3208 TRUCK ENGINE Caterpillar


Testing And Adjusting

Usage:



Troubleshooting


NOTICE

If the engine is run when there is a problem (malfunction) with the EGR system, be sure to drain the oil from the engine after the problem (malfunction) has been corrected. Install new oil filters and put new oil in the engine.


EGR Systems

Fuel Setting

5P6577 Fuel Setting Tool Group or5P4203 Sleeve Metering Field Service Tool Group 5P6602 Adapter
3P1565 Collet3P1567 Dial Indicator5P6531 Contact Point, 2.25 in. (57.2 mm) long8S7271 Setscrew5P4205 Wrench1D4533 Bolt1D4538 Bolt3J6956 Spring5P298 Pin (with 17.8507 stamped on it)

The fuel setting procedure that follows can be done with the fuel pump unit on or off the engine.


NOTICE

The outside surfaces of the fuel pump unit must be clean and free of dirt before any service work is done. Dirt that enters the fuel pump unit will cause much damage.


1. Remove EGR switch cover (2) and solenoid (1).


3208 ENGINE FUEL PUMP UNIT
1. Solenoid. 2. EGR Switch cover.


INSTALLATION OF ADAPTER
3. 5P6602 Adapter. 4. 3P1565 Collet. 5. 3J6956 Spring. 6. 5P298 Zero Set Pin (with 17.8507 stamped on it).

2. Install 5P298 zero set pin (6) in hole. Put 3J6956 Spring (5) on pin (6). Install 3P1565 Collet (4) on 5P6602 Adapter (3). Install Adapter (3).

3. Install setscrew (7) in adapter (3).


SETSCREW INSTALLED
7. 8S7271 Setscrew.

4. Use wrench (8) and tighten setscrew (7) until pin (6) is against pump housing. Install dial indicator (9) with 5P6531 Contact Point in collet (4). Move governor control lever (11) to the full load position. Make an adjustment to the dial indicator (move indicator up or down) until both hands are at zero. Tighten nut of collet only enough to hold indicator in position. Loosen lock (10) and turn bezel until large hand is on zero. Tighten lock (10). Use wrench (8) and turn setscrew (7) counterclockwise six turns.


ADJUSTMENT OF DIAL INDICATOR
8. 5P4205 Wrench. 9. 3P1567 Dial Indicator. 10. Lock. 11. Governor control lever.

5. Release governor control lever (11), and move it to low idle position. Connect the wire clip end of a circuit tester to contact (Z) of EGR switch (12). Put the other end of tester to a good ground on fuel pump. Slowly move governor control lever (11) toward high idle position until light in circuit tester just comes on. Do this several times to make sure of the dimension on indicator (9). This dimension is the fuel setting. For the correct fuel setting, see the FUEL SETTING AND RELATED INFORMATION FICHE.


CHECK OF FUEL SETTING
12. EGR switch. 13. Fuel setting adjustment setscrew. Z. Fuel setting contact.

6. If the dimension on indicator (9) is not correct, make an adjustment to fuel setting. Loosen locknut and turn screw (13) until dimension on indicator (9) is correct.

7. When the adjustment is correct, tighten locknut. Check the adjustment by doing steps 1 through 5 again.

NOTE: If an adjustment is made to the fuel setting, check the adjustment for the contacts of the EGR switch. The same tools are used to adjust the contacts of the EGR switch that are used for fuel setting.

Adjustment Of EGR Switch Contacts

NOTE: Make reference to FUEL SETTING for the tools needed for this procedure.

The fuel setting must be correct before an adjustment is made to the EGR switch contacts.

1. Remove EGR switch cover (2) and solenoid (1).


3208 ENGINE FUEL PUMP UNIT
1. Solenoid. 2. EGR Switch cover.

2. Install 5P298 Zero Set Pin (6) in hole. Put 3J6956 Spring (5) on pin (6). Install 3P1565 Collet (4) on 5P6602 Adapter (3). Install adapter (3).

3. Install setscrew (7) in adapter (3).


INSTALLATION OF ADAPTER
3. 5P6602 Adapter. 4. 3P1565 Collet. 5. 3J6956 Spring. 6. 5P298 Zero Set Pin (with 17.8507 stamped on it).


SETSCREW INSTALLED
7.8S7271 Setscrew.

4. Use wrench (8) and tighten setscrew (7) until pin (6) is against pump housing. Install dial indicator (9) with 5P6531 Contact Point in collet (4). Move governor control lever (11) to the full load position. Make an adjustment to the dial indicator (move indicator up or down) until both hands are at zero. Tighten nut of collet only enough to hold indicator in position. Loosen lock (10) and turn bezel until large hand is on zero. Tighten lock (10). Use wrench (8) and turn setscrew (7) counterclockwise six turns.

5. Connect wire clip end of a circuit tester to contact (X) of EGR switch (12). Put the other end of tester to a good ground on fuel pump. Move governor control lever (11) slowly toward high idle position until light in circuit tester just comes on. Do this several times to make sure of the dimension on indicator (9). Compare this measurement to the CONTINUITY CHECK CHART. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct fuel setting.


ADJUSTMENT OF DIAL INDICATOR
8. 5P4205 Wrench. 9. 3P1567 Dial Indicator. 10. Lock. 11. Governor control lever.

6. Connect the wire clip end of a circuit tester to contact (Y) of EGR switch (12). Put the other end of tester to a good ground on fuel pump. Move governor control lever (11) slowly toward high idle position until light in circuit tester just comes on. Do this several times to make sure of the dimension on indicator (9). Compare this measurement to the CONTINUITY CHECK CHART. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct fuel setting.


CHECK OF CONTACT X
12. EGR Switch. X. EGR Contact.


CHECK OF CONTACT Y
12. EGR Switch. Y. EGR Contact.

7. If the X or Y contact adjustment is not correct as shown in the CONTINUITY CHECK CHART, use a socket and make an adjustment. Turn the contacts clockwise to make the indicator reading smaller. After an adjustment is made, do Steps 5 and 6 again to check the setting.

NOTE: If too much adjustment is needed, check to see if the load stop pin is bent. If the load stop pin is bent, replace with a new part. When a new load stop pin is installed, adjust the fuel setting and EGR switch contacts X and Y.


EGR SWITCH POSITIONS
X. EGR contact. Y. EGR contact. Z. Fuel setting contact.

Voltage Check With EGR Switch Cover In Place

D.C. Voltmeter


EGR SWITCH AND COVER ASSEMBLY
1. EGR switch cover. 2. Bullet connector. 3. Female contact. 4. Male contact. 5. Fuse holder. 6. Wire. 7. Spade terminal.


EGR SWITCH COVER
1. EGR switch cover. 2. Bullet connector. 5. Fuse holder. 6. Wire. 7. Spade terminal. 8. Shut-off solenoid.

1. Disconnect spade terminal (7) on wire (6) from shut-off solenoid (8). Remove shut-off solenoid (8).

2. Connect a 12 volt D.C. supply to spade terminal (7) on wire (6) from EGR switch cover (1).

3. Use a D.C. Voltmeter to measure voltage on the solenoids. Connect the positive (+) lead of the voltmeter to the input of the solenoid. Connect the common (-) lead of the voltmeter to a good ground. The solenoids must be in the circuit. The voltage to the solenoids can be measured at the connection of bullet connector (2). Make a small separation of bullet connector (2) from the other connector. Put the sharp end of the positive (+) lead of the voltmeter against the correct contact (3) or (4) in bullet connector (2).

4. With the governor control lever in low idle position, the voltage to the lower solenoid at female contact (3) must show 10 or more volts on the voltmeter. The voltage to the upper solenoid at male contact (4) must show 1.5 or less volts on the voltmeter. The EGR switch, the actuator solenoid voltages, and the EGR valve positions are as shown in Position 1.


(POSITION 1) EGR SWITCH, ACTUATOR SOLENOID VOLTAGES, AND VALVE POSITION AT LOW LOAD
X. EGR contact. Y. EGR contact. Z. Fuel setting contact.

5. With the voltmeter connected to the upper solenoid at male contact (4), move governor control lever until the voltage measurement on the voltmeter makes a change from 1.5 or less to 10 or more volts. With the governor control lever still in this position, the voltage to the lower solenoid at female contact (3) must show 10 or more volts on the voltmeter. The EGR switch, the actuator solenoid voltages, and the EGR valve positions are shown in Position 2.


(POSITION 2) EGR SWITCH, ACTUATOR SOLENOID VOLTAGES, AND VALVE POSITION AT MEDIUM LOAD
X. EGR contact. Y. EGR contact. Z. Fuel setting contact.


(POSITION 3) EGR SWITCH, ACTUATOR SOLENOID VOLTAGES, AND VALVE POSITION AT HIGH LOAD
X. EGR contact. Y. EGR contact. Z. Fuel setting contact.

6. The voltage to the lower solenoid at female contact (3) must show a change on the voltmeter from 10 or more, to 1.5 or less volts when the governor control lever is moved to the high idle position. The EGR switch, the actuator solenoid voltages, and the EGR valve positions are as shown in Position 3.

If the voltmeter does not show the correct voltage to the solenoids, make a test of the EGR switch. If the EGR switch works correctly, make a replacement of EGR switch cover (1).

Adjustment Of Linkage From Actuator To EGR Valve

5P7345 Calibration Gauge

1. Disconnect EGR tube from EGR valve. Disconnect other end of EGR tube from air inlet manifold. Remove EGR tube.


ADJUSTMENT OF LINKAGE
1. Lever. 2. Rod end. 3. Locknut. 4. Rod.


INSTALLATION OF 5P7345 CALIBRATION GAUGE
1. Lever. 5. 5P7345 Calibration Gauge. 6. EGR Valve.

2. Install 5P7345 Calibration Gauge (5) in small opening in EGR valve (6). Turn lever (1) clockwise and put calibration gauge (5) into opening. Stud on valve (6) goes in hole in calibration gauge (5). Install nut on stud to hold calibration gauge (5) in place.


ADJUSTMENT OF LINKAGE
1. Lever. 2. Rod end. 4. Rod. 5. 5P7345 Calibration Gauge.

3. Loosen locknut (3) on rod (4). Turn rod (4) out of rod end (2) several turns. Then turn rod (4) into rod end (2) until resistance is felt.

4. Tighten locknut (3) to a torque of 63 ± 13 lb. in. (7.0 ± 1.5 N·m).

5. Remove calibration gauge (5) and install EGR tube.

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