3304 Engine S/n 43V, 46V, 48V, 78P, 9Z, 7Z & 12Z

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1 Caterpillar Service Manual 3304 Engine S/n 43V, 46V, 48V, 78P, 9Z, 7Z & 12Z Service Manual 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-ENG3304D

2 SIN 43V. 46V. 48V. 78P. 9Z. 7Z. 12Z

3 3304 VEHICULAR ENGINES SPECIFICATIONS INDEX Air Inlet and Exhaust System Air Cleaner Camshaft Cylinder Head Glow Plug POsitioning Exhaust Manifold Exhaust Pipe and Muffler Turbocharger Turbocharger Impeller Installation , 45 Valves (01) Valves (PC)... " 38, 39 Valve Cover Valve Rocker Arms and Lifters Basic Engine Components Bearing Surface (Journal) Connecting Rods Main Bearings..., 68 Connecting Rod Crankshaft Crankshaft Hub Cylinder Block Counterbored Block Spacer Plate Block Cylinder Liner Cylinder Liner Projection Counterbored Block Spacer Plate Block Fan Drive Flexible Drive Coupling... 76, 77 Checking and Adjusting Alignment of the Flexible Drive Coupling Flywheel Flywheel Housing Flywheel Housing Bore..., 75 Flywheel Housing Tightening Flywheel Ring Gear..., 72 Main Bearing and Connecting Rod Bearings Pistons and Rings Keystone Straight Side Cooling System Coolant Flow Switch , 59 Fan Drive Radiator V-Belt Tension Chart Water Pump Water Temperature Regulator Electrical System Alternators Alternator Regulator Generator Regulators Generators... 84, 85 Starter Magnetic Switches Starter Motors Starter Solenoids Engine Design Engine Mounting Bolts Fuel System Fuel System Timing Fuel System Usage Chart... 6 Service Meter Tachometer Drive Fuel System - Scroll (01) Fuel Injection Fuel Injection Pump Housing Fuel Transfer Pump Governor Governor Housing Injection Nozzle Fuel System - Scroll (PC) Fuel Bypass Valve Fuel Injection Equipment Fuel Transfer Pump..., 30 Governor (Earlier) Governor (Later) Fuel System - Scroll (PC & 01) Timing Gears Fuel System - Sleeve Metering (DI) Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Control (04E) Governor Control (120G & 130G) Governor Control (225) Governor Control (518) Injection Nozzle Fuel System - Sleeve Metering (PC)... 8 Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Control (920 & 930) Governor Control (950) Governor Control (951) Governor Control (955L) Fuel System - Sleeve Metering (PC & 01) Timing Gears... ' Water Separator Gauges Converter Oil Temperature Indicator Fuel Pressure Indicator Oil Pressure Indicator Water Temperature Indicator General Tightening Torques... 4 Lubrication System Engine Oil Pressure Oil Breather Cap Oil Filter , 56 Oil Pump Oil Pressure Switch Torque for Flared and O-Ring Fittings

4 3304 VEHICULAR ENGINE INDEX SYSTEMS OPERATION Air Inlet and Exhaust System Air Inlet and Exhaust System and 32 Timing Gears Turbocharger Valves and Valve Mechanism Basic Block Cran kshaft Cylinder Block and Liners Pistons, Rings, and Connecting Rods Cooling System... " 38 Coolant for Air Compressor Electrical System Charging System Components Electrical System Schematic Other Components Starting System Components Fuel System (Scroll-DI) Fuel Injection Pump Fuel System Timing Governor (Hydra-Mechanical) Injection Nozzles Introduction Fuel System (Scroll-PC) Fuel Injection Pump Fuel Injection Valve Fuel System Timing Glow Plugs... " 26 Governor Operation Introduction Fuel System (Sleeve Metering) Adjustments To The Sleeve Metering Fuel System Fuel Flow After Engine Stops Running Fuel Flow Using The Priming Pump and Bleed Valve Fuel Flow With Engine Running... 7 System With Constant Bleed Valve System With Siphon Break... 7 System With Siphon Break and Constant Bleed Valve... '" 13 System Without Siphon Break or Constant Bleed Valve Fuel Injection Pump Operation Fuel Injection Valve-PC Fuel Injection Valves Fuel Priming Pump Fuel Ratio Control Fuel System Operation Fuel System Timing... 6 Fuel Transfer Pump Glow Plugs-PC Governor Injection Nozzle-DI Introduction Non-Adjustable Dashpot Governor Siphon Break Water Separator... 6 General Information Engine Design Fuel System Usage Chart... 5 Lubrication System Oil Flow In The Engine Oil Flow Through The Oil Filter and Oil Cooler

5 3304 VEHICULAR ENGINE INDEX TESTING AND ADJUSTING Air Inlet and Exhaust System Checking Inlet Manifold Pressure At Torque Flow Checking Fuel Injection Pump Timing (PC Engines Only) Converter Stall Speed Compression Crankcase (Crankshaft Compartment) Pressure Fuel Injection Lines Fuel System Inspection Start-Up Procedure Cylinder Head Test Sequence - Precombustion Chamber (PC) Glow Plug and Precombustion Chamber Removal and Installation Measurement of Exhaust Temperatures Measurement of Pressure in Inlet Manifold Procedure for Measuring Camshaft Lobes Restriction of Air Inlet and Exhaust Turbocharger Valve Clearance Fuel Nozzle Testing 7N449 Fuel Injection Nozzles Testing Capsule-Type Fuel Injection Nozzles Troubleshooting of 7N449 Fuel Injection Nozzles Fuel System (Scroll-DI) Checking the Fuel Injection Valves Checking the Plunger and Lifter Washer of an Injection Pump Fuel Injection Pump Timing Dimension Setting: Basic Block Off Engine Connecting Rod and Main Bearings Connecting Rods and Pistons Cylinder Block Cylinder Liner Projection , 123 Counterbored Block Spacer Plate Block Flywheel and Flywheel Housing Oil Pump Installation Piston Ring Groove Gauge Fuel Injection Timing Check (Timing Pin Method) Fuel Rack Setting Fuel System Adjustments Injection Pump (Install) Injection Pump (Remove) Fuel System (Scroll-PC) Checking the Fuel Injection Valves Checking the Plunger and Lifter Washer of an Injection Pump Fuel Injection Service Cooling System Checking Coolant Temperature Checking Fan Speed Checking Radiator Air Flow Filler Cap and Pressure Relief Valve Gauge for Water Temperature Pressure Cap Testing Radiator and Cooling System for Leaks Testing the Cooling System V-Belt Tension Chart Visual Inspection of the Cooling System Water Temperature Regulators Electrical System Battery Charging System Starting System Accessory Drive Shaft Timing Checking With 8S4620 Gauge Checking With 8S7167 or 5P4158 Gauge Fuel Injection Pump Timing Dimension Setting: Off Engine Fuel Rack Setting Injection Pump Injection Pump Installation Injection Valve (Capsule-Type Nozzle) Governor Adjustments Fuel Ratio Control Setting Fuel System (Sleeve Metering) Fuel Injection Service Fuel Pump Calibration Fuel Ratio Control Setting Fuel System Adjustments Fuel System Setting... '.' Flexible Drive Coupling Governor Adjustments Checking Flexible Drive Coupling Alignment... " 128 Lubrication System Fuel System Oil Pressure is High Adjustment and Cleaning of 7N449 Fuel Injection Oil Pressure is Low Nozzles Too Much Bearing Wear Checking Engine Cylinders Separately Too Much Oil Consumption Checking Engine Timing With 6V3100 Diesel Engine Timing Indicator Group Troubleshooting Engine Speed Measurement Finding Top Center Compression Position for No. 1 Piston NOTE: This book has been completely changed from the former issue. SPECIFICATIONS 4 NOTE: For Specifications with illustrations, make reference to SPECIFICA TIONS for 3304 VEHICULAR ENGINE, Form No. SENR7590. If the Specifications in Form SENR7590 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

6 SLEEVE METERING FUEL SYSTEM, SYSTEMS OPERATION FUEL INJECTION PUMP OPERATION The main components of a fuel injection pump in the sleeve metering fuel system are: plunger (7), barrel (3), and sleeve (8). The plunger moves up and down inside the barrel and sleeve. The barrel is stationary while the sleeve is moved up and down around the plunger to make a change in the amount of fuel for injection. 5 L FUEL INJECTION PUMP OPERATION X2 2. Chamber. 3. Barrel. 5. Fuel inlet (fi" port). 7. Plunger. 8. Sleeve. 9. Fuel outlet (spill port). 11. Lifter. 12. Camshaft. A. Before injection. B. Start of injection. C. End of injection Before Injection Before the engine can start or run correctly, the housing and fuel injection lines must be full of fuel and the sleeve (8) must be high enough on the plunger to close the fuel outlet (9) (spill port) during part of the stroke cycle. Chamber (2) fills with fuel through the fuel inlet (5) (fill port) which is under the level of the fuel in the housing. FUEL INJECTION PUMP OPERATION 1. Reverse flow check valve. 2. Chamber. 3. Barrel. 4. Spring. 5. Fuel inlet (fill port). 6. Retainer. 7. Plunger. 8. Sleeve. 9. Fuel outlet (spill port). 10. Sleeve control lever. 11. Lifter. 12. Camshaft. The plunger, barrel, and sleeve are a fitted set and they must be kept together. Lifter (11) and plunger (7) are lifted through a full stroke by each revolution of the camshaft (12). The force of spring (4) on plunger (7) through retainer (6) holds the lifter against the camshaft through the full stroke cycle. Injection Injection starts after the rotation of the camshaft lifts plunger (7) far enough into barrel (3) to close fuel inlet (5). At this time, both the fuel inlet and fuel outlet are closed. As more rotation of the camshaft lifts the plunger farther into the chamber of the barrel, the fuel in the chamber is put under more and more pressure. This pressure is felt by reverse flow check valve (1) and the fuel injection valve. When the pressure is high enough to open the fuel injection valve, injection starts. Injection stops when the rotation of the camshaft has lifted the plunger far enough to open fuel outlet (9). This puts the fuel outlet above the top of sleeve (8). 17

7 ENGINE DISASSEMBLY AND ASSEMBLY INDEX Air Cleaner Alternator Balancer Shafts Balancer Shaft Bearings Camshaft Camshaft Bearings Connecting Rod Bearings Crankcase Guards Crankshaft ,115 Crankshaft Front Seal and Wear Sleeve Crankshaft Main Bearings Crankshaft Rear Seal and Wear Sleeve ,111 Cylinder Head Cylinder Liners ,93 Engine... :... :... '.' Engine Side Guards Exhaust Manifold Fan and Fan Drive... 61,62 Fan and Fan Drive, Disassemble & Assemble ,64 Flywheel Flywheel Housing Front Support Fuel Check Valve and Bypass Valve (Sleeve Metering Fuel System) Fuel Filter Base Fuel Lines Fuel Priming Pump Fuel Injection Pump Housing and Governor (Compact Fuel System)... 46,47 Fuel Injection Pump Housing and Governor (Sleeve Metering Fuel System)... 27,28 Fuel Injection Pump Housing and Governor, Separation and Connection (Compact Fuel System)... 48,49 Fuel Injection Pump Housing and Governor, Separation and Connection (Sleeve Metering Fuel System) Fuel Injection Pump Housing, Disassemble & Assemble (Compact Fuel System) Fuel Injection Pump Housing, Disassemble & Assemble (Sleeve Metering Fuel System) Fuel Injection Pumps (Sleeve Metering Fuel System) ,42 Fuel Injection Pumps, Disassemble & Assemble (Sleeve Metering Fuel System) Fuel Injection Valves Fuel Transfer Pump (Compact Fuel System) Fuel Transfer Pump, Disassemble & Assemble (Compact Fuel System) Fuel Transfer Pump (Sleeve Metering Fuel System)

8 ENGINE DISASSEMBLY AND ASSEMBLY INDEX Glow Plugs Governor, Disassemble & Assemble (Compact Fuel System) GovernOr, Disassemble & Assemble (Sleeve Metering Fuel System) Hood Hydraulic Pump Muffler Oil Filter Base Oil Filter Base, Disassemble & Assemble Oil Pan Oil Pan Plate ,101 Oil Pump Oil Pump, Disassemble & Assemble Pistons ,87 Pistons, Disassemble & Assemble Precieaner Precombustion Chambers Primary Fuel Filter..., Radiator Core Radiator and Guard... '"... 72,73 Rocker Shaft and Push Rods... : Rocker Shaft, Disassemble & Assemble Starting Motor. '" Timing Gear Cover... 75,76 Timing Gears and Plate Transmission Oil Cooler Valves Valve Cover Valve Guides Valve Lifters... : Valve Seat Inserts Vibration Damper and Pulley Water Directors., Water Pump..., Water Pump, Disassemble & Assemble Water Temperature Regulator &. WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 7

9 ENGINE DISASSEMBLY AND ASSEMBLY 8

10 ENGINE DISASSEMBLY AND ASSEMBLY PRIMARY FUEL FILTER, FUEL PRIMING PUMP REMOVE PRIMARY FUEL FILTER P8250 Tools Needed Strap Wrench A start by: a) remove engine side guards (right side only) 1. Turn the fuel supply valve on the bottom of the fuel tank to the "OFF" position. 2. Remove primary fuel filter (1) with tool (A). INSTALL PRIMARY FUEL FILTER Put clean diesel fuel on the gasket of the filter element. Install the primary fuel filter (1) by hand. When gasket makes contact with filter base, tighten % turn more. 2. Turn the fuel valve to the "ON" position. end by: a) install engine s.ide guards (right side only) REMOVE FUEL PRIMING PUMP Turn the fuel supply valve on the bottom of the fuel tank to the "OFF" -position. 2. Remove two bolts (1). 3. Remove the fuel priming pump (2) and gasket. INSTALL FUEL PRIMING PUMP Put a new gasket (2) on the fuel filter base. 2. Put the fuel priming pump (1) in position and install the bolts that hold it. 3. Turn the fuel supply valve to the "ON" position. 9

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