Installation of 3208T Remanufactured Engine for Industrial, Truck and Electrical Power Generation (EPG) Engines{1200} Caterpillar


Installation of 3208T Remanufactured Engine for Industrial, Truck and Electrical Power Generation (EPG) Engines{1200}

Usage:

0R1150, 0R1151, 0R1152, 0R1154 and 0R3687 Remanufactured Engine

Introduction

This instruction contains adaptability and installation information for the Remanufactured Engines listed in the chart that follows.

NOTE: If the engine or the block is to be used for a core credit, refer to:

Reference: *PEGP7818-01 ... Core Acceptance Criteria (Engines) ...

and/or

*PEGP7825-01 ... Core Acceptance Criteria (Short Block)

Reference Literature

Exchange of Parts

Each Remanufactured Engine is built to a reference engine arrangement, as given in the chart above.

No modification or parts exchange is necessary if the replacement engine arrangement is the same as the original engine arrangement.

Some modification or parts exchange may be necessary when the Remanufactured Engine reference arrangement number is different than the original engine arrangement number.

Use the reference literature when necessary to exchange parts between the original and new engine.

NOTE: Although some of the parts on the new engine may be different from those on the original engine, an exchange may NOT be necessary, depending upon the specific application.

In some installations it may be more advantageous to make minor modifications to the machine frame or engine mounting rails, rather than to exchange components between the Remanufactured Engine and the original engine.

Before installation of the Remanufactured Engine, make sure the flywheel housing, flywheel and vibration damper/crankshaft pulley are compatible with your application.

Each Remanufactured Engine is rated at a specific power rating at a specific rpm.

The Remanufactured Engine that is to be installed will not necessarily have the same kW (Hp)/rpm rating as the original engine that it is replacing.

The kW (Hp)/rpm rating setting(s) of the Remanufactured Engine can be adjusted to the same kW (Hp)/rpm rating as the original engine.

NOTE: Do NOT change/adjust any fuel setting(s) before referring to the:

* FUEL SETTING INFORMATION LIBRARY ... and/or
* FUEL SETTING AND RELATED INFORMATION microfiche.

For maximum life of the Caterpillar Remanufactured Engine, the following components MUST be inspected for reusability before installation:

Air Compressor

The engine oil is the source of lubrication and must be inspected for contamination as foreign material from a failure of the former engine can decrease engine life.

Worn air compressors can be a source of high oil consumption by pumping oil into the engine air intake pipe, or the vehicle's air tanks.

Air Cleaner

The engine air inlet system should be inspected and components replaced if worn:

* Install a new air filter element.
* Install all hoses and clamps as necessary.
* Inspect air inlet piping and connections for leaks.
* Repair or replace as required.

Radiator

* Clean and/or flush as required.
* Inspect for exterior fin damage.
* Inspect for leaks.
* Install new hoses and clamps.

Viscous Fan Clutch (If equipped)

If the engine is equipped with a viscous fan clutch:

* Inspect for leaks.
* Check fan speed to be sure of proper operation.

Water Separator (Recommended)

Some of the Remanufactured Engines that come from the factory may NOT have a factory installed water separator.

However, it is a Caterpillar recommendation that a water separator be installed.

Inspect the original water separator for reusability or replace as needed.

If the original is used, refer to the Operation & Maintenance Manual before installation.

Oil Pan

Compare the oil pan configuration on the Remanufactured Engine with that of the original engine.

If they are different:

* The oil pan from the remanufactured engine must be changed to match the original engine.
* If the oil pan is changed:
* The oil pump suction bell must be changed to fit the oil pan sump location.
* The dipstick and guide tube may also need to be changed and/or recalibrated for a particular application.

Fuel System

Compare power ratings and rpm settings on the engine information plate of the Remanufactured Engine to the information with the same settings of the original engine.

If the settings are different:

* Some fuel system adjustment(s) must be made.

If a part(s) change or fuel setting is required, for a specific engine application, refer to the:

* Fuel Setting Information Library ... and/or
* Fuel Setting and Related Information Library
* Parts Book1
* Service Manual


1The engine arrangement number, stamped on the 9L6531 Engine Information Plate, can also be used to reference the Parts Book for the parts required within a specific engine arrangement.

NOTE: Whenever engines are reset to new specifications, a 4W5140 Plate stamped with the NEW specifications, MUST be installed over a portion of the original engine's 9L6531 Engine Information Plate.

Refer to:

* Service Magazine ... March 5, 1984
* Engine News ... April 7, 1984
* Truck Engine News ... April 4, 1984.

Flywheel

The original engine flywheel must be removed, cleaned and inspected for reusability.

If the original flywheel can not be used again, refer to the specific Parts Book to find the correct part number flywheel to use.

Install the flywheel on the Remanufactured Engine and tighten the bolts to the correct torque.

Refer to the Service Manual for the torque specifications.


NOTICE

The 0R3687 Remanufactured Engine features a 3 ring piston design, a different damper and a DIFFERENT flywheel than the original engine with the 2 ring piston design.

The 0R3687 Remanufactured Engine is equipped with the new damper only. The reuse of the original flywheel, installed onto a 0R3687 Remanufactured Engine, can cause vibrational problems.

While general experience says any vibration problems should be minimal, the reuse of the original should be the customers decision.

Caterpillar does NOT assume any responsibility for ANY subsequent damage and/or repairs traceable to the reuse of the original flywheel or similar design flywheel installed onto a 0R3687 Remanufactured Engine.


Refer to Truck Engine News ... June 1989, for a listing of the part numbers of flywheels used with the 3 ring design piston.

Governor (Accelerator) Control

Remove the governor (accelerator) control from the original and install onto the Remanufactured Engine.

Refer to the Service Manual for correct adjustment.

Remove any remaining componets, alternator, starter motor etc., from the original engine and inspect for reusability.

The componets, if not in acceptable condition for reuse, should be reconditioned, or replaced with new or remanufactured parts.

Turbocharger (Identification)

The type (early model ... later model) turbocharger MUST be identified before any turbocharger or componets are exchanged/transferred.

Early Model Turbocharger


Example of early model design turbocharger. Reference (E) is the rear face of the flywheel housing.

Some early model engines have a turbocharger (1) that fastens to a mounting bracket (2).

The Mounting bracket is installed in the vee of the cylinder block.

Later model engines have the turbocharger installed in the vee, but it fastens directly to the cylinder block and mounting bracket (2) is not needed.

Later Model Turbocharger


Example of later model design turbocharger. Reference (E) is the rear face of the flywheel housing.

All turbocharged Remanufactured Engines will have the later model turbocharger with no mounting bracket.

When a turbocharged Remanufactured Engine is installed as a replacement for an earlier model turbocharged engine, the exhaust pipe-to-turbocharger connection must be modified for the:

* Correct alignment and exhaust pipe size between the exhaust pipe tubing ... and
* The lowered centerline and smaller diameter of the Remanufactured Engine turbocharger.

NOTE: Early model turbochargers require:

* A 101.6 mm (4.00 in) nominal outside diameter exhaust pipe tubing to connect to turbocharger outlet (C).

Later model turbochargers require:

* A 88.90 mm (3.50 in) nominal outside diameter exhaust pipe tubing to connect to turbocharger outlet (D).

Exhaust Manifold

Two different exhaust manifold groups 9N3612 or 1W1448, are used on the later model engines that have the turbocharger fastened directly to the cylinder block (does not have a mounting bracket).

The Remanufactured Engine (EXCEPT 0R3687)1 is built using ONLY the 9N3612 Exhaust Manifold Group.


1The 0R3687 is built with the 1W1448 Exhaust Manifold Group.

The 9N3612 Exhaust Manifold Group includes the necessary parts to connect the exhaust manifolds to the turbocharger:

* 1 each 2W1929 Exhaust Manifold (L.H.)
* 1 each 2W1930 Exhaust Manifold (R.H.) ... and
* 2 each 1W7794 Tube Assemblies (bellows type)

NOTE: In some applications, Ford C Series and International Harvester Trucks, the exhaust manifold on the Remanufactured Engine can have interference with the truck frame.

If the manifold interference occurs in these applications, it may be necessary to remove the manifold from the Remanufactured Engine and install a 1W1448 Exhaust Manifold Group:

* 1 each 2W1931 Exhaust Manifold (L.H.)
* 1 each 2W1932 Exhaust Manifold (R.H.)
* 2 each 1W7793 Tube Assemblies (bellows type)

NOTE: In some applications, an economical decision should be made to either:

* Make minor modifications to the machine frame or engine mounting rails ... or
* Install the 1W1448 Exhaust Manifold Group.

NOTE: For identification purposes, the manifold part number is cast onto the surface of each manifold.

Sperry-New Holland Combines

For Remanufactured Engines that are to be installed in Sperry-New Holland Combines:

* Remove the load stop pin and install a 4W9007 Torque Control Pin (spring end up).
* Remove the torque control group and install an 8N3840 Temperature Compensator Conversion Group.
* Remove the governor outer spring and install the correct outer spring as a replacement.

Refer to:

* Service Magazine ... April 8, 1985
* Engine News ... April, 1985
* Service Manual

0R1150 Remanufactured Engine

This chart can be used as a guide for the parts and configuration differences between the 0R1150 Remanufactured Engine and the original engine arrangement.

0R1151 Remanufactured Engine (California Arrangement)

This chart can be used as a guide for the parts and configuration differences between the 0R1151 Remanufactured Engine and the original engine arrangement.

0R1151 Remanufactured Engine (California Arrangement)

0R1152 Remanufactured Engine

This chart can be used as a guide for the parts and configuration differences between the 0R1152 Remanufactured Engine and the original engine arrangement.

0R1154 Remanufactured Engine

This chart can be used as a guide for the parts and configuration differences between the 0R1152 Remanufactured Engine and the original engine arrangement.

Before Shipment of the Original Engine to the Factory

The engine coolant must be drained from the engine:

* Remove the six engine drain plugs.
* Drain cylinder block.
* Store drain plugs in package and secure with wire to engine.

Install all parts removed from new engine into the original engine.

Caterpillar Information System:

Service Information and Use of 8T5300 Engine Timing Indicator Group{0782} Service Information and Use of 8T5300 Engine Timing Indicator Group{0782}
Use of 8T5200 Signal Generator/Counter Group{0778, 0783, 0785} Use of 8T5200 Signal Generator/Counter Group{0778, 0783, 0785}
Using Caterpillar Cylinder Pack Pulling Tools{1239} Using Caterpillar Cylinder Pack Pulling Tools{1239}
Use And Maintenance Of 8T0910 Fuel Sulfur Analyzer Group{0786, 1280} Use And Maintenance Of 8T0910 Fuel Sulfur Analyzer Group{0786, 1280}
Installation of 3208 Remanufactured Engine (Natural Aspiration) for Industrial, Vehicular or Lift Truck Applications{1000} Installation of 3208 Remanufactured Engine (Natural Aspiration) for Industrial, Vehicular or Lift Truck Applications{1000}
Using The 6V9450 Engine Pressure Group{781} Using The 6V9450 Engine Pressure Group{781}
Installation of 0R2547 Remanufactured 3406 Truck Engine (Arrangement No. 4W2297){1000} Installation of 0R2547 Remanufactured 3406 Truck Engine (Arrangement No. 4W2297){1000}
"A Series" Governor And Air/Fuel Ratio Control Response And Low Power Test{0374} "A Series" Governor And Air/Fuel Ratio Control Response And Low Power Test{0374}
Installation of 7W2743 Speed Switch Assembly{7427} Installation of 7W2743 Speed Switch Assembly{7427}
Installation Of 7W1479 Magneto{1552} Installation Of 7W1479 Magneto{1552}
Crankshaft Cleaning Procedure{1202} Crankshaft Cleaning Procedure{1202}
Fuel System and Fuel Ratio Control Test Procedure{1264, 1278} Fuel System and Fuel Ratio Control Test Procedure{1264, 1278}
Installation Of 8N3945 Bushing In 8N9679 Governor Housing{1287} Installation Of 8N3945 Bushing In 8N9679 Governor Housing{1287}
Converting 3208TA Pleasure Craft Marine Engines From 355BHP To 375BHP{1050, 1251, 1350, 1379} Converting 3208TA Pleasure Craft Marine Engines From 355BHP To 375BHP{1050, 1251, 1350, 1379}
Use Of 8T5120 and 8T5130 Crimp Tool Groups In Either the 7S1100 Press Arrangement or 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Press{0738, 5057} Use Of 8T5120 and 8T5130 Crimp Tool Groups In Either the 7S1100 Press Arrangement or 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Press{0738, 5057}
Using The 8T5230 Air Regulated Wrench Group{0602, 0765} Using The 8T5230 Air Regulated Wrench Group{0602, 0765}
Adding Segment Bolt Holes To General-Purpose Buckets{6818} Adding Segment Bolt Holes To General-Purpose Buckets{6818}
Installation of 3406B Remanufactured Truck Engine in Ford Trucks{1000} Installation of 3406B Remanufactured Truck Engine in Ford Trucks{1000}
Installation of 3406B Remanufactured Truck Engine in Freightliner Trucks{1000} Installation of 3406B Remanufactured Truck Engine in Freightliner Trucks{1000}
Installation of OR1291 or OR1292 Short Block Group{1200} Installation of OR1291 or OR1292 Short Block Group{1200}
Installation of Head Gasket (With New Torque Procedure){1100} Installation of Head Gasket (With New Torque Procedure){1100}
Installation of 0R1160, 0R1161 and 0R1248 Remanufactured Cylinder Head Groups{1100} Installation of 0R1160, 0R1161 and 0R1248 Remanufactured Cylinder Head Groups{1100}
Installation of 0R0918 Remanufactured Oil Pump{1304, 7754} Installation of 0R0918 Remanufactured Oil Pump{1304, 7754}
USING THE FT1984 AIR-TO-AIR AFTERCOOLER LEAK TEST GROUP{1063} USING THE FT1984 AIR-TO-AIR AFTERCOOLER LEAK TEST GROUP{1063}
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