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Caterpillar 3208 GEN SET ENGINE 30A — Disassembly and Assembly

For the Caterpillar 3208 GEN SET ENGINE 30A.

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Before you start

  • NOTE: The following photos show a TYPICAL EXAMPLE and are not an exact representation of the
  • NOTE: The fuel injection pump housing has a thrust washer for the fuel injection pump camshaft. The
  • NOTE: Any time the drive sleeve is removed from the camshaft, a new one must be installed. The
  • NOTE: The fuel injection pump camshaft must be held in toward the fuel transfer pump during
  • NOTE: A new drive sleeve must be installed because a used drive sleeve can slip on the camshaft.

Procedure

  1. 1. Install the fuel injection pump housing on tool (A).
  2. 2. Remove seven bolts (1) and governor housing (2).
  3. 3. Remove the plug from the cover, and install tool (B) in the hole as shown. Turn the injection pump
  4. 5. Remove four bolts (5) and fuel transfer pump body (6) from the housing.
  5. 6. Disconnect drain line (7) from the fitting on the back of fuel transfer pump body.
  6. 8. Remove seals (10) from the pump body.
  7. 9. Remove drive gear (11) and the key from the camshaft.
  8. 1. Install key (1) and drive gear (2) on the shaft.
  9. 2. Put No. 3 Aviation Permatex on the outside diameter of the seals for body (3).
  10. 3. Use tooling (B) to install the first seal in the body with the lip down and the second seal with the lip
  11. 4. Remove the extra permatex from the body and seals after installation. Be sure the drain hole between
  12. 6. Install tool (C) in the end of the fuel injection pump camshaft. Connect drain line (6) to the fitting on
  13. 7. Install tool (E) in the camshaft so it will not turn.
  14. 8. Put a new sleeve (7) on the camshaft.
  15. 9. Tighten the sleeve into position on the shaft with the 4B4280 Washer of tooling (D) approximately
  16. 10. Use a feeler gauge to check the end play of the camshaft after the sleeve is installed. The end play of
  17. 11. Remove tool (E) from camshaft.
  18. 12. Be sure the governor springs and gasket are in position on governor housing (8). Install the governor
  19. 13. Be sure bolt (9) has the washer and O-ring seal on it when installed.
  20. 14. Remove the fuel injection pump housing from tool (A).

Specs & torque values

  • 11/2 in.)
  • up. Install the first seal to a depth of 11.51 + 0.25 mm (.453 + .010 in.) and the second seal to a depth of
  • 0.76 +: 0.25 mm (.030 + .010 in.).
  • 6.4 mm (.25 in.). Tighten the sleeve the remainder of the way with the 9N5022 Washer until the sleeve
  • the camshaft must be 0.58 + 0.46 mm (.023 + .018 in.).

Source: manual:3208 Fuel Transfer Pump Removal.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.