- Caterpillar Products
- All 3200 Engines
Introduction
Revision | Summary of Changes in SEBF8324 |
22 | Combined and SIS authored information from SEBF8057, SEBF8344, SEBF8353, and added 139 illustrations |
© 2018 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part Numbers
This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
Illustration 1 | g02139237 |
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
Illustration 2 | g00008666 |
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Summary
The installation of new fuel system components is often not necessary during a 3208 Engine overhaul. Fuel system components that are used, yet acceptable according to this Guideline, can give the same performance as new components, until the engine's next overhaul.
The information included in this Guideline should serve as an aid in determining whether used components can be used again. Also included in this guideline are salvage (reconditioning) procedures for components such as the governor, fuel pump, housing, fuel injection pump, fuel shutoff housing, and top cover parts that show specific types of wear.
Information on component identification and interchangeability can be found in SEBD1662 Service Magazine article, April 23, 1986.
During salvage procedures, always correct any conditions which could have caused the original failure or wear and never install a component that falls within the "Do Not Use again" criteria
Service Letters and Technical Information Bulletins
NOTICE |
---|
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
References | |
---|---|
Media Number | Title |
SEHS7292 | Tool Operating Manual, "Using the 5P-4150 Nozzle Testing Group" |
SEHS8144 | Specifications, "Nozzle Test Record" |
SEHS8627 | Special Instruction, "Use of 8S-2245 Injection Nozzle Cleaning Tool Group" |
SEHS9031 | Special Instructions, "Storage Procedure for Caterpillar Products" |
SEHS9847 | Special Instruction, "Creating Fuel Pump, and Fuel Nozzle reference Parts for Checking fuel Pump Test Stands and Nozzle Pop Testers". |
SENR6572 | Service Manual, "Zexel Fuel System" for more testing information on the 3064 and the 3066 engines. |
SENR6573 | Service Manual, "Nippondenso Fuel System" for more testing information on the 3064 and the 3066 engines. |
SMHS7760 | Special Instruction, "Use Of FT1525 Alignment Pin, FT1526 Salvage Fixture And FT1698 Bearing Installation Tool For Reconditioning Of 3208 Governor Housings". |
SMHS7897 | Special Instruction, "Use Of 6V4068 Tool Group For Installation Of 9N5822 Thrust Washer". |
Tooling and Equipment
NOTICE |
---|
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Required Tooling and Equipment | |
---|---|
Part Number | Description |
Dial Bore Gauge Kit | |
Drill Bit | |
Drill Bit | |
Automatic Tape Measure | |
Curved Handle Wire Brush | |
Screw Extractor | |
Flashlight | |
Caliper | |
Steel Ruler | |
Seal Pick | |
Polishing Wheel | |
Feeler Gauge | |
Eye Loupe | |
Surface Reconditioning Pad | |
Inspection Mirror | |
Surface Condition Brush | |
Microscope, Pocket
40x |
|
Paper Towel | |
Digital Caliper | |
Level
|
|
Micrometer Tool Set, External |
|
Micrometer Extensions, Internal |
|
Straight Edge | |
Tool Cribbing | |
Digital Caliper
|
|
Micrometer, External |
|
or |
Micrometer, Inside
2.00 - 12.00 inch |
Micrometer, Inside
50 - 300 mm |
|
Micrometer, Outside
0.00 - 4.00 inch |
|
Micrometer, Outside
2.00 - 6.00 inch |
|
Micrometer, Outside
|
|
FT-1525 | Alignment Pin |
FT-1526 | Fixture |
FT-1698 | Driver |
FT-2243 | Weight |
FT-2251 | Shim |
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. |
Measurement Requirements
NOTICE |
---|
Precise measurements shall be made when the component and measurement equipment are at |
Nomenclature
Illustration 3 | g06335502 |
Governor nomenclature (1) Housing (2) Governor Shaft (3) Shaft Thrust Washers (4) Shaft Lever (5) Spring Retainer (6) Dashpot Assembly (7) Dashpot Spool (8) Thrust Collar and Bearing (9) Flyweight Shaft (10) Flyweight Carrier (11) Flyweights (12) Flyweight Shield |
Nomenclature
Illustration 4 | g06338655 |
Fuel pump housing nomenclature (1) Fuel Pump Housing (2) Camshaft (3) Lifter (4) Roller (5) Control Shafts (6) Crossover Levers (7) Sleeve Control Lever (8) Stop Lever Shaft (9) Stop Lever (10) Stop Contact (11) Bellcrank Shaft (12) Bellcrank Lever (13) Spray Shield |
Note: Test the connecting pin of 4N-3922 Crossover Lever Assembly (6) for magnetization. The pin cannot be used again until it has been demagnetized.
Nomenclature
Illustration 5 | g06339167 |
Fuel injection pump nomenclature (1) Plunger and Barrel Assembly (2) Spring (3) Check Valve (4) Clip (5) Bonnet (6) Bushing |
Fuel Shut-Off Housing and Top Cover Parts
Nomenclature
Illustration 6 | g06339231 |
Shut-off housing and top cover nomenclature. (1) Shut-Off Housing (2) Shut-Off Housing Shaft (3) Shut-Off Levers (4) Lock Screws (5) Check Valve (6) Constant Control Bleed Valve (7) Brass Fitting |
Nomenclature
Illustration 7 | g06339275 |
Fuel transfer pump nomenclature. (1) Transfer Pump Housing (2) Transfer Pump Gears (3) Key (4) Tapered Drive Sleeve |
Governor Housing
Illustration 8 | g06335509 |
Bolt hole in the ear of the governor housing has a large crack. |
Use Again - after the part is reworked.
Illustration 9 | g06335516 |
Typical wear on the guide tube. No wear edge can be felt with a fingernail. |
Use Again
Illustration 10 | g06335521 |
Porosity holes in the bearing bore. |
Use Again
Illustration 11 | g06335526 |
The spool has rusted in the tube and will not move. Do not remove the spool because the housing cannot be reused. |
Do Not Use Again
Illustration 12 | g06335530 |
Maximum acceptable amount of wear on the bottom of the governor housing. |
Use Again
Illustration 13 | g06335587 |
Heavy wear on the base of the governor housing |
Governor Shaft
Illustration 14 | g06335615 |
Light wear in the bearing area. No wear step can be felt with a fingernail. |
Use Again
Illustration 15 | g06335631 |
Heavy wear in the bearing area. |
Use Again - after it is reworked.
Note: Heavy wear is normally limited to the end of the shaft.
Governor Shaft Thrust Washers
Illustration 16 | g06335760 |
Thrust washer edges have been worn sharp. |
Do Not Use Again
Illustration 17 | g06335767 |
Examples of normal wear show no sharp edges and no wear steps that can be felt with a fingernail. |
Governor Shaft Lever
Illustration 18 | g06335772 |
Small cracks between bolt holes. |
Use Again
Illustration 19 | g06338601 |
Normal wear on the contact feet shows no flat surfaces. |
Use Again
Illustration 20 | g06338605 |
Flat areas on the contact feet. |
Do Not Use Again
Illustration 21 | g06338608 |
Surface of the contact feet is not even. |
Do Not Use Again
Note: Some governor shaft levers are plated. If pieces of the plating have broken away, do not use the shaft levers again.
Governor Spring Retainer
Illustration 22 | g06338611 |
Heavy wear which can be felt with a fingernail. |
Do Not Use Again
Illustration 23 | g06338616 |
Governor spring retainer. (B) Heavy wear on the surface. (C) Normal wear and no wear step can be felt with a fingernail. |
Do Not Use Again - if wear can be felt with a fingernail.
Governor Dashpot Assembly
Illustration 24 | g06338622 |
Spool valve will not move because of rust. |
Do Not Use Again
Note: The spool valve must move freely to be used again.
Governor Thrust Collar and Bearing
Illustration 25 | g06338625 |
Heavy wear. |
Use Again - after removing both races and the bearing), turn them over as a unit. Check the bearing rollers for flat areas, then reinstall.
Illustration 26 | g06338628 |
Turn over the races and the bearing. |
Illustration 27 | g06338632 |
Governor thrust collar and bearing (B) ( C) Heavier wear |
Do Not Use Again - if wear can be felt with a fingernail.
Governor Flyweight Shaft
Illustration 28 | g06338635 |
Bent shaft |
Do Not Use Again
Illustration 29 | g06338636 |
Normal wear. No wear steps can be felt with a fingernail |
Use Again
Note: Discoloration of the shaft does not indicate a problem.
Governor Flyweight Carrier
Illustration 30 | g06338637 |
Wear has elongated the shape of the pin hole from round to oval. |
Do Not Use Again
Illustration 31 | g06338639 |
Dowel was not correctly installed, but dowel slot is not damaged. |
Governor Flyweight
Illustration 32 | g06338643 |
Wear in the center of the flyweight is acceptable, but it can be an indication of wear in the pin holes of the flyweight carrier. |
Use Again
Illustration 33 | g06338647 |
Heavy wear on flyweight toes. Flat surfaces are worn across the toes. |
Governor Flyweight Shield
Illustration 34 | g06338651 |
Dents in the shield (arrows (A) and (B)). (C) Indentation, refer to the note below. |
Do Not Use Again
Note: Flyweight shields with two small indentations (C) 180 degrees apart can be used again if the flyweight shields are carefully removed and the indentations are not damaged. Flyweight shields that do not have the two small indentations must not be used again.
Fuel Pump Housing
Illustration 35 | g06338669 |
Measure camshaft bearings. |
Use Again - if the inside diameter of the large bearing is
Illustration 36 | g06338681 |
Make a thorough visual inspection of the housing. |
Illustration 37 | g06338685 |
Worn thrust face. |
Use Again - if it can be salvaged according to Special Instruction, SMHS7897, "Use of 6V-4068 Tool Group for Installation of 9N-5822 Thrust Washer".
Note: Some housings with heavy wear on the thrust face cannot be salvaged with the 6V-4068 Tool Group. These housings can be salvaged if the bore is machined oversize, a sleeve is installed, and the bore and thrust face are machined back to the correct size. With any thrust face damage, look closely at the lifter bores for additional damage. Remember to install the new 7W-6335 Steel Backed Sleeve Bearing in the drive end of the fuel injection pump housing to reduce the possibility of sleeve bearing rotation.
Illustration 38 | g06338692 |
Typical wear on the lifter bore |
Use Again - if wear on the lifter bore cannot be felt with the fingertip
Illustration 39 | g06338697 |
Lifter has turned and will not move in the bore. |
Do Not Use Again
Illustration 40 | g06338708 |
Lifter has turned and damaged the bore. |
Do Not Use Again
Illustration 41 | g06338714 |
Typical lifter bore damage. |
Do Not Use Again
Illustration 42 | g06338715 |
Damaged lifter bore caused by a broken guide pin. |
Do Not Use Again
Illustration 43 | g06338719 |
Typical wear patterns caused by the injection pump spring. No wear step can be seen. |
Use Again
Illustration 44 | g06338726 |
Typical wear of the bypass valve seat. |
Use Again
Illustration 45 | g06338732 |
Broken lifter guide. |
Camshaft
Illustration 46 | g06338741 |
Light metal smearing of the thrust face. |
Use Again - after all high areas are removed with a hard stone and the thrust face is polished with a 6V-6147 Polishing Wheel.
Illustration 47 | g06338746 |
Heavy metal smearing of the thrust face. |
Do Not Use Again
Illustration 48 | g06338750 |
Acceptable wear. |
Use Again - after the lobe is polished with a 6V-6147 Polishing Wheel and has a minimum Rockwell hardness of C59. Use a Shore Scleroscope to check hardness.
Illustration 49 | g06338752 |
Light lobe wear. |
Use Again - after the lobe is polished with a 6V-6147 Polishing Wheel.
Illustration 50 | g06338772 |
Mild lobe damage has been removed with a |
Use Again
Illustration 51 | g06338774 |
Damage on lobe can easily be seen. |
Do Not Use Again - unless the lobe has a Rockwell C59 minimum hardness after it is welded and ground. Use a Shore Scleroscope to check hardness.
Illustration 52 | g06338777 |
Light seal wear. |
Use Again
Illustration 53 | g06338780 |
Heavy seal wear. |
Use Again - after the area is polished with a 6V-6147 Polishing Wheel.
Illustration 54 | g06338781 |
Sharp edges caused by heavy seal wear have been removed with a |
Illustration 55 | g06338783 |
Light rust and bearing journal wear. |
Use Again - after the area is polished with a 6V-6147 Polishing Wheel.
Illustration 56 | g06338785 |
Rust and scoring |
Use Again - only if the rust and scoring are removed with a 6V-6147 Polishing Wheel.
Illustration 57 | g06338795 |
Light damage to serrations |
Use Again
Illustration 58 | g06338799 |
Heavy damage to serrations. |
Lifters
Illustration 59 | g06338805 |
Spalling on the skirt. |
Do Not Use Again
Illustration 60 | g06338849 |
Spalling on the skirt. |
Do Not Use Again
Illustration 61 | g06338859 |
Plunger lifter contact area. |
(A) Normal wear. No wear step can be felt with fingernail. - Use Again
(B) Heavier wear. No wear step can be felt with a fingernail. - Use Again
(C) Scuffing and small wear step can be felt with a fingernail. - Do Not Use Again
(D) Heavy wear and wear step can be felt with a fingernail. - Do Not Use Again
Illustration 62 | g06338875 |
Plunger lifter contact area. |
(A) Heavy metal smearing - Do Not Use Again
(B) Light scoring and light smearing - Do Not Use Again
(C) Light scoring and no metal smearing - Use Again
(D) Normal wear - Use Again
Illustration 63 | g06338881 |
Skirt wear. |
Use Again
Illustration 64 | g06338887 |
Skirt wear. |
Use Again
Illustration 65 | g06338891 |
Rust deposits. Do not polish |
Do Not Use Again
Illustration 66 | g06338901 |
Rust deposits. Do not polish |
Rollers
Illustration 67 | g06338903 |
Examples of roller wear. |
(A) Normal wear - Use Again
(B) Scoring - Do Not Use Again
(C) Pitting - Do Not Use Again
Control Shafts
Illustration 68 | g06338908 |
Measure spring tension of the break-over lever with an FT-2243 Weight. The FT-2243 Weight should be |
Use Again - if the lever does not break open.
Cross-Over Levers
Illustration 69 | g06338914 |
Small crack is visible. |
Do Not Use Again
Illustration 70 | g06338917 |
Wear between flats. |
Sleeve Control Levers
Illustration 71 | g06338921 |
Normal wear |
Use Again
Illustration 72 | g06338926 |
Normal wear. No wear step can be felt with a fingernail. |
Use Again
Illustration 73 | g06338929 |
Small wear step can be felt with a fingernail. |
Do Not Use Again
Illustration 74 | g06338930 |
Heavy wear step. |
Do Not Use Again
Illustration 75 | g06338932 |
Cracked sleeve control lever. |
Stop Lever Shaft
Illustration 76 | g06339112 |
Normal wear. No wear step can be felt with a fingernail. |
Stop Lever
Illustration 77 | g06339120 |
Examples of stop pin contact area |
(A) and (B), acceptable wear - Use Again
(C) Heavy wear - Do Not Use Again
Illustration 78 | g06339124 |
Examples of dashpot contact area. |
(A) and (B), acceptable wear - Use Again
(C) Heavy wear - Do Not Use Again
Stop Contact
Illustration 79 | g06339135 |
Examples of stop contact wear. |
(A) Contact surface is not even - Do Not Use Again
Bellcrank Shaft
Illustration 80 | g06339140 |
Normal wear. Shafts are not bent and no wear step can be felt with a fingernail. |
Bellcrank Lever
Illustration 81 | g06339141 |
Nicks in the bellcrank lever. |
Use Again
Illustration 82 | g06339143 |
Flat areas are indications of wear on the ball. |
Do Not Use Again
Illustration 83 | g06339147 |
Heavy wear on the foot. |
Spray Shield
Illustration 84 | g06339151 |
Dents and cracks on the spray shields. |
Do Not Use Again
Illustration 85 | g06339153 |
Gradual loss of material caused by spill port pressure pulses at the end of injection. |
Plunger and Barrel Assembly
Illustration 86 | g06339176 |
Use a strong light and a magnifier to inspect plunger and barrel assembly. |
Illustration 87 | g06339182 |
Material broken away from around the spill port. |
Do Not Use Again
Illustration 88 | g06339186 |
Fine scratches along the length of the plunger. |
Do Not Use Again
Illustration 89 | g06339191 |
Examples of dulling on the plunger. |
(A) Heavy dulling - Do Not Use Again
(B) Very light dulling - Use Again
Illustration 90 | g06339194 |
Scoring width is |
Illustration 91 | g06339195 |
Rust and pits on the plunger. |
Do Not Use Again
Illustration 92 | g06339198 |
Checking fit for sleeve, plunger, and barrel. |
Do Not Use Again - if the fit is too loose, the fit is too tight, the parts will not move, or there are any nicks on the plunger and /or inside the sleeve or barrel.
Note: To check the way the sleeve, plunger, and barrel fit, hold the part as shown and check to see how loose or tight the fit feels. Make sure that the part has enough lubrication on it before checking the fit.
Illustration 93 | g06339201 |
Typical wear patterns on the barrel. |
Use Again
Illustration 94 | g06339204 |
Metal has smeared. |
Springs
Illustration 95 | g06339210 |
Maximum amount of acceptable wear on the spring. |
Use Again
Illustration 96 | g06339214 |
Heavy wear on the spring. |
Do Not Use Again - if two or more coils are worn flat or if the coil shows heavy scoring.
Illustration 97 | g06339217 |
Heavy wear and scoring on the spring. |
Check Valve
Illustration 98 | g06339220 |
Damaged check valves. (A) Scratches and nicks (B) Wear edge |
Clips
Illustration 99 | g06339222 |
Examples of clips. |
(A) Normal Clip - Use Again
(B) Broken clip - Do Not Use Again
Bonnets
Illustration 100 | g06339223 |
Pitting under the flange of the bonnet. |
Do Not Use Again
Illustration 101 | g06339225 |
Scoring in the bottom of the bonnet. |
Use Again - if the diameter of the hole does not look much smaller.
Bushings
Illustration 102 | g06339228 |
Damaged serrations. |
Do Not Use Again
Illustration 103 | g06339230 |
Damaged threads |
Do Not Use Again
Note: If there is metal smearing on the bottom surface, or any surface of the bushing that is not even, do not use again.
Shut-off Housing
Illustration 104 | g06339232 |
Broken housing. |
Shut-Off Housing Shaft
Illustration 105 | g06339235 |
Three examples of wear in the bearing area. |
(A) Acceptable amount of wear - Use Again - no polishing necessary
(B) Heavier wear - Use Again - after polishing
(C) Very heavy wear - Do Not Use Again
Illustration 106 | g06339245 |
Four examples of wear in the seal area. |
(A) Typical wear - Use Again - after polishing
(B) Acceptable wear - Use Again - no polishing is necessary
(C) Typical wear - Use Again - after polishing
(D) Heavy wear. Deep wear groove is visible - Do Not Use Again
Shut-Off Levers
Illustration 107 | g06339248 |
Four examples of wear in the solenoid contact area. |
(A) (B) (C) Acceptable wear - Use Again
(D) Heavy wear - Do Not Use Again
Illustration 108 | g06339249 |
Four examples of wear in the pin contact area |
(A) (B) Acceptable wear - Use Again
(C) (D) Heavy wear - Do Not Use Again
Illustration 109 | g06339252 |
Use a ruler to check the straightness of the lever. |
Use Again - if the lever lies flat against the ruler.
Illustration 110 | g06339254 |
Lever is bent. |
Use Again - after the lever has been straightened. Check for cracks after straightening.
Shut-Off Lever Screws
Illustration 111 | g06339258 |
Self-locking screw with nylon plug. |
Use Again - only with 9S-3263 Loctite Compound.
Check Valve
Illustration 112 | g06339261 |
Typical condition of check valve. Install new check valve only during a complete overhaul. |
Constant Control Bleed Valve and Drain Fitting
Illustration 113 | g06339270 |
Install new constant control bleed valve and/or brass drain fitting only if it is damaged or bent. The ones shown above have no damage. |
Transfer Pump Housing
Illustration 114 | g06339285 |
Normal amount of wear. |
Use Again
Illustration 115 | g06339289 |
Porosity hole in the casting. |
Use Again
Illustration 116 | g06339292 |
Damage on the face caused by action of the large gear. |
Do Not Use Again
Illustration 117 | g06339295 |
Damage in the bore caused by misalignment during assembly. |
Use Again - after it is salvaged.
Illustration 118 | g06339300 |
Wear on the lower surface (between the two lines) caused by action of the large gear. |
Use Again - As is, but only if no sharp edge can be felt with a finger. If a sharp edge can be felt, use again after it is salvaged.
Illustration 119 | g06339302 |
Check for a sharp edge. |
Transfer Pump Gears
Illustration 120 | g06339308 |
Wear on the side of the gear teeth. |
Use Again
Illustration 121 | g06339310 |
Heavy wear on one side of the keyway |
Do Not Use Again
Illustration 122 | g06339312 |
Wear on both sides of the keyway. |
Keys
Illustration 123 | g06339317 |
Four examples of wear on keys |
(A) Small amount of wear on the side and top of the key - Use Again
(B) Heavy wear on one side has worn the key near the edge of the pin. Wear on the top is not heavy - Do Not Use Again
(C) Heavy wear on one side has worn the key near the edge of the pin. Wear on the top is heavy - Do Not Use Again
(D) Very heavy wear on the one side and top of the key - Do Not Use Again
Tapered Drive Sleeves
Illustration 124 | g06339327 |
Example of normal wear. |
Use Again
Illustration 125 | g06339330 |
Example of normal wear and some nicks |
Use Again
Illustration 126 | g06339332 |
Example of light scoring |
Use Again - after scoring is removed with a 6V-6147 Polishing Wheel.
Illustration 127 | g06339335 |
Example of heavy damage |
Do Not Use Again
Illustration 128 | g06339337 |
This type of damage is an indication there was not enough contact area for the camshaft serrations. |
Do Not Use Again
Illustration 129 | g06339338 |
More than one set of serrations is an indication that the drive sleeve has been reused. |
Do Not Use Again - because a drive sleeve should only be reused once.
Illustration 130 | g06339340 |
Single set of serrations. |
Improved Fuel Pump Plunger Helps Prevent Plunger and Sleeve Scuffing
Illustration 131 | g06339206 |
Improved (A) and former (B) fuel pump plungers. |
The fuel pump plunger used in the 1W-3010 Fuel Injection Pump Assembly for SMFS governor and fuel injection pump groups has been improved. The improvements include balance grooves as shown in Illustration 131. The balance grooves help prevent plunger and sleeve scuffing associated with poor quality fuels. Plunger scuffing can cause governor instability due to the change in fuel delivery from one cylinder to another or from increased sleeve to plunger friction.
The new plungers can be used on the following machines: 225 (51U), 225B (2ZD), 225D (2SJ), 229 (1GF), 231D (5WJ, 1NK) Excavators, 227 (10W) Loggers, and 613C (92X) Wheel Tractors.
Salvage Procedures for Governor Housing
Illustration 132 | g06335592 |
(A) FT-1698 Driver
(B) FT-1525 Alignment Pin (C) FT-1526 Fixture |
Illustration 133 | g06335595 |
Fabricate and install an aluminum shim after machining the base of the governor (refer to FT-2251 Shim, Governor Housing for machining specifications). |
Three areas of the governor housing can be salvaged; the cracked bolt holes in the ear (refer to Illustration 8), the bottom of the housing (refer to Illustration 13), and the governor shaft bores.
- To salvage bolt holes in the ear of the housing that have cracks or are broken, weld the area with aluminum weld material and redrill the bolt hole.
- To salvage the bottom of the housing, remove the locating dowel in the bottom of the base, machine up to
1.58 mm (0.06220 inch) from the original face, and install a fabricated aluminum shim (Illustration 13). - To salvage governor shaft bores that show wear, install governor shaft bushings according to Special Instruction, SMHS7760, "Use of FT-1525 Alignment Pin and FT-1526 Salvage Fixture for Reconditioning of 3208 Governor Housings".
Salvage Procedure for Governor Shaft
- Fabricate a sleeve from
17.46 mm (0.68740 inch) diameter steel tubing with3.18 mm (0.12520 inch) wall thickness. - Remove the lever.
- Machine the end of the shaft for a light press fit with the sleeve.
- Install the sleeve.
- Machine the sleeve to a diameter of
154.88 ± 0.008 mm (6.09763 ± 0.00031 inch) . - Install the lever. Be sure that the lever is installed in the correct relation to the two bolt holes.
Salvage Procedure for Fuel Transfer Pump Housing
Use the procedure that follows to salvage fuel transfer pump housings that have damage to the bore caused by the large gear.
- Install the housing in a chuck on a lathe.
Show/hide table
Illustration 134 g06339306 Show/hide tableNOTICE Never remove any metal from the bottom face (C).
- Use an indicator to put diameter (A), Illustration 134) of the housing alignment with the centerline of the lathe chuck.
- Machine
3.05 mm (0.12008 inch) from gear bore diameter (B), Illustration 134). - Put a thin layer of Belzona Molecular Release Agent on the bottom face (C) and outer face (D) of the housing to prevent adhesion (permanent contact) with the Belzona Molecular Metal. Allow the Belzona Molecular Release Agent to dry for ten minutes.
- Add Belzona Molecular Metal to gear bore diameter (B).
- Machine gear bore diameter (B).
Tamper Resistant Plugs and Bolts
Illustration 135 | g06339384 |
Locations of the new |
The 3208 Commercial Engines will have the new
Removal and Installation Procedure
If an adjustment is required with tamper resistant bolts, the bolts must be removed. Use the procedure that follows to remove the tamper resistant bolts.
- Use a 1U-5592 Drill Bit (118 degree) or a 1U-5634 Drill Bit (135 degree split point) to drill a 7/64 inch hole in the center of the bolt to be removed.
- Use a 4C-3365 Screw Extractor (5/32 - 7/32 inch), in the hole drilled in Step 1, to remove the bolt.
- When installing a new tamper resistant bolt, tighten the bolt until the bolt head shears off (approximately
12 ± 3 N·m (8.85072 ± 2.21268 lb ft) for 1/4 inch diameter tamper resistant bolts, or25 ± 6 N·m (18.43900 ± 4.42536 lb ft) for 5/16 inch diameter tamper resistant bolts).
Orifice Reverse Flow Check Valve
Illustration 136 | g06339351 |
Comparison of the fuel injection valves. (A) Valve (orifice delivery valve) (B) Valve assembly (orifice reverse-flow check valve) |
Engine Serial Numbers | ||
---|---|---|
Application | Effective Serial No. | Adaptable To |
Marine (1)(TA) | 01Z-11361 | 01Z4042-11360 |
Remanufactured | 93Z-3721 | 93Z1551-3720 |
(1) | Not applicable to the turbocharged only marine (01Z) or the NA marine (75V). |
Valve assembly (B) prevents compression gases from entering the nozzle and fuel lines if the nozzle sticks open due to debris. In most situations, this will allow the next injection stroke(s) to clear the debris from the nozzle.
Valves (A) would not prevent gases from entering the nozzle or fuel lines if the nozzle stuck open due to debris, and the debris could not be cleared out by more injection strokes.
The 1W-6987 Valve Assembly (ORFC) is effective with the engines listed in Table 4. It can be used as a direct replacement for the former 4W-5869 Valve (ODV). These engines have the Cat 7000 Series Nozzles, except for the turbocharged-aftercooled (TA) marine engine. The valves are also identified by notches on the sides of the external fuel line nuts. Change valves only in complete sets.
Governor Housing Check Valve
Illustration 137 | g06339356 |
Location of check valve added to the governor housing. (1) New valve assembly (2) |
The check valve limits the pump suction pressure inside the cavity and prevents entry of air by the shaft seal. This minimizes the possibility of low power and hard starting.
The 9Y-4966 Valve Assembly is effective with 3208 Marine Engines, 75V9816 and 01Z15404.
The valve can be installed in the governor housing on earlier engines by reaming out the existing hole near the main shaft seal, as shown in Illustration 137. The valve is preset to open at the proper suction pressure and this setting should not be changed
Fuel Injection Pump Housing Sleeve Bearings
A sleeve bearing is used in the drive end of the fuel injection pump housings used on all 3208 Engines equipped with sleeve metering fuel systems. The 5P-4810 Sleeve Bearing was all bronze. The direct replacement 7W-6335 Sleeve Bearing has steel-backed bronze construction and a slightly larger outside diameter. These changes will produce a tighter fit in the fuel injection pump housings and reduce the possibility of sleeve bearing rotation in the housing.
Shut-Off Group
Illustration 138 | g06339369 |
Location where 1/4-28 threaded rod can be installed to push the solenoid plunger down to shut off fuel and stop the engine. (1) Rubber boot (2) 1/4-28 threaded hole in top of solenoid plunger |
Components of the 7C-0948 Electrical Shut-Off (24 volt) | ||
---|---|---|
Quantity | Part Number | Description |
1 | Solenoid Assembly | |
1 | Wire Assembly | |
2 | Bolt | |
1 | Gasket | |
1 | Diode |
Components of the 7C-0949 Electrical Shut-Off (12 volt) | ||
---|---|---|
Quantity | Part Number | Description |
1 | Solenoid Assembly | |
1 | Wire Assembly | |
2 | Bolt | |
1 | Gasket |
Electric Shut-Off Groups With Manual Override
Electrical shut-off groups, 12 and 24 volt, with manual override are available on 3208 Marine Engines with energize-to-shut-off fuel solenoid as an attachment. The 7C-0948 Electrical Shut-Off (24 volt) and 7C-0949 Electrical Shut-Off(12 volt) are direct replacements for the earlier shut-off groups.
The manual override feature enables the engine to be shut off in the event of an electrical or solenoid malfunction. The top of the plungers in the new solenoids has internal 1/4-28 threads (2), Illustration 138. A threaded rod can be installed in the top of the plunger through a hole in the rubber boot. The threaded rod can be pushed down to shut off the fuel and stop the engine.
Lines and Nozzles
Illustration 139 | g06339371 |
Typical location of fuel injection line clamps. (1) Typical fuel injection line clamp with rubber damper. (2) Typical metal-to-metal fuel injection line clamp. |
Fuel Injection Line Clamps
After repairs, some fuel injection line clamps are being incorrectly tightened. These clamps, fasten two, or more fuel injection lines together to help reduce vibration. Refer to Illustration 138. It is important to use the correct tightening torque to prevent distortion of the clamps and to make sure that the clamps stay tight. Engines with metal-to-metal clamps should be tightened to
NOTICE |
---|
Over-tightening a metal-to-metal clamp can result in distorting the clamp and decreasing the clamping ability. Do not reuse distorted metal-to-metal clamps. |
Note: The 6V-4980 Torque Screwdriver Tool is available for tightening small fasteners up to
Some early model engines used clamps with rubber dampers that should be tightened to
Bleed Screw Washer (Seal)
Illustration 140 | g06339374 |
Location of washer (1) under the nozzle bleed screw (3208 Engine shown). (1) Replace washer (seal) under bleed screw. |
Anytime the bleed screw on the side of 7000 Series Fuel Nozzles is removed or loosened, it is important to replace the washer (seal) under this screw with a new washer. Refer to Illustration 140. There have been several documented cases where the bleed screw leaked because its washer was not replaced after the screw was removed for service work
Refer to the applicable parts book for the correct washer part number. Tighten the bleed screw to
"Special instruction"SEHS7292, "Use of 5P-4150 Nozzle Testing Group and 8S-2245 Cleaning Kit" also states that a new washer (seal) should be used. Make a special note in this Special Instruction and in the other publications or wall charts.
Compression Seal Washer (Gas Seal)
Compression Seal Washer Identification | ||||
---|---|---|---|---|
Engine | Fuel Nozzle Part Number | Washer Part Number | Material | Thickness |
3208 | Copper | |
||
3208 | Copper | |
The Caterpillar 7000 Series Fuel Injection Nozzle is used on many direct injection 3200 Engines. This nozzle is identified as the 7000 Series because the last four digits of the part number begin with the number 7.
Most of the compression seal washers used on these nozzles have now been changed to a copper material. The nylon compression seal washers could lose a small amount of thickness because of installation force and operating temperatures. The copper compression seal washers provide a more consistent holding force. Table 7 provides the new compression seal washers and provides seal identification for each fuel nozzle and engine application. The compression seal washer, the carbon dam (seal), and the bleed screw seal washer should be replaced each time the nozzle is tested.
Bleed Screw
Illustration 141 | g06339379 |
Bleed screw identification (1) "Torx" socket head screw (2) Hex socket head bleed screw |
If a bleed screw (1) is damaged or lost, replace it with an 8C-3234 Screw ('Torx' socket head). The installation torque of the 8C-3234 Screw is