Usage:
BEFORE DOING ANY WORK ON THE ENGINES:
* Find the part number and the arrangement number of the remanufactured (new) engine on the caution and information plate on the top of the right rocker-arm cover, or the right side of the block.
* Find the arrangement number of the core (old) engine on the caution and information plate on top of one of the rocker-arm covers, or the right side of the block.
* See the INDEX on pages 2 and 3 to find the page number for your conversion. Make the conversion according to the instructions opposite the old engine arrangement number in the left column.
* Read the conversion instructions carefully. Since one remanufactured engine arrangement is a replacement for several old engine arrangements, some item exchanges will not be necessary. Example: If the flywheel housing number in the new engine arrangement is different than the flywheel housing number on your old engine, the conversion instructions will tell you to exchange the housings. Check the housing carefully. An exchange may not be necessary in your specific application.
BEFORE RETURN SHIPMENT OF THE OLD ENGINE TO THE FACTORY:
* Remove the drain plugs. Make sure all of the coolant is removed from the engine. Do not install the plugs back in the engine. Make a package for storage of the plugs. Use wire to fasten the package to the engine.
* All parts removed from the new engine must be installed on the old engine.
NOTE: Sometimes it is necessary, by law, to keep the sound suppression material on the rocker-arm covers and the block. The rocker-arm covers on the old engine can be cleaned and exchanged with the covers on the new engine. The sound suppression material on the block can be removed and installed on the new engine.
IMPORTANT: * Water separators are to be used with all 3208 remanufactured engines to protect the engines from contaminated fuel.
* The new engine as sent from the factory will not necessarily have the same BHP (brake horse-power) as your old engine. The correct low-idle and high-idle rpm, and fuel rack settings are in the book, RACK SETTING INFORMATION.
| NOTICE |
|---|
To prevent oil leaks when a flywheel with eight bolt holes is assembled to a crankshaft flange that has ten holes, two A2291 Screws (or two 7/16"-20 × .62" screws with no head) are needed; put 9S3263 Thread Lock on the threads and install the screws in the extra holes of the flange, so both ends of the screws are below the inner and outer surfaces of the flange. |
NOTE: For easy reference of related engine parts, fold out page 36.
Index
Industrial Engines
Marine Engines
*New engine arrangements as sent from the factory. No conversion will be necessary.
Remanufactured Engine Part Number R684 - Arrangement Number 6N2892
Remanufactured Engine Part Number R685 - Arrangement Number 6N2900
Remanufactured Engine Part Number R686 - Arrangement Number 6N2899
Remanufactured Engine Part Number R689 - Arrangement Number 6N2898
Remanufactured Engine Part Number R693 - Arrangement Number 6N3030
Remanufactured Engine Part Number R714 - Arrangement Number 6N7273
Remanufactured Engine Part Number R723 - Arrangement Number 6N780
Remanufactured Engine Part Number R777 - Arrangement Number 6N2903
1. LEFT ROCKER-ARM COVER
2. RIGHT ROCKER-ARM COVER
3. PCV VALVE
4. AIR INLET PIPE
5. PCV VALVE CLAMP
6. LEFT LIFTING BRACKET
7. RIGHT LIFTING BRACKET
8. ENGINE OIL PAN
9. OIL LEVEL GAUGE
10. OIL LEVEL GAUGE GUIDE
11. OIL LEVEL GAUGE GUIDE ASSEMBLY
12. OIL PORT CORK
13. OIL PORT PLUG
14. INLET OIL SUCTION PIPE
15. INLET WATER ELBOW
16. SHUNT LINE WATER CONNECTOR
17. FUEL FILTER
18. OIL FILLER CAP
19. ENGINE FRONT SUPPORT
20. OUTLET WATER CONNECTOR
21. AIR CLEANER ADAPTER
22. LEFT EXHAUST MANIFOLD
23. RIGHT EXHAUST MANIFOLD
24. FLYWHEEL HOUSING
25. OIL FILTERS
26. OIL COOLER COVER
27. OIL COOLER BASE
28. WATER LINE HOSE
29. WATER LINE HOSE
30. WATER LINE ELBOW
31. WATER PUMP PULLEY
A. WATER LINE NIPPLE (Location)
NOTE: For maximum life of the Caterpillar remanufactured engine, be sure that the following components are checked during installation:
Air Compressor
As the air compressor uses engine oil, be sure it is clean inside. Foreign material from the former engine can decrease engine life.
Air Cleaner
Install new element in the air cleaner. Install hoses and clamps. Inspect all of the tubes for leaks.
Radiator
Make sure that the radiator is clean inside and outside. Install new hoses and clamps. Check for leaks.