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C at e r p i l l a r
Service Manual
3204 Engine
S/n 10X1 & up
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
CT-S-ENG 3204
FORM NO. SENR2168-01
FOR USE IN SERVICE MANUAL:
215 EXCAVATOR;
FORM NO. SENR2165
,
.,-
I
INDEX
6
ENGINE DISASSEMBL Y AND ASSEMBLY
start by:
a) remove flywheel
NOTE: When a replacement of the rear seal is made,
a replacement of the wear sleeve is to be made also.
1. Remove the crankshaft rear seal with tool (A).
2. Install tool (C) in the rear seal bore.
3. Install tool (8) between tool (C) and wear
sleeve. Turn tool (8) 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 1161-12
Tools Needed A
5P7293 Installer TYPICAL EXAMPLE
5P290 Locator
1P5515 Bolt 2
9S8858 Nut 2 ----1:=:AJ~:I.L..L;
~~~____-----3
install the seal on wear sleeve (2). f) Put installer (5) in position on the locator.
d) Put 7F2770 Cement on the outer metal g) Put clean engine oil on the face of nut (4)
surface of the seal. and install it on the locator. Tighten the nut
e) Put the wear sleeve (2) and seal (1) in posi- until installer (5) is at bottom.
tion on locator (3) with the outside dia- h) Remove tooling (A) and check the wear
meter bevel of the wear sleeve toward the sleeve and seal for the correct position after
outside. installation. The wear sleeve must be even
NOTE: Make sure the lip of the seal is toward the with the flywheel mounting flange.
front of the engine before the seal is pushed in posi- end by:
tion as shown. a) install flywheel
123
3204 VEHICULAR ENGINE SPECIFICATIONS
FOR 215 EXCAVATOR
INTRODUCTION
The specifications given in this book are on the basis can be used again. If the part is equal to or within the
of information available at the time it was written. The 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.
have the most current information which is available. A comparison can be made between the measure-
For a list of the most current modules and form numbers ments of a worn part, and the specifications of a new
available for each Service Manual, see the SERVICE part to find the amount of wear. A part that is worn can
MANUAL CONTENTS MICROFICHE REG 1139F. be safe to use if an estimate of the remainder of its
When the words "use again" are in the description, service life is good. If a short service life is expected,
the specification given can be used to determine if a part replace the part.
77200X2
NOTE: For Systems Operation and Testing and Adjusting, make reference
to 3204 VEHICULAR ENGINE FOR 215 EXCAVATOR, Form No.
SENR2137.
I
NOTE: The "C" is an indication of a change from the former issue.
INDEX
2
Index Valve Cover ................................................................ 14
Valve Cover Base ....................................................... 14
Valve Lifters ................................................................ •
Air Cleaner Housing ................................................... 6
Alternator .................................................................... 6 Water Pump ................................................................ 13
Water Pump, Disassemble & Assemble...... ............... •
Camshaft ..................................................................... • Water Temperature Regulator ..................................... 8
Camshaft Bearings ..................................................... •
Connecting Rod Bearings .......................................... • ·For disassembly and assembly information for these
Crankshaft And Gear ................................................. • components, see 3204 Vehicular Engine, Disassembly
Crankshaft Front Pulley .............................................. 12 And Assembly Manual, Form No. SENR3230.
Crankshaft Front Seal ................................................. •
Crankshaft Main Bearings.......................................... •
Crankshaft Rear Seal And Wear Sleeve .................... •
Cylinder Head Assembly ............................................ • A WARNING
Cylinder Head Assembly, Disassemble &
Assemble ....................................................................• Disconnect batteries before performance of any
service work.
Engine (See D4B & 935B Power Train, Disassembly
And Assembly Manual, form No. SENR3547)
Engine Oil Cooler, Support and Bypass Valve .......... 8
Exhaust Manifold ........................................................ •
Hood ........................................................................... 5
Muffler ......................................................................... 7
Starting Motor............................................................. 6
Support Bracket (931C) ............................................. 4
Index