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Service Manual

C at e r p i l l a r
Service Manual
3306 Engine Diesel
S/n 34N

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF


CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-ENG 3306
FORM NO. REG01349-01
FOR USE IN SERVICE MANUALS:
D4 TRACTOR, REG00632
D4 TRACTOR, SPECIAL APPLICATION,
REG00784
D5 TRACTOR, REG00633
D5 TRACTOR, SPECIAL APPLICATION,
REG00785
D6 TRACTOR, R EG00530
D6 TRACTOR, SPECIAL APPLICATION,
REG00871
D7 TRACTOR, REG00691
D7G TRACTOR, SENR7112
" -........:l:J MOTOR GRADER, REG01544
NO. 12-NO. 14 MOTOR
GRADER, REG00507
NO. 14G MOTOR GRADER, REG01542
NO. 112F MOTOR GRADER, REG00885
120G MOTOR GRADER, REG01654
NO. 120-NO. 140 MOTOR GRADERS,
REG00762
130G-140G MOTOR GRADERS,
REG01652
225 EXCAVATOR, REG01578
235 EXCAVATOR, REG01388
518 SKIDDER, REG00971
528 SKIDDER, REGOl133
561 PIPELAYER, REG00913
571-572 PIPE LAYERS, REG00699
571G-572G PIPELAYERS,SENR7120
627 TRACTOR-SCRAPER, REG00496
627 TRACTOR-SCRAPER, REG01609
637 TRACTOR .sCRAPER, R EG00700
814 TRACTOR, 815-816 COMPACTORS,
REG00786
920-930 WHEEL LOADERS, REG00514
941 TRAXCAVATOR, REG00527
950 WHEEL LOADER, REG00548
951 TRAXCAVATOR, REG00783
955 TRAXCAVATOR, REG00634
966 WHEEL LOADER, REG00484
977 TRAXCAVATOR, REG00635
980 WHEEL LOADER, REG00698

SERVICE MANUAL

3304 & 3306


VEHICLE ENGINES
SERIAL NUMBERS
3304: 78P
3306: 3N
3304 & 3306 VEHICLE ENGINES INDEX

SYSTEMS OPERATION
Air Inlet and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 Governor Operation ................................ 21
Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Engines With Turbochargers .......................... 23 Sleeve Metering Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
Engines Without Turbochargers ............. . . . . . . . . .. 24 Adjustments to the Sleeve Metering Fuel System .......... 15
Timing Gears ..................................... 25 Fuel Flow After Engine Stops Running .......... . .. . . .. 12
Turbocharger .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24 Fuel Flow Using the Priming Pump and Bleed Valve ....... 12
Valves and Valve Mechanisms ......................... 24 Fuel Flow With Engine Running .................. 6, 8, 10
Fuel Injection Pump Operation ..................... 13
Basic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Fuel Priming Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 13
Fuel Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 Fuel System Operation. . . . . . . . . . . . . . . . . . . . . . . . .. . . 15
Coolant for Air Compressor .......................... 29 Fuel System Timing . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. 5
Cooling System Components ......................... 29 Fuel Transfer Pump ................................ 13
Governor ........................................ 18
Electrical System .................................... 31 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 5
Charging System Components ..................... 31, 32 Sleeve Po sition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 14
Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33, 34 Water Separator .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting System Components ........................ , 33
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Fuel Systems (Sleeve Metering & Scroll) .................. , 22
Fuel Injection Valve ............................... , 22 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. 26
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 Lubrication System Components . . . . . . . . . . . . . .. . . . . . .. 26
Oil Flow in the Engine . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. 27
Scroll Fuel System ................................... 20 Oil Flow Through the Oil Filter and Oil Cooler . . .. . . . . . .. 26
Fuel Injection Pump Operation ....................... 20

TESTING AND ADJUSTING


Air Inlet and Exhaust System ........................... 77 Oil Pressure is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 82
Checking Inlet Manifold Pressure At Torque Too Much Bearing Wear ............................. 83
Converter Stall Speed ............................ 77 Too Much Oil Consumption .......................... 82
Crankcase (Crankshaft Compartment) Pressure ........... 78
Cylinder Condition ................................. 78 Scroll Fuel System ................................... 67
Cylinder Head .................................... 80 Accessory Drive Shaft Timing ........................ 71
Measurement of Exhaust Temperatures ................. 78 Check Fuel Injection Pump Lifter
Measurement of Pressure in Inlet Manifold. . . . . . . . . . . . . .. 77 Washer and Pump Plunger ......................... 67
Precombustion Chamber Position ...................... 80 Checking Fuel Injection Pump Timing; On Engine ... 69, 70, 71
Restriction of Air Inlet and Exhaust ................... 77 Checking Fuel Injection Valve ........................ 67
Valve Clearance Setting .......................... 79, 80 Deceleration Control Adjustment ...................... 76
Fuel Bypass Valve ................................. 69
Basic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 89 Fuel Injection Adjustments .......................... 69
Connecting Rods and Main Bearings .................... 89 Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Connecting Rods and Pistons ......................... 89 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90 Fuel Injection Pump Installation ...................... 68
Cylinder Liner Projection ........................... , 89 Fuel Injection Pump Timing Dimension Setting; Off Engine. 71
Flywheel and Flywheel Housing .............. 90,91,92,93 Fuel Injection Service ............................. " 68
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 93 Fuel Injection Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Vibration Damper ................................. 93 Fuel Rack Setting ............................... 72, 73
Fuel Ratio Control Setting .......................... , 74
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 84 Fuel System Adjustments ............................ 69
Checking Coolant Temperatures .................... 84, 85 Governor Adjustments .............................. 74
Checking Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 86 Governor Control and Deceleration Linkage Adjustments ... 75
Checking Pressure Cap or Relief Valve . . . . . . . . . . . . . . . . .. 87 Locating Top Center Position for No.1 Cylinder .......... 69
Checking Radiator Air Flow. . . . . . . . . . . . . . . . . . . . . . . . .. 86 Testing Fuel Injection Equipment ..................... 67
Gauge for Water Temperature ........................ 88 Visual Inspection .................................. 67
Testing the Cooling System .......................... 84
Visual Inspection of the Cooling System ................ 84 Sleeve Metering Fuel System ....................... , . . .. 54
Water Temperature Regulator ........................ 88 Checking Balance Point (Full Load Speed) ............... 60
Checking Timing by Fuel Flow Method ................. 58
Electrical System .................................... 95 Checking Timing by Timing Pin Method ................ 56
Alternator Regulator ............................ 96, 97 Finding Top Center Compression Position
Battery .......................................... 95 for No.1 Piston ................................. 55
Charging System ................................... 95 Fuel Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64
Shutoff Solenoid ................................. 101 Fuel Ratio Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . .. 64
Starting System ................................... 97 Fuel System Adjustments ............................ 56
Fuel System Inspection ............................. 54
Flexible Drive Coupling ............................... 94 Fuel System Setting ................................ 61
Checking Flexible Drive Coupling Alignment . . . . . . . . . . . .. 94 Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59
Testing Fuel Injection Equipment ..................... 54
Lubrication System .................................. , 82
Oil Pressure is High ................................ , 83 Troubleshooting .................................. 35-53

3
ELECTRICAL SYSTEM SYSTEMS OPERATION

The only part in the alternator which has move-


ment is the rotor. The rotor is held in position by a
ball bearing at the drive end and a roller bearing at
the rectifier end.
The compartment for the regulator is sealed.
The regulator controls the alternator output
according to the needs of the battery and the other
components in the electrical system.

Generator

The generator is belt driven by the diesel engine_


The generator keeps the battery charged and GENERATOR REGULATOR
supplies current to operate the electrical com- 1. Cutout relay. 2. Current regulator. 3. Voltage regu-
ponents. lator. 4. Battery terminal. 5. Generator terminal. 6. Field
terminal.
T89405)(1
2
regulator points, opening and closing, controls the
output voltage of the generator. The points can
open and close as often as 200 times per second.

The current regulator limits the current pro-


duced by the generator to allow the generator to
continue producing voltage equal to battery volt-
age. When the generator produces current equal to
the current regulator setting, the regulator contact
points open. Open points lower the generator
4 current. Low current allows the spring to close the
points and generator current is again high. The
CUTAWAY VIEW OF A GENERATOR
opening and closing of the current regulator points,
1. Brush assembly. 2. Field. 3. Commutator. 4. Armature. limits the current produced by the generator. The
Generator Regulator points can open and close as often as 200 times per
second.
The generator regulator controls the output of
the generator. The regulator incorporates three 2
controls: the cutout relay, the voltage regulator
and the current regulator. Each control has contact
points which are operated by electromagnets.

Springs hold the cutout relay points open and


the voltage regulator and current regulator contact
points closed. The spring tension for each unit is a
force opposing the force of the electromagnets.
J J
The cutout relay prevents the battery from
motorizing a generator that is not producing 6 7 8 9 T89407Xl
enough voltage. Generator voltage approximately
REGULATOR WIRING SCHEMATIC
equal to battery voltage will close the cutout relay (Typical "A" Circuit illustrated)
points. This closes the circuit between the gener-
1. Battery. 2. Cutout relay. 3. Current regulator. 4.
ator and the battery. The generator can now Voltage regulator. 5. Generator. 6. Ammeter. 7. Battery
supply the battery and the components of the terminal. 8. Generator terminal. 9. Field terminal.
electrical system with power.

The voltage regulator prevents the generator When generator electric loads are low and the
from producing damaging high voltage. Generator battery requires very little charging, the VOLT-
voltage slightly higher than battery voltage opens AGE REGULATOR contact points are operating.
the regulator points causing the generator output When electric loads are high, the CURRENT
voltage to lower. Low generator voltage allows the REGULATOR contact points are operating. The
spring to close the regulator points and generator contact points of the two units, will never open at
voltage is again high. The action of the voltage the same time.

32
3306 VEHICULAR ENGINE SPECI FICATIONS

CYLINDER LINER

(1) Bore in liner


(new) ..... . 4.751 ± .001 in. (120.68 ± 0.025 mm)

Use again maximum bore when measured


near upper end of the wear surface of the
cylinder liner . . . . . . . . . . . . . . . . . . . . . . 4.755 in. (120.78 mm)
(2) Th ickness of flange
on liner .......... . .4048 ± .0008 in. (10.282 ± 0.020mm)

(3) Put filler band in diesel fuel, then immediately install on the
cylinder liner. Put a thin layer of SAE 30W oil on the band then
immediately install the cylinder liner in the cylinder block before
expansion of the band.
NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS;
PISTONS AND CYLINDER LINERS, Form No. SEBF8001.

CYLINDER LINER PROJECTION

Make reference to CYLINDER LINER PROJECTION in Testing and


Adjusting for the complete procedure.
1. Install tooling as shown. Tighten bolts (1) evenly in four steps:
1st step ................................ 5 lb. ft. (7 N·m)
2nd step .............................. 151b. ft. (20 N·m)
3rd step. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 lb. ft. (35 N·m)
4th step. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50 lb. ft. (70 N'mt
2. Measure cylinder liner projection with dial indicator (7) clamped in
1 P2402 Block (6) as shown. Measure at four places around each
cylinder liner near the clamped area.
Average of four projection
measurements from any cylinder liner
must be ............. .0020 to .0056 in. (0.051 to 0.141 mm)

Maximum permissible difference between all

-----
four measurements ......................001 in. (0.03 mm)
A59800X1 ........
Maximum permissible difference between
average projection of any two
cylinders next to each
other ................................. 001 in. (0.03 mm)

NOTE: If liner projection is not correct, turn the liner to a new


position within the bore. If projection can not be corrected this way,
move the I iner to a different bore. I f the projection can not be
corrected this way, make reference to Special Instruction, Form No.
FM055228 for complete instructions on the use of 8S3140 Counterbor-
ing Tool Arrangement.
(1) Bolts [5/8" NC, 5.5 in. (140 mm) 10ngJ.

(2) Crossbar (from 8B7548 Push-Puller!


SHIM THICKNESS, COLOR CODE, AND PART NUMBER
(3) 4B4281 Washers
.007 in. .008 in. .009 in . .015 in. .030 in .
(4) 1 P2394 Adapter Plate
(0.18 mm) (0.20 mm) (0.23 mm) (0.38 mm) (0.76 mm)
(5) 3H465 Plates
BLACK RED GREEN BROWN BLUE
(6) 1 P2402 Block
8S6045 8S6046 8S6047 8S6048 8S6049
(7) 1 P2403 Dial Indicator

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST


34 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
SLEEVE METERING FUEL SYSTEM TESTING AND ADJUSTING

TIMING PIN COVER

1. Timing pin. 2. Bolt. 4. Cover.

4. Put timing pin (1) in hole (3). Turn the


flywheel slowly in a counterclockwise direc-
tion, as seen from the flywheel end. until
timing pin (I) goes into the notch in the
camshaft.

CAUTION: The flywheel must be turned slowly so


that damage is not done to the fuel system when
the timing pin goes into the notch in the camshaft.

DRIVE GEAR FOR THE FUEL


INJECTION PUMP
5. Bolt.

8. Install tools as shown and loosen the drive gear


for the fuel injection pump from the drive
sleeve for the fuel injection pump.

INSTALLING TIMING PIN

1. Timing pin. 3. Hole for timing pin.

5. Put a 3/8"-16 NC bolt in the timing hole in


the flywheel housing. If the bolt can be
installed in the hole in the flywheel, the timing
of the fuel injection pump is correct.

6. If the bolt does not go into the hole in the


flywheel, remove cover (4) from the front
housing.
7. Loosen bolt (5) holding the drive gear for the PULLER TOOLS INSTALLED
fuel injection pump to the drive sleeve for fuel 6. 8S2264 Puller Group. 7. 8B7560 Step Plate. 8.3/8"-24
injection pump. NF bolts, 3 1/2" long. 9. 3/8" 1.0. Flat washer.

59
SLEEVE METERING FUEL SYSTEM TESTING AND ADJUSTING

11. Install a 3/8 in.-24 NF bolt, 1/2 in. (12.7


mm) long in one of the holes in the drive gear.
Put a torque wrench on this bolt with the
wrench in a line with the center of the drive
gear, and give it a torque of 45 to 50 lb. ft. (60
to 70 N·m) in a clockwise direction as seen
from the front of the engine. While holding
this torque, tighten bolt (5) for the drive gear
to a torque of 110 ± SIb. ft. (149 ± 7 N·m).
Remove timing pin (1) from the fuel pump
TIMING BOLT INSTALLED and the 3/8 in.-16 NC bolt from the flywheel.
10. Bolt.

TIMING BOLT INSTALLED

10. Bolt.

TIGHTENING DRIVE GEAR FOR


THE FUEL INJECTION PUMP
(Typical Example)

TIMING BOLT LOCATION 12. Turn the engine flywheel two complete revolu-
Plug in hole for timing bolt (10). tions. If the 3/8"-16 bolt goes in the hole in
the flywheel when the timing pin is installed in
the notch in the camshaft, the timing is
correct.

13. If the 3 /8" -16 bolt can not be installed in the


9. Remove the 3/8"-16 NC bolt (10) from the hole in the flywheel, do steps 4 through 11
flywheel. Turn the flywheel clockwise at least again.
60° beyond the point where the 3/8"-16 bolt
(10) can be installed. Checking Timing by Fuel Flow Method

Tools Needed: lP540 Flow Checking Tool Group.


10. Tighten the bolt (5) finger tight. Be sure that 5P6524 Engine Timing Indicator Group.
the timing pin (1) is in the notch in the
camshaft. Turn the flywheel counterclockwise See Special Instruction Form No. SMHS7083
until the 3/8"-16 bolt (10) can be installed in for complete instructions for the fuel flow method
the flywheel. of engine timing (injection sequence).

60
3300 SERIES ENGINES DISASSEMBLY AND ASSEMBLY
WITH SPACER PLATE

CYLINDER HEAD
INSTALL CYLINDER HEAD 1100-12
1. Thoroughly clean the spacer plate and bot-
tom surface of the cylinder head. Install a
new head gasket (2), water ferrules (1) and 0-
ring seal (3) on the hollow dowel.
NOTE: Be sure a new gasket has been installed
between spacer plate and cylinder block. See IN-
STALL SPACER PLATE.
2. Fasten a hoist and install the cylinder head
assembly (4) on the cylinder block.
3. Install the push rods and put the rocker shaft
in position on the cylinder head. Put 5P3931
Anti-Seize Compound on the threads of the
cylinder head and rocker shaft bolts. Install
the bolts and washers and tighten the bolts as oG oE oC oA
follows: ~ g g 15
Step 1. Tighten all bolts in number sequence IJ ~ ~ 6
to a torque of 115 lb. ft. (155 N ·m). fL. Ig ~ 6
Step 2. Again tighten all bolts in number fl~~ ~ ~ !J
sequence to a torque of 185 ± 13 lb. 77084Xl

ft. (250 ± 17 N·m).


Step 3. Again tighten all bolts in number
sequence (hand torque only) to a
torque of 185 ± 13 lb. ft. (250 ± 17
N·m).
Step 4. Tighten all bolts in letter sequence to
a torque of 22 lb. ft. (30 N ·m).
Step 5. Again tighten all bolts in letter se-
quence to a torque of 32 ± 51b. ft. (43
± 7 N·m).
Step 6. Again tighten all bolts in letter se-
quence to a torque of32±5Ib. ft. (43
± 7 N·m).
4. Make adjustment of valves to have a clear-
ance of .015 in. (0.38 mm) for intake and .025
in. (0.64 mm) for exhaust.

5. Install oil return line (6) on the turbocharger.


6. Install oil supply line (5) on the turbo-
charger.

7. Tighten the two bolts (8) in the water pump.


8. Install the two bolts (7) that hold the water
pump to the cylinder head.
end by:
a) install fuel injection lines

23