Caterpillar (CAT) 3024C Engines (SENR5004-02/SENR5005-03/SENR5006-04) OEM Service & Repair Manual

3024C Engine for Caterpillar Built Machines S/N – SENR5004-02 SENR5005-03 SENR5006-04

3024C Engine for Caterpillar Built Machines Section Total Page Page SENR5004-02 Specifications INDEX 1 1 Engine Design 3 3 Fuel Injection Lines 4 4 Fuel Injection Pump 5 5 Fuel Injection Nozzles 6 6 Fuel Transfer Pump 7 7 Rocker Shaft 8 8 Valve Mechanism Cover 9 9 Cylinder Head Valves 10 10 Cylinder Head 13 13 Exhaust Manifold 15 15 Camshaft 16 16 Camshaft Lobe Lift Retainer Plate for the Camshaft Engine Oil Lines 18 18 Engine Oil Filter 19 19 Engine Oil Relief Valve 20 20 Engine Oil Pump 21 21 Engine Oil Pressure 23 23 Engine Oil Pan 24 24 Oil Suction Tube and Oil Strainer Water Temperature Regulator 25 25 Water Temperature Regulator Housing Cylinder Block 26 26 Crankshaft 27 27 Measure Wear on the Crankshaft Measure the Main Bearing Clearance Crankshaft Main Bearing Cap Connecting Rod Bearing Journal 30 30 Main Bearing Journal 31 31 Connecting Rod 32 32 Markings on the Connecting Rod Distortion of the Connecting Rod Piston and Rings 34 34 Markings on the Piston Piston Rings Pistons Housing (Front) 36 36 Gear Group (Front) 37 37 Flywheel 38 38 Flywheel Housing 39 39 Crankshaft Pulley 40 40 Belt Tension Chart 41 41 Fan Drive 42 42 Engine Lifting Bracket 43 43 Alternator and Regulator 44 44 Electric Starting Motor 45 45 Starting Motor

Start Relays Coolant Temperature Switch 47 47 Engine Oil Pressure Switch 48 48 Glow Plugs 49 49 Fuel Shutoff Solenoid 50 50 SENR5005-03 Systems Operation INDEX 1 51 Engine Design 5 55 3024C Engine General Information 6 56 Engine Description Lifting the Engine 3024C Engine Model Views Fuel System 8 58 General Operation of the Fuel System Governor Fuel Injection Pump Fuel Injection Nozzles Fuel Transfer Pump Glow Plugs Air Inlet and Exhaust System 13 63 Cylinder Head And Valves Lubrication System 15 65 Cooling System 17 67 Basic Engine 18 68 Cylinder Head and Block Pistons and Connecting Rods Timing Gear Case and Gears Electrical System 20 70 Engine Electrical System Automatic Shutdown System Automatic Shutdown Conditions Charging System Components Alternator Regulator Starting System Components Solenoid Electric Starting Motor Other Components Circuit Breaker SENR5005-03 Testing and Adjusting Troubleshooting 25 75 Introduction Troubleshooting The Fuel Injection Nozzles On The Engine The engine is difficult to start or the engine runs rough. The engine exhaust has too much black smoke. The engine has lost power and the engine uses too much fuel. The engine is misfiring, running rough, or running poorly. Troubleshooting Fuel Injection Nozzles on a Nozzle Tester Back leakage The fuel injection nozzle does not inject fuel in the correct quantity or in the correct pattern. Troubleshooting the Engine

The engine will not start. The engine starts and the engine runs for a brief period of time and the engine stops. The engine misfires or the engine runs rough. The engine runs evenly, but the engine loses power. The engine lacks power. The engine has excessive vibration. The engine has excessive combustion noise. The engine has excessive valve compartment noise. Engine oil is in the cooling system. Engine knock occurs. The rocker arm has insufficient movement and the valve lash exceeds the specification. A cylinder head valve is loose. Oil condenses at the exhaust. The valve lash is less than the required specification. Engine components have early wear. Coolant is in the engine oil. The engine exhaust has too much black smoke or too much gray smoke. The engine exhaust has too much white smoke or too much blue smoke. The engine has low oil pressure. The engine oil pressure is too high. The engine uses too much engine oil. The engine overheats. The exhaust temperature is too high. The starting motor does not turn or the starting motor turns too slowly. The starting motor turns, but the pinion gear does not engage the flywheel ring gear. The engine does not crank or the engine rotates slowly when the keyswitch is in the start position. The starting motor continues to run after the ignition switch is released. The pinion gear does not disengage after the engine starts to run. The alternator does not charge the battery or the alternator charge rate is slow or irregular. The alternator charges the battery to a voltage that is too high. The alternator is noisy. Fuel System - Inspect 40 90 Air in Fuel - Test 41 91 Engine Speed - Check 43 93 Finding Top Center Position for No. 1 Piston 44 94 Fuel Injection Nozzle - Test 46 96 Inspection and Cleaning of the Fuel Injection Nozzles Leakage Test Pressure Test Test for the Nozzle Spray Pattern Fuel Injection Timing - Check 50 100 Fuel Quality - Test 51 101 Fuel System - Prime 52 102 Fuel System Pressure - Test 54 104 Gear Group (Front) - Time 56 106 Air Inlet and Exhaust System - Inspect 57 107 Exhaust Temperature - Test 58 108 Measure the Exhaust Temperature Engine Crankcase Pressure (Blowby) - Test 59 109 Compression - Test 60 110 Compression Engine Valve Lash - Inspect/Adjust 62 112 Valve Lash Check Valve Lash Adjustment Valve Depth - Inspect 65 115 Valve Guide - Inspect 66 116

Engine Oil Pressure - Test 67 117 Engine Oil Pump - Inspect 68 118 Excessive Bearing Wear - Inspect 70 120 Excessive Engine Oil Consumption - Inspect 71 121 Engine Oil Leaks on the Outside of the Engine Engine Oil Leaks into the Combustion Area of the Cylinders Cooling System - Check - Overheating 72 122 Cooling System - Inspect 74 124 Cooling System - Test 75 125 Test Tools For The Cooling System Making the Correct Antifreeze Mixtures Checking the Filler Cap Testing The Radiator And Cooling System For Leaks Cooling System Conditioner Water Temperature Regulator - Test 81 131 Water Pump - Inspect 82 132 Piston Ring Groove - Inspect 83 133 Inspect the Piston and the Piston Rings Inspect the Clearance of the Piston Ring Inspect the Piston Ring End Gap Connecting Rod - Inspect 85 135 Distortion of Connecting Rod Inspect the Bearings and Piston Pin for Wear Connecting Rod Bearings - Inspect 87 137 Main Bearings - Inspect 88 138 Cylinder Block - Inspect 89 139 Cylinder Head - Inspect 90 140 Piston Height - Inspect 92 142 Flywheel - Inspect 94 144 Alignment of the Flywheel Face Flywheel Runout Flywheel Housing - Inspect 95 145 Face Runout (Axial Eccentricity) of the Flywheel Housing Bore Runout (Radial Eccentricity) of the Flywheel Housing Gear Group - Inspect 97 147 Alternator - Test 98 148 Battery - Test 99 149 Charging System - Test 100 150 Alternator Regulator Coolant Temperature Switch - Test 101 151 Electric Starting System - Test 102 152 Engine Oil Pressure Switch - Test 103 153 Fuel Shutoff Solenoid - Test 104 154 Glow Plugs - Test 105 155 Continuity Test Glow Plug Circuit SENR5006-04 Disassembly and Assembly INDEX 1 157 Fuel Transfer Pump - Remove 5 161 Removal Procedure Fuel Transfer Pump - Install 6 162 Installation Procedure Fuel Injection Lines - Remove and Install 7 163 Removal Procedure

Installation Procedure Fuel Injection Nozzles - Remove 10 166 Removal Procedure Fuel Injection Nozzles - Install 11 167 Installation Procedure Fuel Shutoff Solenoid - Remove and Install 12 168 Removal Procedure Installation Procedure Governor - Disassemble 14 170 Disassembly Procedure Removal of the Governor Weight Assembly Removal of the lever for the Engine Stop Remove the linkage for the fuel injection pump Remove the Speed Control Lever for the Engine Governor - Assemble 17 173 Assembly Procedure Install the Speed Control Lever for the Engine Install the Linkage for the Fuel Injection Pump Installation of the Lever for the Engine Stop Installation of the Governor Weight Assembly Fuel Injection Pump - Remove 20 176 Removal Procedure Fuel Injection Pump - Install 21 177 Installation Procedure Exhaust Manifold - Remove and Install 22 178 Removal Procedure Installation Procedure Inlet and Exhaust Valve Springs - Remove and Install 24 180 Removal Procedure Installation Procedure Inlet and Exhaust Valves - Remove and Install 27 183 Removal Procedure Removal Procedure (Alternate Method) Installation Procedure Installation Procedure (Alternate Method) Engine Oil Line - Remove and Install 30 186 Removal Procedure Installation Procedure Engine Oil Relief Valve - Remove and Install 31 187 Removal Procedure Installation Procedure Engine Oil Pump - Remove 33 189 Removal Procedure Engine Oil Pump Idler Hub Engine Oil Pump - Install 36 192 Installation Procedure Idler Hub Engine Oil Pump Water Pump - Remove 39 195 Removal Procedure Water Pump - Install 41 197 Installation Procedure Water Temperature Regulator - Remove and Install 42 198 Removal Procedure Installation Procedure

Flywheel - Remove 44 200 Removal Procedure Flywheel - Install 46 202 Installation Procedure Crankshaft Rear Seal - Remove 48 204 Removal Procedure Crankshaft Rear Seal - Install 49 205 Installation Procedure Flywheel Housing - Remove and Install 50 206 Removal Procedure (Engines with Flywheel Housing and Back plate) Removal Procedure (Engines with Flywheel Housing) Installation Procedure (Engines with Flywheel Housing and Back plate) Installation Procedure (Engines with Flywheel Housing) Crankshaft Pulley - Remove and Install 55 211 Removal Procedure Installation Procedure Crankshaft Front Seal - Remove 57 213 Removal Procedure Crankshaft Front Seal - Install 58 214 Installation Procedure Housing (Front) - Remove 59 215 Removal Procedure Housing (Front) - Install 61 217 Installation Procedure Crankcase Breather - Remove and Install 62 218 Removal Procedure Installation Procedure Valve Mechanism Cover - Remove and Install 64 220 Removal Procedure Installation Procedure Rocker Shaft and Pushrod - Remove 66 222 Removal Procedure Rocker Shaft - Disassemble 68 224 Disassembly Procedure Rocker Shaft - Assemble 69 225 Assembly Procedure Rocker Shaft and Pushrod - Install 70 226 Installation Procedure Cylinder Head - Remove 71 227 Removal Procedure Cylinder Head - Install 73 229 Installation Procedure Lifter Group - Remove and Install 75 231 Removal Procedure Installation Procedure Camshaft - Remove 77 233 Removal Procedure Camshaft - Install 79 235 Installation Procedure Engine Oil Pan - Remove and Install 81 237 Removal Procedure Installation Procedure Pistons and Connecting Rods - Remove 83 239 Removal Procedure Pistons and Connecting Rods - Disassemble 84 240 Disassembly Procedure

Pistons and Connecting Rods - Assemble 86 242 Assembly Procedure Pistons and Connecting Rods - Install 88 244 Installation Procedure Connecting Rod Bearings - Remove 90 246 Removal Procedure Connecting Rod Bearings - Install 91 247 Installation Procedure Crankshaft Main Bearings - Remove 93 249 Removal Procedure Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft Main Bearings - Install 95 251 Installation Procedure Crankshaft Main Bearings Crankshaft Bearing (Front) Crankshaft - Remove 97 253 Removal Procedure Crankshaft - Install 98 254 Installation Procedure Bearing Clearance - Check 99 255 Measurement Procedure Coolant Temperature Switch - Remove and Install 101 257 Removal Procedure Installation Procedure Engine Oil Pressure Switch - Remove and Install 103 259 Removal Procedure Installation Procedure Glow Plugs - Remove and Install 105 261 Removal Procedure Installation Procedure V-Belts - Remove and Install 107 263 Removal Procedure Installation Procedure Alternator - Remove and Install 109 265 Removal Procedure Installation Procedure Electric Starting Motor - Remove and Install 110 266 Removal Procedure Installation Procedure

Caterpillar (CAT) 3024C Engines (SENR5004-02/SENR5005-03/SENR5006-04) OEM Service & Repair Manual

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