Caterpillar 3208 Series Diesel Engines Repair Service Manual
Complete service repair manual for Caterpillar 3208 Diesel Engines (GENERATOR SET ENGINE, INDUSTRIAL ENGINE, MACHINE ENGINE, TRUCK ENGINE, MARINE ENGINE), with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Caterpillar 3208 Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines).pdf
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines).pdf
SEBR541 - Service Manual (3208 Diesel Truck Engine).pdf
SEBR0541 - Service Manual (3208 Diesel Truck Engine).pdf
SEBU6090 - Engine Safety (3208 Marine Engine).pdf
SEBU6090 - Maintenance Intervals (3208 Marine Engine).pdf
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display).pdf
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products).pdf
SENR2131 - Specifications (3208 Marine Engine).pdf
SENR2132 - Systems Operation (3208 Marine Engine).pdf
SENR2132 - Testing & Adjusting (3208 Marine Engine).pdf
SENR2133 - Specifications (3208 Marine Engine Attachments).pdf
SENR2134 - Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 - Testing & Adjusting (3208 Marine Engine Attachments).pdf
SENR2135 - Disassembly and Assembly (3208 Marine Engine).pdf
SENR2995 - Product Safety.pdf
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products).pdf
SENR3130 - Torque Specifications.pdf
SENR3581 - Disassembly and Assembly (3208 Marine Engine).pdf
SENR3581 - Specifications (3208 Marine Engine).pdf
SENR3581 - Systems Operation (3208 Marine Engine).pdf
SENR3581 - Testing and Adjusting (3208 Marine Engine).pdf
SENR3581 - Troubleshooting (3208 Marine Engine).pdf
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols.pdf
SENR4606 - Specifications (3208 INDUSTRIAL & MARINE ENGINES).pdf
SENR4607 - Systems Operation (3208 INDUSTRIAL & MARINE ENGINES).pdf
SENR4607 - Testing & Adjusting (3208 INDUSTRIAL & MARINE ENGINES).pdf
SENR4631 - Disassembly and Assembly (3208 INDUSTRIAL & MARINE ENGINES).pdf
SENR7089 - Systems Operation (3208 INDUSTRIAL & MARINE ENGINES ATTACHMENTS).pdf
SENR7089 - Testing & Adjusting (3208 INDUSTRIAL & MARINE ENGINES ATTACHMENTS).pdf
SENR7090 - Specifications (3208 INDUSTRIAL AND MARINE ENGINE ATTACHMENTS).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
UENR3262 - Disassembly & Assembly - Seal Installation.pdf
PRODUCT DETAILS:
Total Pages: 2,431 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
ENGINE - GENERATOR SET
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF
ENGINE - INDUSTRIAL
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC
ENGINE - MACHINE
Model Prefix
3208 ENGINE - MACHINE 03Z
3208 ENGINE - MACHINE 79V
3208 ENGINE - MACHINE 90N
3208 ENGINE - MACHINE 93Z
ENGINE - TRUCK
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z
MARINE PRODUCTS
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V
MAIN SECTIONS
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)......3
Abbreviations and Symbols......4
ETR Component Descriptions......13
ETR Introduction......26
ETR Junction Box-Switchgear Not Required (OP,WT)......28
ETR Junction Box-Switchgear Not Required (OP,WT,OS)......45
ETR Junction Box-Switchgear Required (OP,WT,OS)......70
Junction Box and Enclosure Group......94
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)......99
Crank Terminate Speed Calibration......100
Diode Test......102
Electric Protection System Functional Test......103
Engine Oil Pressure Switch Test......106
General Testing and Adjusting Information......108
General Troubleshooting Information......111
Magnetic Pickup Test......112
Oil Step Speed Calibration......115
Overspeed Calibration......117
Overspeed Verification Test......119
Slave Relay Test......121
Troubleshooting the ETR Full Protective System (OP, WT, OS)......123
Troubleshooting the ETR Partial Protection System (OP, WT)......137
Water Temperature Contactor Switch Test......146
SEBR0541 - Service Manual (3208 Diesel Truck Engine)......148
Cover - Introduction......149
Part 1 Specifications......163
Part 2 System Operation......204
Part 3 Testing and Adjusting......236
Part 4 Troubleshooting Guide......281
Part 5 General Instructions Disassembly and Reassembly......327
Part 6 Disassembly and Reassembly......336
Part 7 Air Compressors......447
Part 8 Reconditioning Procedures......471
SEBR541 - Service Manual (3208 Diesel Truck Engine)......501
Cover - Introduction......502
Part 1 Specifications......516
Part 2 System Operation......557
Part 3 Testing and Adjusting......589
Part 4 Troubleshooting Guide......634
Part 5 General Instructions Disassembly and Reassembly......680
Part 6 Disassembly and Reassembly......689
Part 7 Air Compressors......800
Part 8 Reconditioning Procedures......824
SEBU6090 - Engine Safety (3208 Marine Engine)......854
SEBU6090 - Maintenance Intervals (3208 Marine Engine)......863
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display)......914
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products)......998
Basic Circuit Theory......999
Basic Electrical Components......1010
Battery......1039
Charging System......1058
Circuit Voltage......1085
Electrical Measurement......1093
Electrical Schematic......1106
Electricity - How It Works......1113
Magnetism......1127
Ohms Law......1136
Solid State Electrical Components......1144
Starting System......1160
SENR2131 - Specifications (3208 Marine Engine)......1179
Aftercooler......1181
Air Inlet Manifold......1183
Alternators And Regulators......1185
Automatic Timing Advance Unit......1190
Bearings For Connecting Rods And Mains......1191
Belt Tension Chart......1193
Camshaft......1194
Connecting Rod......1197
Crankshaft Seals......1199
Crankshaft......1201
Cylinder Block......1203
Cylinder Head......1206
Drive Gear For The Injection Pump......1210
Electric Starter Motor......1212
Engine Design......1218
Engine Oil Cooler And Filter......1219
Flywheel Housing Bore......1221
Flywheel Housing Runout......1224
Flywheel Housing......1226
Flywheel Runout......1229
Flywheel......1232
Fuel Filter Base......1234
Fuel Injection Nozzles......1236
Fuel Injection Pump......1239
Fuel Transfer Pump......1242
Governor......1244
Introduction......1246
Oil Filter Group......1247
Oil Level Gauge......1248
Oil Pan......1250
Oil Pump......1251
Pistons And Rings......1254
Pulley And Damper Group......1260
Shutoff Solenoids......1264
Turbochargers......1266
Valve Covers......1272
Valve Rocker Arms And Lifters......1273
Valve Seats And Inserts......1275
Valves......1278
Water Cooled Exhaust Manifold......1281
Water Pump......1283
Water Temperature Regulators......1285
SENR2132 - Systems Operation (3208 Marine Engine)......1287
SENR2132 - Testing & Adjusting (3208 Marine Engine)......1337
SENR2133 - Specifications (3208 Marine Engine Attachments)......1418
Ammeters......1419
Circuit Breakers......1420
Control Relay......1422
Cooling System Pressure Cap......1423
Digital Tachometer......1424
Expansion Tank......1425
Indicators For Engine Oil Pressure......1426
Indicators For Gear Oil Pressure......1428
Indicators For Transmission Oil Pressure......1430
Indicators For Water Temperature......1431
Instrument Panel (Single & Dual Station Application)......1434
Introduction......1436
Jacket Water Heaters......1437
Junction Box......1438
Magnetic Pickup......1439
Magnetic Starting Switch Assembly......1440
Marine Gear Oil Cooler......1442
Pressure Switches......1444
Sea Water Pump......1447
Sending Units For Oil Pressure......1448
Sending Units For Water Temperature......1452
Service Meters......1454
Tachometer Calibration Chart......1455
Temperature Sensors......1456
Water Temperature Switches......1457
SENR2134 - Systems Operation (3208 Marine Engine Attachments)......1459
SENR2134 - Testing & Adjusting (3208 Marine Engine Attachments)......1472
SENR2135 - Disassembly and Assembly (3208 Marine Engine)......1480
Automatic Timing Advance......1482
Bearing Clearances......1485
Camshaft & Gears......1487
Camshaft Bearings......1492
Check Valve & Bypass Valve......1495
Connecting Rod Bearings......1497
Crankcase Ventilator......1499
Crankshaft & Gear......1500
Crankshaft Front Seal......1504
Crankshaft Main Bearings......1506
Crankshaft Pulley......1509
Crankshaft Rear Seal & Wear Sleeve......1511
Cylinder Head Assemblies......1514
Disassemble & Assemble Governor......1524
Engine Oil Cooler......1527
Exhaust Manifolds......1531
Expansion Tank & Heat Exchanger......1535
Flywheel Housing......1537
Flywheel......1539
Fuel Filter Base 2......1541
Fuel Injection Lines......1543
Fuel Injection Nozzles......1545
Fuel Injection Pump Housing & Governor......1553
Fuel Injection Pump Housing......1563
Fuel Injection Pumps......1567
Fuel Transfer Pump......1571
Marine Transmission......1574
Oil Filter Base 1......1576
Oil Pan......1578
Oil Pump & Relief Valve......1580
Pistons & Connecting Rod Assemblies......1584
Raw Water Aftercooler & Air Inlet Manifold......1590
Raw Water Pump......1593
Rocker Shaft Assemblies & Push Rods......1602
Shutoff Housing......1605
Timing Gear Cover & Oil Pump......1608
Turbocharger......1611
Valve Covers......1619
Valve Lifters......1621
Water Pump......1623
Water Temperature Regulators......1629
SENR2995 - Product Safety......1631
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products)......1639
SENR3130 - Torque Specifications......1659
Air Brake Fittings......1660
Air Conditioning Fittings......1662
Bulkhead Nuts......1664
English (SAE) Fasteners......1667
Flare Fittings......1672
General Information......1676
Ground Engaging Tool (G.E.T.) Fasteners......1679
Hose Clamps......1681
Installation of Fittings......1684
Metric (ISO) Fasteners......1688
Miscellaneous Fittings......1694
O-Ring Face Seal Fittings......1696
Plugs......1698
Straight Thread O-Ring Fittings......1702
Tapered Pipe Thread Fittings......1707
SENR3581 - Disassembly and Assembly (3208 Marine Engine)......1709
General Information......1710
Starting Motor - Assemble - 37-MT and 41-MT......1713
Starting Motor - Assemble - 42-MT......1721
Starting Motor - Disassemble - 37-MT and 41-MT......1727
Starting Motor - Disassemble - 42-MT......1734
SENR3581 - Specifications (3208 Marine Engine)......1740
SENR3581 - Systems Operation (3208 Marine Engine)......1757
Component Description......1758
General Information......1764
Normal Operation......1766
SENR3581 - Testing and Adjusting (3208 Marine Engine)......1777
Brush and Brush Holder - Check......1778
No Load - Test......1781
Pinion Clearance - Adjust......1784
Starting Motor Solenoid - Test......1799
SENR3581 - Troubleshooting (3208 Marine Engine)......1806
Engine Does Not Crank with Starting Motor On and Pinion Engaging Ring Gear......1807
General Information......1811
Service Tools......1814
Starting Motor Does Not Turn or Turns Slowly......1815
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols......1820
Electrical Power Graphic Symbols......1821
Fluid Power Graphic Symbols......1829
SENR4606 - Specifications (3208 INDUSTRIAL & MARINE ENGINES)......1850
Air Inlet Manifold......1852
Alternators And Regulators......1853
Automatic Timing Advance Unit......1865
Bearings For Connecting Rods And Mains......1866
Belt Tension Chart......1868
Camshaft......1869
Connecting Rod......1871
Crankcase Ventilation Valve......1873
Crankshaft Seals......1875
Crankshaft......1877
Cylinder Block......1879
Cylinder Head......1882
Drive Gear For The Injection Pump......1886
Electric Starter Motor......1888
Engine Design......1893
Engine Oil Cooler And Filter......1894
Exhaust Manifolds......1897
Flywheel Housing Bore......1899
Flywheel Housing Runout......1902
Flywheel Runout......1904
Flywheel......1907
Fuel Filter Base......1909
Fuel Injection Nozzles......1911
Fuel Injection Pump......1914
Fuel Temperature Compensating Torque Control Group......1917
Fuel Transfer Pump......1918
Governor......1920
Introduction......1922
Oil Level Gauge......1923
Oil Pans......1924
Oil Pump......1926
Pistons And Rings......1931
Pulley And Damper......1934
Regulator......1935
Shutoff Solenoids......1936
Turbocharger......1938
Valve Covers......1940
Valve Rocker Arms And Lifters......1941
Valve Seats And Inserts......1943
Valves......1949
Water Pump......1955
Water Temperature Regulator......1956
SENR4607 - Systems Operation (3208 INDUSTRIAL & MARINE ENGINES)......1957
SENR4607 - Testing & Adjusting (3208 INDUSTRIAL & MARINE ENGINES)......2014
SENR4631 - Disassembly and Assembly (3208 INDUSTRIAL & MARINE ENGINES)......2095
Air Inlet Manifold......2097
Automatic Timing Advance......2101
Bearing Clearances......2104
Camshaft & Gears......2106
Camshaft Bearings......2110
Check Valve & Bypass Valve......2112
Connecting Rod Bearings......2114
Crankcase Ventilator Valve......2116
Crankshaft & Gear......2119
Crankshaft Front Seal......2123
Crankshaft Main Bearings......2125
Crankshaft Pulley......2128
Crankshaft Rear Seal & Wear Sleeve......2132
Cylinder Head Assemblies......2135
Engine Oil Cooler......2144
Exhaust Manifolds......2147
Expansion Tank & Heat Exchanger......2152
Flywheel Housing......2155
Flywheel......2156
Fuel Filter Base......2158
Fuel Injection Lines......2160
Fuel Injection Nozzles......2163
Fuel Injection Pump Housing & Governor......2171
Fuel Injection Pump Housing......2187
Fuel Injection Pumps......2190
Fuel Return Manifolds......2194
Fuel Transfer Pump......2195
Governor......2198
Marine Transmission......2200
Oil Filter Base & Engine Oil Cooler......2202
Oil Filter Base......2207
Oil Pan......2209
Oil Pump & Relief Valve......2211
Pistons & Connecting Rod Assemblies......2218
Rocker Shaft Assemblies & Push Rods......2226
Rocker Shaft Assemblies......2227
Sea Water Pump......2229
Shutoff Housing......2240
Timing Gear Cover & Oil Pump......2243
Turbocharger (Marine Engine)......2250
Valve Covers......2258
Valve Lifters......2260
Water Pump......2261
Water Temperature Regulators......2270
SENR7089 - Systems Operation (3208 INDUSTRIAL & MARINE ENGINES ATTACHMENTS)......2272
SENR7089 - Testing & Adjusting (3208 INDUSTRIAL & MARINE ENGINES ATTACHMENTS)......2282
SENR7090 - Specifications (3208 INDUSTRIAL AND MARINE ENGINE ATTACHMENTS)......2306
Air Compressor......2307
Ammeters......2308
Circuit Breaker......2309
Cooling System Pressure Cap......2311
Digital Tachometer......2312
Engine Support Group......2313
Expansion Tank......2314
Fan Mounting Pulley Assemblies......2316
Fuel Pressure Indicator......2318
Indicators For Engine Oil Pressure......2319
Indicators For Water Temperature......2324
Instrument Panel (Single & Dual Station Application)......2328
Introduction......2330
Jacket Water Heaters......2331
Magnetic Pickup......2333
Mounting Group For AT540, MT643, And MT653 Allison Transmission......2334
Power Takeoff Clutches......2336
Pressure Switches......2340
Rear Stub Shaft......2344
Sending Units For Oil Pressure......2345
Sending Units For Water Temperature......2350
Service Meters......2352
Starter Magnetic Switch......2353
Tachometer Calibration Chart SMCS - 1000; 7405......2355
Temperature Sensors......2356
Water Separator......2357
Water Temperature Switches......2358
Spec+Sheets Cat+3208+Propulsion......2360
Spec+Sheets+-+Cat+3208+Propulsion......2364
UENR3262 - Disassembly & Assembly - Seal Installation......2368
Duo-Cone Seals - Install......2369
Lip Type Seals - Install......2397
O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY O-RINGS & OTHER O-RING APPLICATIONS......2406
Caterpillar 3208 Series Diesel Engines Repair Service Manual
