Escolar Documentos
Profissional Documentos
Cultura Documentos
SENR7590-01
D4 TRACTOR, REG00632
D4E TRACTOR, SENR7624
D4 SA TRACTOR, REG00784
D4E SA TRACTOR, SENR7636
NO. 112F MOTOR GRADER, REG00885
120G MOTOR GRADER, REG01654
130G & 140G MOTOR GRADERS,
REG01652
225 EXCAVATOR, REG01578
518SKIDDER, REG00971
920 & 930 WHEEL LOADERS, REG00514
941 TRACK-TYPE LOADER, REG00527
950 WHEEL LOADER, REG00548
951 TRACK-TYPE LOADER, REG00783
955 TRACK-TYPE LOADER, REG00634
955L TRACK-TYPE LOADER, SENR7364
955L TRACK-TYPE LOADER, SENR7672
p(i©Di©iifeira
3304 Vehicular Engine
7Z1-UP
3304 VEHICULAR ENGINES SPECIFICATIONS
INTRODUCTION •'^
The specifications given in thisbook are on the basis can be used again. If the part is equal to or within the
of infoniiation available at the it was written. The
time specification given, use the part again.
specifications torques, pressures of operation, mea-
surements, adjustments and other items can change at When the word "permissible" " is in the description,
any time. These changes can effect the service given to the specification given is the "maximum or minimum"
the product. Get the complete and most current infor- tolerance permitted before adjustment, repair and/or
mation before you start any job. Caterpillar Dealers new parts are needed.
NOTE: For Systems Operation and Testing and Adjusting, make reference to
3304 VEHICULAR ENGINES, Form No. SENR7591.
Bore
ENGINE DESIGN
4.75 in. (120.7 mm)
^
Stroke 6.0 in. (152.4 mm)
Number of Cylinders 4
Cylinder Arrangement 'in-line
Firing Order (Injection Sequence) 1, 3, 4, 2
Direction of Rotation
(when seen from flywheel end) Counterclockwise
*No. 1 Cylinder Is Opposite Flywheel End.
EXHAUST VALVES
2 3
INTAKE VALVES
NOTE: This book has been completely changed from the former issue.
^
3304 VEHICULAR ENGINES SPECIFICATIONS
INDEX
Air Inlet and Exhaust System Engme Design 2
Air Cleaner 43 Engine Mounting Bolts 76
Camshaft 37 Fuel System
Cylinder Head 42 Fuel System Timing 6
Glow Plug Positioning 41 Fuel System Usage Chart 6
Exhaust Manifold 43 Service Meter 7
Exhaust Pipe and Muffler 43 Tachometer Drive 7
Turbocharger 46-51 Fuel System — Scroll (Dl) 31
Turbocharger Impeller Installation 44, 45 Fuel Injection 32
Valves (Dl) 40 Fuel Injection Pump Housing 31
Valves (PC) 38, 39 Fuel Transfer Pump 35
Valve Cover 42 Governor 34
Valve Rocker Ar'ms and Lifters 37 Governor Housing 33
Injection Nozzle 33
Basic Engine Components Fuel System — Scroll (PC) 27
Bearing Surface (Journal)
Fuel Bypass Valve 30
Connecting Rods 69
Fuel Injection Equipment 27
Main Bearings 68
Fuel Transfer Pump 30
Connecting Rod 66
Governor (Earlier) 28
Crankshaft 67
Governor (Later) 29
Crankshaft Hub
Fuel System — Scroll {PC & Dl)
70
36
Cylinder Block
Timing Gears 36
Counterbored Block 60
Fuel System —
Sleeve Metering (Dl) 18
Spacer Plate Block 61
Fuel Injection Equipment 18-20
Cylinder Liner 62
Fuel Ratio Control 21
Cylinder Liner Projection
Fuel Transfer Pump 21
Counterbored Block 62
Governor Control {D4E) 23
Spacer Plate Block 63
Governor Control (120G & 130G) 22
Fan Drive 71
Governor Control (225) 24
Flexible Drive Coupling 76, 77
Governor Control (518) 24
Checking and Adjusting Alignment of the
Injection Nozzle 21
Flexible Drive Coupling 78 Fuel System — Sleeve Metering (PC) 8
Flywheel 73 Fuel Injection Equipment 8-12
Flywheel Housing 74
Fuel Ratio Control 13
Flywheel Housing Bore 75 Fuel Transfer Pump 13
Flywheel Housing Tightening 72
Governor Control (920 & 930) 14
Flywheel Ring Gear 72
Governor Control (950) 16
Main Bearing and Connecting Rod Bearings 70 Governor Control (951) 17
Pistons and Rings
Governor Control (955L) 15
Fuel System — Sleeve Metering (PC &
Keystone 64
Dl) 25
Straight Side 65 Timing Gears 26
Water Separator 25
Cooling System
Coolant Flow Switch 59 Gauges
Fan Drive 71
Converter Oil Temperature Indicator 97
Radiator 58 Fuel Pressure Indicator 96
V-Belt Tension Chart 57
Oil Pressure Indicator 97
Water Pump 57
Water Temperature Indicator 96
Water Temperature Regulator 59 General Tightening Torques 4
E^fe^&a
E^^gp
^^^p^^^r^^^^vsss)
oaa PB
INVERTED O-RING
45°FLARED 37 FLARED 45 FLARED FITTING - PLUG SWIVEL NUTS
TUBE 3.18 4.78 6.35 7.92 9.52 TUBE 12.70 15.88 19.05 22.22 25.40 31.75 38.10 50.80
SIZE SIZE
(O.D.) .125 .188 .250 .312 .375 (O.D.) .500 .625 .750 .875 1.000 1.250 1.500 2.000
SERVICE METER
(EARLIER MODELS)
AI756axl
6N5906
Polarity is negative ground.
TACHOMETER DRIVE
(1) Torque for cable nut 100 ± 20 lb. in. (11.3 + 2.3 N-m)
4 5 VIEW A-A
(worn) 006 in. (0.15 mm) Make reference to the chart "BYPASS VALVE SPRINGS."
(2) Diameter of fuel control shaft (6) Diameter of front bearing surface (journal) of the
(new) 3530 ± .0003 in. (8.966 ± 0.008 mm) camshaft (new) 9990 ± .0005 in. (25.375 ± 0.013 mm)
Bore In the housing for fuel control shaft Bore in the front bearing for the camshaft
(new) 3543 ± .0005 in. (8.999 ± 0.013 mm) (new) 1 .0005 ± .0005 in. (25.413 ± 0.013 mm)
Maximum permissible clearance between the bore Maximum permissible clearance between the bearing
in the housing and the fuel control shaft and the camshaft bearing surface (journal)
(worn) 003 in. (0.08 mm) (worn) 003 in. (0.08 mm)
GOVERNOR SPRINGS
3304 VEHICULAR ENGINES SPECIFICATIONS
(SLEEVE METERING FUEL SYSTEM — PC)
((.OF LIFTER
A98051X1
Install guide pin (A) to deptti (B) [.642 ± .003 in. (16.31 ± 0.08 mm)].
Slot in guide pin (A) must be in area shown from center of lifter.
(12) Body.
TYPICAL ILLUSTRATION
Free length after test 1 .74 ± ,02 in, (44,2 ± 0,5 mm)
Outside diameter 1,518 in. (38,56 mm)
11
3304 VEHICULAR ENGINES SPECIFICATIONS
)
-^r-n
GOVERNOR CONTROL
(920 & 930 Wheel Loaders)
OFF
L>nCIZI3-e,
B41 448X1
GOVERNOR CONTROL
(955L Track-Type Loader)
2. Adjust length of rod (3) so lever (5) is in the OFF position at the Angle A for lever (1) and governor
engine. Tighten nuts (4) on rod (3). control (2) is 102 ± 5°
15
3304 VEHICULAR ENGINES SPECIFICATIONS
GOVERNOR CONTROL
(950 Wheel Loader)
B41 450X1
4. Adjust length of rod (3) and install pin (6). Tighten locknuts on
LINKAGE ADJUSTMENT PROCEDURE: rods.
GOVERNOR CONTROL
(951 Track-Type Loader)
B41451X1
LINKAGE ADJUSTMENT PROCEDURE: Adjust length of rod (5) so lever the engine the OFF
3. (6) at is in
17
3304 VEHICULAR ENGINES SPECIFICATIONS
4 5 VIEW A-
Firing order (injection sequence) 1, 3, 4, 2 (3) End play for camshaft with sleeve installed
Injection timing before TC (top center):
(new) 023 ± .018 in. (0.58 ± 0.46 mm)
NOTE: When installing sleeve on end of camshaft, support the cam-
Direct Injection Engines
with turbocharger 23 ± 1
° shaft to prevent damage to parts inside of injection pump and gover-
nor housing.
Direct Injection Engines
°
without turbocharger 29 ± 1
(1) Diameter of rear bearing surface Length under test force 880 in. (22.35 mm)
(journal) of the camshaft
Test force 3.53 ± .18 lb. (15.7 ± 0.8 N)
(new) 2.3720 ± .0005 in. (60.249 ± 0.013 mm)
Free length after test 1.73 in. (43.9 mm)
Bore in the rear bearing for the camshaft
(new) 2.3750 ± .0005 in. (60.325 ± 0.013 mm) Outside diameter 527 in. (13.39 mm)
Maximum permissible clearance between the Pressure of fuel in housing for
bearing and the camshaft bearing surface fuel injection pumps,
(journal) (worn) 006 in. (0.15 mm) (Full Load) 30 ± 5 psi (205 ± 35 kPa)
(2) Diameter of sleeve control shaft (6) Diameter of front bearing surface
(new) 3530 ± .0003 in. (8.966 ± 0.008 mm) Oournal) of the camshaft
GOVERNOR SPRINGS
3304 VEHICULAR ENGINES SPECIFICATIONS
^lOF lifter
Install guide pin (A) to depth (B) [.642 ± .003 in. (16.31 ± 0.08 mm)].
Slot in guide pin (A) must be in area shown from center of lifter.
(11) Spring for the terminal shaft. Install the spring (1 1) for the termi-
nal shaft so that the end of the spring is in the 30° range as
shown.
GOVERNOR CONTROL
(120G and 130G Motor Graders)
To shut engine OFF, pull up on accelerator treadle (11). 8. Loosen locknut (14) and adjust length of rod so top of de-
1. Tighten nut (A) just enough so position of control lever (2) is celerator treadle (9) is .19 in. (4.8 mm) above floor plate (10)
not affected by the operation of the accelerator treadle (11) as shown. If machine is equipped with a thick floor insulation
and decelerator treadle (9). pad, (used with enclosed cab), adjust decelerator treadle (9)
so top of treadle is .38 in. (9.7 mm) above top of floor plate and
2. With the parking brake ON and engine stopped, BE SURE dis- tighten locknut (14).
connect sw/itch is OFF.
9. Move control lever (2) to HIGH IDLE position.
3. Remove pin (4).
10. Turn HIGH IDLE stop (5) until it touches lever (12) and lighten
4. Loosen LOW IDLE stop (7) and HIGH IDLE stop (5) so they locknut (6).
do not touch lever (12).
11. Loosen locknut (16) and adjust accelerator treadle (11) so that
5. tvlove control lever (2) to LOW IDLE position. distance from bottom of plate on treadle to top of floor plate
(10) is 2.38 ± .12 in. (60.5 + 3.0 mm) as shown.
6. Turn LOW IDLE stop (7) until it touches lever (12) and tighten
locknut (8). 12. Move lever (3) to HIGH IDLE position and adjust length of
GOVERNOR CONTROL
(D4E Tractor)
A48074X2
NOTE: With control lever in high idle position and governor control
1. With pin removed from lever (4) move lever (4) to high idle position
shaft in full on position, put lever (4) on shaft at angle (D).
(rearward),
Angle (D) is 40'
2. Move lever (Y) rearward until interference occurs in linkage.
Dimension (A) (approximately) 14.2 in. (361 mm) 3. Adjust rod end (Z) to position holes short of alignment [approx. .2
Tighten nut (1) to 18 ± 5 lb. ft. (24 ± 7 N-m) mm)] with hole in lever (4).
in. (5
Dimension (B) (approximately) 19.2 in. (488 mm) 4. t\/lovelever (4) to shutoff position and lever (Y) forward until inter-
f^ Tighten nuts (2) to 18 ± 5 lb. ft. (24 ± 7 N>m)
ference occurs. Holes In rod end (Z) must be forward of hole in
lever (4). If additional adjustment is required repeat Step 3, [.2 in.
Dimension (C) (approximately) 18.7 in. (475 mm) (5 mm) dim. may be decreased],
Tighten nut (3) to 18 + 5 lb, ft. (24 ± 7 N-m) 5. Install pin and cotter.
23
.
GOVERNOR CONTROL
(518 Skldder)
B42382X1
Angle (A) is 28 + 5°
Dimension (B) is 2.25 ± .03 in. (57.2 ± 0.8 mm)
GOVERNOR CONTROL
(225 Excavator)
B41452X1
AS7414X1
WATER SEPARATOR
TIMING GEARS
(1) Torque for bushing 130 +10 or -5 lb. ft. (177 +14 or -7 N-m)
27
3304 VEHICULAR ENGINES SPECIFICATIONS
GOVERNOR
(EARLIER)
Free length after test 2.34 ± .03 in. (59,4 ± 0.8 mm)
Outside diameter 1.39 in, (35.3 mm)
(3) 9L3617 Spring For Governor;
Color code (stripes) 1 blue, 1 white
Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)
Outside diameter 1 .39 in. (35.3 mm)
(3) 8IV19140 Spring for governor:
Free length after test 2.34 ± .03 in. (59.4 + 0.8 mm)
Outside diameter 1 .38 in. (35.1 mm)
GOVERNOR
(LATER)
Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)
Outside diameter 1.38 in. (35.1 mm)
(3) Collar for spring.
29
3304 VEHICULAR ENGINES SPECIFICATIONS
(1) Bore of bearing (new) . , .4953 + .0003 in. (12.581 ± 0.008 mm)
(2) Depth of bore in body
(new) 3750 + .0003 in. (9.525 ± 0.008 mm)
Thicl<ness of gear (new) . . .3730 ± .0003 in. (9.474 ± 0.008 mm)
(3) Torque for nut 22 ± 5 lb. ft. (28 ± 7 Nm)
(4) Clearance between gear and
cover (new) 0014 to .0026 in. (0.036 to 0.066 mm)
Maximum permissible clearance between gear
and cover (worn) 0035 in. (0.089 mm)
(5) Shaft diameter (new) . . . .4937 ± .0001 in. (12.540 ± 0.003 mm)
Bore in shaft bearing
(new) 4953 ± .0003 in. (12.581 ± 0.008 mm)
Maximum permissible clearance betv\«en shaft
and bearing (worn) 003 in. (0.08 mm)
(6) 8M3210 Spring:
1
3304 VEHICULAR ENGINES SPECIFICATIONS
FUEL INJECTION
A-5P4158 GAUGE
TYPICAL EXAMPLE
GOVERNOR
A81478X1
B14464X1 5
(1) Torque for nut 9 ± 3 lb. ft. (12 ± 4 Nm) (4) 4N6681 Spring tor governor-
(2) 3P131 Spring: Color code (stripes) 2 purple
Length under test force 430 in. (10.92 mm) Put force on spring of 4.0 lb. (18 N)
Test force 21 ± .02 lb. (0.95 ± 0.09 N) Then add more force to make spring
Free length shorter by 90 in. (22.9 mm)
after test 85 in. (21.6 mm) Total test force 14.8 ± .48 lb. (67 ± 2 N)
Outside diameter 370 in. (9.40 mm) Free length
(3) Seat. Install a spring washer, flat washer and spring washer after test 2.24 ± .03 in. (56.9 ± 0.8 mm)
between seat (3) and spring (4) as shown. Outside diameter 1.373 in. (34.87 mm)
(4) 9L6446 Spring for governor:
(5) 4N5549 Spring for over-fueling:
Color code (stripes) 1 blue, 1 green Length under test force 209 in. (5.31 mm)
Put force on spring of 4.0 lb. (18 N) Test force 65 ± .03 lb. (2.9 ± 0.1 N)
Then add more force to make spring Free length after test 859 in. (21.82 mm)
shorter by 80 in. (20.3 mm)
Outside diameter 429 in. (10.90 mm)
Total test force 12.4 + .24 lb. (55 ± 1 N)
(6) Diameter of the outersurface of the cylinder
Free length (new) 1.2172 ± .0005 in. (30.917 ± 0.013 mm)
after test 2.24 ± .03 in. (56.9 ± 0.8 mm)
Bore in the gear
Outside diameter 1.371 In. (34.82 mm) (new) 1.2192 ± .0005 in. (30.968 ± 0.013 mm)
NOTE: Governor weights must pivot freely.
35
3304 VEHICULAR ENGINES SPECIFICATIONS
TIMING GEARS
CAMSHAFT
C. Subtract base circle (STEP B) from lobe height (STEP A). The
difference is actual lobe lift (4).
37
3304 VEHICULAR ENGINES SPECIFICATIONS
VALVES
(PC)
Valves (Cont.)
(PC)
39
3304 VEHICULAR ENGINES SPECIFICATIONS
VALVES
(Dl)
Spring must not be bent more than 072 in. (1 .83 mm)
(2) Height to top of
valve guide 875 in. (22.23 mm) B9217X1
(3) Diameter of valve stem
(new) 3717 ± .0003 in. (9.441 ± 0.008 mm)
Use again minimum diameter 3704 in. (9.408 mm)
Bore in valve guide with guide installed in the head.
Exhaust
valves 1.896 ± .005 in. (48.16 ± 0.13 mm)
Intake
valve 2.020 + .005 in. (51.31 ± 0.13 mm)
(6) Angle of valve face 29 1/4°
41
3304 VEHICULAR ENGINES SPECIFICATIONS
CYLINDER HEAD
NOTE: Dimension from top of closed valve to face of cylinder head Step 3. Again tighten all bolts in number
must be according to the specifications in VALVES. sequence to 185 ± 13 lb. ft. (250 ± 17 Nm)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts in the Step 4. Tighten all bolts in letter sequence
Step sequence that follov»/s: (hand torque only) to 32 ± 5 lb. ft. (43 ± 7 Nm)
Step 1. Tighten all bolts in number
sequence to 1 15 lb. ft. (155 Nm)
0^ 03 02 06
11
b o
4 5 10
.0 o o o o
VALVE COVER
77077X I
Put 5H2471 Cement on the face of valve cover and top side of gasket.
EXHAUST MANIFOLD
AIR CLEANER
(1) Tighten nuts that hold air filter
to elbow 20 ± 5 lb. ft. (25 ± 7 Nm)
(2) Tighten wing nuts to 35 ± 5 lb. in. (4.0 ± 0.6 Nm)
43
3304 VEHICULAR ENGINES SPECIFICATIONS
Schwitzer ONLY
Installation Procedure Chart
A. Put 6V1541 Quick Pure Primer on the nut and the shaft threads to clean them, if
necessary.
B. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
CAUTION
Do not let the retaining compoun get into the compressor wheel bore on the shaft,
because it can make removal of the compressor wheel difficult during future turbo-
charger disassembly.
C. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the
compressor. Do not put lubricant on the threads.
(a) more than .31 in. (7.9 mm), use heat for installation.*
(b) .31 in. (7.9 mm) or less, use room temperature installation."
3304 VEHICULAR ENGINES SPECIFICATIONS
TURBOCHARGER
(AiResearch T04B91)
46923-1X3
NOTE: Do not bend or add stress to the shaft when nut is tightened.
Radial play for shaft:
(7)
Maximum permissible end play 004 in. (0.10 mm) seal ring 709 to .71 1 in. (18.01 to 18.06 mm)
TURBOCHARGER
(AIResearch T0490)
47
3304 VEHICULAR ENGINES SPECIFICATIONS
TURBOCHARGER
(AIResearch T1210 and T1224)
T98428X4
tighten to 175 ± 15 lb. in. (19.8 ± 1.7 N-m) seal ring 008 to .015 in. (0.20 to 0.38 mm)
TURBOCHARGER
I (Schwitzer 3LK)
73113X2
Make reference to GUIDELINES FOR REUSABLE PARTS TURBO- (5) Maximum permissible gap of oil seal ring,
CHARGERS, Form Nos. SEBF8018 & SEBF8019. measured in bore of housing 007 in, (0,18 mm)
(1) End play for stiaft (6) See TURBOCHARGER INSTALLATION,
(new) 0045 ± .0015 In. (0.114 ± 0.038 mm)
(7) Bore in
Maximum permissible end play (worn) . . .008 in, (0.20 mm) housing 75025 ± ,00025 in, (19,0564 ± 0,0064 mm)
(2) Thickness of thrust Outside diameter of the
bearing 21 1 ± .001 in. (5.36 ± 0.03 mm) bearing 74625 ± ,00025 in, (18,9548 ± 0,0064 mm)
(3) Diameter of surface on shaft (journal) for Maximum permissible clearance between
the bearing 44015 ± .00015 in. (11.1798 ± 0.0038 mm) bearing and bore in housing 0045 in, (0,114 mm)
Bore in the (8) Thickness of each thrust
bearing 44165 ± .00015 in. (11.2179 ± 0.0038 mm) ring 1005 ± ,0005 in, (2,553 + 0,013 mm)
Maximum permissible clearance between (9) Torque for bolts holding
bearing and shaft 0018 in. (0.046 mm) impeller housing 60 lb, in, (6,8 N-m)
(4) Put 5P3931 Anti-Seize Compound on (10) Put 5P3931 Anti-Seize Compound on
threads and tighten bolt holding band threads of bolts holding turbocharger to manifold
clamp to 120 lb. in. (13,6 N-m) and tighten to 40 ± 4 lb, ft, (55 ± 5 N-m)
49
3304 VEHICULAR ENGINES SPECIFICATIONS
TURBOCHARGER
(Schwitzer 3LM)
A22019X2
(1) End play for shaft (new) 002 to ,005 in. (0.05 to 0.13 mm) Bore in housing
for bearing 7500 to .7505 in. (19.050 to 19.063 mm)
(2) Put 5P3931 Anti-Seize Compound on threads and tighten
bolts holding impeller housing to 60 lb. in. (6.8 Nm) Diameter of surface of bearing
forhousing 7460 to .7465 in. (18.948 to 18.961 mm)
(3) Put 5P3931 Anti-Seize Compound on threads
and tighten bolts holding turbine Diameter of surface of
housing to 11 to 12 lb. ft. (15 to 17 Nm) bearing for shaft 4415 to .4418 in. (11.214 to 11.222mm)
(4) Maximum permissible gap of oil seal ring, Diameter of surface of shaft for
measured in bore of housing 007 in. (0.18 mm) bearing (journal) 4400 to .4403 in. (11.176 to 11.184 mm)
(5) See TURBOCHARGER IIVIPELLER INSTALLATION. Length of bearing 2.425 to2.426 in. (61.60 to61.62 mm)
TURBOCHARGER
(Schwitzer F444, 4LF504 and E Models)
T97594X1
Make reference to ANALYZING TURBOCHARGER FAILURE, Form (4) Put 5P3931 AntiSelze Compound on threads and
No. FEG45138. tighten bolt holding band clamp to 120 lb. in. (13.6 N-m)
51
3304 VEHICULAR ENGINES SPECIFICATIONS
OIL PUMP
(2P7830, 5S3876 & 7S9840)
Clearance between shaft and Length under test force 1.548 in. (39.32 mm)
bearing (new) 0018 ± .0008 in. (0.046 ± 0.020 mm)
Test force 12.27 lb. (54.6 N)
Maximum permissible clearance between shaft
Free length after test 2.163 in. (54.94 mm)
and bearing (worn) 008 in. (0.20 mm)
Outside diameter 72 in. (18.3 mm)
Length of gear 9975 ± .0005 in. (25.337 ± 0.013 mm)
(9) Torque for nut holding drive gear 60 lb. ft. (80 N-m)
Depth of counterbore
for gear 1.0008 ± .0008 in. (25.420 ± 0.020 mm) Tighten farther to get alignment for cotter pin.
OIL PUMP
(781849 & 7S9461)
53
3304 VEHICULAR ENGINES SPECIFICATIONS
OIL PUMP
(2P1785 and 6N2642)
ta-.^j„.^
All steps of this procedure must be followed for the pressure findings Step 3. Run the engine to get the oil temperature at 210° F (99° C).
to be usable.
NOTE: A 5° F (3° C) increase in oil temperature gives approximately
Step 1. Besure that the engine is filled to thecorrect level with either 1 psi (7 kPa) decrease in oil pressure.
SAE 10 or SAE 30 oil. If any other viscosity of oil is used, the
information in the ENGINE OIL PRESSURE CHART does
Step 4. Keep the engine oil temperature constant. With the engine at
not apply.
therpm from the chart, read the pressure gauge.
Step 2. Find a location on the engine oil manifold to install a tee. The
Make a comparison between the pressure reading on the test gauge
and the minimum permissible pressure from the ENGINE OIL PRES-
easiest method is to remove the sending unit for the present
gauge and install a tee at this location. Install a probe from
SURE CHART. If the pressure reading on the test gauge is below
the minimum permissible pressure, find the cause and correct it.
the 9S9102 Thermistor Thermometer Group in one side of
Operation of the engine with low oil pressure can be the cause of
the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic
engine failure or of a reduction in engine life.
Test Box to the other side of the tee.
OIL FILTER
(7S6638, 7S6639 & 9S1806)
WATER PUMP
(1) Oil seal. Put engine oil on the seal lip. Assemble with the lip
c. Install the seal assembly around the shaft, with the 7N7843
Installation Tool, (the tool with the seal group) until the car-
is
bon face makes contact with the shiny face of the ring (2).
RADIATOR
T93973
Clean the threadsof the studs with 8M8060 Quick Cure Primer.
Then put 9S3265 Retaining Compound on the threads before in-
stalling them.
7N208 Regulator:
Temperature when completely open 195= F (90 "
C)
77719X1
Minimum open distance 375 in. (9.53 mm)
59
3304 VEHICULAR ENGINES SPECIFICATIONS
CYLINDER BLOCK
(Counterbored Block)
(1) Depth of bore in block
for liner 401 ± .001 in. '10.19 ± 0.03 mm)
NOTE: For fieighit of liner over top of block make reference to CYL-
INDER LINER PROJECTION.
(2) Camshaft bearing bore
installed 2.3150 ± .0020 in. (58.801 ± 0.051 mm)
Bore in block for camshaft
bearings 2.5630: .0010 in. (65.100 ± 0.025 mm)
Depth to installcamshaft
bearings at both ends of
block ... .06 ± .02 in. (1.5 ± 0.5 mm)
NOTE: The camshaft bearing at the front of the block must be in-
stalled with oil holes in a horizontal position and joint at the top
within ± 15° from vertical.
(8) Torque for bolts holding bearing caps for main bearings:
CYLINDER BLOCK
(With Spacer
\ r Plate)/
(1) Thickness of
spacer plate 3925 ± .0010 in. (9.970 ± 0.025 mm)
Thickness of
spacer plate gasket . . . .0082 ± .0010 in. (0.208 ± 0.025 mm)
NOTE: For height of liner over top of spacer plate make reference to
CYLINDER LINER PROJECTION.
(2) Camshaft bearing bore
(installed) 2.3150 ± .0020 in. (58.801 ± 0.051 mm)
Bore in block for camshaft
bearings 2.5630 ± .0010 in. (65.100 ± 0.025 mm)
Depth to install camshaft
bearings at both ends of
block 06 ± .02 in. (1.5 + 0.5 mm)
NOTE: The camshaft bearing the front of the block must be in-
at
stalled with oil holes in a horizontal position and joint at top within ±
15° from vertical.
NOTE: Install bearing caps with the part number toward the front of
the engine. Be sure that the mark (number) on the bearing cap next
to the bolt hole is in agreement with the mark in the cylinder block,
CAUTION
Ttiere are holes in the bores for the main bearings, between
cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These
holes must have either orifices (10) or plugs (9) installed.
NOTE: If a turbocharger is installed on the engine, be sure to install
orifices (10) and an engine oil cooler.
NOTE: If the engine has an engine oil cooler and no turbocharger
be sure to install orifices (10).
61
3304 VEHICULAR ENGINES SPECIFICATIONS
CYLINDER LINER
1. Install gasket and spacer plate (2) witti bolts (3) and two 1S379
Wasfiers. Tighiten bolts (3) evenly in four steps:
Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.
CONNECTING ROD
Install the connecting rod in the piston with the slot for the bearing tab
on the same side as the V mark on the piston.
CRANKSHAFT
) 2
Without tabs
6N8940 1850 ± .0015 in. (4.699 ± 0.038 mm)
9S3037 2320 ± .0015 in. (5.894 ± 0.038 mm)
with tabs:
Push wear sleeve and seal into position with correct tooling.
Make reference to Special Instruction, Form No. SMHS7100 for
instructions and the correct tooling for installing wear sleeves
and seals.
3304 VEHICULAR ENGINES SPECIFICATIONS
A06090X1
A06090X1
Make reference to GUIDELINE FOR REUSABLE PARTS; MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.
FAN DRIVE
V///
(1) Fill chamber between bearings half full of 1P808 Grease before
bolts are tightened.
71
3304 VEHICULAR ENGINES SPECIFICATIONS
(2) Flywheel.
Install ring gear (1) on flywheel (2) so that the chamfer side (4) of ring
gear (1) is as shown.
CAUTION: Do not heat ring gear to more than 600°F (316°C) before
installing on the flywheel.
FLYWHEEL HOUSING
TIGHTENING
NOTE: On some engines the timing bolt hole is below the starter.
TYPICAL ILLUSTRATION
FLYWHEEL
3. Turn the flywheel and read the indicator every 90°. Put a force on
the flywheel to the rear before each reading.
1. Install the dial indicator (3) and make an adjustment of the uni-
versal 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°.
5. Runout (eccentricity) for the bore for the pilot bearing for the fly-
wheel clutch, must not exceed .005 in. (0.13 mm)
CHECKING FLYWHEEL CLUTCH
PILOT BEARING BORE
73
3304 VEHICULAR ENGINES SPECIFICATIONS
FLYWHEEL HOUSING
2. Put a force on the crankshaft toward the rear before reading the
indicator 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).
A (BOTTOM)
C (TOP)
NOTE: Use a torque wrench to get the correct torque for all the engine
mounting bolts.
Tighten the bolts which hold the rear Tighten the bolts which hold the front support
brackets to the frame to 225 + 25 lb. ft. (300 ± 35 N m) to the frame to 460 ± 50 lb. ft. (624 ± 70 Nm)
225 Excavator
Tighten the bolts which hold the support
for the hydraulic pump drive housing to the
frame to 350 + 35 lb. ft. (470 ± 45 N
TO413
(1) Torque tor bolts 80 ± 5 lb. ft. (1 10 ± 7 Nm)
(2) Torque for bolt holding flange
to drive 160 ± 10 lb. ft. (219 ± 14 Nm)
(3) Maximum permissible "runout" axial alignment of face
(total indicator readingi 026 in. (0.66 mm)
(4) Maximum permissible "eccentricity" radial off
center of flywheel output flange rim to torque
converter shaft (total indicator reading) 080 in. (2.03 mm)
77
.
A09406- 1X1
2. Fasten a 3/8 in. (9.5 mm) diameter rod 3 in. (76.2 mm) long to the
torque converter input shaft with a 1J9778 Hose Clamp. Install a
7H1948 Snug onto the rod. Assemble a 7H1942 Indicator (with a
7m940 Universal Attachment), and 7H1945 Holding Rod into the
7H1948Snug.
3. Put the universal attachment on the outside diameter of the engine
output flange. Rotate the indicator until it stops on "0". Turn the
torque converter input shaft 360°. Record the indicator measure-
ment at each 90°of rotation.
4. The total indicator reading through 360° of rotation must not be
more than .080 in. (2.03 mm). The alignment can be made correct
by loosening the engine rear bolts and moving the engine from side
to side. If the alignment up and down is not correct, install or
remove shims under the engine rear supports.
5. If the holes for the support bolts have become larger because of
wear, dowels should be installed after the engine has been fastened
down. [See Step (8)1 .
7. Turn the torque converter input shaft 360°. Record the indicator
measurement at each 90° of rotation. The total indicator reading
through 360° of rotation must not be more than .026 in. (0.66
mm). The alignment can be made correct by loosening the engine
front support bolts and moving the front of the engine side to side.
8. Check the vertical and horizontal alignment again. When the align- A09407- X
1 1
ALTERNATORS
(4) Torque for terminal nuts 30 to 35 lb. in. (3.4 to 4.0 Nm)
(5) Torque for bolts holding the
regulator 45 to 50 lb. in. (5.1 to 5.7 Nm)
•Including the 9S2329 Regulator (Prestolite Number VSH6401)
79
3304 VEHICULAR ENGINES SPECIFICATIONS
Alternators (Cont.)
(2) Torque for cover screws 20 ± 5 lb. in. (2.3 ± 0.6 N-m)
Torque for output (POS) terminal ... 5 ± 1 lb. ft. (7 ± 1 N-m)
Alternators (Cont.)
Circuit B
n (1)
(2)
Torque for nut holding pulley
10
±
±
5 lb. ft.
1
(100 ± 7
81
3304 VEHICULAR ENGINES SPECIFICATIONS
Alternators (Cont.)
ALTERNATOR REGULATOR
83
L
)
GENERATORS
Circuit A
Speed for testing 1 720 rpm
Field current at 24V and 80° F (27° C) 83 to .89 A
Circuit A
Speed for testing 1800 rpm
Field current at 24V and 80° F (27° C) 94 to 1 .02 A
e a _
Output at 1800 rpm and 28.5V when cold 15 A
Output when cold 28.5 V
(1 Tension of brush spring 16 oz. (4.4 N)
Circuit A
Speed for testing 1700 rpm
Field current at 24V 80° F (27° C) 83 to.89 A
Output at 1 700 rpm and 26V when cold 20 A
Output when cold 26 V
Generators (Cont.)
GENERATOR REGULATORS
Circuit A
(1) Cutout relay:
Air gap between armature and core 067 in. (1 .70 mm)
Point gap 016 in. (0.41 mm)
Voltage setting range at 85° F (29° C):
85
3304 VEHICULAR ENGINES SPECIFICATIONS
Circuit A
(1) Cutout relay:
Air gap between armature and core 067 in. (1 .70 mm)
Point gap 016 in. (0.41 mm)
Voltage setting range at 85° F (29° C):
Circuit A
(1) Cutout relay:
Air gap between armature and core 060 in. (1 .52 mm)
Voltage setting range at 85° F (29° C) 27.5 to 29.5 V
(4) Torque for bolts 36 ± 6 lb. in. (4.1 ± 0.7 Nm)
Air gap between armature and core 027 in. (0.69 mm)
Point gap 031 in. (0.79 mml
Closing range when cold 24.0 to 26.0 V
(2) Current regulator:
Air gap between armature and core 039 In. (0.99 mm)
Current setting range 14 to 15 A
(3) Voltage regulator:
Air gap between armature and core 043 in. (1 .09 mm)
Voltage setting range at 85° F (29° C) 26.8 to 28.2 V
(4) Torque for bolts 36 ± 6 lb. in. (4.1 + 0.7 N-m)
Air gap between armature and core 051 in. (1.30 mm)
Point gap 016 to .024 in. (0.41 to 0.61 mm)
Switch in 26 to 27 V
Reverse current (less than) 10 A
Voltage regulator:
87
3304 VEHICULAR ENGINES SPECIFICATIONS
STARTER MOTORS
Minimum speed with no load 5500 rpm Minimum speed with no load 5500 rpm
Maximum speed with no load 7500 rpm Maximum speed with no load 7500 rpm
Current consumption (draw) at no load: Current consumption (draw) at no load:
Maximum at 20V 65 A
(1) Tension of brush spring 52 to 65 oz. (14.5 to 18.1 N)
Maximum at 20V 77 A
(1) Tension of brush spring 80 to 90 oz. (22.2 to 25.0 N)
89
)
Maximum at 207 65 A
(3) Clearance for ttie pinion . . . .020 to .050 in. (0.51 to 1.27 mm)
Minimum 140 A
91
3304 VEHICULAR ENGINES SPECIFICATIONS
Maximum at 23V 1 10 A
Stall torque test:
7N3621 24V
7M4291 24V (Delco-Remy Number 1119866)
Current consumption (draw) at 20 V 3.5 to 3.9 A
(1) 7M7553 Spring:
STARTER SOLENOIDS
93
3304 VEHICULAR ENGINES SPECIFICATIONS
(3) Torque for terminal screws . . 16 to 30 lb. in. (1.8 to 3.4 N-m)
r^
3T3369 24V (Presfolite Number SAT-4105)
9S7976 24V (Preslolite Number SAT-4103)
8S1529 24V (Prestolite Number SAT-4101)
Current consumption (draw):
95
3304 VEHICULAR ENGINES SPECIFICATIONS
CALIBRATIOIM CHART
3304 VEHICULAR ENGINES SPECIFICATIONS
CALIBRATION CHART
o
n
o
®
CITERPILLAR
o.
SENR7590-01
Printed In U.S.A. (10/81)