3209 DISSEL TRUG SERIAL NUMBERS. 32Y1-UP. §1Z1-UP. SPECIFICATIONS (Section 1) TROUBLESHOGTING GUIDE (Sec GENERAL INSTRUCTIONS (D & A) | LOW EMISSION ENGINE (EARLIER) WITH : EXHAUST GAS RECIRCULATION (Section 8) LOW EMISSION ENGINE (LATER) (S.oe ‘ons given in this book The spec information available at the time the buok wais writen, ‘These specifications give the torques. oper INTRODUCTION re basisull ng pres. sare, measurements of new parts, adjustments and oth- critems that Will affect the service of the product When the words “use again’’ are in the description, the specificaitons given can be used to determine if @ part can be used again, If the part is equal to of within the specification given, use the part again. When the word “permissible’-is in the description, the speci ication Inited before aujusiment. pair andlor new pare ak needed A comparison can be made.betwen the measurement of a worn part, and the specifications of a new part t find the amount of wear. A part that is worn can be safi use if an estitnate ofthe remainler of its service life good. If a short service life is expected, replace. thi part NOTE: The specifications given for "use again” and “permissible” are intended for guidance only and Caterpillar Tractor Co. hereby express- ranty of the reuse of any component. fy denies and excludes any representation, “7 go ir Compressor ‘Ait induction and Exhaust System ‘ir niet Manors .. : Canshatt Gyinder Head cs Manila and Veniliaion Vaive VaNS-ssereeewree vane Covers Vane Rocker Armand Cam Followers Vane Seats and Inserts Basic Engine Components Bearings for Connecting Rods and Mains Connecting Rod Grankehat .. Grinder Block Flywneeh aes hywhee! Runout ywnost Housing Bore Flywhee! Housing Runout ‘Mounting Group for AT540, MITEAS, and MTEES Alsen Teansmnission Betons and Rings Fully and Dampor Cecling Systm Fan Mousting Pulley Assemies, Vee Bel Tension Chart Wialee PUMP vecsesense coon Wiser Temperature Regulator SYSTEMS OPERATION (Section 2) ‘Arise and Exhaust Syetam Basi BOE en Crarkshalt Cyincor Blac Gylnds Head Picton, Rings and Connecting Fods Yibraion Danger Cocting Sy ra Becca System SPECIFICATIONS (Section 1)», 20 Shutoif Solenoids Starter Motors Starter Solenoids Engine Design Fast System ‘Automatic Timing Advance Unit. Drive Gear for the Injection Pump.” Fol Filler Basa fs. Fuel injec Fuel Transte Governor Injection No=sie Lubrication System ‘Olt Cooler and Filter Oil Level Gauge Ou Pan, ii Pump Torque for Flared Fu System ‘automatic Timing Avance Constant Bleed Vai Flow a! Foal Using te Pang Puma Fuel dunetion Bio ‘Operation of Fue! Injecion Pups (Operation of 9N3O79 Fue! Injection Water Separator es Lubication Som Engingg wit Fis By Engites with Ol Fite Bypass208 DIESEL 7 ns Main Bearings. ting Flods and Pistons Flywhee! and Fiywae! Housing 5P3519 Piston Ring Groove Gauge. ‘ang Engine Timing and Automatic Time ‘ovance Unit with 83109 Dies0! Engine Teng __ lineation Group... cneseng Engine Gylindare Separataly Ghecting Tekng by Fuel Fon Mathes Checsin} Timing By Timing Pin Method) Crossover Levers. Coeeking tment 1g Tap Cstiter Compression Position for Fue injection Linas ¥ esting te Cocieg 3 BES“ v-Beit Tension Chart HF’ Visual Inspection of Cooling System Fi Water Pump Pressure Chock Co. 38 Fue! njection Pumps. Fusi Pump Calibration FL Air Injat ang exhay 301 Checking... ‘Gylincer Comer 331 Asjustment Measurement of Exnaust Temperatures SO gat Fue! System Adjustments: Procedurs or Mensuting Camehatt Lobes 233 System Inspection Roe 5 Of Arr inieh and Exhaust conse 331 SA BAHerY vr eeeeene Charging System Ligecation System “Feo Much Component Wear TROUBLESHOOTING GUIDE (Section 4) 7 498 Low Power Troubleshaoting Difficult Starting (Engine Crankshalt Turns Freely) ..... 4-91 +Misiving and Running Rough DItficut Staring (Engine Crankshalt Will Not Ty : 4.95 Primary Engine Test for High Fuel Consumption a Primary Engine Test for Low Power jin Grankcase Oi 4-44). Proniem with Verile or Vehicle Operation igh Fuet Consumption Troubleshoating.......e+-ss1.1 484 | Too Much Exhoust Smoke (Black or Gray) ‘Yoo Much Exhaust Smoke {White oF Blue} oduetion tothe Troubleshooting Guide ... 43 eo ‘ibrati¢§ Troubleshooting (Engine) DEE Of COOLEM sessessceessssserersessneeees aa GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY (Section 5) Lites ana Wires Locks Srication Fora Mabuill Engine 7 Procedure tor Pevesure LuBriestion & | Preload. Pressing Parts i Are Lane ae Removal and installation ee ues for Lise of Tools fe ust Preventive Gompaund Stee ng Cop Pligg Aches Peet tiie cont Butordeemty oer Sony pia a sre ee sy