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Product: GAS ENGINE

Model: G3306 GAS ENGINE 68D
Configuration: G333C OR 3306 ENGINE 68D00001-UP

Reuse And Salvage Guidelines

Specifications To Machine Reaction Faces For Flywheel Assemblies on 3208 Engines
Media Number -SEBF8050-04 Publication Date -21/09/2004 Date Updated -21/09/2004

SEBF80500001

Specifications To Machine Reaction Faces For Flywheel Assemblies on 3208 Engines

SMCS - 1156

SEBF8050-04

CATERPILLAR® September 2004

SMCS Code: 1156

GUIDELINE FOR

REUSABLE PARTS

AND SALVAGE OPERATIONS

Specifications To Machine Reaction Faces For Flywheel Assemblies On
3208 Engines

SUMMARY OF REVISIONS

Page Description

All Revised format.

1 Added definition of “Minimum “Use

Again” Thickness” to General
Tolerances.
2
Revised Chart 1. Part numbers have
been added and removed.
3
Revised Chart 2. Removed footnote
2 and part numbers have been added
4 and removed.

Added definition of Dimensions A

and B to Illustration 4 caption.

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Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and
salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the Company
makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information available from
Caterpillar to ensure such changes and improvements are incorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer Support
(309) 494-1934.

Summary

Reaction faces of 3208 Engine flywheels can become damaged through normal wear and/or clutch damage. If the damage is light, the flywheel can
be used again after the reaction face is measured, and if necessary, machined according to the specifications given in this guideline. If the damage
is heavy and machining will not remove the damage, the flywheel cannot be used again.

When replacement parts are required for

this product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type,
strength and material.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury or death.

Flywheel Balance
The flywheels for 3208 Engines have a programmed unbalance and require that bob weights be used for checking flywheel balance. The crankshaft, front pulley and flywheel are
individually unbalanced and, when assembled, are balanced assemblies.

General Tolerances
Remove the flywheel from the engine. Clean the flywheel in a petroleum-based solvent. The flywheel must be free of dirt and oil prior to inspection.

Next, visually inspect the flywheel using a strong light source, as it may otherwise be difficult to distinguish small scratches and cracks. (A liquid
magnetic particle inspection system may also be used to ensure the results.)

The reaction face must have a flatness of 0.05 mm (0.002 inch) and be parallel by no more than 0.13 mm (0.005 inch) to the crankshaft-mounting
surface. Grinding is an acceptable method to obtain this finish and should not cause the flywheel to be rebalanced.

Next, install the flywheel on the engine and check flywheel run out according to the specifications given in the Service Manual.

The definition of Minimum “Use Again” Thickness is the maximum amount of wear permitted when a part is installed again. If the thickness is
less than the dimension given, a new part must be installed.

Surface Finish (All)

After the flywheel has been cleaned, inspected and ground (if necessary), use a surface finish analyzer* to check the surface finish of the reaction face. The surface finish should be similar
to that of a new flywheel. Refer to Chart 1 for surface finish specifications.

*See Guideline For Reusable Parts, SEBF8034-04, for a complete list of surface finish analyzer suppliers.

Chart 1.
Surface Finish Specifications For Reaction
Face

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Reaction Face Maximum

Type Part Number Surface
Finish1

7C-3437 3.5 m (140

CRB2 ”)
9Y-9315

9L-6392 3.5 m (140

RB3 ”)
9Y-9310

9L-6393 3.5 m (140

RB3 ”)
9Y-9311

3N-9439 3.5 m (140

”)

4N-4853 3.5 m (140

”)

5N-4782 6 m (240 ”)

8N-8036 3.5 m (140

Flat-Type ”)

1W-7785 3.5 m (140

CRB2 ”)
9Y-9310

1W-7786 3.5 m (140

CRB2 ”)
9Y-9311

9Y-93104 3.5 m (140

”)

2W-0307 3.5 m (140

CRB2 ”)
9Y-9310

9Y-93114 3.5 m (140

”)

9Y-93154 3.5 m (140

”)

9L-6717 10 m (400
Deep-Type CRB2 ”)
9Y-9314

9L-7484 3.5 m (140

”)

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1N-2987 10 m (400
RB3 ”)
4N-8544

4N-6750 10 m (400
”)

4N-8541 10 m (400
”)

4N-8544 10 m (400
”)

4N-8547 10 m (400
CRB2 ”)
4W-7595

6N-4480 10 m (400
”)

6N-8797 10 m (400
”)

6N-8798 10 m (400
”)

9N-6446 10 m (400
”)

2W-0304 10 m (400
CRB2 ”)
4N-8544

4W-7595 10 m (400
”)

7W-1533 10 m (400
”)

Chart 1. (Continued
Surface Finish Specifications For Reaction
Face

Reaction Face Maximum

Type Part Number Surface
Finish1

Deep-Type 9Y-93144 6 m (240 ”)

Ear-Type 9L-6394 10 m (400

”)

9L-6395 10 m (400
”)

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9L-6396 10 m (400
”)

9L-6397 10 m (400
CRB2 ”)
1W-7787

9N-6449 10 m (400
CRB2 ”)
1W-8577

1W-7787 10 m (400
CRB2 ”)
9Y-9312

1W-8577 10 m (400
CRB2 ”)
9Y-9313

9Y-93124 10 m (400
”)

9Y-93134 10 m (400
”)

1
Maximum roughness.
2
(CRB) Cancelled, Replaced By.
3
(RB) Replaced By.
4
New part since last update.

Tolerances To Machine
Reaction Faces
For the following types of flywheels refer to Chart 2 for part numbers and thickness tolerances for both new and “Use Again” specifications.

Illustration 1

Flat-type flywheel

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Illustration 2

Deep-type flywheel

Illustration 3

Ear-type flywheel

Chart 2.
Tolerances To Machine Reaction Forces

Flywheel Type Part Number Thickness (New)6 Minimum “Use Again”

Thickness6

Flat-type 7C-3437, 9L-6392, 9L

-6393, 38.10  0.25 mm 35.10 mm
3N-9439, 5N-4782, (1.500  0.010 inch) (1.382 inch)
1W-7785,
1W-7786, 2W-0307,
9Y-9310,
9Y-9311, 9Y-9315

4N-4853, 8N-8036 71.42  1.5 mm 68.42 mm

(2.812  0.010 inch) (2.694 inch)

Deep-type 9L-6717, 9L-7484, 1N

-2987,
4N-6750, 4N-8541, 4N -5 -
-8544,
4N-8547, 6N-4480, 6N
-8797,

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6N-8798, 9N-6446,
2W-0304,
4W-7595, 7W-1533,
9Y-9314

Ear-type 9L-6394, 9L-6395, 9L-

6396, 38.10  0.38 mm 36.10 mm
9L-6397, 9N-6449, (1.500  0.015 inch) (1.421 inch)
1W-7787,
1W-8577, 9Y-9312,
9Y-9313

5
Due to the stresses encountered during the resurfacing machining process, Caterpillar does not recommend the reuse of Deep-type flywheels
that prove to require machining.
6
Distance from the crankshaft-mounting surface to the reaction face (Dimension B in Illustration 4 for ear-type flywheels).

Ear-type Flywheels

Illustration 4

Section of ear-type flywheel.

Dimension A: Distance between the reaction face and the top of the ears.

Dimension B: Flywheel thickness.

The ears (surface parallel to the reaction face) must be machined the same amount as the reaction face. The distance between the reaction face and
the top of the ears (Dimension A in Illustration 4) is very important. This distance retains the correct amount of clutch pressure.

Worn areas on the ears can be rebuilt using the welding procedure found in Special Instruction SEHS8652, “Cylinder Block Salvage Procedure,”
Page 3, second column.

Note: Because the flywheel is made of cast iron, a special electrode, 1U-5379 1/8” Weld Rod, must be used.

Manufacturers Of Flywheel
Grinding Equipment

Winona Van Norman

4730 W. Highway 61

Winona, Minnesota 55987

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U.S.A.

Phone: (800) 533-8008

DCM Tech, Inc.

P.O. Box 25

Winona, Minnesota 55987

U.S.A.

Phone: (800) 533-5339

George Olcott Co.

P.O. Box 783

Scottsborough, Alabama 35768

U.S.A.

© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved

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