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Crawlers, Dozers, Loaders & Backhoes Discussion Forum

CAT 3204 proublem (D3)

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murray

04-11-2006 14:43:30




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Well ya all know how old people are and see perceived value in their equipment. So we have this D3 with a 3204 engine with a hole in the block and about 90% tracks told Dad to sell it as is and take what he could get but nooOOOOoo were (translated ME) gonna put in a engine and try and sell it for the price he thought it was worth plus the cost of the new engine. GRRRRR So Cat don't think a block is worth much with a hole in it (go figure) and a rebuilt long block cost just over $8000. I followed the instructions that came with the engine and from the service manual to the letter. Told dad that there were special tools that were needed but that just brought on the normal grumbling so I made do with what I had. The cam shaft had to come out to put on the front timing gear backing plate and I was very careful to line up the marks as it showed in the service manual. This is the older version with pre-chambers and there is no fuel pump timing marks or pins. So not having the CAT timing alignment plate I used the drip method by using a dial indicator for degrees before TDC and set the injector pump accordingly. That took awhile to set everything up and do but it seemed to work fine. With the motor in I did as the instructions said and pumped the oil system full of oil until it ran out of the rocker arms. I also pressurized and bled the fuel system. With every thing back together and the fluids toped off it was time to start it it took awhile but it finally barked to life but did not run well at all. Blamed it on the old fuel that smelled like varnish so drained the tank and put in new fuel and bled the system again. Still running no better and very noisy decided to take it out side and just let it run and see if it would smooth up. Left it run for about 45 minutes and when I returned there was oil all over and running down the side from the breather. GRRRRR RR Well back in the shop and off with the rocker cover and discover a broken bolt (1 of 4)that holds the rocker assembly down. Well must have been a bad bolt so replaced it and readjusted the valves to the CAT specks. Reassembled and still it ran no better. Starting to get irritated by this time. So checked to se what cylinders were not firing right and decided to switch the injectors to verify that it wasn't a bad one when I removed the rocker cover I discovered that the bolt was once again broken and also that the push rods were all but one bent. Well the only thing I can think is that I must have F'd up the cam timing marks. So after not sleeping to well today tore the whole thing back apart and pulled the engine and low and behold the cam marks are right on just as the Manuel shows it. So apparently something else is not right. Any ideas what it might be?

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J. Schwiebert

04-12-2006 04:09:01




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 Re: CAT 3204 proublem (D3) in reply to murray, 04-11-2006 14:43:30  
Is there any way you can take a dial indicator and find exact TDC and do you have the specs for when the valves open and acess to a degree wheel like you would use for a high? performance engine? Just thinking out loud. J.



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the tractor vet

04-11-2006 16:17:16




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 Re: CAT 3204 proublem (D3) in reply to murray, 04-11-2006 14:43:30  
Well if ya got broken bolts and bent push rods tubes what ever then the valves are hitting the pistons (1) ya got the wrong pistons for the head (2) the wrong crank (3) the cam is set wrong , now i am by no means a Cat expert and when Cat Cummins Detroit IH tells ya ya need this here special tool then they mean it > SO something is causeing the valve to hit the pistons and thus breaking bolts and bending things So i guess ya had better pull the head and look . One time while working on a case that had a cracked head the farmer went after a new head and brought it in and like a dummy i did not check it i just put it on and as soon as i lit the engine i knew that something was not wright and shut it down to find that the head that he brought was for a 730-930 and this was on a 1030 but the guy that farmer got the head from would not refund or take the head back and exchange it last time i ever let a farmer get the parts . Heck Cat could have screwed up . Would not be the first time that the book was wrong .

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murray

04-11-2006 18:15:59




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 Re: CAT 3204 proublem (D3) in reply to the tractor vet, 04-11-2006 16:17:16  
I have the Cat service manuel and the only special tools that would have been nice to have would have been the rear main seal installation tool and the fuel injector pump timing plate. The one I made basically a puller. They give you a couple of different ways to time the fuel injector pump its just the plate would have made it easier and the closest Cat dealer is 60 miles and they don't loan tools so I would have had to buy it so I did it the hard way. But doing it the hard way helped me to better understand how it worked. My thinking is they may have the wrong pistons or they planed the head and didn't mill reliefs for the valves. I'm not sure but if they put in the direct injection pistons they may be different from the ones for the pre-chamber engine. But I don't want to take of the head unless they tell me to as it came all together. To say that I'm completely disgusted is an understatement.

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Bob/Ont

04-12-2006 03:49:41




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 Re: CAT 3204 proublem (D3) in reply to murray, 04-11-2006 18:15:59  
Murray, would the engine rotate a complete 360 deg when you got it? If so likely a small oversight when building it that turned into a disaster. Top of block may have been cleaned up too many times. If the timing marks are right they messed up building it. Take it back to them as it is now and let them figure it out. If you had got the timing marks wrong you would have noticed trying to turn the engine to set the fuel pump timing. If the top deck was machined too much you might not find out untill the engine got up to temp and the pistons grew a bit from heat.
Later Bob.

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