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Crawlers, Dozers, Loaders & Backhoes Discussion Forum

Re: Cat 3204 running rough

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03-29-2013 19:51:33

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Transfer pump should be located between the engine oil filter and the oil cooler. You should need an 11/16" and 9/16" wrench and no more. IIRC, you'll see a larger line (mabey 7/16") with an elbow that feeds into the transfer pump. This line comes from the tank. Above this line will be the outlet line from the transfer pump and this feeds over to the main fuel filter on the left side of the engine. Basically... remove the larger line from the elbow. Then remove the smaller line above that goes to the filter. Then remove the elbow. There will be an o-ring on the elbow but it's common. Next you remove the longer hex piece... this is the screen. Also will have an o-ring... again, common. Now... if you didn't have a large flow of fuel when you removed that first line, trace it back to the tank and find out why. Otherwise, clean the screen and reassemble. Here is where the fun starts.... and you'll damn well learn to NOT do this again... Take the filter off and fill it. Remove the 3/4" hex bolt/bleeder on the TOP REAR of the injection pump. Now with the shutoff pushed forward/off, crank the engine until you get clear fuel from the bleeder and reinstall. THen... open the lines at the injectors and make sure you use two wrenches... one to hold the fixture and one to remove the compression nut... otherwise you twist the injector lines off inside. Now set the throttle to max delivery and crank. I probably wouldn't be too shy to pour some ether to it to help with the cranking. When you see some good blasts of fuel coming out at the injectors or on the drip rail that runs along the head... start closing them up and keep cranking.
I hope your batteries are good. If they're not, make her run on ether while bleeding or it will never get bled.


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Stick welding

03-30-2013 19:16:20

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 Re: Cat 3204 running rough in reply to RodInNS, 03-29-2013 19:51:33  
This machine has a different pump than the one you describe. There is no 3/4" plug on the top. I have good fuel flow to the transfer pump. I took the fuel line off the elbow on the hex (transfer pump screen) and then removed the elbow and screen at the same time. The screen had what looked like brass slivers sticking out of it. Further inspection revealed them to be some type of strong fibrous material. I pulled out as many as I could and then sprayed some cleaner in the elbow on the other end. I blew through the elbow and it seemed to have a restriction like there's a smaller orifice in the hex part or the fibers are a finer screen. It wasn't plugged solid though.

I put it back together and tried it out. I didn't have to bleed it cause I already had it running. I had the fuel line loose and turned the machine over just to lift the boom a little and it fired so I tightened the fuel line and loosened the injector lines to bleed it. It started right up so I lifted the loader all the way up and put an angle iron on the cylinder. It ran good for 45 minutes this time but then started acting up again. I limped it back to where I could work on it, took an hour to move 1/4 mile! When it would die or almost die, it would have puffs of black smoke for a few seconds then clear up and rev faster. When under a load it would just bog right down. Could it be a check valve problem or in need of a new transfer pump? Never had any problems like this before.

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03-31-2013 13:22:46

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 Re: Cat 3204 running rough in reply to Stick welding, 03-30-2013 19:16:20  
If the screen is staying clear and you have good flow to the transfer pump then I'd say the transfer pump is the problem... Check for a bleeder on the filter housing if there's none on the pump manifold. Open the bleeder and see if it will shoot fuel when you crank. It should...


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03-30-2013 19:55:55

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 Re: Cat 3204 running rough in reply to Stick welding, 03-30-2013 19:16:20  
I am going to pull my transfer pump apart as a cat mechanic told me the check valves and/or springs inside can get gunked up and the springs can corrode and break.said it was common on the Mitsubishi transfer pumps.

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Stick welding

03-30-2013 19:19:57

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 Re: Cat 3204 running rough in reply to Stick welding, 03-30-2013 19:16:20  
Forgot to mention I took the screen back off and it was clean with no more fibers in it.

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Stick welding

03-29-2013 21:14:36

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 Re: Cat 3204 running rough in reply to RodInNS, 03-29-2013 19:51:33  
I've ran it out of fuel before and it wasn't too involved to prime. The fuel lines all look the same size. The fuel pump is on the bottom of the injection pump. I'll take the longer hex piece off and clean the screen. It's the lower fitting. Some of the fuel lines are hard to follow because they go behind the filter. When I emptied the old filter, the fuel was green colored, then black colored when almost empty. The green color might have been from the fuel conditioner and the black maybe from dirt that had been filtered? It has an 8D battery but it's getting old. I can boost it though for faster cranking.

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03-30-2013 05:59:20

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 Re: Cat 3204 running rough in reply to Stick welding, 03-29-2013 21:14:36  
What vintage is this machine? It may have a different pump than the sleeve metered job on mine... but I've never found it easy to bleed when it's actually out of fuel. If you catch it and stop when it gets the staggers, you can clean the screen and it will restart without bleeding, but if it full out quits... it will take a while.

I'd say the black slime, etc is the result of water and probably algae in the tank. Dunno about the green.... unless it's dye in the fuel. Around here some suppliers like Ultramar dye their road fuel green.... and I mean GREEN like St. Patty's day beer.


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Stick welding

03-30-2013 11:04:56

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 Re: Cat 3204 running rough in reply to RodInNS, 03-30-2013 05:59:20  
It's a Japan built 1986 with the improved 3204 DI. I think the fuel conditioner was a green color and the black maybe from dirt the filter picked up? Before when it quit loosening the injector lines on the pump was enough to get it going again. The fact I had it running when I last parked it and it started right up yesterday after sitting for a couple weeks would indicate something may be blocking fuel flow. I think if it had a leak somewhere it wouldn't have started so easily after sitting. I'll clean the screens at the lift pump and the fuel shut off and see if that's the problem.

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03-30-2013 06:09:00

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 Re: Cat 3204 running rough in reply to RodInNS, 03-30-2013 05:59:20  
I have always bled my filter by the method in my maintenance manual--the top of the filter housing has a bleeder screw on the left side . I open that and let gravity feed until no air bubbles. Never had to crack an injector.

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03-30-2013 17:20:48

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 Re: Cat 3204 running rough in reply to dpendzic, 03-30-2013 06:09:00  
Mine doesn't have a filter bleeder that I can recall. It wouldn't much matter if it did or not. Even bleeding the top of the pump manifold is insufficient when it really air locks... Mine is an 87 D4H with the Mitsu/3204T


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03-30-2013 17:49:28

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 Re: Cat 3204 running rough in reply to RodInNS, 03-30-2013 17:20:48  
yep--lots of different arrangements--mine is a 1987 D3b, Mitsubishi, engine serial 45v51332, arrangement 2w7487.
no primer pump, filter bled, constant fuel delivery problems since i bought it in 2008
can"t find any way to get to a possible screen in the fuel tank

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