY FOR TEST E. Gauge protector valve. H. On-off valve. K. Pump isolator valve.

4. Open gauge protector valve (E). Operate the pump to make a slow increase in pressure until the valve in the fuel injection nozzle just starts to open. Read the maximum gauge pressure at the instant fluid flows from the tip.

NOTE: It is possible for the pressure reading of the gauge to go down fast if the valve makes a noise (chatters) when it opens. It is also possible for the pressure reading of the gauge to be almost constant when the valve in the fuel injection nozzle opens.

NOTE: The valve in the fuel injection nozzle can be good and still not make a noise (chatter), or not have a very fine vapor (spray) from the orifices in the tip of the fuel injection nozzle during Step 4.

If the opening pressure is not within specifications, do not use the fuel injection nozzle again.

II. Flush the Nozzle 1. Close gauge protector valve (E). Close on-off valve (H). Open pump isolator valve (G).

NOTE: Make sure nozzle extends inside and below the top of FT1384 Extension (F).

2. Operate the pump rapidly for three full strokes.

III. Tip Leakage Test 1. Remove all fuel from the nozzle tip and body with a clean cloth.

2. Put a clean cloth around the body of the nozzle to take in any leakage from the bleed screw hole and prevent any fuel leakage to drain down to the tip of the nozzle.

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NOZZLE READY FOR TEST E. Gauge protector valve. H. On-off valve. K. Pump isolator valve.

3. Open gauge protector valve (E). Close on-off valve (H). Open pump isolator valve (K).

4. Make and hold for 15 seconds a pressure of 200 psi (1380 kPa) less than the opening pressure measured in VOP Test I and make a note of the number of drops that fall.

5. If the nozzle is not within specifications, DO NOT USE THE NOZZLE.

IV. Orifice Restriction Test 1. Close gauge protector valve (E) and on-off valve (H). Open pump isolator valve (K).

2. Point the tip of the fuel injection nozzle into the 8S2270 Fuel Collector and FT1384 Extension.

3. Make a slow increase in pressure and look at the orifice discharge pattern (shape of discharge) when fluid begins to flow thorugh the fuel injection nozzle. The discharge must be the same through all four orifices. Any change either vertically or horizontally, is an indication of a bad nozzle.

GOOD NOZZLE (USE AGAIN)

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TYPICAL DISCHARGE PATTERN FOR ORIFICE WITH A RESTRICTION (REPLACEMENT NECESSARY)

TYPICAL DISCHARGE PATTERN WITH HORIZONTAL DISTORTION (REPLACEMENT NECESSARY)

TYPICAL DISCHARGE PATTERN WITH VERTICAL DISTORTION (REPLACEMENT NECESSARY)

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V. Bleed Screw Leakage Test 1. Install bleed screw and seal (4) in fuel injection nozzle. Tighten the bleed screw to a torque of 16 ± 2 lb. in. (1.8 ± 0.2 N·m).

NOTICE Do not tighten the bleed screw more than the torque shown. The bleed screw or seal can be damaged.

2. Put the tip of the fuel injection nozzle down inside the 8S2270 Fuel Collector and FT1384 Extension.

3. Close on-off valve (H). Open gauge protector valve (E) and pump isolator valve (K).

4. Pump the tester until fuel injection nozzle is full of fluid and the pressure on the gauge is 4000 psi (27500 kPa).

NOTE: 15 or 20 strokes of the pump can be necessary for the pressure to get to 4000 psi (27500 kPa).

5. If there is leakage, replace the 8N4174 Seal. Inspect the washer face of the bolt for damage, replace if needed. Test the nozzle again. If there is still leakage, the fuel injection nozzle must be replaced.

6. If no fuel leakage is found, the fuel injection nozzle is acceptable. Put a new seal (3) on the nozzle.

Install a new carbon dam (2) in nozzle groove with 6V4979 Carbon Seal Tool (N).

INSTALLING CARBON DAM 2. Carbon dam. 3. Seal. N. 6V4979 Carbon Seal Tool.

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Fuel Injection Lines Fuel from the fuel injection pumps goes to the fuel injection nozzles through the fuel injection lines.

When fuel injection lines are disconnected or removed, always put caps or plugs on the ends to keep dirt out of the lines. When fuel injection lines are installed, be sure all clamps and dampers are installed in their original location.

The nuts that hold a fuel injection line to an injection nozzle and injection pump must be tightened to the correct torque. If the nut is loose, fuel will leak from the connection. If the nut is tightened too tight, the inside diameter of the line will become smaller and cause a restriction to the flow of fuel in the line. Use a torque wrench and a 5P144 Fuel Line Socket to tighten the fuel injection line nuts to 30 ± 5 lb. ft. (40 ± 7 N·m).

Fuel injection lines which are bent, damaged or rubbing can leak and cause a fire. Replace any lines which have damage or leaks that can not be corrected when tightened to the correct torque.

Checking The Plunger And Lifter Of An Injection Pump NOTE: There are no different size spacers available to adjust the timing dimension of the fuel injection pumps. If the pump plunger or the lifter is worn, they must be replaced. Because there is no adjustment to the timing dimension possible, there is NO OFF ENGINE LIFTER SETTING PROCEDURE. When there is too much wear on the fuel injection pump plunger, the lifter may also be worn and there will not be good contact between the two parts. To stop fast wear on the end of a new plunger, install new lifters in the place of the lifters that have wear.

WEAR BETWEEN LIFTER AND PLUNGER Fig. A. Illustrates the contact surfaces of a new pump plunger and a new lifter. In Fig. B the pump plunger and lifter have

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worn considerably. Fig. C shows how the flat end of a new plunger makes poor contact with a worn lifter, resulting in rapid wear to both parts.

An injection pump can have a good fuel flow coming from it but not be a good pump because of slow timing that is caused by wear on the bottom end of the plunger. When making a test on a pump that has been used for a long time, use a micrometer and measure the length of the plunger. If the length of the plunger is shorter than the minimum length (worn) dimension given in the chart, install a new pump.

Look for wear at the top part of the plunger. Check the operation of the plunger according to the instructions for the Fuel Injection Test Bench.

Removal And Installation Of Fuel Injection Pumps 8S4613 Wrench.8S2244 Extractor6V4186 Timing Pin.

Removal of Fuel Injection Pumps

NOTICE Before any parts are removed from the fuel injection pump housing, thoroughly clean all dirt from the housing. Dirt that gets inside the pump housing will cause much damage.

NOTE: The fuel rack must be in the center position before the fuel injection pumps can be removed.

1. Remove fuel filter base (1) and the fuel line from the fuel filter base to the fuel transfer pump.

2. Remove bolts (2) and timing pin cover (3) from the fuel injection pump housing.

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FUEL INJECTION PUMP HOUSING 1. Fuel filter base.

FUEL INJECTION PUMP HOUSING 2. Bolts. 3. Timing pin cover.

3. Move the governor lever to the FUEL OFF position and install timing pin (4) in the rack centering hole as shown.

4. With the timing pin in position, move the governor lever to the high idle position. The fuel rack will move until the edge of the groove in the rack makes contact with the timing pin. The fuel rack is now in the center position. Fasten the governor lever in the HIGH IDLE position.

TIMING PIN INSTALLED 4. Timing pin.

5. Remove the fuel injection line from the fuel injection pump.

6. Put the 8S4613 Wrench into spline of bushing that holds the fuel injection pump in the housing.

Remove the bushing.

7. Install 8S2244 Extractor (5) on the threads of the injection pump. Carefully pull the pump straight up out of the bore.

Be careful when an injection pump is disassembled. Do not damage the surface on the plunger. The plunger and barrel are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part is worn, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel. When injection pumps and spacers are removed from the fuel injection pump housing, keep the parts together so they can be installed in the same location in the housing.

Installation of Fuel Injection Pumps

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NOTICE The fuel rack MUST BE IN THE CENTER POSITION before the correct installation of an injection pump is possible.

1. Put the fuel rack in the center position. Make reference to Removal of Fuel Injection Pumps.

2. Put the 8S2244 Extractor on the threads of the fuel injection pump.

3. Make sure the lifter for the pump to be installed is at the bottom of its travel.

4. Put the groove of barrel (6) in alignment with the middle (fourth) tooth of gear segment (7).

5. Look into the bore for the fuel injection pump and locate both dowels. There is a dowel in the lifter and a dowel in the opposite side of the bore in the fuel injection pump housing. Put the groove in the pump barrel in alignment with the large dowel in the pump housing and put the slot (groove) on the opposite side of the gear teeth on the sector gear in alignment with the small dowel in the lifter. Install the fuel injection pump straight down into the bore.

6. Push down on extractor (5) (hand force only) and install O-ring and bushing that holds the injection pump in the pump housing. If the pump is in the correct position, the bushing will turn into the threads of the fuel injection housing with the fingers until it is even with the top of the housing. When the bushing is installed correctly, tighten the bushing to 120 ± 10 lb. ft. (160 ± 14 N·m).

FUEL PUMP INSTALLATION 5. 8S2244 Extractor. 6. Groove of barrel. 7. Fourth tooth of gear segment.

NOTICE The bushing must be tightened to the correct torque. Damage to the housing will be the result if the bushing is too tight. If the bushing is not tight enough, the pump will have leakage.

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7. Install the fuel injection line to the pump and tighten to 30 ± 5 lb. ft. (40 ± 7 N·m).

8. Remove timing pin (4) and install timing pin cover (3).

NOTICE If one or more of the fuel injection pumps have been installed wrong, it is possible for the engine to run out of control when started. When any of the fuel injection pumps have been removed and installed, take the precautions (steps) that follow to stop the engine if it starts to overspeed (run out of control).

a. Remove the air cleaner. b. Set the governor at low idle.

Be careful when plate is put against air inlet opening. Due to excessive suction, the plate can be pulled quickly against air inlet opening. To avoid crushed fingers, do not put fingers between plate and air inlet opening.

STOPPING THE ENGINE (TYPICAL EXAMPLE)

c. Start the engine, and if engine starts to overspeed (run out of control) put a steel plate over the air inlet to stop the engine.

Finding Top Center Compression Position For No. 1 Piston 5P7307 Engine Turning Tool Group.3/8-16 NC Bolt.

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No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.

1. Remove the valve cover.

2. Remove plug (1).

NOTE: The engine is seen from the flywheel end when direction of crankshaft rotation is given.

3. Remove the starter motor and install 5P7307 Engine Turning Tool Group.

4. Turn the flywheel clockwise approximately 60°.

LOCATION OF PLUG 1. Plug.

5. Now turn the flywheel counterclockwise until a 3/8" 16 NC bolt (2) can be put through hole (3) and installed in the timing bolt hole in the flywheel.

6. Look at the valves for No. 1 cylinder (the two valves at the front of the engine). The intake valve and exhaust valve for No. 1 cylinder must be closed. If they are closed, you will be able to move both rocker arms up and down by hand.

7. If the intake valve and exhaust valve for No. 1 cylinder are not closed, remove bolt (2). Turn the crankshaft counterclockwise 360° and install bolt (2). Both valves are now closed. This is top center (TC) compression position for No. 1 piston.

INSTALLING BOLT 2. Bolt. 3. Hole.

NOTE: If the flywheel bolt hole is turned beyond hole (3) and bolt (2) can not be installed, turn the flywheel clockwise approximately 60°. Then, turn it counterclockwise until bolt (2) can be installed.

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The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center.

Checking Engine Timing With 6V3100 Diesel Engine Timing Indicator Group 6V3100 Diesel Engine Timing Indicator Group.

Special Instruction Form No. SEHS7742 is with the tool group and gives instructions for the test procedure.

NOTICE The engine must be stopped while the timing indicator is being connected.

6V3100 DIESEL ENGINE TIMING INDICATOR GROUP 1. Engine timing indicator. 2. TDC magnetic transducer. 3. Pipe adapter. 4. Injection transducer. 5. 5P7437 Adapter. 6.

5P7435 Tee Adapter. 7. 5P7436 Adapter.

1. Make reference to Operation Instructions inside the lid of the 6V3100 Diesel Engine Timing Indicator Group for complete instructions and calibration.

2. Loosen all fuel line clamps that hold No. 1 fuel injection line and disconnect fuel injection line (8) for No. 1 cylinder at the fuel injection pump. Slide the nut up and out of the way. Put 5P7436 Adapter (7) in its place and turn adapter (7) onto the fuel pump bonnet until the top of the bonnet threads are approximately even with the bottom of the "window" in the adapter.

3. Put the 5P7435 Tee Adapter (6) on the Injection transducer (4) and put the end of the 5P7435 Tee Adapter (6) in the "window" of the 5P7436 Adapter (7).

4. Put fuel injection line (8) on top of 5P7435 Tee Adapter (6). Install 5P7437 Adapter (5) and tighten to 30 lb. ft. (40 N·m).

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TRANSDUCER IN POSITION (TYPICAL EXAMPLE) 4. Injection transducer. 8. Fuel injection line for No. 1 cylinder.

5. Remove the plug from the flywheel housing. Install pipe adapter (3) into the hole the plug was removed from. Tighten only a small amount.

6. Push the TDC magnetic transducer (2) into the pipe adapter (3) until it makes contact with the flywheel. Pull it back out 1.6 mm (.06 in.) and lightly tighten the knurled locknut.

7. Connect the cables from the transducers to the Engine Timing Indicator. Make a calibration check of the indicator. For calibration procedure, make reference to Special Instruction Form No. SEHS7742.

8. Start the engine. Get the engine to operating temperature. With the engine at low idle, check engine timing. Increase engine speed and check timing at 2100 rpm.

TRANSDUCER IN POSITION 2. TDC magnetic transducer.

The TIMING CHART gives the acceptable dynamic (engine in motion) timing range as read on the Timing Indicator Group. The TIMING CHART is for the 3204 Engine with 21 ± 1° static (engine stopped) timing.

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If the engine timing is not correct, make reference to CHECKING TIMING BY TIMING PIN METHOD for the procedure to change engine timing.

Checking Timing By Fuel Flow Method 1P540 Flow Checking Tool Group5P6524 Engine Timing Indicator Group 9S215 Dial Indicator3S3268 Contact Point, .25 in. (6.4 mm) long5P7266 Adapter3P1565 Collet 8S2296 Rod, 5.25 in. (133.4 mm) long6V2023 Flow Checking Adapter The distance of piston (7) from top center when inlet port (6) just closes can be determined by the use of the procedure that follows. Use the chart to find the conversion of dial indicator reading to crankshaft degrees.

MEASUREMENT OF PISTON TRAVEL 1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator and 3S3268 Contact Point. 3. 5P7266 Adapter. 4. 8S2296 Rod, 133.4 mm (5.25 in.) long. 5. Cylinder head. 6. Inlet port. 7. Piston.

NOTE: The fuel system timing has a tolerance of ± 1°.

NOTE: When reference is made to crankshaft rotation, the engine is seen from the flywheel end.

1. Put No. 1 piston at top center (TC) on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON. 2. Remove the timing bolt from the flywheel.

3. Remove No. 1 fuel injection line and nozzle.

4. Put a small amount of clean oil on 8S2296 Rod (4) and put the rod in 5P7266 Adapter (3).

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5. Put adapter (3) in same hole that No. 1 fuel nozzle was removed from. Fasten adapter (3) to head with bolt and spacer from fuel nozzle.

6. Install 3P1565 Collet Clamp (1) in the top of adapter (3).

7. Install 3S3268 Contact Point on 9S215 Dial Indicator (2) and put indicator (2) in adapter (3) thru collet (1).

8. Position the dial indicator (up or down) so small pointer is on "0" (zero) and tighten collet (1).

NOTICE Do not tighten collet too much or damage to the dial indicator can result.

9. Loosen the screw that locks the dial face. Move the dial face until the larger pointer is on "0" (zero) and tighten the lockscrew.

10. Turn the crankshaft a minimum of 45 degrees in a clockwise direction. Slowly turn the crankshaft in a counterclockwise direction until a maximum reading is seen on the dial indicator. Adjust the indicator up or down in the collet until the revolution counter is at +.300 in. (Black Numbers). Tighten the collet to hold the indicator in this position. Loosen the bezel lock and turn the bezel until the zero on the face of the dial is in alignment with the hand. Tighten the bezel lock.

11. Slowly turn the crankshaft in a counterclockwise direction until the dial indicator moves beyond .020 in. Now turn the crankshaft in the opposite direction until the dial indicator is at .020 in.

12. Make a pointer from a piece of wire and install on a bolt near the front pulley. Make a temporary mark on the front pulley in relation to the pointer.

13. Turn the crankshaft in a clockwise direction beyond the maximum indicator reading and beyond .020 in. Now turn the crankshaft in a counterclockwise direction until the dial indicator is .020 in.

14. Make a second temporary mark on the front pulley in relation to the pointer. Now make a mark on the front pulley that is one-half the distance between the two temporary marks. This mark is the point of most accuracy for top center No. 1 piston.

15. Turn the crankshaft in a clockwise direction approximately 45 degrees and then turn the crankshaft in a counterclockwise direction to the top center mark that was made in Step 14. If needed, adjust the dial indicator as in Step 10.

16. Turn the crankshaft in a clockwise direction approximately 45 degrees.

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6V2023 FLOW CHECKING ADAPTER GROUP 8. Tube. 9. Connector assembly. 10. Fitting. 11. Sealing washer. 12. Adapter. 13. Locknut. 14. Pin. 15. Nut.

17. Install 6V2023 Flow Checking Adapter Group on No. 1 fuel injection pump. Use the procedure that follows to install the group. a. Turn fitting (10) out of adapter (12) until .20 in. (5.0 mm) of pin (14) can be seen. b. Put 6V2023 Flow Checking Adapter Group on No. 1 fuel injection pump and tighten nut (15) to 30 lb. ft. (40 N·m). c. Turn fitting (10) into adapter (12) until pin (14) just makes contact with the reverse flow check valve in the fuel injection pump bonnet. This is the point of first resistance. d. Turn the fitting into the adapter an additional 1/4 turn. e. Move sealing washer (11) against the adapter. Tighten locknut (13) finger tight against sealing washer (11). f. Tighten tube (8) to connector assembly (9) so that the end of tube (8) is in a position above horizontal and higher than the end on the connector assembly.

18. Disconnect the fuel line at the fuel filter. Use an adapter to connect 5J4634 Hose Assembly (18) to the fuel filter base.

19. Disconnect the fuel return line from the constant bleed valve. Put cap (16) on the constant bleed valve.

If shop air is used, set the tank regulator to the minimum psi (kPa) setting. If air pressure is too high, fittings and hoses can be blown off or the tank can explode causing personal injury. Do not exceed 60 psi (415 kPa) air pressure in the tank.

20. Put 1 gal. (4 liters) of clean fuel in the tank assembly. Move the governor lever to full fuel-on position. Put 15 psi (105 kPa) of air pressure in the tank. Use the hand pump or shop air.

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FLOW CHECKING ADAPTER GROUP INSTALLED (TYPICAL EXAMPLE)

CONSTANT BLEED VALVE (TYPICAL EXAMPLE) 16. Cap.

21. Put pan (17) under the end of tube (8) for the fuel that comes out of the tube.

22. Turn the crankshaft, slow, in a counterclockwise direction. Do this until the flow of fuel from the end of tube assembly (8) is 6 to 12 drops per minute.

23. Stop rotation of the crankshaft when the flow of fuel is 6 to 12 drops per minute. Take a reading of the measurement on dial indicator (3).

24. To check for correct timing of the fuel system, make a comparison of the reading on the dial indicator (3) with the correct measurement in the chart. Timing must be set within ± 1° of correct timing angle.

FUEL FLOW CHECK OF TIMING (TYPICAL EXAMPLE) 8. Tube. 17. Pan. 18. 5J4634 Hose Assembly.

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NOTE: If the timing of the fuel system is more than 1° different than the correct timing angle given in the chart, make reference to INJECTION TIMING ADJUSTMENT (ON ENGINE).

Checking Timing By Timing Pin Method 6V4186 Timing Pin.FT1538 Fuel Pump Timing Gear PullerFT1823 Modified 15/16" Hex Socket5P8676 Extension 1. Put No. 1 piston at top center on the compression stroke. Make reference to LOCATING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON. Remove the timing bolt and rotate the crankshaft clockwise 30°.

2. Remove fuel filter base (1) and the fuel line from the fuel filter base to the fuel transfer pump.

3. Remove bolts (2) and timing pin cover (3) from the fuel injection pump housing.

FUEL INJECTION PUMP HOUSING 1. Fuel filter base.

4. Install 6V4186 Timing Pin (4) in the fuel injection pump housing as shown. Slowly rotate the crankshaft counterclockwise until timing pin (4) goes into the groove in the fuel pump camshaft.

5. Put the timing bolt in the timing hole in the flywheel housing. If the bolt can be installed in the timing hole in the flywheel, the timing of the fuel injection pump is correct.

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TIMING PIN COVER 2. Bolt. 3. Timing pin cover.

6. If the timing bolt does not go into the timing hole in the flywheel, the timing is not correct. Do the steps that follow to adjust the fuel injection pump timing.

7. Remove plug (5) from the front cover.

TIMING PIN INSTALLED 4. 6V4186 Timing Pin.

FRONT COVER 5. Plug.

NOTICE The tooling must be installed in the position shown so the locks will not damage the water passage in the timing gear cover.

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8. Install assembled tooling in the timing gear housing and tighten the locks to hold the tooling in place.

PULLER TOOLING ASSEMBLED 6. FT1823 Socket. 7. FT1538 Fuel Pump Timing Gear Puller. 8. 5P8676 Extension.

PULLER TOOLING INSTALLED

9. Turn the extension counterclockwise to loosen the bolt in the timing gear. As the bolt is loosened it will push against the assembled tooling and push the shaft of the pump drive through the timing gear to loosen the timing gear on the shaft.

10. Turn the flywheel clockwise, as seen from the flywheel end, at least 30° beyond the point where the 3/8"-16 NC bolt can be installed.

11. Tighten the bolt that holds the fuel pump drive gear finger tight. Turn the flywheel counterclockwise, as seen from the flywheel end, until the 3/8"-16 NC bolt can be installed in the flywheel.

12. Tighten the bolt that holds the fuel pump drive gear to 108 ± 5 lb. ft. (149 ± 7 N·m).

13. Remove the pin and bolt. Turn the flywheel two complete revolutions counterclockwise, as seen from the flywheel end. If the bolt and pin can be installed, the on engine timing is correct.

14. If the bolt and pin can not be installed, do steps 8 through 13 again.

Fuel Setting Procedure 6V4186 Timing Pin.6V2106 Rack Adjustment Tool Group.6V7941 Compressor, Overfueling Spring.6V2031 Rack Position Indicator Group.

9S229 Contact Point, .38 in. (9.7 mm) long.5P4814 Collet.6V3075 Dial Indicator.

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8S4627 Circuit Tester.

The static fuel setting can be done with the fuel injection pump and governor on or off the engine.

1. Remove the fuel filter and base from the fuel injection pump housing. Remove cover (1) from the side of the fuel injection pump housing.

FUEL INJECTION PUMP AND GOVERNOR 1. Cover.

2. Install 5P4814 Collet (2) on 6V2014 Bracket Assembly (3).

BRACKET ASSEMBLY INSTALLED 2. 5P4814 Collet. 3. Bracket assembly.

3. Install the bracket assembly on the fuel pump housing. Lever (5) on the bracket assembly must be in slot (4) on the fuel rack. Push up on the bracket assembly while the bolts are tightened.

After the bracket assembly is tightened to the pump housing, shaft (6) must have axial (in and out) movement. If there is no axial movement of shaft (6), check to be sure lever (5) is in the slot on the fuel rack and that the bracket assembly is installed correctly. Check to make sure that lever (5) is not bent. Lever (5) must be perpendicular (at right angle) to the mounting face of the bracket assembly.

4. Put 9S229 Contact Point, .38 in. (9.7 mm) long on 6V3075 Dial Indicator (7) and install dial indicator in collet (2).

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COVER REMOVED 4. Slot on fuel rack.

BRACKET ASSEMBLY 5. Lever. 6. Shaft.

DIAL INDICATOR INSTALLED 7. 6V3075 Dial Indicator.

5. Remove plug (8) from the rear of the governor housing.

6. Move the governor control lever to the FUEL OFF position (rotate governor shaft clockwise).

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REAR OF GOVERNOR HOUSING 8. Plug.

TIMING PIN INSTALLED 9. 6V4186 Timing Pin.

7. Install 6V4186 Timing Pin (9) in the hole in the bracket assembly. Push timing pin in until contact is made with the fuel rack. Hold the timing pin gently against the fuel rack for Steps 8 and 9. If too much force is used to hold the timing pin the fuel rack can stick and cause an incorrect zero reading.

8. Hold the governor control lever in the HIGH IDLE position (rotate governor shaft counterclockwise).

9. Insert 6V7942 Hook (10) into the hole that plug (8) was removed from. Engage the end of hook (10) with collar (11) and pull toward the rear of the governor housing until the collar stops moving.

This will make sure the fuel rack stops against the timing pin. This is the rack zero position.

10. With the hook still pulled toward the rear of the governor, loosen collet (2) and adjust the revolution counter on the dial indicator to zero. Tighten the collet just enough to hold the indicator in this position. Move the dial of the indicator to get alignment of the pointer and zero.

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6V7942 HOOK IN USE 10. 6V7942 Hook.

CUTAWAY VIEW OF GOVERNOR 10. Hook. 11. Collar.

6V7941 COMPRESSOR ASSEMBLY 12. Rod. 13. Knob.

11. Remove timing pin (9).

12. Turn rod (12) out of 6V7941 Compressor Assembly (14) until knob (13) is 1.0 in. (25.4 mm) from the compressor body. Install 6V7941 Compressor Assembly (14) in the hole plug (8) was removed from.

NOTE: The 6V7941 Compressor Assembly is used to compress the overfueling spring. The overfueling spring must be compressed to get an accurate fuel setting measurement.

COMPRESSOR ASSEMBLY INSTALLED 14. 6V7941 Compressor Assembly.

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NOTE: The procedure to check the fuel setting is different than the procedure to adjust the fuel settings. Follow Steps 13 through 17 to check the fuel settings. Follow Steps 18 through 23 to adjust the fuel settings.

13. Fasten the clip end of 8S4627 Circuit Tester (15) to rack contact screw (16) and put the other end to a good electrical ground.

CHECKING STATIC FUEL SETTING 15. 8S4627 Circuit Tester. 16. Rack contact screw. 17. Adjustment screw cover.

14. Hold the governor control lever in the FUEL ON position (rotate lever fully counterclockwise).

15. Turn rod (12) of compressor assembly (14) in (clockwise) until the light in circuit tester (15) goes off and the dial indicator hands move an additional 2 mm in the negative (-) direction after the light goes out.

NOTICE DO NOT turn the rod any further in if the rod begins to tighten.

Damage to the governor can occur if the rod is turned in further.

16. Slowly turn rod (12) out (counterclockwise) until the circuit tester light just comes on. This is the static fuel setting. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct static fuel setting.

NOTE: When the rod is turned out, there will be a small initial movement of the dial indicator hands, then, they will stop moving while the rod is turned out for approximately another 11/2 turns. Now the indicator hands will begin to move again and will follow the turning of the rod until the setting is reached. It is important that the rod be turned slowly so that the rack can follow the governor components.

17. Continue to turn the rod out until the indicator hand stops moving. Then turn the rod out two additional turns. The reading on the indicator is the torque rise static setting. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct static torque rise setting.

18. If the fuel setting or the torque rise setting is not correct, remove adjustment screw cover (17) from the rear of the governor housing.

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ADJUSTMENT SCREW COVER REMOVED 18. Torque rise adjustment screw. 19. Fuel setting screw.

19. Determine how much the settings will have to be changed (see examples). Use the chart that follows to determine how far the adjusting screws must be turned.

Example #1

Since "desired setting" is higher than "actual reading," turn adjusting screw out (counterclockwise) approximately 1/4 turn. Recheck the new setting and readjust if necessary.

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Example #2

Since "desired setting" is lower than "actual reading," turn adjusting screw in (clockwise) approximately 11/8 turn. Recheck the new setting and readjust if necessary.

Example #3

Negative numbers work differently than positive numbers. If one number (-1.25) has a larger digital value than another one (-1.05), the first number (-1.25) is actually less than the other one. Therefore, in this example the "desired setting" is lower than the "actual reading." Turn the adjusting screw in (clockwise) approximately 1/4 turn. Recheck the new setting and readjust if necessary.

Example #4

The "desired setting" is higher than the "actual reading." Turn the adjusting screw out (counterclockwise) approximately 11/8 turns. Recheck the new setting and readjust if necessary.

Example #5

The "desired setting" is lower than the "actual reading." Turn the adjusting screw in approximately 27/8 turns.

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Example #6

The "desired setting" is higher than the "actual reading." Turn the adjusting screw out approximately 27/8 turns.

20. If both settings are to be increased, turn torque rise adjustment screw (18) out (counterclockwise) the same number of turns as fuel setting adjustment screw (19) is going to be changed. If the static fuel setting is going to be decreased, it is not necessary to change the torque rise setting at this time.

21. Use 6V2106 Rack Adjustment Tool Group (20) to loosen the locknuts for adjustment screws and to turn the adjustment screws.

ADJUSTING FUEL SETTING 20. 6V2106 Rack Adjustment Tool Group.

22. Adjust the fuel setting screw the number of turns determined in Step 19. Always recheck the setting after each adjustment and adjust again if needed.

23. After the static fuel setting is correct, adjust the torque rise adjustment screw the number of turns determined in Step 19. Always recheck the setting after each adjustment and adjust again if needed.

Engine Speed Measurement 6V3121 Multitach Group or6V4950 Injection Line Speed Pickup Group

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6V3121 MULTITACH GROUP 1. Carrying case. 2. Power cable. 3. Tachometer generator. 4. Tachometer drive group. 5. Multitach.

The 6V3121 Multitach Group can measure engine speed from a tachometer drive on the engine. It also has the ability to measure engine speed from visual engine parts in rotation.

6V4950 INJECTION LINE SPEED PICKUP GROUP 6. 6V6144 Pickup. 7. 6V6113 Amplifier.

Special Instruction Form No. SEHS7807 is with the 6V3121 Multitach Group and gives instructions for the test procedure.

The 6V4950 Injection Line Speed Pickup Group is another diagnostic tool accessory that can be used with the 6V2100 Multitach. It can be used on all Caterpillar Diesel Engines equipped with .25 in. (6 mm) single wall fuel injection lines. With this pickup group, engine speed can be measured quickly, automatically, and with an accuracy of ± 1 rpm.

Special Instruction Form No. SEHS8029 is with the group and gives instructions for use of the 6V4950 Injection Line Speed Pickup Group.

Governor Adjustments NOTICE A mechanic with training in governor adjustments is the only one to make the adjustment to the set point rpm.

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Engine rpm must be checked with an accurate tachometer. Make reference to ENGINE SPEED MEASUREMENT.

Low Idle Adjustment NOTE: The correct LOW IDLE rpm is given in the FUEL SETTING AND RELATED INFORMATION FICHE.

To help prevent an accident caused by parts in rotation, work carefully around an engine that has been started.

Start the engine and run until the temperature of normal operation is reached. Check low idle rpm with no load on the engine. If an adjustment is necessary, use the procedure that follows: 1. To adjust the LOW IDLE rpm, start the engine and run with the governor in the low idle position.

Loosen the locknut for low idle screw (2). Turn the low idle screw to get the correct low idle rpm.

Increase engine speed and return to low idle and check low idle speed again. Tighten the locknut.

LOW IDLE ADJUSTMENT 1. Cover. 2. Low idle screw.

Checking Set Point (Balance Point) The engine set point is an adjusted specification and is important to the correct operation of the engine. High idle rpm is NOT an adjusted specification. Set point (formerly balance point) is full load rpm plus an additional 20 rpm. Set point is the rpm at which the fuel setting adjustment screw and stop or first torque spring just start to make contact. At this rpm the fuel setting adjustment screw and stop or first torque spring still have movement between them. When additional load is put on the engine, the fuel setting adjustment screw and stop or first torque spring will become stable against each other. Set point is controlled by the fuel setting and the high idle adjustment screw.

There is a new and more accurate method for checking the "set point," formerly called the balance point, of the engine. If the tools for the new method are not available, there is an alternate method for checking the "set point."

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6V4060 Engine Set Point Indicator Group.

The 6V4060 Engine Set Point Indicator Group with the 6V2100 Multitach can be used to check the set point. Special Instruction Form No. SEHS7931 gives instructions for installation and use of this tool group.

6V4060 ENGINE SET POINT INDICATOR GROUP

Alternate Method 8S4627 Circuit Tester.6V3121 Multitach Group.

If the set point is correct and the high idle speed is within specifications, the fuel system operation of the engine is correct. The set point for the engine is: A. At 20 rpm greater than full load speed.

B. The rpm where the fuel setting adjustment screw and stop or first torque spring just make contact.

Use the procedure that follows to check the set point. Make reference to TECHNIQUES FOR LOADING ENGINES in Special Instruction Form No. SEHS7050.

TERMINAL LOCATION 3. Brass terminal screw.

1. Connect a tachometer which has good accuracy to the tachometer drive.

2. Connect the clip end of the 8S4627 Circuit Tester to the brass terminal screw (3) on the governor housing. Connect the other end of the tester to a place on the fuel system which is a good ground connection.

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

3. Start the engine.

4. With the engine at normal conditions for operation, run the engine at high idle.

5. Make a record of the speed of the engine at high idle.

6. Add load on the engine slowly until the circuit tester light just comes on (minimum light output).

This is the set point.

7. Make a record of the speed (rpm) at the set point.

8. Repeat Step 6 several times to make sure that the reading is correct.

9. Stop the engine. Make a comparison of the records from Steps 5 and 7 with the information from the ENGINE INFORMATION PLATE. If the ENGINE INFORMATION PLATE is not available see the FUEL SETTING AND RELATED INFORMATION FICHE. The tolerance for the set point is ± 10 rpm. The tolerance for the high idle rpm is ± 30 rpm. If the readings from Steps 5 and 7 are within the tolerance, no adjustment is needed.

NOTE: It is possible in some applications that the high idle rpm will be less than the lower limit. This can be caused by high parasitic loads such as hydraulic pumps, compressors, etc.

Adjusting Set Point (Balance Point) 1. If the set point and the high idle rpm are within tolerance, no adjustment is to be made.

2. If the set point rpm is not correct, remove cover (1) and loosen locknut. Turn adjustment screw (4) to adjust the set point to the mid point of the tolerance.

SET POINT ADJUSTMENT 4. Adjustment screw.

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3. When the set point is correct, check the high idle rpm. The high idle rpm must not be more than the high limit of the tolerance.

If the high idle rpm is more than the high limit of the tolerance, check the governor spring and flyweights. If the high idle rpm is less than the low limit of the tolerance, check for excess parasitic loads and then the governor spring and flyweights.

Dashpot Screw Adjustment

DASHPOT SCREW ADJUSTMENT 1. Dashpot adjustment screw.

The dashpot adjustment screw does not normally need adjustment from the factory setting. If the engine is slow to change rpm with a change in load, it is possible that the dashpot adjustment screw is not adjusted correctly.

1. Turn dashpot adjustment screw (1) in (clockwise) until it stops.

2. Turn dashpot adjustment screw out (counterclockwise) 1/2 ± 1/4 turn.

Fuel System (Earlier & Later) Later Fuel System NOTICE Later engine arrangements, shown on the chart, have a different fuel injection pump group. The later engines use a timing pin to set the fuel injection pump timing. Fuel system adjustment procedures and timing for later engines have changed.

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Fuel System (Earlier & Later) Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system.

Many times work is done on the fuel system when the problem is really with some other part of the engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust.

Smoke that comes from the exhaust can be caused by a bad fuel injection valve, but it can also be caused by one or more of the reasons that follow: a. Not enough air for good combustion. b. An overload at high altitude. c. Oil leakage into combustion chamber. d. Not enough compression.

Fuel System Inspection 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. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.

2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a bad bend.

3. Install a new fuel filter. Clean the fuel screen located in the inlet valve of the fuel transfer pump.

4. Remove any air that may be in the fuel system. If there is air in the fuel system, use the priming pump and loosen the nuts holding the fuel lines to the outside of the cylinder head, one at a time. Do this until fuel, without air, comes from the fuel line connection.

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Checking Engine Cylinders Separately An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.

Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the injection pump and injection valve for that cylinder.

Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of a nozzle with a defect.

Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by a nozzle with a defect.

The most common defects found with the fuel injection valves are: 1. Carbon on tip of the nozzle or in the nozzle orifice.

2. Orifice wear.

3. Dirty nozzle screen.

NOTICE Do not test or disassemble nozzles unless you have the correct service tools.

NOTE: Do not disassemble fuel nozzles before they have been tested. See TESTING FUEL INJECTION NOZZLES FOR DI ENGINES or TESTING CAPSULE-TYPE FUEL INJECTION NOZZLES FOR PC ENGINES.

Testing 9L6969 Fuel Injection Nozzles For DI Engines *

5P4150 Nozzle Testing Group.5P4244 Adapter.8S2270 Fuel Collector.FT1384 Extension.8S2245 Cleaning Tool Group.

8S2258 Brass Wire Brush.8S2250 Nozzle Holding Tool.8S2252 Carbon Seal Installation Tool.

1F1153 Needle Nose Pliers.8H8505 Combination Wrench.8H8502 Combination Wrench.8S2274 Socket.8S1589 Socket.9S5031 Socket.5P4813 Socket.5/64" Hex Wrench.

*

Special Instruction Form No. SEHS7292.

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5P4150 NOZZLE TESTING GROUP A. 5P4721 Tube. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa) used to test PC capsule valves. C. 2P2324 Gauge, 0 to 5000 psi (0 to 34 500 kPa) used to test DI capsule valves and pencil-type nozzles. D. Gauge protector valve for 5P4146 Gauge (B). E. Gauge protector valve for 2P2324 Gauge (C). F. On-off valve. G. Pump isolator valve. H. 5P4720 Fitting. J. 5P8744 Adapter for capsule nozzles. K. 5P4244 Adapter for pencil-type nozzles.

NOTICE Be sure to use clean SAE J967 Calibration Fluid when tests are made.

Dirty test fluid will damage components of fuel injection nozzles. The temperature of the test fluid must be 65 to 75° F (18 to 24° C) for good test results.

EXTRA VALVE L. Gauge protector valve (must be in open position at all times).

Order calibration fluid by part number, in the quantities needed, according to the information that follows: 6V6068 Calibration Fluid, 5 U.S. gal. (18.9 liter).

6V6067 Calibration Fluid, 55 U.S. gal. (208.2 liter)

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To test a DI fuel injection nozzle, all six steps of the test procedure must be completed, and the step sequence must be follows: I. Return Leakage Test.

II. Valve Opening Pressure Test.

III. Flush the Nozzle.

IV. Tip Leakage Test.

V. Orifice Restriction Test.

VI. Cap Leakage Test.

NOTE: Do all tests before the nozzle is disassembled for cleaning, or before any adjustments are made to a nozzle. A test can show that the nozzle must not be used again.

Nozzle Preparation for Test Before fuel injection nozzle (1) can be tested, all loose carbon around the tip of the nozzle must be removed with the 8S2258 Brass Wire Brush (M).

REMOVING CARBON DAM 1. Fuel injection nozzle. 2. Carbon dam. 3. Seal. Remove carbon dam (2) with a needle nose pliers and remove seal (3) from the nozzle.

NOTICE Do not use a steel brush or a wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. Too much use of the 8S2258 Brass Wire Brush will also remove the coating that is on the nozzle for protection.

Clean the groove for carbon seal dam (2) and the body of the nozzle below the groove with the 8S2258 Brass Wire Brush (M). Remove the carbon, but be sure not to use the brush enough to cause damage to the body of the nozzle.

NOTE: A change in color in the area below the groove is normal and does not effect the body of the nozzle.

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8S2245 CLEANING KIT (M) 8S2258 Brass Wire Brush. (N) 8S2252 Carbon Seal Tool. (P) 8S2250 Nozzle Holding Tool.

I. Return Leakage Test 1. Put nozzle (1) and 8S2250 Nozzle Holding Tool (P) in a vise and remove cap (4).

FUEL INJECTION NOZZLE 4. Cap. 5. Nut.

2. Use 5P4244 Adapter (Q) to connect fuel injection nozzle (1) to the tester. Nut (5) can be tightened by hand if 1H1023 O-ring Seal (6) is not damaged.

3. Install FT1384 Extension (R) in 8S2270 Fuel Collector (S) and put parts into position under nozzle.

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FUEL INJECTION NOZZLE CONNECTOR 5. Nut. 6. 1H1023 O-ring Seal for fuel line.

4. Put the tip of the fuel injection nozzle a little above the horizontal position. Tighten the nut by hand that connects the fuel injection nozzle to the tester.

NOZZLE POSITION FOR RETURN LEAKAGE TEST 1. Fuel injection nozzle. Q. 5P4244 Adapter. R. FT1384 Extension. S. 8S2270 Fuel Collector.

5. Close on-off valve (F). Open pump isolator valve (G).

6. Open gauge protector valve (E) and operate the tester slowly until the pressure is at 1400 to 1600 psi (9630 to 11045 kPa).

7. Look at the leakage from the return at the top (pressure screw end) of the fuel injection nozzle.

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II. Valve Opening Pressure Test (VOP) 1. Loosen nut (5) and turn nozzle tip down so that it extends into FT1384 Extension (R) as shown.

2. Tighten nut (5) to 5P4244 Adapter (Q). Nut (5) can be tightened by hand if 1H1023 O-ring Seal (6) is not damaged.

3. Close on-off valve (F). Open pump isolator valve (G).

NOZZLE CONNECTED TO 5P4150 NOZZLE TESTER

When fuel injection nozzles are tested, be sure to wear eye protection.

Test fluid comes from the orifices in the nozzle tip with high pressure.

The fluid can pierce (go thru) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the 8S2270 Fuel Collector and FT1384 Extension.

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NOZZLE READY FOR TEST E. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

NOTICE Put a shop towel around the top of the nozzle (pressure screw end) to take in any fuel leakage.

4. Open gauge protector valve (E). Operate the pump to make a slow increase in pressure until the valve in the fuel injection nozzle just starts to open. Read the maximum gauge pressure at the instant fluid flows from the tip.

NOTE: It is possible for the pressure reading of the gauge to go down fast if the valve makes a noise (chatters) when it opens. It is also possible for the pressure reading of the gauge to be almost constant when the valve in the fuel injection nozzle opens.

NOTE: The valve in the fuel injection nozzle can be good and still not make a noise (chatter), or not have a very fine vapor (spray) from the orifices in the tip of the fuel injection nozzle during Step 4.

If the opening pressure is less than 1900 psi (13 090 kPa), do not use the fuel injection nozzle again.

III. Flush the Nozzle 1. Close gauge protector valve (E). Close on-off valve (F). Open pump isolator valve (G).

NOTE: Make sure nozzle extends inside and below the top of FT1384 Extension (R).

2. Operate the pump rapidly for three full strokes.

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IV. Tip Leakage Test 1. Remove all fuel from the nozzle tip and body with a cloth.

2. Put a clean cloth around the top of the body of the fuel injection nozzle (pressure screw end) to take in the leakage and prevent any fuel leakage to drain down to the tip of the nozzle.

CLOTH ON TOP OF NOZZLE E. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

3. Open gauge protector valve (E). Be sure the nozzle tip is completely dry.

4. Make and hold for 15 seconds a pressure of 200 psi (1380 kPa) less than the opening pressure measured in VOP Test II. 5. If nozzle is not within specification, do not use the nozzle.

V. Orifice Restriction Test 1. Close gauge protector valve (E) and on-off valve (F). Open pump isolator valve (G).

2. Point the tip of the fuel injection nozzle into the 8S2270 Fuel Collector and FT1384 Extension.

3. Make a rapid increase in pressure and look at the orifice discharge pattern (shape of discharge) when fluid begins to flow through the fuel injection nozzle. The discharge must be the same through all four orifices. Any change, either vertically or horizontally, is an indication of a bad nozzle.

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GOOD NOZZLE (USE AGAIN)

TYPICAL DISCHARGE PATTERN FOR ORIFICE WITH A RESTRICTION (RECONDITIONING OR REPLACEMENT NECESSARY)

TYPICAL DISCHARGE PATTERN WITH HORIZONTAL DISTORTION (RECONDITIONING OR REPLACEMENT NECESSARY)

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TYPICAL DISCHARGE PATTERN WITH VERTICAL DISTORTION (RECONDITIONING OR REPLACEMENT NECESSARY)

VI. Cap Leakage Test 1. Remove fuel injection nozzle (1) from the 5P4150 Nozzle Tester and put it in 8S2250 Nozzle Holding Tool (P).

NOZZLE CAP INSTALLATION 1. Fuel injection nozzle. 4. Cap. 6. 1H1023 O-ring Seal.

2. Install new 1H1023 O-ring Seal (6).

3. Install cap (4) and tighten to 110 to 120 lb. in. (12.4 to 13.6 N·m).

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TIGHTENING CAP 7. 9S5031 Socket. P. 8S2250 Nozzle Holding Tool.

NOTICE Do not tighten the cap more than torque shown or the new O-ring seal will be damage.

4. Put fuel injection nozzle (1) on the 5P4150 Nozzle Tester with the nozzle tip in the 8S2270 Fuel Collector and FT1384 Extension.

5. With gauge protector valve (E) open, pump the tester until cap (4) is completely full of fuel and the pressure on the gauge is 4000 psi (27 500 kPa).

NOTE: 15 to 20 strokes of the pump can be necessary for the pressure to reach 4000 psi (27 500 kPa).

6. If there is leakage, make a replacement of 1H1023 Seal (6) and inspect cap (4) for cracks. Test the nozzle again. If there is still leakage, replacement of fuel injection nozzle is necessary.

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INSTALLING CARBON DAM 2. Carbon dam. 3. Seal. N. 8S2252 Carbon Seal Tool.

7. If no fuel leakage is found, fuel injection nozzle is acceptable. Slide new seal (3) into position over the nozzle. Install new carbon dam (2) in nozzle groove with 8S2252 Carbon Seal Tool (N).

Troubleshooting Of 9L6969 Fuel Injection Nozzles Use the guide that follows to troubleshoot for problems with the fuel injection nozzles.

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Adjustment And Cleaning Of 9L6969 Fuel Injection Nozzles For the procedure to clean the nozzles, see Special Instruction Form No. SEHS7292.

NOTE: Do not clean or adjust a nozzle with a valve opening pressure (VOP) less than 1900 psi (13 090 kPa).

Valve Opening Pressure (VOP) Adjustment

FUEL INJECTION NOZZLE 1. Fuel injection nozzle. 2. Locknut (for pressure adjustment screw). 3. Pressure adjustment screw. 4. 1H1023 O-ring Seal for cap. 5. Locknut (for lift adjustment screw). 6. Lift adjustment screw.

1. Remove fuel injection nozzle (1) from the 5P4150 Nozzle Tester and put it in the 8S2250 Nozzle Holding Tool (P).

LOOSENING LOCKNUT 1. Fuel injection nozzle. 7. 8H8502 Combination Wrench. P. 8S2250 Nozzle Holding Tool.

2. Loosen locknut (5) that holds lift adjustment screw (6). Turn lift adjustment screw (6) counterclockwise two turns.

NOTICE If the lift adjustment screw is not turned counterclockwise two turns, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.

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3. Hold lift adjustment screw (6) with a 5/64" hex wrench (8) and remove locknut (5).

REMOVING LOCKNUT 5. Locknut (for lift adjustment screw). 8. 5/64" hex wrench.

LOOSENING LOCKNUT 1. Fuel injection nozzle. 9. 8H8505 Combination Wrench.

4. Loosen locknut (2) that holds pressure adjustment screw (3).

5. Put fuel injection nozzle (1) on the nozzle tester. Turn pressure adjustment screw (3) clockwise with 5P4813 Socket (10). Each one-fourth of a turn will increase the opening pressure approximately 250 psi (1720 kPa).

OPENING PRESSURE ADJUSTMENT 10. 5P4813 Socket.

6. Turn pressure adjustment screw (3) clockwise until the valve opening pressure is within specifications.

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NOTE: If nozzle can not be adjusted to specifications, make a replacement of the nozzle.

TIGHTENING LOCKNUT 1. Fuel injection nozzle. 9. 8H8505 Combination Wrench. 10. 5P4813 Socket.

7. Hold pressure adjustment screw (3) and tighten locknut (2) just enough so that pressure adjustment screw (3) will not turn.

8. After the opening pressure adjustment is made, install locknut (5) that holds lift adjustment screw (6). Make the valve lift adjustment. See VALVE LIFT ADJUSTMENT.

Valve Lift Adjustment 1. With the valve opening pressure correct, pump test oil through the fuel injection nozzle. At the same time, hold locknut (5) and slowly turn lift adjustment screw (6) clockwise until the pressure starts to increase above the opening pressure.

2. To be sure the valve is on the seat, increase the pressure 200 to 500 psi (1380 to 3450 kPa) more than the opening pressure.

NOTICE Do not bend the valve or damage the seat by turning lift adjustment screw (6) with too much force.

NOTE: Some test fluid can be at the tip of the fuel injection nozzle, but a constant flow of drops (dribble) must not be seen.

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TIGHTENING LOCKNUT 1. Fuel injection nozzle. 7. 8H8502 Combination Wrench. 8. 5/64" Hex Wrench.

3. Turn lift adjustment screw (6) counterclockwise 3/4 ± 1/8 of a turn.

4. Hold lift adjustment screw (6) with 5/64" hex wrench (8) and tighten locknut (5) just enough so that lift adjustment screw (6) will not turn.

Tightening Locknuts and Cap 1. Remove fuel injection nozzle (1) from the 5P4150 Nozzle Tester and put it in 8S2250 Nozzle Holding Tool (P).

FUEL INJECTION NOZZLE 1. Fuel injection nozzle. 2. Locknut (for pressure adjustment screw). 3. Pressure adjustment screw. 4. 1H1023 O-ring Seal for cap. 5. Locknut (for lift adjustment screw). 6. Lift adjustment screw.

2. Tighten locknut (2) that holds pressure adjustment screw (3) to 70 to 80 lb. in. (8.0 to 9.1 N·m).

TIGHTENING PRESSURE SCREW LOCKNUT (Typical Example) 11. 8S2274 Socket. P. 8S2250 Nozzle Holding Tool.

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3. Tighten locknut (5) that holds lift adjustment screw (6) to 35 to 45 lb. in. (4.0 to 5.1 N·m).

TIGHTENING VALVE LIFT SCREW LOCKNUT (Typical Example) 12. 8S1589 Socket.

4. Install new 1H1023 O-ring seal (4).

5. Install the cap and tighten to 110 to 120 lb. in. (12.4 to 13.6 N·m).

NOTICE Do not tighten the cap more than torque shown or the new O-ring seal will be damaged.

TIGHTENING CAP 13. 9S5031 Socket.

With the adjustments and tests complete, check for leakage between the cap and the body of the fuel injection nozzle. See Cap Leakage Test in section TESTING 9L6969 FUEL INJECTION NOZZLES.

Testing 9N3979 And 1W5829 Fuel Injection Nozzles For DI Engines *

5P4150 Nozzle Testing Group.5P4244 Adapter.8S2270 Fuel Collector.FT1384 Extension.8S2245 Cleaning Tool Group.

8S2258 Brass Wire Brush.8S2250 Nozzle Holding Tool.8S2252 Carbon Seal Installation Tool.

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1F1153 Needle Nose Pliers.8H8505 Combination Wrench.8H8502 Combination Wrench.8S2274 Socket.8S1589 Socket.9S5031 Socket.5P4813 Socket.5/64" Hex Wrench. *

Special Instruction Form No. SEHS7292.

5P4150 NOZZLE TESTING GROUP A. 5P4721 Tube. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa) used to test PC capsule valves. C. 2P2324 Gauge, 0 to 5000 psi (0 to 34 500 kPa) used to test DI capsule valves and pencil-type nozzles. D. Gauge protector valve for 5P4146 Gauge (B). E. Gauge protector valve for 2P2324 Gauge (C). F On-off valve. G. Pump isolator valve. H. 5P4720 Fitting. J. 5P8744 Adapter for capsule nozzles. K. 5P4244 Adapter for pencil-type nozzles.

EXTRA VALVE L. Gauge protector valve (must be in open position at all times).

NOTICE Be sure to use clean SAE J967 Calibration Fluid when tests are made.

Dirty test fluid will damage components of fuel injection nozzles. The temperature of the test fluid must be 65 to 75°F (18 to 24°C) for good test results.

Order calibration fluid by part number, in the quantities needed, according to the information that follows: 6V6068 Calibration Fluid, 5 U.S. gal. (18.9 liter).

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6V6067 Calibration Fluid, 55 U.S. gal. (208.2 liter) To test a fuel injection nozzle, all five steps of the test procedure must be completed, and the step sequence must be as follows: I. Valve Opening Pressure Test.

II. Flush the Nozzle.

III. Tip Leakage Test.

IV. Orifice Restriction Test.

V. Cap Leakage Test.

NOTE: Do all tests before the nozzle is disassembled for cleaning, or before any adjustments are made to a nozzle. A test can show that the nozzle must not be used again.

Nozzle Preparation for Test Before fuel injection nozzle (1) can be tested, all loose carbon around the tip of the nozzle must be removed with the 8S2258 Brass Wire Brush (M).

REMOVING CARBON DAM 1. Fuel injection nozzle. 2. Carbon dam. 3. Seal. Remove carbon dam (2) with needle nose pliers and remove seal (3) from the nozzle.

NOTICE Do not use a steel brush or a wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. Too much use of the 8S2258 Brass Wire Brush will also remove the coating that is on the nozzle for protection.

Clean the groove for carbon seal dam (2) and the body of the nozzle below the groove with the 8S2258 Brass Wire brush (M). Remove the carbon, but be sure not to use the brush enough to cause damage to the body of the nozzle.

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NOTE: A change in color in the area below the groove is normal and does not affect the body of the nozzle.

Remove cap (4) from nozzle for all tests except Cap Leakage Test.

8S2245 CLEANING KIT M. 8S2258 Brass Wire Brush. N. 8S2252 Carbon Seal Tool. P. 8S2250 Nozzle Holding Tool.

I. Valve Opening Pressure Test (VOP) 1. Loosen nut (5) and turn nozzle tip down so that it extends into FT1384 Extension (R) as shown.

FUEL INJECTION NOZZLE 4. Cap. 5. Nut.

2. Tighten nut (5) to 5P4244 Adapter (Q). Nut (5) can be tightened by hand if 1H1023 O-ring Seal (6) is not damaged.

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FUEL INJECTION NOZZLE CONNECTOR 5. Nut. 6. 1H1023 O-ring Seal for fuel line.

NOZZLE CONNECTED TO 5P4150 NOZZLE TESTER (Typical Example) Q. 5P4244 Adapter. R. FT1384 Extension. S. 8S2270 Collector.

When fuel injection nozzles are tested, be sure to wear eye protection.

Test fluid comes from the orifices in the nozzle tip with high pressure.

The fluid can pierce (go thru) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the 8S2270 Fuel Collector and FT1384 Extension.

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NOZZLE READY FOR TEST E. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

NOTICE Put a shop towel around the top of the nozzle (pressure screw end) to take in any fuel leakage.

3. Close on-off valve (F). Open pump isolator valve (G).

4. Open gauge protector valve (E). Operate the pump to make a slow increase in pressure until the valve in the fuel injection nozzle just starts to open. Read the maximum gauge pressure at the instant fluid flows from the tip.

NOTE: It is possible for the pressure reading of the gauge to go down fast if the valve makes a noise (chatters) when it opens. It is also possible for the pressure reading of the gauge to be almost constant when the valve in the fuel injection nozzle opens.

NOTE: The valve in the fuel injection nozzle can be good and still not make a noise (chatter), or not have a very fine vapor (spray) from the orifices in the tip of the fuel injection nozzle during Step 4.

If the opening pressure is less than 1500 psi (10 300 kPa), do not use the fuel injection nozzle again.

II. Flush the Nozzle 1. Close gauge protector valve (E). Close on-off valve (F). Open pump isolator valve (G).

NOTE: Make sure nozzle extends inside and below the top of FT1384 Extension (R).

2. Operate the pump rapidly for three full strokes.

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III. Tip Leakage Test 1. Remove all fuel from the nozzle tip and body with a cloth.

2. Put a clean cloth around the top of the body of the fuel injection nozzle (pressure screw end) to take in the leakage and prevent any fuel leakage to drain down to the tip of the nozzle.

3. Open gauge protector valve (E). Be sure the nozzle tip is completely dry.

4. Make and hold for 15 seconds a pressure of 200 psi (1380 kPa) less than the opening pressure measured in VOP Test I. 5. If the nozzle is not within specifications, DO NOT USE THE NOZZLE.

CLOTH ON TOP OF NOZZLE E. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

IV. Orifice Restriction Test 1. Close gauge protector valve (E) and on-off valve (F). Open pump isolator valve (G).

2. Point the tip of the fuel injection nozzle into the 8S2270 Fuel Collector and FT1384 Extension.

3. Make a rapid increase in pressure and look at the orifice discharge pattern (shape of discharge) when fluid begins to flow through the fuel injection nozzle. The discharge must be the same through all four orifices. Any change, either vertically or horizontally, is an indication of a bad nozzle.

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GOOD NOZZLE (USE AGAIN)

TYPICAL DISCHARGE PATTERN FOR ORIFICE WITH A RESTRICTION (RECONDITIONING OR REPLACEMENT NECESSARY)

TYPICAL DISCHARGE PATTERN WITH HORIZONTAL DISTORTION (RECONDITIONING OR REPLACEMENT NECESSARY)

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TYPICAL DISCHARGE PATTERN WITH VERTICAL DISTORTION (RECONDITIONING OR REPLACEMENT NECESSARY)

V. Cap Leakage Test 1. Remove fuel injection nozzle (1) from the 5P4150 Nozzle Tester and put it in 8S2250 Nozzle Holding Tool (P).

2. Install new 1H1023 O-ring Seal (6).

3. Install cap (4) and tighten to 110 to 120 lb. in. (12.4 to 13.6 N·m).

NOZZLE CAP INSTALLATION 1. Fuel injection nozzle. 4. Cap. 6. 1H1023 O-ring Seal.

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TIGHTENING CAP 7. 9S5031 Socket. P. 8S2250 Nozzle Holding Tool.

NOTICE Do not tighten the cap more than torque shown or the new O-ring seal will be damaged.

4. Put fuel injection nozzle (1) on the 5P4150 Nozzle Tester with the nozzle tip in the 8S2270 Fuel Collector and FT1384 Extension.

5. With gauge protector valve (E) open, pump the tester until cap (4) is completely full of fuel and the pressure on the gauge is 4000 psi (27 500 kPa).

NOTE: 15 to 20 strokes of the pump can be necessary for the pressure to reach 4000 psi (27 500 kPa).

There must be no leakage between the cap and the body of fuel injection nozzle.

6. If there is leakage, make a replacement of 1H1023 Seal (6) and inspect cap (4) for cracks. Test the nozzle again. If there is still leakage, replacement of fuel injection nozzle is necessary.

7. If no fuel leakage is found, fuel injection nozzle is acceptable. Slide new seal (3) into position over the nozzle. Install new carbon dam (2) in nozzle groove with 8S2252 Carbon Seal Tool (N).

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INSTALLING CARBON DAM 2. Carbon dam. 3. Seal. N. 8S2252 Carbon Seal Tool.

Troubleshooting Of 9N3979 And 1W5829 Fuel Injection Nozzles Use the guide that follows to troubleshoot for problems with the fuel injection nozzles.

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Adjustment And Cleaning Of 9N3979 And 1W5829 Fuel Injection Nozzles For the procedure to clean the nozzles, see Special Instruction Form No.SEHS7292.

NOTE: Do not clean or adjust a nozzle with a valve opening pressure (VOP) less than 1500 psi (10 300 kPa).

Valve Opening Pressure (VOP) Adjustment

FUEL INJECTION NOZZLE 1. Fuel injection nozzle. 2. Locknut (for pressure adjustment screw). 3. Pressure adjustment screw. 4. 1H1023 O-ring Seal for cap. 5. Locknut (for lift adjustment screw). 6. Lift adjustment screw.

1. Remove fuel injection nozzle (1) from the 5P4150 Nozzle Tester and put it in the 8S2250 Nozzle Holding Tool (P).

LOOSENING LOCKNUT 1. Fuel injection nozzle. 7. 8H8502 Combination Wrench. P. 8S2250 Nozzle Holding Tool.

2. Loosen locknut (5) that holds lift adjustment screw (6). Turn lift adjustment screw (6) counterclockwise two turns.

NOTICE If the lift adjustment screw is not turned counterclockwise two turns, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.

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3. Hold lift adjustment screw (6) with a 5/64" hex wrench (8) and remove locknut (5).

REMOVING LOCKNUT 5. Locknut (for lift adjustment screw). 8. 5/64" hex wrench.

LOOSENING LOCKNUT 1. Fuel injection nozzle. 9. 8H8505 Combination Wrench.

4. Loosen locknut (2) that holds pressure adjustment screw (3).

5. Put fuel injection nozzle (1) on the nozzle tester. Turn pressure adjustment screw (3) clockwise with 5P4813 Socket (10). Each one-fourth of a turn will increase the opening pressure approximately 250 psi (1720 kPa).

OPENING PRESSURE ADJUSTMENT 10. 5P4813 Socket.

6. Turn pressure adjustment screw (3) clockwise until the valve opening pressure is within specifications.

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NOTE: If nozzle can not be adjusted to specifications, make a replacement of the nozzle.

TIGHTENING LOCKNUT 1. Fuel injection nozzle. 9. 8H8505 Combination Wrench. 10. 5P4813 Socket.

7. Hold pressure adjustment screw (3) and tighten locknut (2) just enough so that pressure adjustment screw (3) will not turn.

8. After the opening pressure adjustment is made, install locknut (5) that holds lift adjustment screw (6). Make the valve lift adjustment. See VALVE LIFT ADJUSTMENT.

Valve Lift Adjustment 1. With the valve opening pressure correct, pump test oil through the fuel injection nozzle. At the same time, hold locknut (5) and slowly turn lift adjustment screw (6) clockwise until the pressure starts to increase above the opening pressure.

2. To be sure the valve is on the seat, increase the pressure 200 to 500 psi (1380 to 3450 kPa) more than the opening pressure.

NOTICE Do not bend the valve or damage the seat by turning lift adjustment screw (6) with too much force.

NOTE: Some test oil can be at the tip of the fuel injection nozzle, but a constant flow of drops (dribble) must not be seen.

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TIGHTENING LOCKNUT 1. Fuel injection nozzle. 7. 8H8502 Combination Wrench. 8. 5/64" Hex Wrench.

3. Turn lift adjustment screw (6) counterclockwise 3/4 ± 1/8 of a turn.

4. Hold lift adjustment screw (6) with 5/64" hex wrench (8) and tighten locknut (5) just enough so that lift adjustment screw (6) will not turn.

Tightening Locknuts and Cap 1. Remove fuel injection nozzle (1) from 5P4150 Nozzle Tester and put it in 8S2250 Nozzle Holding Tool (P).

FUEL INJECTION NOZZLE 1. Fuel injection nozzle. 2. Locknut (for pressure adjustment screw). 3. Pressure adjustment screw. 4. 1H1023 O-ring Seal for cap. 5. Locknut (for lift adjustment screw). 6. Lift adjustment screw.

2. Tighten locknut (2) that holds pressure adjustment screw (3) to 70 to 80 lb. in. (8.0 to 9.1 N·m).

TIGHTENING PRESSURE SCREW LOCKNUT (Typical Example) 11. 8S2274 Socket. P. 8S2250 Nozzle Holding Tool.

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3. Tighten locknut (5) that holds lift adjustment screw (6) to 35 to 45 lb. in. (4.0 to 5.1 N·m).

4. Install new 1H1023 O-ring seal (4).

TIGHTENING VALVE LIFT SCREW LOCKNUT (Typical Example) 12. 8S1589 Socket.

5. Install the cap and tighten to 110 to 120 lb. in. (12.4 to 13.6 N·m).

NOTICE Do not tighten the cap more than torque shown or the new O-ring seal will be damaged.

TIGHTENING CAP 13. 9S5031 Socket.

With adjustments and tests complete, check for leakage between the cap and the body of the fuel injection nozzle. See Cap Leakage Test in section TESTING 9N3979 and 1W5829 FUEL INJECTION NOZZLES.

Testing Capsule-Type Fuel Injection Nozzles For PC Engines 5P4150 Nozzle Testing Group 5P4720 Fitting5P8744 Adapter or5P4717 Adapter 8S2270 Fuel CollectorFT1384 Extension

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NOTICE Be sure to use clean SAE J967 Calibration Fluid when tests are made.

Dirty test fluid will damage components of fuel injection nozzles. The temperature of the test fluid must be 65 to 75°F (18 to 24°C) for good test results.

Order calibration fluid by part number, in the quantities needed, according to the information that follows: 6V6068 Calibration Fluid, 5 U.S. gal. (18.9 liter).

6V6067 Calibration Fluid, 55 U.S. gal. (208.2 liter).

5P4150 NOZZLE TESTING GROUP A. 5P4721 Tube. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa) used to test PC capsule valves. C. 2P2324 Gauge, 0 to 5000 psi (0 to 34 500 kPa) used to test DI capsule valves and pencil-type nozzles. D. Gauge protector valve for 5P4146 Gauge (B). E. Gauge protector valve for 2P2324 Gauge (C). F. On-off valve. G. Pump isolator valve. H. 5P4720 Fitting. J. 5P8744 Adapter for capsule nozzles. K. 5P4244 Adapter for pencil-type nozzles.

EXTRA VALVE L. Gauge protector valve (must be in open position at all times).

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When fuel injection nozzles are tested, be sure to wear eye protection.

Test fluid comes from the orifices in the nozzle tip with high pressure.

The fluid can pierce (go thru) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the 8S2270 Fuel Collector and FT1384 Extension.

The test procedures that follow will give an indication of nozzle condition. A nozzle that has a defect is not always the only cause for a specific engine problem.

Nozzle Tester Preparation Find an old capsule type fuel nozzle and weld the orifice closed. Keep this fuel nozzle with the tester group for use in the future.

NOTE: Do not weld the fuel nozzles that are to be tested.

Illustration I shows the latest 5P8744 Adapter. Illustration II shows the former 5P4717 Adapter.

Unless some indication is made, the procedure is the same for use of either adapter.

ILLUSTRATION I 1. Test nozzle (welded orifice). 2. Bottom part of 5P8744 Adapter (J). J. 5P8744 Adapter. M. FT1384 Extension. N. 8S2270 Fuel Collector.

ILLUSTRATION II 1. Test nozzle (welded orifice). 2. Bottom part of 5P4717 Adapter (J). J. 5P4717 Adapter.

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1. Install the top part of adapter (J) that holds the capsule valve.

2. Put test nozzle (1) (with welded orifice) in the bottom part (2) of adapter (J) that holds the capsule valve. Install and tighten bottom part (2) to top part of adapter (J).

3. Close on-off valve (F). Open pump isolator valve (G). Open gauge protector valve (E).

4. Operate the tester pump until a pressure of 3500 psi (24 000 kPa) is read on 2P2324 Gauge (C).

Now, close pump isolator valve (G).

5. Check all connections for leaks. Tighten connections to stop any leaks that are found.

6. Open on-off valve (F) and remove test (welded) fuel nozzle.

Do not loosen the bottom half of the adapter to remove fuel nozzle until on-off valve is opened and no pressure is read on the gauge. Unless the high pressure is released in the pump, the fuel discharge from the adapter can cause injury to the operator.

NOTE: To prevent fuel leakage, the top surface of the test (welded) nozzle, and all other nozzles that are to be tested, must be free of scratches or burrs (sharp edges).

The procedure for NOZZLE TESTER PREPARATION must be done each time any of the conditions that follow exist: a. The complete 5P8744 or 5P4717 Adapter is removed and installed again. b. Before and after a series of tests. c. There is an indication of a problem with the nozzle tester.

Fuel Nozzle Test Sequence To test PC capsule-type fuel nozzles, use the sequence that follows: I. Nozzle Installation II. Pressure Loss Test III. Valve Opening Pressure Test (VOP)

NOTICE Do not use a drill or a reamer on the orifice of a nozzle. Do not use a steel brush or a wire wheel to clean the tip of the nozzle. The orifice and the valve can be damaged easily.

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NOTICE DO NOT use a drill or a reamer on the orifice of a nozzle. DO NOT use a steel brush or a wire wheel to clean the tip of the nozzle. The orifice and the valve can be damaged easily.

I. Nozzle Installation 1. Put one of the nozzles to be tested in the bottom part (2) of adapter (J). Install and tighten bottom part (2) to top part of adapter (J).

AIR REMOVAL FROM TESTER 2. Bottom part of adapter (J). J. 5P8744 Adapter.

2. Close on-off valve (F). Open gauge protector valve (D) one-half turn. Open pump isolator valve (G) one-half turn.

3. Bleed (remove) air from the tester as follows: a. Loosen bottom part (2) of adapter (J) one-half turn. b. Operate the pump until clear test oil (free of air bubbles) leaks past the threads at top of adapter (J).

NOTE: With some 5P8744 Adapters, pressure may start to increase before there is an indication of clear test oil. To correct this condition, do Step C. c. Tighten bottom part (2) of adapter (J).

NOTE: The 5P8744 Adapter makes its own seal, and normally needs very little force when turned on bottom part (2) of the adapter.

II. Pressure Loss Test 1. Open gauge protector valve (D) an extra amount of one-half turn (the total amount is now one turn open).

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2. Operate pump to increase pressure slowly to 300 psi (2050 kPa), and close pump isolator valve (G).

Now turn gauge protector valve (D) to adjust pressure again to 300 psi (2050 kPa).

3. After 30 seconds, take a pressure reading from the gauge. The pressure at this time must not be below 100 psi (690 kPa) reading on the dial face.

TESTER NOMENCLATURE B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). D. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

PRESSURE LOSS RANGE FOR GOOD NOZZLE

4. The valve must not lose more than 200 psi (1380 kPa).

5. If the pressure loss is not in the 200 psi (1380 kPa) range as shown, stop the test sequence, Do not use the fuel nozzle again.

6. If nozzle is in specification range, see VALVE OPENING PRESSURE TEST (VOP).

III. Valve Opening Pressure Test (VOP) 1. Open pump isolator valve (G) one-half turn.

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2. Operate the pump to increase the pressure slowly until test oil comes from the nozzle tip.

3. The pressure reading on the gauge at this time must be in the pressure range of 400 to 750 psi (2750 to 5200 kPa) as shown.

TESTER NOMENCLATURE B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). D. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

VALVE OPENING PRESSURE (VOP) RANGE FOR GOOD NOZZLE

4. If the valve opening pressure (VOP) is not in the 400 to 750 psi (2750 to 5200 kPa) range as shown, do not use the fuel nozzle again.

Fuel Injection Service Injection Valve (DI Nozzle) If a fuel injection nozzle has been removed from the head, test the nozzle before it is again installed in the head. See TESTING FUEL INJECTION NOZZLES FOR DI ENGINES. Check to see that the bore and nozzle seat in the head is clean before fuel injection nozzle is installed.

It is important to keep the correct torque on the fuel line nut (1) of the nozzle (3). Tighten the nut to

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the adapter (2) with a torque of 30 ± 5 lb. ft. (40 ± 7 N·m) before bolt is tightened on clamp (4) and spacer.

FUEL INJECTION NOZZLES INSTALLED 1. Nut. 2. Adapter. 3. Nozzle. 4. Clamp.

Injection Valve (Capsule-Type Nozzle) 5P166 Wrench.

If a fuel injection nozzle has been removed from the precombustion chamber, test the nozzle before it is again installed in the precombustion chamber. See TESTING CAPSULE-TYPE FUEL INJECTION NOZZLES FOR PC ENGINES. Check and clean the seat in the precombustion chamber before the fuel injection valve is installed. It is important to keep the correct torque on the nut that holds the fuel nozzle in the precombustion chamber. Tighten the nut to 55 ± 5 lb. ft. (75 ± 7 N·m). There will be damage to the nozzle if the nut is too tight. If the nut is not tight enough, the nozzle can leak.

INNER FUEL INJECTION LINE INSTALLATION 5. Inner fuel injection line. 6. Adapter. A. 5P166 Wrench.

Install inner fuel injection line (5) to adapter (6) and to the nozzle. Tighten nuts of both ends to 30 ± 5 lb. ft. (40 ± 7 N·m). Use 5P166 Wrench (A) to tighten the fuel line nut at the nozzle.

Governor Adjustments NOTICE

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A mechanic with training in governor adjustments is the only one to make the adjustment to the set point rpm.

Engine rpm must be checked with an accurate tachometer. Make reference to ENGINE SPEED MEASUREMENT.

Low Idle Adjustment NOTE: The correct LOW IDLE rpm is given in the FUEL SETTING AND RELATED INFORMATION FICHE.

To help prevent an accident caused by parts in rotation, work carefully around an engine that has been started.

Start the engine and run until the temperature of normal operation is reached. Check low idle rpm with no load on the engine. If an adjustment is necessary, use the procedure that follows: 1. To adjust the LOW IDLE rpm, start the engine and run with the governor in the low idle position.

Remove cover (1) and turn the screw nearest the cylinder block. Clockwise rotation of the screw gives a reduction of engine rpm. Increase engine speed and return to low idle and check low idle speed again.

COVER AND TERMINAL LOCATION 1. Cover. 2. Brass terminal screw.

Checking Set Point (Balance Point) The engine set point is an adjusted specification and is important to the correct operation of the engine. High idle rpm is NOT an adjusted specification. Set point (formerly balance point) is full load rpm plus an additional 20 rpm. Set point is the rpm at which the fuel setting adjustment screw and stop or first torque spring just start to make contact. At this rpm the fuel setting adjustment screw and

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stop or first torque spring still have movement between them. When additional load is put on the engine, the fuel setting adjustment screw and stop or first torque spring will become stable against each other. Set point is controlled by the fuel setting and the high idle adjustment screw.

There is a new and more accurate method for checking the "set point," formerly called the balance point, of the engine. If the tools for the new method are not available, there is an alternate method for checking the "set point."

6V4060 Engine Set Point Indicator Group.

The 6V4060 Engine Set Point Indicator Group with the 6V2100 Multitach can be used to check the set point. Special Instruction Form No. SEHS7931 gives instructions for installation and use of this tool group.

6V4060 ENGINE SET POINT INDICATOR GROUP

Alternate Method 8S4627 Circuit Tester.6V3121 Multitach Group.

If the set point is correct and the high idle speed is within specifications, the fuel system operation of the engine is correct. The set point for the engine is: A. At 20 rpm greater than full load speed.

B. The rpm where the fuel setting adjustment screw and stop or first torque spring just make contact.

Use the procedure that follows to check the set point. Make reference to TECHNIQUES FOR LOADING ENGINES in Special Instruction Form No. SEHS7050.

1. Connect a tachometer which has good accuracy to the tachometer drive.

2. Connect the clip end of the 8S4677 Circuit Tester to the brass terminal screw (2) on the governor housing. Connect the other end of the tester to a place on the fuel system which is a good ground connection.

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

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3. Start the engine.

4. With the engine at normal conditions for operation, run the engine at high idle.

5. Make a record of the speed of the engine at high idle.

6. Add load on the engine slowly until the circuit tester light just comes on (minimum light output).

This is the set point.

7. Make a record of the speed (rpm) at the set point.

8. Repeat Step 6 several times to make sure that the reading is correct.

9. Stop the engine. Make a comparison of the records from Steps 5 and 7 with the information from the ENGINE INFORMATION PLATE. If the ENGINE INFORMATION PLATE is not available see the FUEL SETTING AND RELATED INFORMATION FICHE. The tolerance for the set point is ± 10 rpm. The tolerance for the high idle rpm is ± 30 rpm. If the readings from Steps 5 and 7 are within the tolerance, no adjustment is needed.

NOTE: It is possible in some applications that the high idle rpm will be less than the lower limit. This can be caused by high parasitic loads such as hydraulic pumps, compressors, etc.

Adjusting Set Point (Balance Point) 1. If the set point and the high idle rpm are within tolerance, no adjustment is to be made.

2. If the set point rpm is not correct, remove cover (1). Turn the screw that is farthest from the cylinder block to adjust the set point to the mid point of the tolerance.

3. When the set point is correct, check the high idle rpm. The high idle rpm must not be more than the high limit of the tolerance.

If the high idle rpm is more than the high limit of the tolerance, check the governor spring and flyweights. If the high idle rpm is less than the low limit of the tolerance, check for excess parasitic loads and then the governor spring and flyweights.

Engine Speed Measurement 6V3121 Multitach Group or6V4950 Injection Line Speed Pickup Group

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6V3121 MULTITACH GROUP 1. Carrying case. 2. Power cable. 3. Tachometer generator. 4. Tachometer drive group. 5. Multitach.

The 6V3121 Multitach Group can measure engine speed from a tachometer drive on the engine. It also has the ability to measure engine speed from visual engine parts in rotation.

6V4950 INJECTION LINE SPEED PICKUP GROUP 6. 6V6114 Pickup. 7. 6V6113 Amplifier.

Special Instruction Form No. SEHS7807 is with the 6V3121 Multitach Group and gives instructions for the test procedure.

The 6V4950 Injection Line Speed Pickup Group is another diagnostic tool accessory that can be used with the 6V2100 Multitach. It can be used on all Caterpillar Diesel Engines equipped with .25 in. (6 mm) single wall fuel injection lines. With this pickup group, engine speed can be measured quickly, automatically, and with an accuracy of ± 1 rpm.

Special Instruction Form No. SEHS8029 is with the group and gives instructions for use of the 6V4950 Injection Line Speed Pickup Group.

Injection Pump (Remove) 5P6577 Fuel Setting Tool Group.

3P1544 Pin.8S2244 Extractor.8S4613 Wrench.

NOTICE

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The fuel rack must be in the center position before the injection pumps are removed. There will be damage to the lifter and injection pump if the rack is not in the center position.

GOVERNOR AND INJECTION PUMP HOUSING 1. Control lever. 2. Plug. 3. Cover. 4. Stop collar.

1. Remove cover (3). Turn stop collar (4) 180°.

2. Remove plug (2). Move governor control lever (1) to shutoff (fully clockwise).

3. Install the 3P1544 Pin in the hole for plug (2). Move the governor control lever in the fuel on direction (counterclockwise). The pin will stop the rack at the center position.

4. Remove the fuel injection line from the injection pump.

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INJECTION PUMP HOUSING 5. Bushing. 6. Seal.

5. Use the 8S4613 Wrench to remove bushing (5). Remove seal (6). Use the 8S2244 Extractor to remove the injection pump assembly.

Be careful when injection pumps are disassembled. Do not damage the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part is worn, install a complete new pump assembly. Be careful when the plunger is put in the bore of the barrel.

Look for wear at the top part of the plunger. Check the operation of the plunger according to the instructions for the Fuel Injection Test Bench.

An injection pump can have a good fuel flow output but not be a good pump because of slow timing that is caused by wear on the bottom end of the plunger. When a test is made on a pump that has been used for a long time, use a micrometer and measure the length of the plunger. If the length of the plunger is shorter than the minimum length (worn) dimension given in the chart, install a new pump.

When there is too much wear on the pump plunger, the lifter may also be worn and there will not be good contact between the two parts. To stop fast wear on the end of a new plunger, install new lifters in the place of the lifters that have wear.

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Injection Pump (Install) 5P6577 Fuel Setting Tool Group.

3P1544 Pin. 8S2244 Extractor.8S4613 Wrench.

1. Make sure the fuel rack is in the center position. See INJECTION PUMP (REMOVE).

2. Put 8S2244 Extractor (1) on the injection pump.

3. Put slot (2) of the bonnet and slot (3) of the barrel in alignment with slot (4) of gear segment (5).

4. Look inside the bore for the injection pump to find dowel (8). Put slot (3) of the barrel in alignment with the dowel. Put the injection pump straight down into the bore.

5. Install seal (7). Put bushing (6) in position. Push down on the extractor (hand force only). If the injection pump is in the correct position and the lobe of the injection pump camshaft is not up, the fingers can be used to turn the bushing until it is even with the top of the housing. When the bushing is installed correctly, tighten it to 154 ± 11 lb. ft. (205 ± 15 N·m).

NOTICE Damage to the housing will be the result if the bushing is too tight. If the bushing is not tight enough the pump will have leakage.

ALIGNMENT OF INJECTION PUMP PARTS 1. 8S2244 Extractor. 2. Slot in bonnet. 3. Slot in barrel. 4. Slot in gear segment. 5. Gear segment.

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INJECTION PUMP HOUSING 6. Bushing. 7. Seal. 8. Dowel. 9. Small dowel.

A check for correct installation of each injection pump can be made. a. Remove the governor weight assembly. b. Measure the total amount of rack travel. It must be approximately .800 in. (20.32 mm). If the travel is less than this the pump is not installed correctly.

NOTE: One tooth off will cause a reduction in travel of .2 in. (5 mm). c. If a pump was installed wrong, remove it. Check to make sure small dowel (9) in the lifter assembly is not broken. Carefully follow Steps 1 through 5 again.

NOTICE If one or more of the fuel injection pumps have been installed wrong, it is possible for the engine to run out of control when started. When any of the fuel injection pumps have been removed and installed with the fuel injection pump housing on the engine, take the cautions (steps)

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that follow to stop the engine if it starts to overspeed (run out of control).

a. Remove the air cleaner. b. Set the governor control at low idle.

Be careful when plate is put against air inlet opening. Due to excessive suction, the plate can be pulled quickly against air inlet opening. To avoid crushed fingers, do not put fingers between plate and air inlet opening.

c. Start the engine, and if engine starts to overspeed (run out of control), put a steel plate over the air inlet to stop the engine.

Fuel Injection Lines Fuel from the fuel injection pumps is sent through the fuel injection lines to the fuel injection nozzles.

Each fuel injection line of an engine has a special design and must be installed in a certain location.

When fuel injection lines are removed from an engine, put identification marks or tags on the fuel lines as they are removed, so they can be put in the correct location when they are installed. Put caps or plugs on the ends to keep dirt out. When fuel injection lines are installed, be sure all clamps and dampers are installed in their original location.

The nuts that hold a fuel injection line must be kept tight. Use a torque wrench and a 5P144 Socket to tighten the fuel line nuts to 30 ± 5 lb. ft. (41 ± 7 N·m).

Fuel injection lines which are bent, damaged or rubbing can leak and cause a fire. Replace any lines which have damage or leaks that can not be corrected when tightened to the correct torque.

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Fuel Pressure Control Fuel pressure in the injection pump manifold is the result of a restriction caused by an orifice in the return to tank elbow. The fuel transfer pump is designed to give the flow necessary to keep the manifold pressure at 30 to 50 psi (205 to 345 kPa).

Finding Top Center Compression Position For No. 1 Piston 5P7307 Engine Turning Tool Group.3/8-16 NC Bolt.

No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.

With the fuel injection lines removed, fuel can spray (discharge) from the fuel injection pumps when rotation of the engine is made with the governor control in the fuel-on position. This can result in personal injury or fire. Move the governor control to "fuel-off - engine stop" position before fuel injection lines are removed.

1. Remove the fuel injection lines.

2. Remove the valve cover.

3. Remove plug (1).

4. Remove the starter motor and install 5P7307 Engine Turning Tool Group.

5. Turn the flywheel clockwise approximately 60°.

6. Now turn the flywheel counterclockwise until a 3/8"16 NC bolt (2) can be put through hole (3) and installed in the timing bolt hole in the flywheel.

NOTE: The engine is seen from the flywheel end when direction of crankshaft rotation is given.

7. Look at the valves for No. 1 cylinder (the two valves at the front of the engine). The intake valve and exhaust valve for No. 1 cylinder must be closed. If they are closed, you will be able to move both rocker arms up and down by hand.

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LOCATION OF PLUG 1. Plug.

8. If the intake valve and exhaust valve for No. 1 cylinder are not closed, remove bolt (2). Turn the crankshaft counterclockwise 360° and install bolt (2). Both valves are now closed. This is top center (TC) compression position for No. 1 piston.

INSTALLING BOLT 2. Bolt. 3. Hole.

NOTE: If the flywheel bolt hole is turned beyond hole (3) and bolt (2) can not be installed, turn the flywheel clockwise approximately 60°. Then, turn it counterclockwise until bolt (2) can be installed.

The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center.

Fuel Injection Timing Check (Timing Pin Method) 5P6577 Fuel Setting Tool Group.

3P1544 Pin. 5P7307 Engine Turning Tool Group.3/8"-16 NC Bolt.

1. Put No. 1 piston at top center on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON. Remove the 3/8"-16 NC bolt from the flywheel. Turn the flywheel approximately 30° clockwise, as seen from the flywheel end.

2. Remove plug (1). Put the 3P1544 Pin in the hole for plug (1). Turn the flywheel slowly counterclockwise, as seen from the flywheel end, until the pin goes into the notch in the injection pump camshaft.

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NOTICE The flywheel must be turned slowly so that damage is not done to the fuel system when the pin goes into the notch.

FUEL PUMP DRIVE HOUSING 1. Plug.

3. Put the 3/8"-16 NC bolt in the timing hole in the flywheel housing. If the bolt can be installed in the hole in the flywheel, the timing of the fuel injection pump is correct. If it can not be installed see INJECTION TIMING ADJUSTMENT (ON ENGINE).

Fuel Injection Timing Check (Fuel Flow Method) 1P540 Flow Checking Tool Group.5P6524 Engine Timing Indicator Group.

5P7266 Adapter.9S215 Dial Indicator.3P1565 Collet Clamp.3S3268 Contact Point, .25 in. (6.4 mm) long.8S2296 Rod, 5.25 in. (133.4 mm) long.

5P7307 Engine Turning Tool Group.3/8"-16 NC Bolt.

5P6524 ENGINE TIMING INDICATOR GROUP 1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator. 3. 5P7266 Adapter. 4. 8S2296 Rod, 5.25 in. (133.4 mm) long. A. 3S3268 Contact Point, .25 in. (6.4 mm) long.

Travel of piston (7), from point of closing inlet port (6) to top center, can be found by using the procedure that follows:

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NOTE: The fuel system timing has a tolerance of ± 1°.

1. Put No. 1 piston at top center (TC) on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON. 2. Remove the timing bolt from the flywheel.

3. Remove the rocker arm shaft assembly and the No. 1 fuel injection nozzle from the cylinder head.

4. Install the fuel injection lines, except line for No. 1 cylinder, that were removed at Step 1 (finding top center).

5. Put a small amount oc clean oil on 8S2296 Rod (4) and put the rod in 5P7266 Adapter (3).

6. Put adapter (3) in same hole that No. 1 fuel nozzle was removed from. Fasten adapter (3) to head with bolt and spacer from fuel nozzle.

7. Install 3P1565 Collet Clamp (1) in the top of adapter (3).

8. Install 3S3268 Contact Point (A) on 9S215 Dial Indicator (2) and put indicator (2) in adapter (3) thru collet (1).

9. Position the dial indicator (up or down) so small pointer is on "0" (zero) and tighten collet (1).

NOTICE Do not tighten collet too much or damage to the dial indicator can result.

MEASUREMENT OF PISTON TRAVEL

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1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator and 3S3268 Contact Point (A). 3. 5P7266 Adapter. 4. 8S2296 Rod, 5.25 in. (133.4 mm) long. 5. Cylinder head. 6. Inlet port. 7. Piston.

10. Loosen the screw that locks the dial face. Move the dial face until the larger pointer is on "0" (zero) and tighten the lock screw.

11. Turn the crankshaft a minimum of 30° in the CLOCKWISE direction (when seen from the flywheel end of the engine).

12. Turn the crankshaft in the COUNTERCLOCKWISE direction (when seen from the flywheel end of the engine) until the dial indicator gives an indication of maximum piston travel. Make an adjustment to the dial indicator, if necessary, to put both pointers of the dial indicator on "0" (zero).

13. Install 6V2023 Adapter Group on No. 1 injection pump. a. Turn fitting (8) so that less than .2 in. (5 mm) of pin (14) is extended. b. Remove tube (13). Put the adapter group in position on No. 1 injection pump. Tighten nut (11) to 30 lb. ft. (40 N·m) maximum. c. Turn fitting (8) down until pin (14) makes contact with the reverse flow check valve. d. Turn the fitting an additional 1/4 turn. e. Push washer (10) against adapter (12). Tighten nut (9) finger tight. Install tube (13) on the adapter group.

6V2023 ADAPTER GROUP 8. Fitting. 9. Nut. 10. Washer. 11. Nut. 12. Adapter. 13. Tube. 14. Pin.

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1P540 FLOW CHECKING TOOL GROUP 15. 5J4634 Hose Assembly. 16. Tank assembly.

14. Disconnect the fuel line at the fuel filter. Use an adapter to connect 5J4634 Hose Assembly (15) to the fuel line.

15. Turn the crankshaft approximately 45° in a clockwise direction (when seen from the flywheel end of the engine.)

If shop air is used, set the tank regulator to the minimum psi (kPa) setting. If air pressure is too high, fittings and hoses can be blown off or the tank can explode causing personal injury. Do not exceed 60 psi (415 kPa) air pressure in the tank.

16. Put 1 U.S. Gal. (4 liters) of clean fuel in the tank assembly (16). Move the governor lever to full "fuel-on" position. Put 15 psi (105 kPa) of air pressure in the tank by using the hand pump or shop air.

17. Hold a pan under the free end of tube (13) for the fuel that comes out.

18. Turn the crankshaft slowly in direction of normal rotation (counterclockwise when seen from the flywheel end of the engine). Do this until the flow of fuel that comes from the end of tube (13) is 6 to 12 drops per minute [point of closing inlet port (6)].

19. Stop rotation of the crankshaft when the flow of fuel is 6 to 12 drops. Take a reading of the measurement on the dial indicator.

20. To check for correct timing angle of the fuel system in degrees, make a comparison of the measurement on the dial indicator with the measurements in the FLOW TIMING CONVERSION CHART that follows.

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NOTE: If the timing of the fuel system is more than 1° different than the correct timing angle given in the chart, make reference to INJECTION TIMING ADJUSTMENT (ON ENGINE).

Checking Engine Timing With 6V3100 Diesel Engine Timing Indicator Group 6V3100 Diesel Engine Timing Indicator Group.

6V3100 DIESEL ENGINE TIMING INDICATOR 1. Engine timing indicator. 2. TDC magnetic transducer. 3. Pipe adapter. 4. Injection transducer. 5. 5P7437 Adapter. 6.

5P7435 Tee Adapter. 7. 5P7436 Adapter.

Special Instruction Form No. SEHS7742 is with the tool group and gives instructions for the test procedure.

NOTICE The engine must be stopped while the timing indicator is being connected.

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TRANSDUCER IN POSITION 4. Injection transducer. 8. Fuel injection line for No. 1 cylinder.

1. Make reference to Operation Instructions inside the lid of the 6V3100 Diesel Engine Timing Indicator (1) for complete instructions and calibration.

2. Disconnect the fuel injection line (8) for No. 1 cylinder. Slide the nut up and out of the way. Then use the 5P7436 Adapter (7) in its place and turn the 5P7436 Adapter (7) onto the fuel pump bonnet until the top of the bonnet threads are approximately even with the bottom of the "window" in the 5P7436 Adapter (7).

3. Put the 5P7435 Tee Adapter (6) on the Injection transducer (4) and put the end of the 5P7435 Tee Adapter (6) in the "window" of the 5P7436 Adapter (7).

4. Remove air from the fuel line (8) and move the end of it down on top ofthe 5P7435 Tee Adapter (6). Hold the fuel line (8) in place with the 5P7437 Adapter (5) and tighten to a torque of no more than 30 lb. ft. (41 N·m).

5. Remove plug and install the pipe adapter (3) into the TDC static pin timing hole and tighten just more than finger tight.

6. Push the TDC magnetic transducer (2) into the pipe adapter (3) until it makes contact with the flywheel. Pull it back out .06 in. (1.6 mm) and finger tighten the knurled locknut.

TRANSDUCER IN POSITION 2. TDC magnetic transducer.

7. Connect the cables from the transducers to the Engine Timing Indicator. Calibrate and make adjustments. For calibration procedure refer to Special Instruction Form No. SEHS7742.

8. Start the engine. With engine at operating temperature, run the engine at low idle speed 800 rpm and check engine timing. Increase engine speed and check timing at 2500 rpm.

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The Timing Chart gives the acceptable dynamic (engine in motion) timing range as read on the Timing Indicator Group. The Timing chart is for 3204 Engine with 22 ± 1° static (engine stopped) timing.

Make reference to Fuel Injection Timing Check (Timing Pin Method) for the correct procedure for checking and changing the timing.

Fuel Injection Timing Adjustment (On Engine) 5P6577 Fuel Setting Tool Group.

3P1544 Pin. 5P7307 Engine Turning Tool Group.3/8"-16 NC Bolt.FT1538 Fuel Pump Timing Gear Puller.FT1537 Modified 3/4" Hex Socket.5P8676 Extension.

1. Do the FUEL INJECTION TIMING CHECK (TIMING PIN METHOD). If the timing is not correct, do the steps that follow: 2. Remove plug (1) from the front cover.

FRONT COVER 1. Plug.

NOTICE The tooling must be installed in the position shown so the locks will not damage the water passage in the timing gear cover.

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3. Install assembled tooling in the timing gear housing and tighten the locks to hold the tooling in place.

PULLER TOOLING ASSEMBLED 2. FT1537 Socket. 3. FT1538 Fuel Pump Timing Gear Puller. 4. 5P8676 Extension.

PULLER TOOLING INSTALLED

4. Turn the extension counterclockwise to loosen the bolt in the timing gear. As the bolt is loosened it will push against the assembled tooling and push the shaft of the pump drive through the timing gear to loosen the timing gear on the shaft.

5. Turn the flywheel clockwise, as seen from the flywheel end, at least 30° beyond the point where the 3/8"-16 NC bolt can be installed.

6. Tighten the bolt that holds the fuel pump drive gear finger tight. Turn the flywheel counterclockwise, as seen from the flywheel end, until the 3/8"-16 NC bolt can be installed in the flywheel.

7. Tighten the bolt that holds the fuel pump drive gear to 108 ± 5 lb. ft. (149 ± 7 N·m).

8. Remove the pin and bolt. Turn the flywheel two complete revolutions counterclockwise, as seen from the flywheel end. If the bolt and pin can be installed, the on engine timing is correct.

9. If the bolt and pin can not be installed, do steps 2 through 8 again.

NOTE: If the on engine timing is correct and the engine still runs rough, make reference to INJECTION TIMING ADJUSTMENT (OFF ENGINE).

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Fuel Injection Timing Adjustment (Off Engine) 5P6600 Off Engine Lifter Setting Tool Group.

1P7420 Pointer Assembly.S1617 Bolt, 5/16"-18 NC, .75 in. (19.1 mm) long.6V3035 Shaft Assembly.1P7410 Timing Plate.2S6160 Washer.S509 Bolt, 3/8"-16 NC, .75 in. (19.1 mm) long.

5P4165 Indicator Group.

8S3158 Indicator.3P1565 Collet Clamp.5P4159 Gauge Stand.5P4165 Base.5P4163 Contact Point, 4.75 in. (120.7 mm) long.5P4157 Gauge, 4.00 in. (101.6 mm) long.5P4158 Gauge, 2.00 in. (50.8 mm) long.

8S4613 Wrench.8S2244 Extractor.

NOTE: A 6F6922 Depth Micrometer with a 4 to 5 in. (102 to 127 mm) rod can be used in place of the dial indicator.

This method of adjustment corrects for wear of components in the injection pump housing.

GOVERNOR AND INJECTION PUMP HOUSING 1. S1617 Bolt. 2. 1P7420 Pointer Assembly. 3. 6V3035 Shaft Assembly.

1. Put 1P7420 Pointer Assembly (2) in position, as shown, on the pump housing. Use S1617 Bolt (1) to hold it in place.

2. Slide 6V3035 Shaft Assembly (3) onto the camshaft. Make sure the key on the shaft assembly is fully engaged in the timing notch. Tighten the screw that holds the shaft assembly in place.

3. Install 1P7410 Timing Plate (4), 2S6160 Washer (5) and S509 Bolt (6) as shown.

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5P6600 OFF ENGINE LIFTER SETTING TOOL GROUP INSTALLED 4. 1P7410 Timing Plate. 5. 2S6160 Washer. 6. S509 Bolt.

NOTE: The 1P7420 Pointer Assembly holds the rack at zero position when the governor is in the fuel on position.

4. Move the governor control shaft to the fuel on position. Use the 8S4613 Wrench to remove the bushings that hold the injection pumps in the housing. Remove the washers and seals.

5. Use the 8S2244 Extractor to remove the injection pumps.

6. Put the 3P1565 Collet Clamp in the 5P4165 Base. Put the 8S3158 Indicator with the 5P4163 Contact Point through the collet clamp.

7. Use 5P4157 Gauge, 4.00 in. (101.6 mm), and the 5P4159 Gauge Stand, set both dials on the indicator at zero.

8. Turn the timing plate counterclockwise to the degree setting given, in the LIFTER SETTING CHART (OFF ENGINE), for number 1 lifter. The lifters are numbered 1 through 4 from the timing plate end of the injection pump.

9. Use the dial indicator assembly and 5P4158 Gauge (7), 2.00 in. (50.8 mm), to measure timing dimension (9). The correct timing dimension is 4.2675 ± .0020 in. (108.395 ± 0.051 mm).

NOTE: Add 4.00 in. (101.6 mm) to the dial indicator reading to get the timing dimension.

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TYPICAL TIMING DIMENSION MEASUREMENT 7. 5P4158 Gauge, 2.00 in. (50.8 mm). 8. Spacer. 9. Timing dimension.

10. If the timing dimension is not correct change spacer (8). Make reference to the SPACER CHART.

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11. Turn the timing plate counterclockwise, check the timing dimension for each lifter at the given setting. Change spacers (8) as necessary.

12. Make reference to INJECTION PUMP (INSTALL) to install the pumps in the housing.

Fuel Rack Setting 5P6577 Fuel Setting Tool Group.

3P1544 Pin. 8S4627 Circuit Tester.1C569 Bolt, 5/16"-18 NC, .50 in. (12.7 mm) long.9S228 Rack Position Tool Group.

8S2283 Dial Indicator.9S225 Bracket Assembly.

5P7335 Rack Adjusting Tool.

1. Disconnect the governor control linkage at the governor lever.

2. Remove plug (1) and cover group (2) from the governor.

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INJECTION PUMP HOUSING 1. Plug.

GOVERNOR 2. cover group. A. Stop collar cover.

3. Turn stop collar (5) 180°, so that stop screw (3) will not be able to make contact with torque spring (4).

4. Move the governor lever to shutoff (fully clockwise).

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GOVERNOR AND INJECTION PUMP HOUSING 3. Stop screw. 4. Torque spring. 5. Stop collar.

5. Install the 9S225 Bracket. Put the 8S2283 Dial Indicator with 9S8883 Contact Point in position so that the indicator will measure movement of the stop collar.

6. Put the 3P1544 Pin in the hole for plug (1). Move the governor lever counterclockwise to the full fuel position. Pull stop collar (5) softly, to remove end clearance, and set both dials on the indicator at zero

BRACKET AND DIAL INDICATOR INSTALLED

7. Move the governor lever clockwise to low idle position.

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8. Remove the 3P1544 Pin. Turn stop collar (5) so that stop screw (3) will be able to make contact with torque spring (4).

9. Connect the 8S4627 Circuit Tester to the brass terminal on the governor and a ground on the governor.

10. Turn the governor lever in the fuel on direction (counterclockwise) until the light in the tester goes on. Turn the governor lever clockwise until the light goes off. Slowly turn the governor lever counterclockwise until the test light has a minimum light output. In this position, stop screw (3) is just in contact with torque spring (4). Read the measurement on the dial indicator.

11. Look in the FUEL SETTING AND RELATED INFORMATION FICHE to find the correct measurement for rack setting.

NOTE: Negative (-) rack is when stop screw (3) makes contact with torque spring (4) before both dials on the indicator reach zero.

12. To make an adjustment of the fuel rack setting, loosen the locknut and turn stop screw (3). A clockwise turn will make a reduction to the rack setting.

NOTE: One full turn of the stop screw changes the rack setting approximately .035 in. (0.89 mm).

13. After the adjustment is made tighten the locknut to 9 ± 3 lb. ft. (12 ± 4 N·m).

14. Do Step 10 again to check the rack setting.

Alternate Method NOTE: This method can only be used if the desired result is a positive rack setting.

Same except for bolt and contact point, use:5P6531 Contact Point 2.25 in. (37.2 mm) long.1D4538 Bolt, 5/16"-18 NC, 2.25 in. (37.2 mm) long.

1. Disconnect the governor control linkage at the governor lever.

2. Remove plug (1) and stop collar cover (A) from the governor.

3. Move the governor lever to shutoff (fully clockwise).

4. Install 9S225 Bracket Assembly (6). Put the 8S2283 Dial Indicator with 5P6531 Contact Point in position so that the indicator will measure movement of stop collar (5).

5. Put the 3P1544 Pin in the hole for plug (1). Move the governor lever counterclockwise to the full fuel position. Pull stop collar (5) softly, to remove end clearance, and set both dials on the indicator at zero.

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TOOLS INSTALLED 6. 9S225 Bracket Assembly. 7. 8S4627 Circuit Tester.

6. Move the governor lever clockwise to low idle position.

7. Remove the 3P1544 Pin. 8. Connect 8S4627 Circuit Tester (7) to the brass terminal on the cover group and to a ground on the governor.

9. Turn the governor lever in the fuel on direction (counterclockwise) until the light in the tester goes on. Turn the governor lever clockwise until the light goes off. Slowly turn the governor lever counterclockwise until the test light has a minimum light output. In this position, stop screw (3) is just in contact with torque spring (4). Read the measurement on the dial indicator.

10. Look in the FUEL SETTING AND RELATED INFORMATION FICHE to find the correct measurement for rack setting. Negative (-) rack measurements can not be made accurately by this method.

11. To make an adjustment of the fuel rack setting, use the 5P7335 Rack Adjusting Tool. Loosen the locknut and turn stop screw (3). A clockwise turn will make a reduction to the rack setting.

NOTE: To use the 5P7335 Rack Adjusting Tool, it is necessary to pivot the bracket assembly to one side. One full turn of the stop screw changes the rack setting approximately .035 in. (0.89 mm).

12. After the adjustment is made, tighten the locknut to 9 ± 3 lb. ft. (12 ± 4 N·m).

13. Do Steps 3 thru 9 again to check the rack setting.

Injection Pump (Remove) 5P130 "O" Set Gauge.8S4613 Wrench.8S2244 Extractor.

Before the fuel injection pumps can be removed, the fuel rack must be put in the center position. To put the rack in the center position, the procedure that follows is necessary.

1. If the governor has a speed limiter, put a 9S8518 Plug (2) in place of existing plug.

2. Put a 9S8521 Rod through the hole in the 9S8518 Plug.

3. Push in on the 9S8521 Rod to get compression of the speed limiter spring. Hold the rod in this position and tighten the 9S8518 Plug enough to hold the rod.

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INSTALLATION OF THE 5P130 GAUGE 1. 5P130 Gauge. 2. 9S8518 Plug. 3. Hole. 4. Slot.

4. Remove small cover over hole (3).

5. Put 5P130 Gauge (1) in hole (3) with slot (4) toward front of engine.

6. Turn the 5P130 Gauge 180° so slot (4) is toward rear of engine. [When governor control is moved to FUEL-ON, the end of the fuel rack (B) must go in slot (4).]

7. Install two bolts (6) to hold the 5P130 Gauge (1) in place.

8. Pull lever (5) of the gauge in the direction of arrow and tighten the screw (A) to hold lever (5) in position.

9. Pull governor control in fuel-on direction until end of fuel rack (B) is in contact with inside of slot (4). Fasten the governor control in this position.

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5P130 GAUGE INSTALLED 4. Slot. 5. Lever. A. Screw. B. Fuel rack.

10. Remove fuel injection line from injection pump.

11. Put 8S4613 Wrench into spline of bushing. Remove bushing.

12. Install 8S2244 Extractor (7) on the injection pump. Pull the pump straight up out of the bore.

When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.

Be careful when injection pumps are disassembled. Do not damage the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part is worn, install a complete new pump assembly. Be careful when the plunger is put in the bore of the barrel.

An injection pump can have a good fuel flow output but not be a good pump because of slow timing that is caused by wear on the bottom end of the plunger. When a test is made on a pump that has been used for a long time, use a micrometer and measure the length of the plunger. If the length of the plunger is shorter than the minimum length (worn) dimension given in the chart, install a new pump.

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Look for wear at the top part of the plunger. Check the operation of the plunger according to the instructions for the Fuel Injection Test Bench.

When there is too much wear on the pump plunger, the lifter washer may also be worn and there will not be good contact between the two parts. To stop fast wear on the end of a new plunger, install new lifters in the place of the lifters that have washers with wear.

WEAR BETWEEN LIFTER WASHER AND PLUNGER Fig. A shows the contact surfaces of a new pump plunger and a new lifter washer. In Fig. B the pump plunger and lifter washer have worn a large amount. Fig. C shows how the flat end of a new plunger makes bad contact with a worn lifter washer, causing rapid wear to both parts.

Injection Pump (Install) 5P130 "0" Set Gauge.8S4613 Wrench.8S2244 Extractor.9S8518 Plug (Earlier Models).9S8521 Rod (Earlier Models).

NOTICE The fuel rack MUST BE IN THE CENTER POSITION before the correct installation of an injection pump is possible.

To put the fuel rack in the center position, the procedure that follows is necessary.

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1. If the governor has a speed limiter (earlier models), put a 9S8518 Plug (2) in place of original plug.

Identification of later models without a speed limiter is made when no plug or hole is found on governor housing.

INSTALLATION OF THE 5P130 GAUGE 1. 5P130 Gauge. 2. 9S8518 Plug. 3. Hole. 4. Slot.

2. Put a 9S8521 Rod through the hole in the 9S8518 Plug.

3. Push in on the 9S8521 Rod to get compression of the speed limiter spring. Hold the rod in this position and tighten the 9S8518 Plug enough to hold the rod.

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5P130 GAUGE INSTALLED 4. Slot. 5. Lever. A. Screw. B. Fuel rack.

4. Remove small cover over hole (3).

5. Put 5P130 Gauge (1) in hole (3) with slot (4) toward front of engine.

6. Turn the 5P130 Gauge 180° so slot (4) is toward rear of engine. [When governor control is moved to fuel-on, the end of fuel rack (B) must go in slot (4).]

7. Install two bolts (6) to hold 5P130 Gauge (1) in place.

8. Pull lever (5) of the gauge in the direction of arrow and tighten screw (A) to hold lever (5) in position.

5P130 GAUGE INSTALLED 5. Lever. 6. Bolts (two).

9. Pull governor control in fuel-on direction until end of fuel rack (B) is in contact with inside of slot (4). Fasten the governor control in this position.

10. Put 8S2244 Extractor (7) on the new injection pump.

11. Put slot (8) of bonnet and slot (9) of barrel in alignment with slot (10) of gear segment (11).

ALIGNMENT OF PARTS FOR INSTALLATION OF INJECTION PUMP 7. 8S2244 Extractor. 8. Slot of bonnet. 9. Slot of barrel. 10. Slot of gear segment. 11. Gear segment. 12. Center tooth of gear segment.

12. Look inside the bore of the injection pump housing to find the dowel. Put slot (9) of the barrel in alignment with the dowel and put the injection pump straight down into the bore.

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13. Push down on extractor (7) (hand force only) and install the bushing that holds the injection pump in the pump housing. If the pump is in the correct position, the bushing will turn into the threads of the injection pump housing with the fingers until it is even with the top of the housing (except for the pump that is in position to fire). When bushing is installed correctly, tighten the bushing to 150 ± 10 lb.ft. (205 ± 14 N·m).

NOTICE Damage to the housing will be the result if the bushing is too tight. If the bushing is not tight enough, the pump will have leakage.

Check for the correct installation of injection pumps with the engine stopped. The governor and governor piston and valve must be removed. Use the 9S240 Rack Position Tool Group and the chart that follows to check for full rack travel.

With the governor piston and valve removed, the total amount of fuel rack travel (from shut-off position to full load position) is approximately .800 in. (20.32 mm). If the pump is installed wrong (center tooth of gear segment is not in correct notch of fuel rack) fuel rack travel will be less than .800 in. (20.32 mm). The injection pump will have to be removed and then installed correctly.

NOTICE If one or more of the fuel injection pumps have been installed wrong, it is possible for the engine to run out of control when started. When any of the fuel injection pumps have been removed and installed with the fuel injection pump housing on the engine, take the cautions (steps)

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that follow to stop the engine if it starts to overspeed (run out of control).

AIR CLEANER REMOVED 13. Air inlet.

a. Remove the air cleaner and hose and let the air inlet open. b. If a pump has been installed wrong and the engine does not run in a normal way, put a steel plate over open air inlet (13) to stop the engine.

Be careful when plate is put against air inlet opening. Due to excessive suction, the plate can be pulled quickly against air inlet pipe. To avoid crushed fingers, do not put fingers between plate and air inlet pipe.

STOPPING THE ENGINE

Fuel Injection Lines Fuel from the fuel injection pumps is sent through the fuel injection lines to the fuel injection valves.

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Each fuel injection line of an engine has a special design and must be installed in a certain location.

When fuel injection lines are removed from an engine, put identification marks or tags on the fuel lines as they are removed, so they can be put in the correct location when they are installed.

The nuts that hold a fuel injection line to an injection valve and injection pump must be kept tight.

Use a torque wrench and a 5P144 Socket to tighten the fuel line nuts to 30 ± 5 lb. ft. (40 ± 7 N·m).

Fuel Pressure Control The fuel transfer pump controls fuel pressure to the fuel injection pump at a pressure of 30 to 50 psi (205 to 345 kPa). As the fuel pressure increases, the stroke of the pump piston decreases, and fuel output becomes less until there is no more fuel delivery.

Finding Top Center Compression Position For No.1 Piston 5P7307 Engine Turning Tool Group.3/8-16 NC Bolt.5P144 Socket.

No.1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.

1. For DI engines, the fuel injection lines must be removed.

With the fuel injection lines removed from DI engines, fuel can spray (discharge) from the fuel injection pumps when rotation of the engine is made with governor control in the fuel-on position. This can result in personal injury or fire. Move the governor control to "fuel-off - engine stop" position before fuel injection lines are removed.

2. Remove the valve cover.

3. Remove plug (1).

LOCATION OF PLUG 1. Plug.

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NOTE: The engine is seen from the flywheel end when direction of crankshaft rotation is given.

4. Remove the starter motor and install 5P7307 Engine Turning Tool Group.

5. Turn the flywheel clockwise approximately 60° 6. Now turn the flywheel counterclockwise until a 3/8"-16NC bolt (2) can be put through hole (3) and installed in the timing bolt hole in the flywheel.

INSTALLING BOLT 2. Bolt. 3. Hole.

7. Look at the valves for No.1 cylinder (the two valves at the front of the engine). The intake valve and exhaust valve for No.1 cylinder must be closed. If they are closed, you will be able to move both rocker arms up and down by hand.

8. If the intake valve and exhaust valve for No.1 cylinder are not closed, remove bolt (2). Turn the crankshaft counterclockwise 360° and install bolt (2). Both valves should now be closed. This is top center (TC) compression position for No.1 piston.

NOTE: If the flywheel bolt hole is turned beyond hole (3) and bolt (2) can not be installed, turn the flywheel clockwise approximately 60°. Then, turn it counterclockwise until bolt (2) can be installed.

The reason for this step is to be sure the play is removed from the timing gears when the engine is put on top center.

Engine Timing (Dynamic Check) The DYNAMIC check of an engine means that the engine is checked while in operation (in motion).

The STATIC check of an engine means that the engine is checked while stopped (not in motion).

6V3100 Diesel Engine Timing Indicator Group Special Instruction Form No. SEHS7742 is with the tool group and gives instructions for the test procedure.

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6V3100 DIESEL ENGINE TIMING INDICATOR 1. Engine timing indicator. 2. Magnetic transducer. 3. Pipe adapter. 4. Injection transducer. 5. 5P7437 Adapter. 6. 5P7435 Tee Adapter. 7. 5P7436 Adapter.

1. Make reference to Operation Instructions inside the lid of 6V3100 Diesel Engine Timing Indicator (1) for complete instructions and calibration.

A high pressure fuel line must be disconnected. To avoid personal injury or fire from fuel spray, the engine must be stopped before the fuel line is disconnected.

TRANSDUCER IN POSITION (Typical Example) 4. Injection transducer. 8. Fuel injection line for No. 1 cylinder.

2. Disconnect fuel injection line (8) for No. 1 cylinder. Slide the nut up and out of the way. Put 5P7436 Adapter (7) in its place and turn the adapter onto the fuel pump bonnet until the top of the bonnet threads are approximately even with the bottom of the "window" in 5P7436 Adapter (7).

3. Put 5P7435 Tee Adapter (6) on Injection transducer (4) and put the end of 5P7435 Tee Adapter (6) in the "window" of 5P7436 Adapter (7).

4. Move the end of fuel line (8) down on top of 5P7435 Tee Adapter (6). Hold fuel line (8) in place with 5P7437 Adapter (5) and tighten to a torque of no more than 30 lb. ft. (40 N·m).

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5. Remove plug (9) from timing hole in flywheel housing. Install pipe adapter (3) into the timing hole and tighten just a small amount more than finger tight.

TIMING HOLE LOCATION (Typical Example) 9. Plug.

6. Push magnetic transducer (2) into adapter (3) until it makes contact with the flywheel. Pull it back out .06 in. (1.5 mm) and finger tighten the knurled locknut.

TRANSDUCER IN POSITION (Typical Example) 2. Magnetic transducer.

7. Connect the cables from the transducer to engine timing indicator (1). Calibrate and make adjustments. For calibration procedure, refer to Special Instruction Form No. SEHS7742.

8. Start the engine. With the engine at operating temperature, run the engine through the rpm check points shown in DYNAMIC TIMING CHART. NOTE: The DYNAMIC TIMING CHART gives the acceptable dynamic (engine in motion) timing range as read on the Timing Indicator Group. Special Instruction Form No. SEHS7742 is with the group and explains how dynamic tolerances are different than static tolerances.

9. If the timing is not within the range shown in the chart, make reference to CAMSHAFT TIMING FOR THE FUEL INJECTION PUMP for the correct procedure to change the timing.

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Timing The Accessory Drive Shaft 5P143 Timing Fixture Plate.

1. Remove the injection pump housing from the engine.

2. Put No.1 piston at top center (TC) on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO.1 PISTON. 3. Install 5P143 Timing Fixture Plate (1) on the rear face of the accessory housing with dowel alignment and bolts installed as illustrated.

5P143 TIMING FIXTURE PLATE INSTALLED 1. 5P143 Timing Fixture Plate.

NOTE: If the timing fixture plate can be installed, the timing is correct. If the timing fixture plate can not be installed, use the procedure that follows.

4. Remove plug (2) from the front cover.

LOCATION OF PLUG 2. Plug.

5. Loosen the bolt that holds the drive gear to the accessory drive shaft.

6. Use a hammer and punch to hit the head of the loosened bolt. This will separate the accessory drive shaft from the gear.

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SEPARATION OF SHAFT AND GEAR

7. Turn the accessory shaft far enough to allow installation of 5P143 Timing Fixture Plate (1).

8. With the timing fixture plate installed correctly, tighten the bolt that holds the gear for the accessory drive shaft to a torque of: PC Engines ... 75 ± 10 lb. ft.(100 ± 14 N·m) DI Engines ... 110 ± 5 lb. ft.(149 ± 7 N·m)

TIGHTENING THE BOLT THAT HOLDS THE ACCESSORY DRIVE GEAR

9. Remove 5P143 Timing Fixture Plate (1) and install plug (2) in the front cover.

10. Turn the camshaft of the injection pump so it is in alignment with the end of the accessory drive shaft. Install the pump housing. Make all necessary connections.

11. Remove the timing bolt from flywheel. Install plug in flywheel housing.

12. The injection pump camshaft is now timed to No.1 cylinder.

Fuel System Adjustments: On Engine Flow Checking Fuel Injection Pump Timing (DI Engines) 1P540 Flow Checking Tool Group.5P6524 Engine Timing Indicator Group.

5P7266 Adapter.9S215 Dial Indicator.3P1565 Collet Clamp.9S8883 Contact Point, .50 in. (12.7 mm) long.8S2296 Rod, 5.25 in. (133.4 mm) long.

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5P6524 ENGINE TIMING INDICATOR GROUP 1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator. 3. 5P7266 Adapter. 4. 8S2296 Rod, 5.25 in. (133.4 mm) long. A. 3S3268 Contact Point, .25 in. (6.4 mm) long.

Travel of piston (7), from point of closing inlet port (6) to top center, can be found by using the procedure that follows.

NOTE: The fuel system timing has a tolerance of ± 1°.

1. Put No.1 piston at top center (TC) on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO.1 PISTON. 2. Remove the timing bolt from the flywheel.

3. Remove the rocker arm shaft assembly and the No.1 fuel injection nozzle from the cylinder head.

4. Install the fuel injection lines, except line for No.1 cylinder, that were removed at Step 1 (finding top center).

5. Put a small amount of clean oil on 8S2296 Rod (4) and put the rod in 5P7266 Adapter (3).

MEASUREMENT OF PISTON TRAVEL 1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator and 3S3268 Contact Point (A). 3. 5P7266 Adapter. 4. 8S2296 Rod, 5.25 in. (133.4 mm) long. 5. Cylinder head. 6. Inlet port. 7. Piston.

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6. Put adapter (3) in same hole that No.1 fuel nozzle was removed from. Fasten adapter (3) to head with bolt and spacer from fuel nozzle.

7. Install 3P1565 Collet Clamp (1) in the top of adapter (3).

8. Install 3S3268 Contact Point (A) on 9S215 Dial Indicator (2) and put indicator (2) in adapter (3) thru collet (1).

9. Position the dial indicator (up or down) so small pointer is on "0" (zero) and tighten collet (1).

NOTICE Do not tighten collet too much or damage to the dial indicator can result.

10. Loosen the screw that locks the dial face. Move the dial face until the large pointer is on "0" (zero) and tighten the lock screw.

11. Turn the crankshaft a minimum of 30° in the CLOCKWISE direction (when seen from the flywheel end of the engine).

12. Turn the crankshaft in the COUNTERCLOCKWISE direction (when seen from the flywheel end of the engine) until the dial indicator gives an indication of maximum piston travel. Make an adjustment to the dial indicator, if necessary, to put both pointers of the dial indicator on "0" (zero).

13. Put 7M1999 Tube Assembly (9) on No.1 injection pump and tighten the nut. The free end of tube assembly (9) must be in a position above horizontal and higher than the end on the injection pump.

1P540 FLOW CHECKING TOOL GROUP 8. 5J4634 Hose Assembly. 9. 7M1999 Tube Assembly. 10. Tank Assembly.

14. Disconnect the fuel line at the fuel filter. Use an adapter to connect 5J4634 Hose Assembly (8) to the fuel line.

15. Turn the crankshaft approximately 45° in a clockwise direction (when seen from the flywheel end of the engine).

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16. Put 1 gal. (4 litres) of clean fuel in the tank assembly (10). Move the governor lever to full fuel-on position. Put 15 psi (105 kPa) of air pressure in the tank. Use the hand pump or shop air.

If shop air is used, set the tank regulator to the minimum psi (kPa) setting. If air pressure is too high, fittings and hoses can be blown off or the tank can explode causing personal injury. Do not exceed 15 psi (105 kPa) air pressure in the tank.

17. Hold a pan under the free end of tube assembly (9) for the fuel that comes out.

18. Turn the crankshaft slowly in direction of normal rotation (counterclockwise when seen from the flywheel end of the engine). Do this until the flow of fuel that comes from the end of tube assembly (9) is 6 to 12 drops per minute [point of closing inlet port (6)].

19. Stop rotation of the crankshaft when the flow of fuel is 6 to 12 drops. Take a reading of the measurement on the dial indicator.

20. To check for correct timing angle of the fuel system in degrees, make a comparison of the measurement on the dial indicator with the measurements in the FLOW TIMING CONVERSION CHART that follows.

NOTE: If the timing of the fuel system is different than the correct timing dimension given in the chart, make reference to TIMING THE ACCESSORY DRIVE SHAFT.

Flow Checking Fuel Injection Pump Timing (PC Engines) 1P540 Flow Checking Tool Group.5P6524 Engine Timing Indicator Group.

5P7267 Adapter.9S215 Dial Indicator.3P1565 Collet.9S8883 Contact Point, .50 in. (12.7 mm) long.3S3264 Rod, 7.12 in. (180.9 mm) long.

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Travel of piston (7), from point of closing inlet port (6) to top center, can be found by using the procedure that follows.

NOTE: The fuel system timing has a tolerance of ± 1°.

1. Put No.1 piston at top center (TC) on the compression stroke. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO.1 PISTON.

MEASURING PISTON TRAVEL 1. 3P1565 Collet Clamp. 2. 9S215 Dial Indicator with 3S3268 Contact Point, .25 in. (6.4 mm) long. 3. 5P7267 Adapter. 4.

Precombustion chamber. 5. 3S3264 Rod, 7.12 in. (180.9 mm) long. 6. Inlet port. 7. Piston.

2. Remove the timing bolt from the flywheel.

3. Remove the fuel nozzle from the precombustion chamber for No. 1 cylinder.

4. Put a small amount of clean oil on 3S3264 Rod (5) and put the rod in adapter (3).

5. Put 5P7267 Adapter (3) in precombustion chamber (4) and tighten the adapter finger tight.

NOTICE Do not use a wrench to tighten the adapter. There will be damage to the nozzle seat if the adapter is too tight.

6. Install 3P1565 Collet Clamp (1) in the top of adapter (3).

7. Put 3S3269 Contact Point on 9S215 Dial Indicator (2).

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8. Put the assembled indicator into adapter (3) thru collet (1). Position the dial indicator (up or down) so small pointer is on "0" (zero) and tighten collet (1).

NOTICE Do not tighten collet too much or damage to the dial indicator can result.

9. Loosen the screw that locks the dial face. Move the dial face until the large pointer is on "0" (zero) and tighten the lock screw.

TOOLS INSTALLED 2. 9S215 Dial Indicator. 3. 5P7267 Adapter. 8. 5J4634 Hose Assembly. 9. 7M1999 Tube Assembly.

10. Turn the crankshaft a minimum of 30° in the CLOCKWISE direction (when seen from the flywheel end of the engine).

11. Turn the crankshaft in the COUNTERCLOCKWISE direction (when seen from the flywheel end of the engine) until the dial indicator gives an indication of maximum piston travel. Make an adjustment to the dial indicator, if necessary, to put both pointers of the dial indicator on "0" (zero).

12. Disconnect the fuel line for No. 1 injection pump at the injection pump housing. Put 7M1999 Tube Assembly (9) on No. 1 injection pump and tighten the nut. The free end of tube assembly (9) must be in a position above horizontal and higher than the end on the injection pump.

13. Disconnect the fuel line at the fuel filter. Use an adapter to connect 5J4634 Hose Assembly (8) to the fuel line.

14. Turn the crankshaft approximately 45° in a clockwise direction (when seen from the flywheel end of the engine).

15. Put 1 gal. (4 litres) of clean fuel in the tank assembly (10). Move the governor lever to full fuel-on position. Put 15 psi (105 kPa) of air pressure in the tank. Use the hand pump or shop air.

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1P540 FLOW CHECKING TOOL GROUP 8. 5J4634 Hose Assembly. 9. 7M1999 Tube Assembly. 10. Tank Assembly.

If shop air is used, set the tank regulator to the minimum psi (kPa) setting. If air pressure is too high, fittings and hoses can be blown off or the tank can explode causing personal injury. Do not exceed 15 psi (105 kPa) air pressure in the tank.

16. Hold a pan under the free end of tube assembly (9) for the fuel that comes out.

17. Turn the crankshaft slowly in direction of normal rotation (counterclockwise when seen from the flywheel end of the engine). Do this until the flow of fuel that comes from the end of tube assembly (9) is 6 to 12 drops per minute [point of closing inlet port (6)].

FUEL FLOW CHECK OF TIMING

18. Stop rotation of the crankshaft when the flow of fuel is 6 to 12 drops. Take a reading of the measurement on the dial indicator.

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19. To check for correct timing angle of the fuel system in degrees, make a comparison of the measurement on the dial indicator with the measurements in the FLOW TIMING CONVERSION CHART that follows.

NOTE: If the timing of the fuel system is different than the correct timing dimension given in the chart, make reference to TIMING THE ACCESSORY DRIVE SHAFT.

Fuel System Adjustments: Off Engine Setting Fuel Injection Pump Dimension 5P6600 Off Engine Lifter Setting Tool Group.

1P7420 Pointer Assembly.S1617 Bolt, 5/16-18 NC, .75 in. (19.1 mm) long.2M5218 Shaft Assembly.1P7410 Timing Plate.2S6160 Washer.S509 Bolt.

5P129 Sleeve.6F6922 Depth Micrometer, 4 to 5 in. (102.0 to 127 mm) rod and 8S7167 Gauge or5P4165 Indicator Group.

8S3158 Indicator.3P1565 Collet Clamp.5P4165 Base.5P4163 Contact Point, 4.75 in. (120.7 mm) long.5P4158 Gauge, 2.00 in. (50.8 mm) long.

8S4613 Wrench.8S2244 Extractor.

Check timing dimension for the fuel injection pumps. Make an adjustment if necessary, with the pump housing off the engine. When an adjustment to the timing dimension is done correctly, fuel injection in the cylinder will be at the correct time. If the timing dimension is too small, fuel injection will be early. If the timing dimension is too large, fuel injection will be late.

The off engine setting makes an adjustment for wear of components in the injection pump housing and the camshaft of the injection pump.

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5P6600 OFF ENGINE LIFTER SETTING TOOL GROUP 1. 1P7410 Timing Plate. 2. 1P7420 Pointer Assembly. 3. 2M5218 Shaft Assembly. 4. 2S6160 Washer. 5. S509 Bolt. 6.

S1617 Bolt.

1. Use the 8S4613 Wrench and 8S2244 Extractor to remove the injection pumps.

2. Fasten the 1P7420 Pointer (2) to the pump housing using S1617 Bolt (6).

INSTALLATION OF THE 1P7420 POINTER 2. 1P7420 Pointer. 6. S1617 Bolt.

3. Put the 5P129 Sleeve (7) on the pump camshaft.

INSTALLATION OF 5P129 SLEEVE 7. 5P129 Sleeve.

4. Put 2M5218 Shaft Assembly (3) in 5P129 Sleeve (7) with the tang into the slot in camshaft.

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MEASURING TIMING DIMENSION (8F6922 Depth Micrometer and 8S7167 Gauge shown) 1. 1P7410 Timing Plate. 4. 2S6160 Washer. 5. S509 Bolt.

5. Put 1P7410 Timing Plate (1) in position on 2M5218 Shaft Assembly (3). Install 2S6160 Washer (4) and S509 Bolt (5).

6. When 5P4165 Indicator Group is used, the procedure that follows is necessary to adjust (calibrate) the dial indicator for the lifter measurements: a. Put the 5P4157 Gauge [4.00 in. (100.6 mm)] on the 5P4159 Gauge Stand. b. With contact point in gauge hole, put the dial indicator and base on top of 5P4157 Gauge. c. Loosen the screw that locks the dial face. Move the dial face until the large pointer is on zero and tighten the screw. d. Make a record of the position of the small pointer. The dial indicator is now adjusted (calibrated).

MEASURING TIMING DIMENSION (5P4165 Indicator Group Shown)

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8. 8S3158 Indicator. 9. 3P1565 Collet Clamp. 10. 5P4156 Base. 11. 5P4158 Gauge - 2 in. (50.8 mm). 12. Spacer. 13.

Timing dimension. 14. 5P4163 Contact Point - 4.75 in. (120.7 mm).

7. To use the timing plate, turn it counterclockwise until the degree setting for the lifter to be checked is in alignment with the pointer. The lifters are numbered 1 thru 4 from the timing plate end of the injection pump.

8. Make reference to the LIFTER SETTING CHART (OFF ENGINE) for the timing dimension of the lifter being checked.

NOTE: When measurement of the pump timing dimension is made, find the difference between the adjustment reading and the present reading on the dial face. A dimension of 4.00 in. (100.6 mm) must be added to the difference in indicator readings for the correct measurement.

9. The correct off engine timing dimension for adjustment of each lifter is: DI Engines ... 4.2675 ± .0020 in.(108.395 ± 0.051 mm) PC Engines ... 4.2675 ± .0020 in.(108.395 ± 0.051 mm) 10. The spacer (12) of each injection pump must be changed to change the timing dimension of that injection pump. Make reference to the spacer chart for spacer thickness.

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11. Make another check of all timing dimensions after all adjustments have been made.

12. After the fuel injection pump housing is again installed on the engine, make reference to INSTALLATION OF INJECTION PUMP to install pumps in housing and to check for full travel of fuel rack.

NOTE: The accessory drive shaft must be in the correct position in relation to the position of the crankshaft before the housing for the injection pumps can be installed.

Fuel Rack Setting 9S228 Rack Position Tool Group or9S240 Rack Position Tool Group.

8S2283 Dial Indicator.9S8883 Contact Point, .50 in. (12.7 mm) long.8S4627 Circuit Tester.9S8521 Rod (for speed limiter).9S8518 Plug (for speed limiter).9S225 Bracket.

5P130 "0" Set Gauge.

TOOLS TO SET FUEL RACK A. 9S225 Bracket. B. 8S2283 Dial Indicator and 9S8883 Contact Point. C. 8S4627 Circuit Tester. D. 9S8521 Rod. E. 9S8518 Plug. F. 5P130 "0" Set Gauge.

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REMOVAL OF COVER 1. Cover.

1. Move the governor control to the "fuel-off" position. Remove cover (1).

2. Put 5P130 Gauge (F) down in hole (2) under cover (1) as shown. After gauge (F) is in hole (2), turn it 180° so slot (3) will face fuel rack (4). [When governor control is moved to fuel-on, end of fuel rack (4) must go in slot (3)]. Hold gauge (F) in position with two bolts through the bolt holes for cover (1).

NOTE: If the governor has a speed limiter, do Steps 3 and 4.

3. Remove the plug from the governor housing.

4. Put 9S8518 Plug (E) in place of the plug. Put 9S8521 Rod (D) through the hole in 9S8518 Plug (E).

Push in on the rod to get compression of the speed limiter spring. Hold the rod in this position and tighten 9S8518 Plug (E) enough to hold 9S8521 Rod (D).

INSTALLATION OF THE 5P130 GAUGE 2. Hole. 3. Slot in spacer. D. 9S8521 Rod. E. 9S8518 Plug. F. 5P130 Gauge.

5. Remove the fuel filter element and the cover at the rear of the governor.

6. Install the 9S225 Bracket (A) to one of the cover bolt holes and install 8S2283 Dial 7. Use finger force to pull top of lever (G) of 5P130 Gauge (F) toward front of engine. Hold the lever in this position or install screw (H) in the lever. Turn governor lever in "fuel-on" direction until end of fuel rack (4) makes contact with slot (3) of 5P130 Gauge (F). Fasten the governor lever in this position.

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5P130 GAUGE INSTALLED 3. Slot. 4. Fuel rack. G. Lever. H. 10-32 NF Screw.

INSTALLATION OF BRACKET AND DIAL INDICATOR 5. Stop collar.

NOTE: To center the fuel rack on engines that have a negative rack setting, turn the stop collar (5) 90° to keep adjustment screw (7) from coming in contact with the stop bar or torque spring (8).

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PUTTING FUEL RACK AT CENTER POSITION 5. Stop collar.

8. Make an adjustment to the dial indicator so both dials will be at zero.

9. Release the governor lever and loosen screw (H) in lever of 5P130 Gauge (F). Turn stop collar (5) so adjustment screw (7) is in alignment with the torque spring (8) or stop bar.

10. Connect the clip end of 8S4627 Circuit Tester (C) to the contact for torque spring (8) or the contact for the rack stop bar. Put the pin end of the tester to a good ground.

11. Turn the governor lever in the "fuel-on" direction until the light in the tester comes on. Now move the governor lever toward the "shut-off" position until the test light goes out. Now slowly, turn the governor lever toward "fuel-on" until the test light has a minimum light output. In this position rack stop collar (5) is just touching torque spring (8) or the stop bar.

ADJUSTMENT SCREW CONTACT WITH TORQUE SPRING 5. Rack stop collar. 6. Locknut. 7. Adjustment screw. 8. Torque spring.

12. Read the measurement on the dial indicator. Look in the FUEL SETTING INFORMATION to find the correct measurement for rack setting.

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13. To make an adjustment to the fuel rack, loosen locknut (6). Turn adjustment screw (7) to change the fuel rack setting.

LOCATION TO MAKE THE ADJUSTMENT 6. Locknut. 7. Adjustment screw.

NOTE: Dial indicator (B) and bracket (A) are shown removed so locknut (6) and adjustment screw (7) can be seen. They do not have to be removed to make this adjustment.

14. After the adjustment procedure is done, tighten locknut (6) to 9 ± 3 lb. ft. (12 ± 4 N·m).

Air Inlet And Exhaust System Restriction of Air Inlet And Exhaust There will be a reduction of horsepower and efficiency of the engine if there is a restriction in the air inlet or exhaust system.

Air flow through the air cleaner must not have a restriction (negative pressure difference measurement between atmospheric air and air that has gone through air cleaner) of more than 30 in. (762 mm) of water.

Back pressure from the exhaust (pressure difference measurement between exhaust at outlet elbow and atmospheric air) must not be more than 34 in. (864 mm) of water.

Measurement Of Pressure In Inlet Manifold The efficiency of an engine can be checked by making a comparison of the pressure in the inlet manifold with the information given in the FUEL SETTING AND RELATED INFORMATION FICHE. This test is used when there is a decrease of horsepower from the engine, yet there is no real sign of a problem with the engine.

The correct pressure for the inlet manifold is given in the FUEL SETTING AND RELATED INFORMATION FICHE. Development of this information is done with these conditions: a. 29.4 in. (747 mm) of mercury barometric pressure b. 85° F (29° C) outside air temperature c. 35 API rated fuel

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Any change from these conditions can change the pressure in the inlet manifold. Outside air that has higher temperature and lower barometric pressure than given above will cause a lower horsepower and a lower inlet manifold pressure measurement than given is the FUEL SETTING AND RELATED INFORMATION FICHE. Outside air that has a lower temperature and a higher barometric pressure will cause higher horsepower and a higher inlet manifold pressure measurement.

A difference in fuel rating will also change horsepower and the pressure in the inlet manifold. If the fuel is rated above 35 API, pressure in the inlet manifold can be less than given in the FUEL SETTING AND RELATED INFORMATION FICHE. If the fuel is rated below 35 API, the pressure in the inlet manifold can be more than given in the FUEL SETTING AND RELATED INFORMATION FICHE. BE SURE THAT THE AIR INLET AND EXHAUST DO NOT HAVE A RESTRICTION WHEN MAKING A CHECK OF PRESSURE IN THE INLET MANIFOLD. Use the 6V3150 Engine Pressure Group to check engine rpm and the pressure in the inlet manifold.

6V3150 ENGINE PRESSURE GROUP 1. Differential pressure gauges. 2. Zero adjustment screw. 3. Pressure gauge 0 to 1100 kPa (0 to 160 psi). 4. Pressure tap.

5. Pressure gauge 0 to 415 kPa (0 to 60 psi).

This tool group has a gauge to read pressure in the inlet manifold. Special Instruction Form No. SEHS7851 is with the tool group and gives instructions for the test procedure.

Exhaust Temperature

1P3060 PYROMETER GROUP

Use the 1P3060 Pyrometer Group to check exhaust temperature. Special Instruction Form No. SMHS7179 is with the tool group and gives instructions for the test procedure. Changes in exhaust temperature can be an indication of changes in the engine or in the conditions of operation.

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Crankcase (Crankshaft Compartment) Pressure Pistons or piston rings that have damage can be the cause of too much pressure in the crankcase. This condition will cause the engine to run rough. There will also be more than the normal amount of fumes coming from the crankcase breather. This crankcase pressure can also cause the element for the crankcase breather to have a restriction in a very short time. It can also be the cause of oil leakage at gaskets and seals that would not normally have leakage.

Compression An engine that runs rough can have a leak at the valves, or have valves that need adjustment. Use the test that follows for a fast and easy method to find a cylinder that has low compression, or does not have good fuel combustion. Find the speed that the engine runs the roughest, and keep the engine at this rpm until the test is finished. Loosen a fuel line nut at fuel injection pump to stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. This test can also be an indication that the fuel injection is wrong, so the cylinder will have to be checked thoroughly. Removal of the head and inspection of the valves and valve seats is necessary to find those small defects that do not normally cause a problem. Repair of these problems is normally done when reconditioning the engine.

An analysis of the engine cylinder condition can be done with controlled pressure air through the cylinder head. Special Instruction GMG00694 explains the procedure and has a complete list of available parts.

1. Remove the fuel injection nozzle from DI engine or fuel injection valve from PC engine.

2. DI Engines: Adapt an air hose to 1P5564 Adapter. Install the 1P5564 Adapter in the fuel injection nozzle opening in the cylinder head.

PC Engines: Remove nozzle from valve body and make a replacement with 1P5569 Tip. Install valve body in prechamber. Install 8S2268 Tube Assembly, 9S7341 Adapter and 7S8890 Adapter to valve body.

Fasten an air hose to 7S8890 Adapter.

3. Start crankshaft rotation until the piston in the cylinder being inspected is at TC on the compression stroke. In this position the valves of this cylinder will be against their seats.

4. Force the air into the cylinder and then check for air leakage. An air leak from the exhaust opening is an indication of exhaust valve leakage and an air leak from the air cleaner inlet is an indication of intake valve leakage. If the air leakage is into the crankcase during this test, the piston or piston rings can be the cause.

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Cylinder Head The cylinder head has exhaust valve seat inserts that can be removed when they are worn or have damage. Also, the DI cylinder head can be machined for the addition of an intake valve seat insert, if necessary. Replacement or reconditioning can be made with the tools that follow.

Valves Valve removal and installation is easier with use of the 7F4291 Valve Spring Compressor Assembly, 8S2277 Adapter Assembly and 5S1322 Valve Keeper Inserter.

Valve Seat Inserts Tools needed to remove and install valve seat inserts are in the 8S7170 Valve Seat Insert Puller Group. Special Instruction Form No. GMG02114 gives an explanation for this procedure. For easier installation, lower the temperature of the insert before it is installed in the head.

Checking Valve Guide Bore Use the 5P3536 Valve Guide Gauge Group to check the bore of the valve guides. Special Instruction Form No. GMG02562 gives complete and detailed instructions for use of the 5P3536 Dial Bore Gauge Group.

If the valve guide bores are larger than the maximum permissible given in the Specifications, use the 5P5170 Knurling Group for reconditioning. Special Instruction SMHS6747 gives explanations on the use of the 5P5170 Knurling Group.

5P3536 VALVE GUIDE GAUGE GROUP

Valve Clearance Setting Check and adjust valve clearance with engine stopped.

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Valve clearance (1) is measured with thickness gauge between the top of the valve stem (5) and the rocker arm (2).

NOTE: When the valve lash (clearance) is checked, adjustment is NOT NECESSARY if the measurement is in the range given in the chart for VALVE CLEARANCE CHECK: ENGINE STOPPED. If the measurement is outside this range, adjustment is necessary. See the chart for VALVE CLEARANCE SETTING: ENGINE STOPPED, and make the setting to the nominal (desired) specifications in this chart.

1. Put No. 1 piston at top center position. Make reference to FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON. Both valves for No. 1 cylinder will be closed.

2. Measure the intake valve clearance for No. 1 and No. 2 cylinders, and the exhaust valve clearance for No. 1 and No. 3 cylinders.

With the fuel injection lines removed from DI engines, fuel can spray (discharge) from the fuel injection pumps when rotation of the engine is made with governor control in the fuel-on position. This can result in personal injury or fire. Move the governor control to "fuel-off-engine stop" position before fuel injection lines are removed.

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VALVE CLEARANCE ADJUSTMENT 1. Valve clearance. 2. Rocker arm. 3. Adjustment screw. 4. Locknut. 5. Valve stem. 6. Shaft for rocker arms. 7. Push rod.

3. To adjust the valve clearance (1), loosen the locknut (4) and turn the adjustment screw (3) as needed to get the correct clearance. Then, hold the adjustment screw (3) with a screw driver and tighten the locknut (4) to 24 ± 5 lb.ft. (30 ± 7 N·m). Check the valve clearance (1) again.

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CYLINDER AND VALVE LOCATION (DI Engine)

CYLINDER AND VALVE LOCATION (PC Engine)

4. Remove the timing bolt and turn the flywheel 360° counterclockwise. Install the timing bolt again in the flywheel. Both valves for No. 4 cylinder will be closed.

NOTE: If the flywheel is turned beyond the exact point to install the timing bolt, turn the flywheel clockwise approximately 60°. Then, turn it counterclockwise carefully until the timing bolt can be installed.

5. Measure the intake valve clearance for No. 3 and No. 4 cylinders, and the exhaust valve clearance for No. 2 and No. 4 cylinders. Adjust when necessary, as explained in Step 3.

6. Remove the timing bolt from the flywheel.

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When the adjustment of the valve lash needs to be done several times in a short period of time, it can be an indication of wear in a different part of the engine. Find the problem and make any necessary repairs to prevent more damage to the engine.

Not enough valve lash, if not corrected, can be the cause of rapid wear of the camshaft and cam followers. Not enough valve lash can also be an indication of the seats for the valves being bad. Some reasons for valve seat damage are fuel injection nozzles with defects, restriction to the inlet air or dirty air filters, wrong fuel setting, or engine used with loads that are too large for the engine.

Too much valve lash, if not corrected, can be the cause for broken valve stems, push rods, or spring retainers. A rapid increase in valve lash can be an indication of any of the following: a. Camshaft and cam followers with wear. b. Rocker arms with wear. c. Push rods that are bent. d. Loose adjustment screw for the valve lash. e. Broken socket on the upper end of a push rod.

If the camshaft and cam followers show signs of rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause when the necessary repairs are made.

Procedure For Measuring Camshaft Lobes To find lobe lift (A) of camshaft, use the following procedure: 1. Measure lobe height (B) of one exhaust and one intake lobe.

2. Measure base circle (C) of one exhaust and one intake lobe.

3. Subtract base circle (C) dimension (STEP 2) from lobe height (B) dimension (STEP 1). The difference is actual lobe lift (A).

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CAMSHAFT LOBE A. Lobe lift. B. Lobe height. C. Base circle.

4. The specified (new) lobe lift (A) is: (a) Exhaust lobe ... .3071 in.(7.800 mm) (b) Intake lobe ... .3077 in.(7.816 mm) 5. The maximum permissible difference between actual lobe lift (STEP 3) and specified lobe lift (STEP 4) is .025 in. (0.64 mm).

Lubrication System One of the problems in the list that follows will generally be an indication of a problem in the lubrication system for the engine.

TOO MUCH OIL CONSUMPTIONOIL PRESSURE IS LOWOIL PRESSURE IS HIGHTOO MUCH BEARING WEARINCREASED OIL TEMPERATURE

Measuring Engine Oil Pressure 5P6225 Hydraulic Test Box.9S9102 Thermistor Thermometer Group.

An oil pressure gauge that has a defect can give an indication of low oil pressure.

An 8M2744 Oil Pressure Gauge which is part of the 5P6225 Hydraulic Test Box can be used to check oil pressure in the system.

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5P6225 HYDRAULIC TEST BOX

This procedure must be followed exactly for the pressure readings to have any value.

NOTE: Before any oil pressure test is made, install a new Caterpillar filter to be sure the filter does not cause a reduction in oil pressure.

1. Be sure that the engine is filled to the correct level with SAE 30 oil. If any other viscosity of oil is used, the information does not apply.

2. Find pressure test location (1) on the oil manifold to install a tee. Install a probe from the 9S9102 Thermistor Thermometer Group in one side of the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic Test Box to the other side of the tee.

OIL MANIFOLD 1. Pressure Test Location.

3. Run the engine to get the oil temperature at 200 ± 10° F (93 ± 6° C).

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

5. An oil pressure reading of 60 to 80 psi (415 to 550 kPa) is normal at rated speed. Do not continue engine operation if oil pressure reading is less than 15 psi (105 kPa).

If the results do not fall within the pressure range given, find the cause and correct it. Engine failure or a reduction in engine life can be the result if engine operation is continued with oil manifold pressure outside this range.

Too Much Oil Consumption

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Oil Leakage on Outside of Engine Check for leakage at the seals at each end of the crankshaft. Look for leakage at the oil pan gasket and all lubrication system connections. Check to see if oil comes out of 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, and this will cause gasket and seal leakage.

Oil Leakage Into Combustion Area of Cylinders Oil leakage into the combustion area of the cylinders can be the cause of blue smoke. There are three possible ways for oil leakage into the combustion area of the cylinders: 1. Oil leakage between worn valve guides and valve stems.

2. Worn or damaged piston rings, or dirty oil return holes.

3. Compression ring not installed correctly.

Too much oil consumption can also be the result if oil with the wrong viscosity is used. Oil with a thin viscosity can be caused by fuel leakage into the crankcase, or by increased engine temperature.

Oil Pressure Is Low Crankcase Oil Level Check the level of the oil in the crankcase. Add oil if needed. It is possible for the oil level to be too far below the oil pump supply tube. This will cause the oil pump to not have the ability to supply enough lubrication to the engine components.

Oil Pump Does Not Work Correctly The inlet screen of the supply tube for the oil pump can have a restriction. This will cause cavitation (low pressure bubbles suddenly made in liquids by mechanical forces) and a loss of oil pressure. Air leakage in the supply side of the oil pump will also cause cavitation and loss of oil pressure. If the bypass valve for the oil pump is held in the open (unseated) position, the lubrication system can not get to maximum pressure. Oil pump rotors that have too much wear will cause a reduction in oil pressure.

Oil Filter Engines with Serial Numbers 45V1 thru 45V32893 A dirty oil filter will cause a reduction in oil pressure. When the oil filter is filled with dirt, a restriction of oil flow thru the filter and a reduction of filtered oil pressure is the result. The 9L9200 Oil Filter Assembly has a bypass valve inside that opens with a pressure difference of 20 ± 2 psi (140 ± 14 kPa). When bypass is open, oil that is not filtered is permitted to flow thru the engine. To correct this problem, install a new Caterpillar filter.

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Engines with Serial Numbers 45V32894-Up A dirty oil filter will cause a reduction in oil pressure. When the oil filter is filled with dirt, a restriction of oil flow thru the filter and a reduction of filtered oil pressure is the result. The oil filter base has a bypass valve inside that opens with a pressure difference of 140 ± 14 kPa (20 ± 2 psi).

When this bypass is open, oil that is not filtered is permitted to flow thru the engine. To correct this problem, install a new Caterpillar filter.

Too Much Clearance at Engine Bearings or Open (Broken or Disconnected Oil Line or Passage) Lubrication System Components that are worn and have too much bearing clearance can cause oil pressure to be low. Low oil pressure can also be caused by an oil line or oil passage that is open, broken or disconnected.

Oil Pressure Is High Oil pressure will be high if the bypass valve for the oil pump can not move from the closed position.

Too Much Bearing Wear When some components of the engine show bearing wear in a short time, the cause can be a restriction in an oil passage. A broken oil passage can also be the cause.

If the gauge for oil pressure shows enough oil pressure, but a component is worn because it can not get enough lubrication, look at the passage for oil supply to the component. A restriction in a supply passage will not let enough lubrication get to a component, and this will cause early wear.

Increased Oil Temperature Look for a restriction in the oil passages of the oil cooler. If the oil cooler has a restriction, the oil temperature will be higher than normal when the engine is operated. The oil pressure of the engine will not get low just because the oil cooler has a restriction.

Cooling System This engine has a pressure type cooling system. A pressure type cooling system gives two advantages.

The first advantage is that the cooling system can have safe operation at a temperature that is higher than the normal boiling (steam) point of water. The second advantage is that this type system prevents cavitation (low pressure bubbles suddenly made in liquids by mechanical forces) in the water pump.

With this type system, it is more difficult for an air or steam pocket to be made in the cooling system.

The cause for increased engine temperature is generally because regular inspections of the cooling system were not made. Make a visual inspection of the cooling system before a test is made with test equipment.

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Visual Inspection Of The Cooling System 1. Check coolant level in the cooling system.

2. Look for leaks in the system.

3. Look for bent radiator fins. Be sure that air flow through the radiator does not have a restriction.

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 the surface that seals the cap. This surface must be clean.

Testing The Cooling System

Remember that temperature and pressure work together. When a diagnosis is made of a cooling system problem, temperature and pressure must both be checked. Cooling system pressure will have an effect on cooling system temperatures. For an example, look at the chart to see the effect of pressure and height above sea level on the boiling (steam) point of water.

Test Tools for Cooling System 9S9102 Thermistor Thermometer Group.9S7373 Air Meter Group.1P5500 Portable Phototach Group.9S8140 Cooling System Pressurizing Pump Group.

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9S9102 THERMISTOR THERMOMETER GROUP

The 9S9102 Thermistor Thermometer Group is used in the diagnosis of overheating (engine hotter than normal) or overcooling (engine cooler than normal) problems. This group can be used to check temperatures in several different parts of the cooling system. The testing procedures is in Special Instruction Form No. SMHS7140.

9S7373 AIR METER GROUP

The 9S7373 Air Meter Group is used to check the air flow through the radiator core. The testing procedure is in Special Instruction Form No. SMHS7063.

1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group is used to check the fan speed. The testing procedure is in Special Instruction Form No. SMHS7015.

The 6V3121 Multitach Group is used to check the fan speed. The testing procedure is in Special Instruction Form No. SEHS7807.

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6V3121 MULTITACH GROUP

Pressure Cap Test 9S8140 Cooling System Pressurizing Pump Group.

One cause for a pressure loss in the cooling system can be a bad seal on the pressure cap of the system. Inspect the pressure cap carefully. Look for damage to the seal or to the surface that seals.

Any foreign material or deposits on the cap, valve, seal, or surface that seals must be removed.

The 9S8140 Cooling System Pressurizing Pump Group is used to test pressure caps and to pressure check the cooling system for leaks.

TYPICAL SCHEMATIC OF PRESSURE CAP A. Sealing surface of cap and radiator.

To check the pressure cap for the pressure that makes the pressure cap open, use the procedure that follows: 1. Remove the pressure cap from the radiator.

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DO NOT loosen the filler or pressure cap on a hot engine. Steam or hot coolant can cause severe burns.

2. Put the pressure cap on the 9S8140 Cooling System Pressurizing Pump Group.

9S8140 COOLING SYSTEM PRESSURIZING PUMP GROUP

3. Look at the gauge for the exact pressure that makes the pressure cap open.

4. Make a comparison of the reading on the gauge with the correct pressure at which the pressure cap must open.

NOTE: The correct pressure that makes the pressure cap open is on the pressure cap. It must not leak at 6.5 psi (45 kPa) and open at 8 psi (55 kPa).

5. If the pressure cap is bad, install a new pressure cap.

Radiator and Cooling System Leak Tests (Systems That Use Pressure Cap) To test the radiator and cooling system for leaks, use the procedure that follows: 1. Remove the pressure cap from the radiator.

DO NOT loosen the filler or pressure cap on a hot engine. Steam or hot coolant can cause severe burns.

2. Make sure the coolant is over the top of the radiator core.

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3. Put the 9S8140 Cooling System Pressurizing Pump Group on the radiator.

4. Get the pressure reading on the gauge to 3 psi (20 kPa) more than the pressure on the pressure cap.

5. Check the radiator for outside leakage.

6. Check all connections and hoses for the cooling system for outside leakage.

7. If you do not see any outside leakage and the pressure reading on the gauge is still the same after 5 minutes, the radiator and cooling system does not have leakage. If the reading on the gauge goes down and you do not see any outside leakage, there is leakage on the inside of the cooling system.

Make repairs as necessary.

Gauge for Water Temperature 9S9102 Thermistor Thermometer Group. or2F7112 Thermometer and 6B5072 Bushing.

TEST LOCATION A. Plug.

If the engine gets too hot and a loss of coolant is a problem, a pressure loss in the cooling system can be the cause. If the gauge for water temperature shows that the engine is too hot, look for coolant leakage. If a place can not be found where there is coolant leakage, check the accuracy of the gauge for water temperature. Remove plug (A) and install the 9S9102 Thermistor Thermometer Group or the 2F7112 Thermometer and 6B5072 Bushing.

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

Start the engine and run it until the temperature is at the desired range according to the test thermometer. If necessary, put a cover over part of the radiator or cause a restriction of the coolant flow. The reading on the gauge for water temperature must be the same as the test thermometer within the tolerance range in the chart.

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WATER TEMPERATURE GAUGE

Water Temperature Regulators 1. Remove the regulator from the engine.

2. Heat water in a pan until the temperature is 192° F (89° C). Move the water around in the pan to make it all the same temperature.

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3. Hang the regulator in the pan of water. The regulator must be below the surface of the water and it must be away from the sides and bottom of the pan.

4. Keep the water at the correct temperature for 10 minutes.

5. After ten minutes, remove the regulator and immediately measure the distance the regulator has opened. The distance must be a minimum of .260 in. (6.60 mm).

6. If the distance is less than .260 in. (6.60 mm), make a replacement of the regulator.

V-Belt Tension Chart

Basic Block Piston Rings A 5P3519 Piston Ring Groove Gauge is available to check ring grooves with straight sides. For instructions on the use of the gauge, see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.

5P3519 PISTON RING GROOVE GAUGE

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Connecting Rods And Pistons Use the 5F9059 Piston Ring Expander to remove or install piston rings.

Use the 5P3524 Piston Ring Compressor to install pistons into cylinder block.

Tighten the connecting rod bolts in the step sequence that follows: 1. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of nut and cap.

2. Tighten all bolts to 30 ± 3 lb. ft. (40 ± 4 N·m).

3. Put a mark on each nut and end of bolt.

4. Tighten each nut 60 ± 5° from the mark.

The connecting rod bearings fit tightly in the bore in the rod. If bearing joints or backs are worn (fretted), check bore size. This can be an indication of wear because of a loose fit.

Connecting Rod And Main Bearings Connecting rod bearings are available with .010 in. (0.25 mm) and .020 in. (0.51 mm) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been "ground" (made smaller than the original size).

Main bearings are available with .010 in. (0.25 mm) and .020 in. (0.51 mm) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been "ground" (made smaller than the original size).

Main bearings for DI engines are also available with a larger outside diameter than the original size bearings. These bearings are for cylinder blocks that have had the bore for the main bearings "bored" (made larger than the original size). The size available is .010 in. (0.25 mm) larger outside diameter than the original size bearings.

Cylinder Block The bore in the block for main bearings can be checked with the main bearing caps installed without bearings. Tighten the nuts that hold the caps to the torque shown in the SPECIFICATIONS. Alignment error in the bores must not be more than .003 in. (0.08 mm). Special Instruction Form No. SMHS7606 gives instructions for the use of 1P4000 Line Boring Tool Group for alignment of the main bearing bores. The 1P3537 Dial Bore Gauge Group can be used to check the size of the bores.

Special Instruction Form No. GMG00981 is with the group.

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1P3537 DIAL BORE GAUGE GROUP

Flywheel And Flywheel Housing 8S2328 Dial Indicator Group.

Heat the ring gear to install it. Do not heat to more than 400° F (204° C). Install the ring gear so the chamfer on the gear teeth are next to the starter pinion when the flywheel is installed.

Face Run Out (axial eccentricity) of the Flywheel Housing If any method other than given here is used, always remember bearing clearance must be removed to get correct measurements.

8S2328 DIAL INDICATOR GROUP INSTALLED

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CHECKING FACE RUNOUT OF THE FLYWHEEL HOUSING A. Bottom. B. Right side. C. Top. D. Left side.

1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before the indicator is read at each point.

3. With dial indicator set at .000 in. (0.0 mm) at location (A), turn the crankshaft and read the indicator at locations (B), (C) and (D).

4. The difference between lower and higher measurements taken at all four points must not be morethan .012 in. (0.30 mm), which is the maximum permissible face run out (axial eccentricity) of the flywheel housing.

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Bore Runout (radial eccentricity) of the Flywheel Housing

8S2328 DIAL INDICATOR GROUP INSTALLED

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CHECKING BORE RUNOUT OF THE FLYWHEEL HOUSING

1. Fasten the dial indicator as shown so the anvil of the indicator will touch the bore of the flywheel housing.

2. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push the crankshaft up against the top of the bearing. Write the measurement for bearing clearance on line 1 in column (C).

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs). This notation is necessary for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by 2. Write this number on line 1 in columns (B) & (D).

4. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).

5. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the chart.

6. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the chart.

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7. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write measurement in the chart.

8. Add lines I & II by columns.

9. Subtract the smaller number from the larger number in line III in columns (B) & (D). The result is the horizontal eccentricity (out of round). Line III, column (C) is the vertical eccentricity.

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

11. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of intersection is in the range marked "Not Acceptable" the flywheel housing must be changed.

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GRAPH FOR TOTAL ECCENTRICITY

Face Runout (axial eccentricity) of the Flywheel 1. Install the dial indicator as shown. Always put a force on the crankshaft in the same direction before the indicator is read so the crankshaft end clearance (movement) is always removed.

2. Set the dial indicator to read .000 in. (0.0 mm).

3. Turn the flywheel and read the indicator every 90°.

4. The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible face runout (axial eccentricity) of the flywheel.

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CHECKING FACE RUNOUT OF THE FLYWHEEL

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Bore Runout (radial eccentricity) of the Flywheel

CHECKING BORE RUNOUT OF THE FLYWHEEL 1. 7H1945 Holding Rod. 2. 7H1645 Holding Rod. 3. 7H1942 Indicator. 4. 7H1940 Universal Attachment.

1. Install 7H1942 Dial Indicator (3) and make an adjustment of 7H1940 Universal Attachment (4) so it makes contact as shown.

2. Set the dial indicator to read .000 in. (0.0 mm).

3. Turn the flywheel and read the indicator every 90°.

4. The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible bore runout (radial eccentricity) of the flywheel.

5. Runout (eccentricity) of the bore for the pilot bearing for the flywheel clutch, must not exceed .005 in. (0.13 mm).

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CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE

Electrical System Test Tools For Electrical System 6V4930 Battery Load Tester.6V4910 AC/DC Clamp-On Ammeter.6V7070 Heavy-Duty Digital Multimeter or6V7800 Regular-Duty Digital Multimeter.

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 tight, and the battery must be fully charged. If the on-engine test shows a defect in a component, remove the component for more testing.

6V4930 BATTERY LOAD TESTER

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The 6V4930 Battery Load Tester is a portable unit in a metal case for use under field conditions and high temperatures. It can be used to load test all 6, 8 and 12V batteries. This tester has two heavy-duty load cables that can easily be fastened to the battery terminals, and a load adjustment knob on the front panel permits a current range up to a maximum of 700 amperes. The tester also has a thermometer to show when the safe operating temperature limit of the unit has been reached.

NOTE: Make reference to Special Instruction, Form No. SEHS8268 for more complete information for use of the 6V4930 Battery Load Tester.

6V4910 AC/DC CLAMP-ON AMMETER

The 6V4910 AC/DC Clamp-On Ammeter is a completely portable, self-contained instrument that allows electrical current measurements to be made without breaking the circuit or disturbing the insulation on conductors. A digital display is located on the ammeter for reading current directly in a range from 1 to 500 amperes. If an optional 6V6014 Cable is connected between this ammeter and one of the digital multimeters, current readings of less than 1 ampere can then be read directly from the display of the multimeter.

A lever is used to open the jaws over the conductor [up to a diameter of 19 mm (.75 in.)], and the spring loaded jaws are then closed around the conductor for current measurement. A trigger switch that can be locked in the ON or OFF position is used to turn on the ammeter. When the turn-on trigger is released, the last current reading is held on the display for 5 seconds. This allows accurate measurements to be taken in limited access areas where the digital display is not visible to the operator. A zero control is provided for DC operation, and power for the ammeter is supplied by batteries located inside the handle.

NOTE: Make reference to Special Instruction Form No. SEHS8030 for more complete information for use of the 6V4910 Clamp-On Ammeter.

6V7070 HEAVY-DUTY DIGITAL MULTIMETER

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The 6V7070 Heavy-Duty Digital Multimeter is a completely portable, hand held instrument with a digital display. This multimeter is built with extra protection against damage in field applications, and is equipped with seven functions and 29 ranges. The 6V7070 Multimeter has an instant ohms indicator that permits continuity checks for fast circuit inspection. It also can be used for troubleshooting small value capacitors.

The 6V7800 Regular-Duty Digital Multimeter (a low cost option to the Heavy-Duty Multimeter) is also available; however, the 6V7800 Multimeter does not have the 10A range or the instant ohms feature of the 6V7070 Multimeter.

NOTE: Make reference to Special Instruction Form No. SEHS7734 for more complete information for use of the 6V7070 and 6V7800 Multimeters.

Battery

Never disconnect any charging unit circuit or battery circuit cable from 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. Damage to the charging unit will result if the connections (either positive or negative) between the battery and charging unit are broken while the charging unit is in operation. This is because the battery load is lost and there is an increase in charging voltage.

High voltage will damage, not only the charging unit, but also the regulator and other electrical components.

Load test a battery that does not hold a charge when in use. To do this, put a resistance across the main connections (terminals) of the battery. For a 6, 8 or 12V battery, use a test load of three times the ampere/hour rating (the maximum test load on any battery is 500 amperes). Let the test load remove the charge (discharge) of the battery for 15 seconds and with the test load still applied, test the battery voltage. A 6V battery in good condition will show 4.5V; and 8V battery will show 6V; a 12V battery will show 9V. Each cell of a battery in good condition must show 1.6V on either a 6, 8 or 12V battery.

Charging System The condition of charge in the battery at each regular inspection will show if the charging system operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed (more than one ounce of water per cell per week or per every 50 service hours).

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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 (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, again make a test to give proof that the units are repaired to their original condition of operation.

Before the start of on-engine testing, the charging system and battery must be checked as shown in the Steps that follow: 1. Battery must be at least 75% (1.240 Sp. Gr.) fully charged and held tightly in place. The Battery holder must not put too much stress on the battery.

2. Cables between the battery, starter and engine ground must be the correct size. Wires and cables must be free of corrosion and have cable support clamps to prevent stress on battery connections (terminals).

3. Leads, junctions, switches and panel instruments that have direct relation to the charging circuit must give correct circuit control.

4. Inspect the drive components for the charging unit to be sure they are free of grease and oil and have the ability to operate the charging unit.

Alternator Regulator There are no adjustments for this alternator regulator. When an alternator charges the battery too much or not enough, and the alternator regulator is found to be at fault, a new alternator regulator will have to be installed.

Starting System Use the multimeter in the DCV range to find starting system components which do not function.

Move the start control switch to activate the starter solenoid. Starter solenoid operation can be heard as the pinion of the starter motor is engaged with the ring gear on the engine flywheel.

If the solenoid for the starter motor will not operate, it is possible that the current from the battery did not get to the solenoid. Fasten one lead of the multimeter to the connection (terminal) for the battery cable on the solenoid. Put the other lead to a good ground. A zero reading is an indication 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. Put the other lead to a good ground. Activate the starter solenoid and look at the multimeter. A reading of battery voltage shows 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. This is an indication of the need for repair to the solenoid or an adjustment to be made to the starter pinion clearance.

Make a test with one multimeter lead fastened to the connection (terminal) for the small wire at the solenoid and the other lead to the ground. Look at the multimeter and activate the starter solenoid. A

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voltage reading shows that the problem is in the solenoid. A zero reading is an indication 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. Make a 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.

A starter motor that operates too slow can have an overload because of too much friction in the engine being started. Slow operation of the starter motor can also be caused by a short circuit, loose connections and/or dirt in the motor.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 11:59:42 UTC+0400 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly IT12 INTEGRATED TOOLCARRIER POWER TRAIN Media Number -SENR4091-01

Publication Date -26/05/2005

Date Updated -15/08/2005

SENR40910028

Engine, Transmission And Transfer Gears SMCS - 1006-010; 1006-029

Remove And Install Engine, Transmission And Transfer Gears

START BY: a. connection of steering frame lock link b. remove cab * c. remove radiator and guard ** d. remove drive shaft (rear) *

This operation is in the Vehicle Systems Disassembly And Assembly section.

**

This operation is in the Engine Disassembly And Assembly section.

NOTE: Put identification marks on all wires, hoses and tube assemblies. Put caps or plugs on these items to keep out dirt or foreign material.

1. Drain the oil from the hydraulic tank. The capacity of the hydraulic tank is 32 liter (8.5 U.S. gal.).

2. Drain the oil from the transmission. The capacity of the transmission is: 3F/1R - 18 liter (4.7 U.S. gal.), 3F/3R - 27 liter (7 U.S. gal.).

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3. Remove the seat and all floor plates from the cab.

4. Disconnect spring (2) from throttle linkage rod (1).

5. Remove the cotter pin and pin that fastens throttle linkage rod (1) to the throttle pedal.

6. Disconnect clip (3) that fastens transmission oil level tube (4) to the filler spout.

7. Disconnect transmission oil level tube (4) from the transfer gear case, and remove tube (4) from the machine.

8. Disconnect tube (5) from the transfer case.

9. Remove the clip that fastens hose (6) to the rear frame at location (X).

10. Disconnect center driveshaft (7) from the parking brake.

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11. Disconnect wire connector (9) for the transmission neutralizer solenoid. Remove two tube assemblies (12). Remove two bolts (10), and remove transmission neutralizer valve (11) from the machine.

12. Disconnect hose (8) from the transmission.

13. Disconnect the two wires from back-up alarm (13).

14. Remove bolts (14) that fasten the transmission control cables to the transmission. Pull the cables toward the front of the machine, and unhook them from the spools.

15. Disconnect brake line (19) from the brake master cylinder.

16. Disconnect hose (17) from the transmission filter. Remove four bolts (15) (not shown) that fasten filter (20) and bracket (16) to the transmission. Remove the components from the machine as a unit.

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17. Disconnect two steering cylinder rod end hoses (18) that run across the front of the transmission.

18. Disconnect clip (23). Remove hose (24), and disconnect hose (21) from fitting (22). Remove fitting (22) from the hydraulic tank.

19. Remove hose (25) from the transmission pump. Remove the transmission suction tube (not shown) that runs to the bottom of the transfer gear case.

20. Disconnect two tubes (26) from the side of the transmission case.

21. Disconnect transmission temperature sending unit (27) from the transmission.

22. Release the parking brake to relieve the tension on pin (29). Remove the cotter pin and pin (29) from the parking brake lever.

23. Disconnect clip (28), and set the parking brake cable aside.

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24. Remove both engine side panels (36) from the machine.

25. Loosen hose clamp (31), and remove the air cleaner and hose from the machine.

26. Disconnect tube (30) for the air filter indicator gauge.

27. Disconnect two heater hoses (33) (one not shown).

28. Disconnect two outlet tubes (34) and suction hose (35) from the hydraulic pump (implement and steering).

29. Disconnect water temperature sending unit (32) from the engine. Remove the two clips that fasten it to the engine, and set it aside.

30. Disconnect tube (37) for the oil pressure gauge.

31. Disconnect the two wires from oil pressure switch (38).

32. Remove the cotter pin and pin (39) from throttle linkage rod (1). Remove throttle linkage rod (1) from the machine.

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33. Disconnect two wires (40) from the positive terminal of the starter solenoid and wire (41) from the wire harness.

34. Disconnect fuel lines (42) and (43) from the fuel injection pump.

35. Disconnect ground wire (44) from the flywheel housing.

36. Remove the cotter pin and pin (45) from the throttle linkage.

37. Remove the bolts that fasten firewall (46) to the fuel tank and the hydraulic tank. Remove firewall (46) from the machine.

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38. Install tooling (A), and fasten a hoist.

39. Disconnect bracket (50) from rear support (49).

40. Remove bolts (48) and four mount assemblies (47).

41. Remove bolts (52) and front supports (51) from the transmission.

42. Remove the engine, transmission and transfer gears from the machine. The weight of the engine, transmission and transfer gears is 911 kg (2010 lb.).

NOTE: The following steps are for installation of the engine, transmission and transfer gears.

43. Install the engine, transmission and transfer gears in the reverse order of removal.

44. Tighten bolts (52) that fasten front supports (51) to the transmission to a torque of 122 N·m (90 lb.ft.).

45. Tighten the nut that fastens two wires (40) to the starter solenoid to a torque of 122 N·m (90 lb.ft.).

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46. tighten the bolt that fastens brake line (19) to the master cylinder to a torque of 70 ± 15 N·m (50 ± 11 lb.ft.).

47. Tighten the bolts that fasten drive shaft (7) to the parking brake flange to a torque of 58 ± 8 N·m (43 ± 6 lb.ft.).

48. After installation of the engine, transmission and transfer gears, remove the air from the brake lines. See Remove Air From The Brake System (Bleed The Brakes) in Testing And Adjusting.

END BY: a. install drive shaft (rear) b. install radiator and guard * c. install cab ** d. separate steering frame lock link *

This operation is in the Engine Disassembly And Assembly section.

**

This operation is in the Vehicle Systems Disassembly And Assembly section.

Separate And Connect Engine, Transmission And Transfer Gears

START BY: a. remove engine, transmission and transfer gears

1. Put the engine, transmission and transfer gears in position on tool (A) and wood blocks as shown.

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2. Fasten a hoist to the transmission and transfer gears. Remove bolts (2) that hold the transmission to the flywheel housing. Make a separation of transmission and transfer gears (1) from the engine. The weight of the transmission and transfer gears is 446 kg (983 lb.).

3. Connect the engine, transmission and transfer gears in the reverse order. Be sure the O-ring seal is in position on the face of the transmission case.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:00:03 UTC+0400 2019

All Rights Reserved.

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Prechamber Nozzle SMCS - 7506-029

(1) Torque for glow plugs (put 5P3931 Anti-Seize Compound on threads) ... 120 ± 24 lb. in.(13.6 ± 2.8 N·m) (2) Torque for all nuts that hold the fuel lines ... 30 ± 5 lb. ft.(40 ± 7 N·m) (3) Torque for the nuts that hold the nozzles ... 55 ± 5 lb. ft.(75 ± 7 N·m) (4) Body.

(5) Rubber ring. Put liquid soap on rubber ring and in bore in cylinder head.

(6) Nozzle. Tighten nozzle finger tight on body (4).

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

(7) Torque for precombustion chamber ... 150 ± 10 lb. ft.(205 ± 14 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:00 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Governor Control Linkage (Governor Control, D3 Tractor & 931 Track-Type Loader) SMCS - 7506-029

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(1) Force to move control lever (approximate) ... 11 lb.(49 N) (2) Guide plate.

(3) Friction disc. Put new disc in kerosene for 24 hours before installation.

(4) Tighten nut only so control lever (1) does not slide when the engine is at high idle.

(5) Cable end.

(6) Governor lever.

(7) Cable end.

Cable adjustment procedure:

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1. Put the governor lever (6) in "shut off" position.

2. Adjust the cable ends (5 and 7) so the control lever (1) is also in "shut-off" position [approximately .5 in. (12mm) from end of slot in guide plate (2)].

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:06 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Governor Control Linkage (For 910 Wheel Loader) SMCS - 7506-029

(1) Governor lever, in high idle position.

(2) Intermediate levers (two levers on same shaft).

(3) Ends for the pedal rod.

(4) Control pedal.

(5) Pedal stop bolt for the high idle position.

(6) Angle between the pedal and the floor plate: Pedal in high idle position ... 28° Pedal in fuel off position ... 65°

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(7) Ends for the governor rod.

(8) Distance between centers of pins ... 44.49 ± .06 in.(1130.0 ± 1.5 mm) Adjustment procedure: 1. Adjust the stop bolt (5) so the pedal stops at the correct high idle angle (6).

2. Disconnect the pedal rod and adjust the pedal rod ends (3) to the correct distance (8). Install the pedal rod.

3. Disconnect the governor rod.

4. Put the governor lever (1) and the control pedal (4) in high idle position. Adjust the rod ends (7) so the rod will fit correctly in the governor lever (1) and in the longer intermediate lever (2).

5. Tighten the locknut of all rod ends.

6. If necessary, adjust the pedal stop bolt (5) again. Adjust so the pedal stops when the governor lever (1) is in high idle position. Tighten the locknut for the stop bolt.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:15 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Governor Control Linkage (6S7071) (Governor And Transmission Control, An Attachment For D3 Tractor & 931 Track-Type Loader) SMCS - 7506-029

(1) Distance between ball joint centers ... 5.32 in.(135.0 mm) (2) Rear intermediate lever.

(3) Handle shaft lever.

(4) Torque for locknuts of ball joints ... 30 ± 5 lb. in.(3.4 ± 0.6 N·m)

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(5) Angle between the rear intermediate lever (2) and a vertical line, in "shut off" position ... 45° (6) Front intermediate lever.

(7) Distance between bracket and end of cable ball joint, in "shut off" position ... 7.84 in.(199.0 mm)

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(8) Control handle in "off" position.

(9) Control handle in "high idle" position.

NOTE: When the governor lever is in maximum "shut off" position, the intermediate levers (2 and 6) and the control handle (8) must also be in "shut off" position as shown.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:20 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Governor Control Linkage (5G2257) (Governor And Transmission Control, An Attachment For D3B Tractor & 931B Track-Type Loader) SMCS - 7506-029

NOTICE Be sure operator can shut the engine off when handle (5) is turned counterclockwise.

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1. Disconnect governor cable (3) at the tank end.

2. Put governor lever (4) in low idle position as shown.

3. Adjust length of rod (2) so distance between center of pins for the rod is ... 0.5 in.(127 mm)

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4. With lever (4) and handle (5) in the position shown, adjust the clevis on cable (3) and connect the clevis to the lever.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:25 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 4

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Transfer Pump SMCS - 1256-015; 1256-016

Disassemble Fuel Transfer Pump START BY: a. remove fuel transfer pump

1. Remove connector (1) and the O-ring seal. Remove connector (2) and the O-ring seal from the pump housing.

2. Remove spring (3), valve (4) and the seal from the pump housing.

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Cover (6) is under spring tension. To prevent personal injury, carefully remove bolts (5) to release the spring tension.

3. Carefully remove bolts (5), cover (6), the seal and spring from the pump housing.

4. Remove plate (7), the valve and seal from the pump housing.

5. Remove snap ring (8) that holds tappet (9) in position. Remove tappet (9) from the pump housing.

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Assemble Fuel Transfer Pump

1. Put tappet (2) in position in the pump housing, and install snap ring (1) that holds it in place.

2. Install seal (6), valve (3) and plate (4) in piston (5) as shown.

3. Install piston assembly (7) and spring (8) in the pump housing as shown.

4. Install seal (10) in cover (9), and put clean diesel fuel on the O-ring seal.

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5. Put cover (10) in position on the pump housing, and install the bolts that hold it in place.

6. Install seal (11) in the bore of the pump housing.

7. Install valve (13) and spring (12) in the pump housing.

8. Be sure the O-ring seals are in position on connector (14) and connector (15), and put clean diesel fuel on the O-ring seals.

9. Install connector (14) and connector (15) in the pump housing.

END BY: a. install fuel transfer pump Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:36 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Governor SMCS - 1264-015; 1264-016

Disassemble Governor

START BY: a. remove fuel injection pump housing and governor NOTE: If it is desired to remove only the governor so the fuel injection pump housing can be disassembled, only do steps. 1, 2, 16, 23, 27, 28, 29, 33, 34, 35, 36 and 39.

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1. Remove two bolts (2) and fuel transfer pump (3).

2. Remove two bolts (1) from the fuel system.

3. Remove six bolts (4), governor housing (5) and the gasket.

4. Remove governor spring (10), two wave washers (7) and (9), one flatwasher (8) and seat (6) from the guide.

5. Remove bolts (12) and cover assembly (11) from the housing.

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6. Remove seal (13) from cover (11) with tooling (B).

7. Loosen low idle adjustment screw (14), and remove spring (15) from the housing.

8. Remove shaft (16) and lever (17) from the housing. Remove the ring from the shaft if necessary.

9. On later engines, remove the control shaft assembly from the housing as follows: a. Remove two screws (19), plate (18) and the washer located under plate (18).

b. Remove stop (20) and the plate located under the stop.

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c. Remove shaft assembly (21), lever (22) and lever (23) from the housing.

d. Remove plate (25) from the shaft assembly. e. Remove pin (26), pin (27) and spring (24) from the shaft assembly.

10. On earlier engines, remove shaft assembly (28), lever (29) and lever (30) from the housing.

11. On earlier engines, disassemble the control shaft assembly as follows:

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a. Remove the two snap rings from pins (33), and remove the pins. Remove plates (31) and stop (32) from the shaft assembly.

b. Remove pin (36), pin (34) and spring (35) from the shaft assembly.

NOTICE Remove check valve (37) only if a replacement is necessary because the check valve will be damaged during removal.

12. Remove check valve (37) if a replacement is necessary.

13. Remove two bolts (38), cover (39) and the gasket from the housing.

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14. Remove insulator (42) and body (41) for the governor dashpot adjustment screw.

15. Remove seal (43) and high idle adjustment screw (40).

16. Remove two bolts (45), housing (44) and the gasket from the fuel injection pump housing.

17. Remove bolts (46) and torque control group (47) as a unit.

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18. Disassemble the torque control group. Inspect insulator (48), shim (49), spring (50), contact (51) and spacer (52) for wear or damage.

19. Remove bolts (53) and block (54) for the full load stop.

20. Remove bolt (57) that holds collar (58) to bolt (55). Remove collar (58) and spring (56) from bolt (55).

21. Remove bolt (55) from the block.

22. Loosen nuts (59), and remove power adjustment screw (60) and torque rise adjustment screw (61) from collar (58) if a replacement is necessary.

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23. Remove bolts (63) and governor servo (62) from the fuel injection pump housing.

24. Remove lockring (68), seat (67), spring (broken link spring) (66) and sleeve (65) from valve (64).

Remove the other lockring (68) from the groove in the center of valve (65).

NOTE: The groove in the bottom of valve (64) must be in alignment with the servo body to permit removal from the fuel rack.

25. Remove valve (64), sleeve (69) and piston (71) from the governor servo. Remove the O-ring seal from sleeve (69).

26. Remove pin (70) and lever (72) from the governor servo.

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27. Use tool (D) to hold spring (74) under compression so ring (73) can be removed. Spring (74) is used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing.

28. Remove ring (73); then remove tool (D).

29. Remove bearing (75), sleeves (76) and spring (74) from the governor shaft.

30. Remove ring (77) and dashpot assembly (78) from the governor shaft.

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31. Use tool (C) to remove snap ring (84) from seat (81). Remove ring (83) and spool (82) from seat (81).

32. Remove seat (81) from spring (80), and remove spring (80) from seat (79).

33. Remove spring (overfueling spring) (85) and riser (86) from the governor shaft.

34. Remove ring (88), races (87) and bearing (89) from the riser.

NOTE: Make a replacement of shield (90) any time it is removed.

35. Use a screwdriver to remove shield (90) as shown.

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36. Remove bolts (91) and carrier (92) for the governor flyweights.

37. Remove dowels (93) and flyweights (95) from the carrier.

38. Remove shaft (94) from the carrier. Remove the dowel from shaft (94).

39. Remove races (96) and bearing (97) from the camshaft in the fuel injection pump housing.

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Assemble Governor

NOTE: If the governor was removed only to permit repair of the fuel injection pump housing, do only Steps 1, 4, 5, 7, 9, 10, 11, 16, 23, 42, 43, 44 and 45.

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NOTE: Put clean engine oil on all parts before assembly. Be sure all oil passages are clear.

1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump housing.

2. Put flyweights (3) in position on carrier (4), and install the dowels to hold the flyweights in place.

The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in.) end play.

3. Install dowel (5) in governor shaft (6), and install the governor shaft in the carrier as shown.

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4. Put the carrier in position on the camshaft, and install the bolts that hold the carrier in place.

NOTE: Make a replacement of shield (7) any time it is removed.

5. Install shield (7) on the carrier, and use tool (A) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° ± 5° apart next to the holes in the shield.

6. Install one race (9), bearing (10), the other race (9), and use tool (B) to install the ring on riser (8) as shown.

7. Install riser (8) and the spring (overfueling spring) on the governor shaft as shown.

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8. Assemble the dashpot as follows: a. Install spring (12) on seat (11), and install seat (13) in spring (12). b. Put spool (14) and ring (15) in position on seat (13), and use tool (B) to install snap ring (16) to hold them in place.

9. Install dashpot assembly (17) on the governor shaft as shown.

NOTE: Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing.

10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown.

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11. Use tool (C) to hold spring (19) under compression, and install ring (22) in the groove in the governor shaft. Remove tool (C).

12. Put lever (27) in position on governor servo (23), and install pin (24) to hold the lever in place.

Use a hammer and chisel to move the metal (stake) four places 90 ° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.

13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown.

14. Install valve (28) in the governor servo as shown.

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15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28), and install the other lockring (32) to hold them in place.

16. Put the governor servo in position on the fuel injection pump housing with piston (26) engaged over rack (33), and install the bolts that hold the governor servo in place.

17. Install torque rise adjustment screw (35) and power adjustment screw (34) in collar (36) as shown.

Install nuts (37) on the screws.

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18. Put bolt (39) in position in block assembly (40), and install spring (38) on the bolt as shown.

19. Put collar (36) in position on bolt (39). Be sure the cutout (slot) in the collar is engaged with dowel (41). Install bolt (42) to hold the collar in place. Be sure bolt (42) fits in the groove of bolt (39).

20. Put block (40) in position on housing (44). Be sure the holes in the block are engaged with dowels (43). Install the bolts that hold the block in place.

21. Assemble the torque control group as follows: a. Install shim (46), spring (50), contact (47) and spacer (51) on insulator (49) as shown. b. Install bolts (53) through retainer (52), bar (48), the insulator assembly and bar (45).

22. Install torque control group (54) on block (40) as shown.

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If housing (44) is installed with the flange on bolt (39) (see illustration B86569X1) on the wrong side of the dashpot, the riser in the governor will be held in the maximum fuel delivery position. To prevent possible personal injury, make sure housing (44) is installed on the fuel injection pump housing with the flange on bolt (39) behind seat (55).

23. Install gasket (56) on fuel injection pump housing (44). Put housing (44) in position on the fuel injection pump housing with bolt (39) behind dashpot (seat) (55). Install the two bolts that hold the housing in place.

24. Use tooling (D) to install lip type seal (57) in the governor outer housing. Install the seal with the lip facing in as shown.

25. Install insulator (fuel setting contact) (58) in the housing. Tighten the insulator to a torque of 4.5 ± 0.5 N·m (40 ± 4 lb.in.).

26. Install adjustment screw (59) and the locknut for the high idle adjustment.

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27. Install the O-ring seal on body (60) for the governor dashpot adjustment. Install body (60) in the housing.

28. Install the gasket and cover (61) on the housing.

29. If it was necessary to replace check valve (62), install a new check valve as shown.

30. Install spring (65) in shaft assembly (63). Install pin (64) in shaft assembly (63) with the tip of the pin engaged in the hole in spring (63). Install pin (66) in the shaft assembly to hold pin (64) in place.

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31. On earlier machines, put stop (69) and plates (67) in position on shaft assembly (63). Install pins (68) to hold the plates and stop in place. Install snap rings (70) to hold pins (68) in place.

32. On later engines, assemble the control shaft as follows: a. Put plate (71) and (73) in position on the shaft assembly as shown. b. Put plate (72), stop (75) and washer (76) in position between plate (71) and (73). Install two screws (74) that hold them in place. Do not tighten the screws at this time.

33. On earlier machines, put levers (77) and (78) in position in the housing as shown. Install shaft assembly (63) to hold the levers in place.

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34. On later engines, install the control shaft assembly in the housing as shown: a. Put levers (80) and (81) in position as shown, and install shaft assembly (79) to hold the levers in place. b. Make sure the large end of low idle adjustment screw (82) (located inside the governor housing) is engaged in the slot in plate (72); then tighten screws (74).

35. Install ring (83) on shaft (84).

36. Put lever (85) in position in the housing as shown. Install shaft (84) to hold the lever in place.

37. On earlier engines, install spring (86) in the hole in the shaft assembly and in the housing. Tighten low idle adjustment screw (87) until it makes contact with shaft assembly (63).

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38. On later engines, install spring (88) in the governor housing as shown. Make sure one end of the spring is engaged on the knob of stop (75).

39. Use tooling (D) to install the lip-type seal in cover (89). Install the seal with the lip of the seal facing in as shown.

40. Install the gasket on cover (89).

41. Put cover (89) in position on the housing, and install the four bolts that hold it in place.

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NOTICE Flat washer (92) must be installed between wave washers (91).

42. Install the governor spring assembly on the guide. Install seat (90), one wave washer (91), flatwasher (92), the other wave washer (91) and spring (93) on the guide as shown.

NOTE: Make sure the seat, washers and spring are on top of lever (81) as shown. These parts must be kept in this position when housing (95) is put in position on the inner governor housing.

43. Put gasket (94) and housing (95) in position on the inner governor housing, and install the eight bolts that hold it in place.

Typical Example

44. Put fuel transfer pump (96) in position on the governor housing, and install the bolts that hold it in place.

45. Make governor adjustments. See Governor Adjustments in Testing And Adjusting.

END BY: a. install fuel injection pump housing and governor

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:41 UTC+0400 2019

All Rights Reserved.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Pumps SMCS - 1251-015; 1251-016

Disassemble Fuel Injection Pump START BY: a. remove fuel injection pumps* *

See Fuel Injection Pump Housing in this module.

NOTICE Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.

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1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).

2. Remove washer (5) from plunger (1).

NOTICE Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.

3. Remove spring (2) from barrel (3).

4. Remove ring (6), and make a separation of barrel (3) and bonnet (4).

5. Remove check assembly (7) and spring (8) from bonnet (4). If check assembly (7) is disassembled, do not mix parts with parts from another check assembly.

Assemble Fuel Injection Pumps NOTICE Put clean fuel oil on all parts during assembly.

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1. Install spring (2) and check assembly (1) in bonnet (3).

2. Install bonnet (3) on barrel (4), and install ring (5) to hold them together. Do not slide bonnet (3) across barrel (4) because check assembly (1) in the bonnet can cause damage to the face of barrel (4).

3. Install spring (8) on barrel (4).

4. Install washer (7) on plunger (6) with the flat side toward the gear on the plunger.

5. Install plunger (6) in barrel (4) until washer (7) is engaged in the spring.

END BY: a. install fuel injection pumps* *

See Fuel Injection Pump Housing in this module.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:47 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Nozzles SMCS - 1254-011; 1254-012

Remove Fuel Injection Nozzles

START BY: a. remove valve cover base

1. Remove bolt (2) and clamp (3) that hold fuel injection nozzle (1) in place.

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2. Use tooling (A), and remove the fuel nozzle from the cylinder head assembly.

NOTE: A replacement of carbon dam seal (5) and washer (compression seal) (4) must be made each time the fuel injection nozzle is removed.

3. Remove carbon dam seal (5) with pliers and washer (4) from the fuel injection nozzle.

Install Fuel Injection Nozzle

START BY: a. remove valve cover base

NOTICE

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Before the fuel injection nozzles are installed, check for fuel leakage and the pressure at which the injection nozzle opens with tool (A). See Testing Fuel Injection Nozzles in Testing And Adjusting.

1. Make sure the bore in the cylinder head assembly and the fuel inlet fitting are clean. Use tool (C) to clean the bore in the cylinder head for the fuel injection nozzle. Use an open end wrench or tap driver to turn tool (C).

2. Install new washer (compression seal) (1) on the fuel injection nozzles.

3. Put carbon dam seal (2) on the small end of tool (B). Expand it by sliding it to the large end. Put tool (B) against the fuel injection nozzle, and slide carbon dam seal (2) off tool (B) onto the nozzle.

Slide the carbon dam seal into position in the groove on the nozzle.

4. Put fuel injection nozzles (3) in position in the cylinder head assembly. Push and turn the nozzle to install it into its correct position.

5. Install clamp (5) and bolt (4) that hold the fuel nozzle in place.

END BY: a. install valve cover base Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:02:51 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Fuel Transfer Pump SMCS - 1256-010

Remove And Install Fuel Transfer Pump 1. Turn off the fuel supply at the fuel tank.

2. Disconnect fuel lines (2) and (4) from the fuel transfer pump.

3. Remove two bolts (1) and fuel transfer pump (3) from the fuel injection pump housing.

4. Remove the O-ring seal from the fuel transfer pump.

NOTE: The following steps are for installation of the fuel transfer pump.

5. Put clean fuel on the O-ring seal. Install the O-ring seal in the groove in the fuel transfer pump.

6. Put fuel transfer pump (3) in position on the fuel injection pump housing, and install two bolts (1).

7. Connect fuel lines (2) and (4) to the fuel transfer pumps.

8. Turn on the fuel supply at the tank.

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Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:07 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 6

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly SUPPLEMENT FOR 3204 ENGINE FOR IT12 INTEGRATED TOOLCARRIER Media Number -SENR4038-00

Publication Date -01/01/1986

Date Updated -11/10/2001

Fuel Injection Pump Housing And Governor SMCS - 1286-011; 1286-012

Remove Fuel Injection Pump Housing And Governor

START BY: a. remove muffler b. remove fuel injection lines 1. Turn off the fuel supply at the fuel tank.

2. Disconnect fuel lines (1) at each end, and remove them from the fuel injection pump housing.

3. Disconnect two fuel lines (4). Put plug and caps on all of the fuel line openings.

4. Remove the cotter pin and pin (3), and disconnect rod end (2) from the governor.

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5. Loosen bolt (5) and nut (6). Move the alternator toward the engine, and remove V-belt (7) from the alternator pulley.

6. Remove the bolts that hold guard assembly (9) in position, and remove the guard assembly.

7. Remove plug (8) from the timing gear cover.

8. Loosen bolt (10) that holds the fuel pump drive gear to the fuel injection pump camshaft a maximum of one turn.

9. Remove three bolts (11).

10. Loosen three nuts (12) that hold the fuel injection pump to the timing gear plate. Loosen the nuts until they are even with the end of the studs.

11. Install tool (A) in the timing gear cover. Tighten the forcing screw in tool (A), and loosen the drive gear from the fuel injection pump camshaft.

12. Remove tool (A) from the timing gear cover.

13. Remove the bolt and washer from the fuel injection pump camshaft.

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14. Remove three nuts (12), and remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is 22 kg (49 lb.).

15. Remove the O-ring seals from the fuel injection pump housing.

Install Fuel Injection Pump Housing And Governor

1. Install the fuel injection pump housing and governor on tooling (A), or use a suitable vise to hold it.

2. Remove the bolts and cover over the timing pin hole in the pump housing.

3. Install the washer and bolt (1) that is used to hold the drive gear to the fuel injection pump camshaft.

4. Install tool (B) in the hole of the fuel injection pump housing. Use bolt (1), and turn the fuel injection pump camshaft until tool (B) engages in the notch in the camshaft.

5. Remove the bolt and washer from the camshaft.

6. Remove the fuel injection pump housing and governor from tooling (A).

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7. Install O-ring seals (2) and (3) in the fuel injection pump housing. Put clean engine oil on the Oring seals.

8. Put the fuel injection pump housing and governor in position on the engine, and install three nuts (4).

9. Put clean oil on the threads of bolt (1). Install the bolt and washer to hold the drive gear to the fuel injection pump camshaft. Tighten the bolt finger tight only.

NOTE: Bolt (1) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned. However, the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on the top center compression position (TDC).

10. Put No. 1 piston at the top center compression position (TDC) with the following procedure: a. Remove plug (5) from the flywheel housing. b. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 × 2 in. (50.8 mm) bolt can be installed through the timing hole in the flywheel housing and into the hole in the flywheel.

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c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (6) for the No. 1 piston can be moved backward and forward by hand.

NOTE: The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°), and install the bolt again.

11. With the timing pin in the notch of the fuel injection pump camshaft and the timing bolt in the flywheel, tighten the bolt which holds the drive gear to the fuel injection pump camshaft to a torque of 175 ± 7 N·m (129 ± 5 lb.ft.).

12. Check the timing as follows: a. Remove both the timing pin and timing bolt. b. Turn the crankshaft clockwise (as seen from the front of the engine) two full turns, and install the timing pin and bolt again. c. The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt cannot be installed at the same time. d. Remove the timing pin and timing bolt when the timing is correct.

13. Install the plug in the flywheel housing.

14. Install three bolts (7).

15. Put the gasket and cover (8) in position on the fuel injection pump housing, and install the bolts that hold them in place.

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16. Install plug (12) in the timing gear cover.

17. Put V-belt (11) in position on the alternator pulley. Adjust the belt tension, and tighten bolts (9) and (10).

18. Use a belt tension gauge, such as a Borroughs Tool Company part No. BT-33-95 to check the belt tension. The gauge reading should be 534 ± 22 N (120 ± 5 lb.) for a new belt and 400 ± 44 N (90 ± 10 lb.) for a used belt.

19. Install guard assembly (13) on the radiator.

20. Put rod end (15) in position, and install the pin (16) and the cotter pin to hold it in place.

21. Connect fuel lines (17).

22. Install fuel lines (14). Install the clips and bolt to hold fuel lines (14) in position.

23. Turn on the fuel supply at the fuel tank.

END BY: a. install fuel lines b. install muffler Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:14 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 1

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Nozzle SMCS - 1286-011; 1286-012

(1) Tighten bleed screw to ... 16 ± 2 lb. in.(1.8 ± 0.2 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:21 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Injection Nozzle SMCS - 1286-011; 1286-012

Bench test nozzles using clean SAE J967 Calibration oil at a temperature of ... 65 to 70°F(18 to 20°C) Nozzle setting pressures (valve lift adjustment screw turned 3/4± 1/8 turn from closed position): 9L6969 Nozzle: Used nozzle ... 1900 to 2900 psi(13 090 to 19 980 kPa) Used, adjusted nozzle ... 2700 to 2900 psi(18 600 to 19 980 kPa) 9N3979 and 1W5829 Nozzles: Used nozzle ... 1500 to 2600 psi(10 300 to 17 690 kPa)

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Used, adjusted nozzle ... 2400 to 2600 psi(16 545 to 17 690 kPa) Return oil leakage test pressure ... 1400 to 1600 psi(9630 to 11 045 kPa) Leakage in 15 seconds (9L6969) ... 2 to 30 drops Leakage in 15 seconds (9N3979 & 1W5829). NO minimum or maximum.

9L6969 Nozzle: Maximum tip leakage is 10 drops in 15 seconds with pressure 200 psi (1380 kPa) less than opening pressure.

9N3979 and 1W5829 Nozzles: Maximum tip leakage is 20 drops in 15 seconds with a pressure of 200 psi (1380 kPa) less than opening pressure.

(1) Torque for valve lift locknut ... 35 to 45 lb. in.(4.0 to 5.1 N·m) (2) Torque for pressure screw locknut ... 70 to 80 lb. in.(8.0 to 9.1 N·m) (3) Torque for cap ... 110 to 120 lb. in.(12.4 to 13.6 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:30 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Equipment SMCS - 1286-011; 1286-012

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 3

Firing order (injection sequence) ... 1, 3, 4, 2 Injection timing before TC (top center) ... 21 ± 1° (1) Torque for bushing ... 120 ± 10 lb. ft.(160 ± 14 N·m) (2) 7N1067 Spring: Length under test force ... 1.713 in.(43.52 mm) Test force ... 26.2 ± 1.3 lb.(116.5 ± 5.8 N)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 3

Free length after test ... 1.918 in.(48.73 mm) Outside diameter ... 1.02 in.(25.9 mm) (3) Length of pump plunger (new) ... 2.9089 ± .0005 in.(73.886 ± 0.013 mm) Minimum permissible lenth (worn) ... 2.9084 in.(73.873 mm) (4) Bore in the bearings for the rack: Bearing at the rear ... .5018 ± .0018 in.(12.746 ± 0.045 mm) Bearing at the front ... .5026 ± .0018 in.(12.767 ± 0.045 mm) Diameter of fuel rack ... .4985 ± .0002 in.(12.662 ± 0.005 mm) (5) Bore in bearings for the camshaft: Front ... 2.1689 ± .0015 in.(55.090 ± 0.038 mm) Rear ... 2.6905 ± .0015 in.(68.339 ± 0.038 mm) Camshaft bearing surface (journal) diameter: Front ... 2.1654 ± .0005 in.(55.000 ± 0.013 mm) Rear ... 2.6870 ± .0005 in.(68.250 ± 0.013 mm) Torque for the nuts that hold the fuel lines (use 5P144 Fuel Line Socket) ... 30 ± 5 lb. ft.(40 ± 7 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:45 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Nozzle SMCS - 1286-011; 1286-012

(1) Tighten bleed screw to ... 16 ± 2 lb. in.(1.8 ± 0.2 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:50 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Pump Housing SMCS - 1286-011; 1286-012

(1) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel hole with aluminum ball) ... .584 ± .002 in.(14.83 ± 0.05 mm) (2) Rack bearing alignment - the center of the rack bearing tab must be within .002 in. (0.05 mm) of a vertical line that: (a) goes through the center of the rack bearing. (b) is parallel to the vertical centerline thru the injection pump bores and camshaft bearing bores.

NOTE: The following tools are available to position the rack bearings correctly: 5P1665 Alignment Plate and 9S6329 Driver.

The correct bearing depth is controlled when driver is stopped by plate.

(3) Install pins until they contact bottom of housing casting.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

(4) Install rear rack bearing to a depth of ... .195 ± .005 in.(4.95 ± 0.13 mm) NOTE: Small holes in bearing must be positioned as shown (parallel to the vertical centerline thru the pump).

(5) Bore in bearings for the camshaft (new) ... 1.8775 ± .0005 in.(47.638 ± 0.013 mm) Diameter of bearing surfaces of the camshaft (new) ... 1.8730 ± .0005 in.(47.574 ± 0.013 mm) Maximum permissible clearance between the bearings and the camshaft ... .010 in.(0.25 mm) (6) Install camshaft bearings flush with front and rear face of housing.

(7) Camshaft bearing oil hole. Position front bearing with oil hole in alignment with drilled oil passages in block.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:03:55 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Injection Nozzle SMCS - 1286-011; 1286-012

Bench test nozzles using clean SAE J967 Calibration oil at a temperature of ... 65 to 70°F(18 to 20°C) Nozzle setting pressures (valve lift adjustment screw turned 3/4± 1/8 turn from closed position): 9L6969 Nozzle: Used nozzle ... 1900 to 2900 psi(13 090 to 19 980 kPa) Used, adjusted nozzle ... 2700 to 2900 psi(18 600 to 19 980 kPa) 9N3979 and 1W5829 Nozzles: Used nozzle ... 1500 to 2600 psi(10 300 to 17 690 kPa)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Used, adjusted nozzle ... 2400 to 2600 psi(16 545 to 17 690 kPa) Return oil leakage test pressure ... 1400 to 1600 psi(9630 to 11 045 kPa) Leakage in 15 seconds (9L6969) ... 2 to 30 drops Leakage in 15 seconds (9N3979 & 1W5829). NO minimum or maximum.

9L6969 Nozzle: Maximum tip leakage is 10 drops in 15 seconds with pressure 200 psi (1380 kPa) less than opening pressure.

9N3979 and 1W5829 Nozzles: Maximum tip leakage is 20 drops in 15 seconds with a pressure of 200 psi (1380 kPa) less than opening pressure.

(1) Torque for valve lift locknut ... 35 to 45 lb. in.(4.0 to 5.1 N·m) (2) Torque for pressure screw locknut ... 70 to 80 lb. in.(8.0 to 9.1 N·m) (3) Torque for cap ... 110 to 120 lb. in.(12.4 to 13.6 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:01 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Transfer Pump (4N6835) SMCS - 1286-011; 1286-012

(1) Torque for outlet valve ... 18 to 22 lb. ft.(25 to 28 N·m)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

(2) Torque for inlet valve ... 18 to 22 lb. ft.(25 to 28 N·m) Outlet fuel pressure from the fuel transfer pump ... 30 to 50 psi(205 to 345 kPa) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:06 UTC+0400 2019

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Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Nozzle SMCS - 1286-011; 1286-012

(1) Tighten bleed screw to ... 16 ± 2 lb. in.(1.8 ± 0.2 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:12 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 2

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Injection Nozzle SMCS - 1286-011; 1286-012

Bench test nozzles using clean SAE J967 Calibration oil at a temperature of ... 65 to 70°F(18 to 20°C) Nozzle setting pressures (valve lift adjustment screw turned 3/4± 1/8 turn from closed position): 9L6969 Nozzle: Used nozzle ... 1900 to 2900 psi(13 090 to 19 980 kPa) Used, adjusted nozzle ... 2700 to 2900 psi(18 600 to 19 980 kPa) 9N3979 and 1W5829 Nozzles: Used nozzle ... 1500 to 2600 psi(10 300 to 17 690 kPa)

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 2

Used, adjusted nozzle ... 2400 to 2600 psi(16 545 to 17 690 kPa) Return oil leakage test pressure ... 1400 to 1600 psi(9630 to 11 045 kPa) Leakage in 15 seconds (9L6969) ... 2 to 30 drops Leakage in 15 seconds (9N3979 & 1W5829). NO minimum or maximum.

9L6969 Nozzle: Maximum tip leakage is 10 drops in 15 seconds with pressure 200 psi (1380 kPa) less than opening pressure.

9N3979 and 1W5829 Nozzles: Maximum tip leakage is 20 drops in 15 seconds with a pressure of 200 psi (1380 kPa) less than opening pressure.

(1) Torque for valve lift locknut ... 35 to 45 lb. in.(4.0 to 5.1 N·m) (2) Torque for pressure screw locknut ... 70 to 80 lb. in.(8.0 to 9.1 N·m) (3) Torque for cap ... 110 to 120 lb. in.(12.4 to 13.6 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:17 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Nozzles SMCS - 1254-011; 1254-012

Remove Fuel Injection Nozzles

START BY: a. remove valve cover base

1. Remove bolt (2) and clamp (3) that hold fuel injection nozzle (1) in place.

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2. Use tooling (A), and remove the fuel nozzle from the cylinder head assembly.

NOTE: A replacement of carbon dam seal (5) and washer (compression seal) (4) must be made each time the fuel injection nozzle is removed.

3. Remove carbon dam seal (5) with pliers and washer (4) from the fuel injection nozzle.

Install Fuel Injection Nozzle

START BY: a. remove valve cover base

NOTICE

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Before the fuel injection nozzles are installed, check for fuel leakage and the pressure at which the injection nozzle opens with tool (A). See Testing Fuel Injection Nozzles in Testing And Adjusting.

1. Make sure the bore in the cylinder head assembly and the fuel inlet fitting are clean. Use tool (C) to clean the bore in the cylinder head for the fuel injection nozzle. Use an open end wrench or tap driver to turn tool (C).

2. Install new washer (compression seal) (1) on the fuel injection nozzles.

3. Put carbon dam seal (2) on the small end of tool (B). Expand it by sliding it to the large end. Put tool (B) against the fuel injection nozzle, and slide carbon dam seal (2) off tool (B) onto the nozzle.

Slide the carbon dam seal into position in the groove on the nozzle.

4. Put fuel injection nozzles (3) in position in the cylinder head assembly. Push and turn the nozzle to install it into its correct position.

5. Install clamp (5) and bolt (4) that hold the fuel nozzle in place.

END BY: a. install valve cover base Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:22 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 4

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Transfer Pump SMCS - 1256-015; 1256-016

Disassemble Fuel Transfer Pump START BY: a. remove fuel transfer pump

1. Remove connector (1) and the O-ring seal. Remove connector (2) and the O-ring seal from the pump housing.

2. Remove spring (3), valve (4) and the seal from the pump housing.

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Cover (6) is under spring tension. To prevent personal injury, carefully remove bolts (5) to release the spring tension.

3. Carefully remove bolts (5), cover (6), the seal and spring from the pump housing.

4. Remove plate (7), the valve and seal from the pump housing.

5. Remove snap ring (8) that holds tappet (9) in position. Remove tappet (9) from the pump housing.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 3 of 4

Assemble Fuel Transfer Pump

1. Put tappet (2) in position in the pump housing, and install snap ring (1) that holds it in place.

2. Install seal (6), valve (3) and plate (4) in piston (5) as shown.

3. Install piston assembly (7) and spring (8) in the pump housing as shown.

4. Install seal (10) in cover (9), and put clean diesel fuel on the O-ring seal.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 4 of 4

5. Put cover (10) in position on the pump housing, and install the bolts that hold it in place.

6. Install seal (11) in the bore of the pump housing.

7. Install valve (13) and spring (12) in the pump housing.

8. Be sure the O-ring seals are in position on connector (14) and connector (15), and put clean diesel fuel on the O-ring seals.

9. Install connector (14) and connector (15) in the pump housing.

END BY: a. install fuel transfer pump Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:31 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 25

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Governor SMCS - 1264-015; 1264-016

Disassemble Governor

START BY: a. remove fuel injection pump housing and governor NOTE: If it is desired to remove only the governor so the fuel injection pump housing can be disassembled, only do steps. 1, 2, 16, 23, 27, 28, 29, 33, 34, 35, 36 and 39.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 2 of 25

1. Remove two bolts (2) and fuel transfer pump (3).

2. Remove two bolts (1) from the fuel system.

3. Remove six bolts (4), governor housing (5) and the gasket.

4. Remove governor spring (10), two wave washers (7) and (9), one flatwasher (8) and seat (6) from the guide.

5. Remove bolts (12) and cover assembly (11) from the housing.

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6. Remove seal (13) from cover (11) with tooling (B).

7. Loosen low idle adjustment screw (14), and remove spring (15) from the housing.

8. Remove shaft (16) and lever (17) from the housing. Remove the ring from the shaft if necessary.

9. On later engines, remove the control shaft assembly from the housing as follows: a. Remove two screws (19), plate (18) and the washer located under plate (18).

b. Remove stop (20) and the plate located under the stop.

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c. Remove shaft assembly (21), lever (22) and lever (23) from the housing.

d. Remove plate (25) from the shaft assembly. e. Remove pin (26), pin (27) and spring (24) from the shaft assembly.

10. On earlier engines, remove shaft assembly (28), lever (29) and lever (30) from the housing.

11. On earlier engines, disassemble the control shaft assembly as follows:

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 5 of 25

a. Remove the two snap rings from pins (33), and remove the pins. Remove plates (31) and stop (32) from the shaft assembly.

b. Remove pin (36), pin (34) and spring (35) from the shaft assembly.

NOTICE Remove check valve (37) only if a replacement is necessary because the check valve will be damaged during removal.

12. Remove check valve (37) if a replacement is necessary.

13. Remove two bolts (38), cover (39) and the gasket from the housing.

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14. Remove insulator (42) and body (41) for the governor dashpot adjustment screw.

15. Remove seal (43) and high idle adjustment screw (40).

16. Remove two bolts (45), housing (44) and the gasket from the fuel injection pump housing.

17. Remove bolts (46) and torque control group (47) as a unit.

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18. Disassemble the torque control group. Inspect insulator (48), shim (49), spring (50), contact (51) and spacer (52) for wear or damage.

19. Remove bolts (53) and block (54) for the full load stop.

20. Remove bolt (57) that holds collar (58) to bolt (55). Remove collar (58) and spring (56) from bolt (55).

21. Remove bolt (55) from the block.

22. Loosen nuts (59), and remove power adjustment screw (60) and torque rise adjustment screw (61) from collar (58) if a replacement is necessary.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 8 of 25

23. Remove bolts (63) and governor servo (62) from the fuel injection pump housing.

24. Remove lockring (68), seat (67), spring (broken link spring) (66) and sleeve (65) from valve (64).

Remove the other lockring (68) from the groove in the center of valve (65).

NOTE: The groove in the bottom of valve (64) must be in alignment with the servo body to permit removal from the fuel rack.

25. Remove valve (64), sleeve (69) and piston (71) from the governor servo. Remove the O-ring seal from sleeve (69).

26. Remove pin (70) and lever (72) from the governor servo.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 9 of 25

27. Use tool (D) to hold spring (74) under compression so ring (73) can be removed. Spring (74) is used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing.

28. Remove ring (73); then remove tool (D).

29. Remove bearing (75), sleeves (76) and spring (74) from the governor shaft.

30. Remove ring (77) and dashpot assembly (78) from the governor shaft.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 10 of 25

31. Use tool (C) to remove snap ring (84) from seat (81). Remove ring (83) and spool (82) from seat (81).

32. Remove seat (81) from spring (80), and remove spring (80) from seat (79).

33. Remove spring (overfueling spring) (85) and riser (86) from the governor shaft.

34. Remove ring (88), races (87) and bearing (89) from the riser.

NOTE: Make a replacement of shield (90) any time it is removed.

35. Use a screwdriver to remove shield (90) as shown.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 11 of 25

36. Remove bolts (91) and carrier (92) for the governor flyweights.

37. Remove dowels (93) and flyweights (95) from the carrier.

38. Remove shaft (94) from the carrier. Remove the dowel from shaft (94).

39. Remove races (96) and bearing (97) from the camshaft in the fuel injection pump housing.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 12 of 25

Assemble Governor

NOTE: If the governor was removed only to permit repair of the fuel injection pump housing, do only Steps 1, 4, 5, 7, 9, 10, 11, 16, 23, 42, 43, 44 and 45.

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NOTE: Put clean engine oil on all parts before assembly. Be sure all oil passages are clear.

1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump housing.

2. Put flyweights (3) in position on carrier (4), and install the dowels to hold the flyweights in place.

The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in.) end play.

3. Install dowel (5) in governor shaft (6), and install the governor shaft in the carrier as shown.

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4. Put the carrier in position on the camshaft, and install the bolts that hold the carrier in place.

NOTE: Make a replacement of shield (7) any time it is removed.

5. Install shield (7) on the carrier, and use tool (A) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° ± 5° apart next to the holes in the shield.

6. Install one race (9), bearing (10), the other race (9), and use tool (B) to install the ring on riser (8) as shown.

7. Install riser (8) and the spring (overfueling spring) on the governor shaft as shown.

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8. Assemble the dashpot as follows: a. Install spring (12) on seat (11), and install seat (13) in spring (12). b. Put spool (14) and ring (15) in position on seat (13), and use tool (B) to install snap ring (16) to hold them in place.

9. Install dashpot assembly (17) on the governor shaft as shown.

NOTE: Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing.

10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown.

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11. Use tool (C) to hold spring (19) under compression, and install ring (22) in the groove in the governor shaft. Remove tool (C).

12. Put lever (27) in position on governor servo (23), and install pin (24) to hold the lever in place.

Use a hammer and chisel to move the metal (stake) four places 90 ° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.

13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown.

14. Install valve (28) in the governor servo as shown.

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15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28), and install the other lockring (32) to hold them in place.

16. Put the governor servo in position on the fuel injection pump housing with piston (26) engaged over rack (33), and install the bolts that hold the governor servo in place.

17. Install torque rise adjustment screw (35) and power adjustment screw (34) in collar (36) as shown.

Install nuts (37) on the screws.

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18. Put bolt (39) in position in block assembly (40), and install spring (38) on the bolt as shown.

19. Put collar (36) in position on bolt (39). Be sure the cutout (slot) in the collar is engaged with dowel (41). Install bolt (42) to hold the collar in place. Be sure bolt (42) fits in the groove of bolt (39).

20. Put block (40) in position on housing (44). Be sure the holes in the block are engaged with dowels (43). Install the bolts that hold the block in place.

21. Assemble the torque control group as follows: a. Install shim (46), spring (50), contact (47) and spacer (51) on insulator (49) as shown. b. Install bolts (53) through retainer (52), bar (48), the insulator assembly and bar (45).

22. Install torque control group (54) on block (40) as shown.

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If housing (44) is installed with the flange on bolt (39) (see illustration B86569X1) on the wrong side of the dashpot, the riser in the governor will be held in the maximum fuel delivery position. To prevent possible personal injury, make sure housing (44) is installed on the fuel injection pump housing with the flange on bolt (39) behind seat (55).

23. Install gasket (56) on fuel injection pump housing (44). Put housing (44) in position on the fuel injection pump housing with bolt (39) behind dashpot (seat) (55). Install the two bolts that hold the housing in place.

24. Use tooling (D) to install lip type seal (57) in the governor outer housing. Install the seal with the lip facing in as shown.

25. Install insulator (fuel setting contact) (58) in the housing. Tighten the insulator to a torque of 4.5 ± 0.5 N·m (40 ± 4 lb.in.).

26. Install adjustment screw (59) and the locknut for the high idle adjustment.

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27. Install the O-ring seal on body (60) for the governor dashpot adjustment. Install body (60) in the housing.

28. Install the gasket and cover (61) on the housing.

29. If it was necessary to replace check valve (62), install a new check valve as shown.

30. Install spring (65) in shaft assembly (63). Install pin (64) in shaft assembly (63) with the tip of the pin engaged in the hole in spring (63). Install pin (66) in the shaft assembly to hold pin (64) in place.

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31. On earlier machines, put stop (69) and plates (67) in position on shaft assembly (63). Install pins (68) to hold the plates and stop in place. Install snap rings (70) to hold pins (68) in place.

32. On later engines, assemble the control shaft as follows: a. Put plate (71) and (73) in position on the shaft assembly as shown. b. Put plate (72), stop (75) and washer (76) in position between plate (71) and (73). Install two screws (74) that hold them in place. Do not tighten the screws at this time.

33. On earlier machines, put levers (77) and (78) in position in the housing as shown. Install shaft assembly (63) to hold the levers in place.

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34. On later engines, install the control shaft assembly in the housing as shown: a. Put levers (80) and (81) in position as shown, and install shaft assembly (79) to hold the levers in place. b. Make sure the large end of low idle adjustment screw (82) (located inside the governor housing) is engaged in the slot in plate (72); then tighten screws (74).

35. Install ring (83) on shaft (84).

36. Put lever (85) in position in the housing as shown. Install shaft (84) to hold the lever in place.

37. On earlier engines, install spring (86) in the hole in the shaft assembly and in the housing. Tighten low idle adjustment screw (87) until it makes contact with shaft assembly (63).

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38. On later engines, install spring (88) in the governor housing as shown. Make sure one end of the spring is engaged on the knob of stop (75).

39. Use tooling (D) to install the lip-type seal in cover (89). Install the seal with the lip of the seal facing in as shown.

40. Install the gasket on cover (89).

41. Put cover (89) in position on the housing, and install the four bolts that hold it in place.

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NOTICE Flat washer (92) must be installed between wave washers (91).

42. Install the governor spring assembly on the guide. Install seat (90), one wave washer (91), flatwasher (92), the other wave washer (91) and spring (93) on the guide as shown.

NOTE: Make sure the seat, washers and spring are on top of lever (81) as shown. These parts must be kept in this position when housing (95) is put in position on the inner governor housing.

43. Put gasket (94) and housing (95) in position on the inner governor housing, and install the eight bolts that hold it in place.

Typical Example

44. Put fuel transfer pump (96) in position on the governor housing, and install the bolts that hold it in place.

45. Make governor adjustments. See Governor Adjustments in Testing And Adjusting.

END BY: a. install fuel injection pump housing and governor

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 25 of 25

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:36 UTC+0400 2019

All Rights Reserved.

Private Network For SIS Licensees.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 11

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Pump Housing SMCS - 1253-015; 1253-016

Disassemble Fuel Injection Pump Housing

NOTE: For removal of the governor from the fuel injection pump housing, see Disassemble Governor.

1. Remove cover (1).

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2. Install tooling (B). Engage the timing pin in the center groove of the fuel rack. Move the fuel rack in the direction of the arrow to find the center groove.

3. Install tooling (D), and remove bushing (2).

4. Install tooling (E), and remove the fuel injection pump.

5. Remove spacer (3).

NOTE: Do not mix components from fuel injection pump assemblies.

6. Remove the remainder of the fuel injection pumps and spacers with Steps 2-5 done again for each injection pump.

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7. Remove cover (4).

8. Remove fuel rack (5).

9. Use a bar magnet to remove lifter assembly (6). Put identification marks on the lifter assemblies as to their location in the fuel injection pump housing.

10. Use tooling (A) to remove snap ring (7).

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NOTE: Do not let the camshaft fall because the machined surfaces will be scratched.

11. Use a plastic hammer to make camshaft (8) move out of washer (9).

12. Remove camshaft (8).

13. Use tool (C) to remove rack rear bearing (10). Remove camshaft rear bearing (11).

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14. Install the location plate from tooling (B). Align the bore in the plate with the O-ring seal counterbore in the fuel injection pump housing. Make a mark for alignment.

15. Remove tooling (B).

16. Use tooling (C) to remove rack bearing (12) and camshaft bearing (13).

Assemble Fuel Injection Pump Housing

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NOTE: Be sure all oil passages are clear, and put clean engine oil on all parts before assembly.

1. Use tooling (A) to install the camshaft bearing in the drive end of the fuel injection pump housing.

With the joint of the bearing toward the top of the fuel injection pump housing, install the bearing so it is 0.25 ± 0.20 mm (.010 ± .008 in.) below the surface of the housing.

2. Use tooling (A) to install the camshaft bearing in the drive end of the fuel injection pump housing.

The joint of the bearing must be installed toward the top of the pump housing. Install the bearing to a depth of 1.00 ± 0.25 mm (.039 ± .010 in.).

3. Use tooling (A) to install the fuel rack rear (governor end) bearing. Install the bearing so it is 7.16 ± 0.13 mm (.282 ± .005 in.) below the surface of the housing.

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4. Install the plate assembly from tooling (B) on the drive end of the fuel injection pump housing to install the bearing for the fuel rack. Use clean grease to hold the new fuel rack bearing on the driver from tooling (B). Install the driver and bearing in the plate assembly with the groove in the driver in alignment with the pin in the plate assembly. Use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against the plate assembly.

5. Remove tooling (B) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 ± 0.25 mm (0.010 ± 0.010 in.) below the surface of the housing.

6. Install fuel injection pump camshaft (1) in the fuel injection pump housing.

7. Put the fuel injection pump housing on end, and put a block under the camshaft.

8. Put washer (2) over the end of the camshaft, and use tooling (A) and (C) to push washer (2) against its seat on the camshaft. The camshaft must have 0.285 ± 0.235 mm (0.0112 ± 0.0093 in.) end play when the washer is pushed against cam shoulder.

9. Use tool (D) to install snap ring (3) in the groove in the camshaft.

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NOTICE If the original lifters are to be installed, be sure to install them in their respective bores in the pump housing. New lifters can be mixed.

10. Install four lifter assemblies (4) in the fuel injection pump housing with the groove in the lifter in alignment with the pin in the housing.

11. Install fuel rack (5) in the fuel injection pump housing. Install the rack with the groove in the end of fuel rack in alignment with the ear (tab) of the rack bearing at the drive end of the fuel injection pump housing.

12. Install the timing pin from tooling (B). Engage the timing pin in the center groove of the fuel rack.

Move the fuel rack in the direction of the arrow to locate the center groove.

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13. Install spacer (6).

14. Put (slot) groove (8) in the gear segment 180° away from groove (7) in the barrel. When the fuel injection pump is installed, groove (7) must engage with the dowel (9).

15. Use tool (E) to install the fuel injection pump. Installation is made easier by rotation of the cam lobe away from the lifter assembly.

16. Install O-ring seal (10).

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17. Install bushing (11). Tighten bushing (11) by hand until the bushing is even with the top of the housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again, and install the bushing again.

18. Use tool (F) and a torque wrench to tighten the bushing to a torque of 163 ± 14 N·m (120 ± 10 lb.ft.).

19. Remove tooling (B).

20. Install tooling (G) and (H) to measure total rack travel. Correct rack travel is 15.70 mm (.618 in.).

A smaller measurement is an indication of incorrect fuel injection pump installation.

21. Complete the installation of the remainder of fuel injection pumps as given in Steps 11-19.

22. Install cover (12) and the gasket.

23. Install the governor on the fuel injection pump housing. See Assemble Governor; then install the fuel injection pump housing and governor on the engine.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3... Page 11 of 11

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:41 UTC+0400 2019

All Rights Reserved.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Pumps SMCS - 1251-015; 1251-016

Disassemble Fuel Injection Pump START BY: a. remove fuel injection pumps* *

See Fuel Injection Pump Housing in this module.

NOTICE Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.

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1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).

2. Remove washer (5) from plunger (1).

NOTICE Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.

3. Remove spring (2) from barrel (3).

4. Remove ring (6), and make a separation of barrel (3) and bonnet (4).

5. Remove check assembly (7) and spring (8) from bonnet (4). If check assembly (7) is disassembled, do not mix parts with parts from another check assembly.

Assemble Fuel Injection Pumps NOTICE Put clean fuel oil on all parts during assembly.

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1. Install spring (2) and check assembly (1) in bonnet (3).

2. Install bonnet (3) on barrel (4), and install ring (5) to hold them together. Do not slide bonnet (3) across barrel (4) because check assembly (1) in the bonnet can cause damage to the face of barrel (4).

3. Install spring (8) on barrel (4).

4. Install washer (7) on plunger (6) with the flat side toward the gear on the plunger.

5. Install plunger (6) in barrel (4) until washer (7) is engaged in the spring.

END BY: a. install fuel injection pumps* *

See Fuel Injection Pump Housing in this module.

Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:46 UTC+0400 2019

All Rights Reserved.

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly 3204 VEHICULAR ENGINES Media Number -SENR3230-00

Publication Date -01/10/1985

Date Updated -30/11/2001

Fuel Injection Nozzles SMCS - 1254-011; 1254-012

Remove Fuel Injection Nozzles

START BY: a. remove valve cover base

1. Remove bolt (2) and clamp (3) that hold fuel injection nozzle (1) in place.

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2. Use tooling (A), and remove the fuel nozzle from the cylinder head assembly.

NOTE: A replacement of carbon dam seal (5) and washer (compression seal) (4) must be made each time the fuel injection nozzle is removed.

3. Remove carbon dam seal (5) with pliers and washer (4) from the fuel injection nozzle.

Install Fuel Injection Nozzle

START BY: a. remove valve cover base

NOTICE

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Before the fuel injection nozzles are installed, check for fuel leakage and the pressure at which the injection nozzle opens with tool (A). See Testing Fuel Injection Nozzles in Testing And Adjusting.

1. Make sure the bore in the cylinder head assembly and the fuel inlet fitting are clean. Use tool (C) to clean the bore in the cylinder head for the fuel injection nozzle. Use an open end wrench or tap driver to turn tool (C).

2. Install new washer (compression seal) (1) on the fuel injection nozzles.

3. Put carbon dam seal (2) on the small end of tool (B). Expand it by sliding it to the large end. Put tool (B) against the fuel injection nozzle, and slide carbon dam seal (2) off tool (B) onto the nozzle.

Slide the carbon dam seal into position in the groove on the nozzle.

4. Put fuel injection nozzles (3) in position in the cylinder head assembly. Push and turn the nozzle to install it into its correct position.

5. Install clamp (5) and bolt (4) that hold the fuel nozzle in place.

END BY: a. install valve cover base Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:04:51 UTC+0400 2019

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IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 320... Page 1 of 3

Shutdown SIS Previous Screen Product: INTEGRATED TOOLCARRIER Model: IT12 INTEGRATED TOOLCARRIER 4NC Configuration: IT12 INTEGRATED TOOLCARRIER 4NC00001-UP (MACHINE) POWERED BY 3204 ENGINE

Specifications 3204 VEHICULAR ENGINE Media Number -REG01254-06

Publication Date -01/03/1984

Date Updated -10/10/2001

Fuel Injection Equipment SMCS - 1254-011; 1254-012

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Firing order (injection sequence) ... 1, 3, 4, 2 Injection timing before TC (top center) ... 21 ± 1° (1) Torque for bushing ... 120 ± 10 lb. ft.(160 ± 14 N·m) (2) 7N1067 Spring: Length under test force ... 1.713 in.(43.52 mm) Test force ... 26.2 ± 1.3 lb.(116.5 ± 5.8 N)

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Free length after test ... 1.918 in.(48.73 mm) Outside diameter ... 1.02 in.(25.9 mm) (3) Length of pump plunger (new) ... 2.9089 ± .0005 in.(73.886 ± 0.013 mm) Minimum permissible lenth (worn) ... 2.9084 in.(73.873 mm) (4) Bore in the bearings for the rack: Bearing at the rear ... .5018 ± .0018 in.(12.746 ± 0.045 mm) Bearing at the front ... .5026 ± .0018 in.(12.767 ± 0.045 mm) Diameter of fuel rack ... .4985 ± .0002 in.(12.662 ± 0.005 mm) (5) Bore in bearings for the camshaft: Front ... 2.1689 ± .0015 in.(55.090 ± 0.038 mm) Rear ... 2.6905 ± .0015 in.(68.339 ± 0.038 mm) Camshaft bearing surface (journal) diameter: Front ... 2.1654 ± .0005 in.(55.000 ± 0.013 mm) Rear ... 2.6870 ± .0005 in.(68.250 ± 0.013 mm) Torque for the nuts that hold the fuel lines (use 5P144 Fuel Line Socket) ... 30 ± 5 lb. ft.(40 ± 7 N·m) Copyright 1993 - 2019 Caterpillar Inc.

Sun Dec 15 12:05:10 UTC+0400 2019

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