Reuse and Salvage of 3208 Engine Sleeve Metering Fuel Systems (SMFS) {0374, 1250} Caterpillar

Caterpillar Products

All 3200 Engines

Introduction

Table 1

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.

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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

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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

Table 2

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

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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.

Table 3

Required Tooling and Equipment
Part Number	Description
1P-3537	Dial Bore Gauge Kit
1U-5592	Drill Bit
1U-5634	Drill Bit
1U-9366	Automatic Tape Measure
1U-9915	Curved Handle Wire Brush
4C-3365	Screw Extractor
4C-9442	Flashlight
4S-9405	Caliper
5P-3920	Steel Ruler
5P-7414	Seal Pick
6V-6147	Polishing Wheel
8H-8581	Feeler Gauge
8S-2257	Eye Loupe
8T-7765	Surface Reconditioning Pad
9U-6182	Inspection Mirror
254-5319	Surface Condition Brush
262-8390	Microscope, Pocket 40x
288-4209	Paper Towel
367-9109	Digital Caliper
385-8484	Level 305 mm (12 inch)
385-4008	Micrometer Tool Set, External 1524 mm (60 inch)
385-9422	Micrometer Extensions, Internal 50 - 609 mm (2 - 24 inch)
386-3364	Straight Edge
420-5317	Tool Cribbing
423-4373	Digital Caliper 0.0 - 203.2 mm (0.00 - 8.00 inch)
431-4150	Micrometer, External 25 mm (1 inch)
473-8688 or 473-8689	Micrometer, Inside 2.00 - 12.00 inch
	Micrometer, Inside 50 - 300 mm
473-8690	Micrometer, Outside 0.00 - 4.00 inch
473-8691	Micrometer, Outside 2.00 - 6.00 inch
473-8691	Micrometer, Outside 50.8 - 152.4 mm (2.00 - 6.00 inch)
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.

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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

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Governor Parts

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

Fuel Pump Housing Parts

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.

Fuel Injection Pump Parts

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

Fuel Transfer Pump Parts

Nomenclature

Illustration 7	g06339275
Fuel transfer pump nomenclature. (1) Transfer Pump Housing (2) Transfer Pump Gears (3) Key (4) Tapered Drive Sleeve

Visual Inspection

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

Use Again

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.

Use Again

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.

Use Again

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.

Do Not Use Again

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 60.389 mm (2.37751 inch) or less and the inside of diameter of the small bearing is 25.438 mm (1.00149 inch) or less.

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.

Do Not Use Again

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 6V-6147 Polishing Wheel.

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 6V-6147 Polishing Wheel.

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.

Do Not Use Again

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

Do Not Use Again

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 255 gram (9 ounce).

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.

Do Not Use Again

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.

Do Not Use Again

Stop Lever Shaft

Illustration 76	g06339112
Normal wear. No wear step can be felt with a fingernail.

Use Again

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

(B) Normal Wear - Use Again

Bellcrank Shaft

Illustration 80	g06339140
Normal wear. Shafts are not bent and no wear step can be felt with a fingernail.

Use Again

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.

Do Not Use Again

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.

Do Not Use Again

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 3.18 mm (0.12520 inch) or more in the area of the spill port.

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.

Do Not Use Again

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.

Do Not Use Again

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.

Do Not Use Again

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.

Do Not Use Again

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.

Use Again

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.

1. 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.

2. 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).

3. 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

1. Fabricate a sleeve from 17.46 mm (0.68740 inch) diameter steel tubing with 3.18 mm (0.12520 inch) wall thickness.

2. Remove the lever.

3. Machine the end of the shaft for a light press fit with the sleeve.

4. Install the sleeve.

5. Machine the sleeve to a diameter of 154.88 ± 0.008 mm (6.09763 ± 0.00031 inch).

6. 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.

1. Install the housing in a chuck on a lathe.
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   Illustration 134	g06339306

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   NOTICE
   Never remove any metal from the bottom face (C).

2. Use an indicator to put diameter (A), Illustration 134) of the housing alignment with the centerline of the lathe chuck.

3. Machine 3.05 mm (0.12008 inch) from gear bore diameter (B), Illustration 134).

4. 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.

5. Add Belzona Molecular Metal to gear bore diameter (B).

6. Machine gear bore diameter (B).

Tamper Resistant Plugs and Bolts

Illustration 135	g06339384
Locations of the new 128-7792 (1) and 128-7795 (2) Tamper Resistant Bolts on 3208 Commercial Engines.

The 3208 Commercial Engines will have the new 128-7792 and 128-7795 Tamper Resistant Bolts on the FRC and cover. Illustration 135 shows the locations of the new tamper resistant bolts.

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.

1. 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.

2. Use a 4C-3365 Screw Extractor (5/32 - 7/32 inch), in the hole drilled in Step 1, to remove the bolt.

3. 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, or 25 ± 6 N·m (18.43900 ± 4.42536 lb ft) for 5/16 inch diameter tamper resistant bolts).

Marine Engine Fuel Systems

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)

Table 4

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) 9.0 ± 0.025 mm (0.35433 ± 0.00098 inch) diameter hole, 23 mm (0.90551 inch) deep.

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

Injection Pump Housing

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

Table 5

Components of the 7C-0948 Electrical Shut-Off (24 volt)
Quantity	Part Number	Description
1	9W-2984	Solenoid Assembly
1	030-6449	Wire Assembly
2	4F-7957	Bolt
1	2W-1706	Gasket
1	1W-9070	Diode

Table 6

Components of the 7C-0949 Electrical Shut-Off (12 volt)
Quantity	Part Number	Description
1	7T-9456	Solenoid Assembly
1	030-6449	Wire Assembly
2	4F-7957	Bolt
1	2W-1706	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 2.3 N·m (20.35672 lb in).

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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 4 N·m (2.95024 lb ft).

Some early model engines used clamps with rubber dampers that should be tightened to 10 N·m (7.37560 lb ft).

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 1.6 ± 0.4 N·m (1.18010 ± 0.29502 lb ft).

"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)

Table 7

Compression Seal Washer Identification
Engine	Fuel Nozzle Part Number	Washer Part Number	Material	Thickness
3208	4W-7016	7W-4485	Copper	1.27 mm (0.05000 inch)
3208	7W-7024	7W-4485	Copper	1.27 mm (0.05000 inch)

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 2.2 ± 0.8 N·m (19.47165 ± 7.08060 lb in).