3306 Diesel Engine S/n 8Z, 10Z, & 13Z

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1 Caterpillar Service Manual 3306 Diesel Engine S/n 8Z, 10Z, & 13Z 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-ENG33068Z

2 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL FUEL SYSTEM SPECIFICATIONS INTRODUCTION The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGl139F. When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again. When the word "permissible" is in the description, the specification given is the' 'maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed. A comparison can be made between the measurements.of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part X2 NOTE: For Systems Operation and Testing and Adjusting, make reference to 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL F~ SYSTEM, Form No. SENR2148. INDEX Air Induction and Exhaust System Air Cleaner Camshaft Cylinder Head Exhaust Manifold Exhaust Pipe and Muffler Muffler Precleaner Turbochargers , 17 Turbocharger Impeller Installation Valves... 9 Valve Cover Valve Rocker Arms and Lifters Basic Engine Components Bearing Surface (Journal) for Connecting Rods Bearing Surface (Journal) for Main Bearings Connecting Rod Crankshaft Crankshaft Hub and Damper Cylinder Block Cylinder Liner Cylinder Liner Projection... '.' Flywheel Flywheel Housing... " 32 Flywheel Housing Bore... " 35 Flywheel Housing Runout Flywheel Runout Main and Connecting Rod Bearings... " 30 Piston and Rings , 26 Timing Gear Cover... '" 31 Trunnion Cooling System Radiator V-Belt Tension Chart Water Pump Water Temperature Regulator Electrical System Alternators... 36, 37 Shutoff Solenoid Solenoids... 39, 40 Starter Motors... ' , 39 Engine Design... ' Fuel System Fuel Injection Equipment... '.... Fuel Transfer Pump.... Governor.... Timing Gears.... Lubrication System Engine Oil Pressure.... Oil Breather Cap Oil Filter.... Oil Pump

3 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL FUEL SYSTEM SPECIFICATIONS GOVERNOR (1) With the governor lever in the maximum shut off position, the dimension from the end of the lever to the rear governor housing face must be ± 1.0 mm (.73 ±.04 in.) (2) 8N9594 Spring for governor: Color code... two light blue stripes Put a load on spring of N (5.0 lb.) Then make spring shorter by mm (.63 in.) Total test force ± 0.9 N (11.8 ±.2 lb.) Free length after test mm (2.34 in.) Outside diameter mm (1.37 in.) (2) 2N2878 Spring for governor: Color code... 1 end brown Put a load on spring of N (6.5 lb.) Then make spring shorter by mm (.421 in.) Total test force ± 0.45 N (10.50 ±.10 lb.) Free length after test ± 0.89 mm (2.340 ±.035 in.) Outside diameter mm (1.34 in.) (2) 8L9790 Spring for governor: Color code one end pink Put a load on spring of N (4.0 lb.) Then make spring shorter by mm (.900 in.) Total test force ± 1.2 N (13.45 ±.27 lb.) Free length after test mm (2.34 in.) Outside diameter mm (1.38 in:) (2) 8M9141 Spring for governor: Color code... one purple stripe Put a load on spring of N (4.0 lb.) Then make spring shorter by mm (.900 in.) Total test force ± 2.2 N (14.8 ±.5 lb.) Free length after test..., 59.5 mm (2.34 in.) Outside diameter mm (1.37 in.) (2) 8L8234 Spring for governor: Color code... 1 white stripe Put a load on spring of N (3 lb.) Then make spring shorter by mm (.900 in.) Total test force ± 1.4 N (9.75 ±.31 lb.) Free length after test ± 0.8 mm (2.34 ±.03 in.) Outside diameter mm (1.353 in.) (3) 4N6410 Spring for dash pot: Color code... 1 pink stripe Length under test force mm (1.030 in.) Test force ± 0.36 N (1.00 ±.08 lb.) Free length after test mm (1.230 in.) Outside diameter mm (.58 in.) (4) 7N7267 Spring for over-fueling: Length under test force mm (.423 in.) Test force ± 0.11 N (.49 ±.03 lb.) Free length after test mm (1.30 in.) Outside diameter mm (.433 in.) 7

4 FORM NO. SENR FOR USE IN SERVICE MANUALS: 9660 WHEEL LOADER SENR SKIDDER REG G MOTOR GRADER REG G MOTOR GRADER REG G & 140G MOTOR GRADERS REG Z ( 10Z L' 13Z SYSTEMS OPERATION TESTING AND ADJUSTING 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL FUEL SYSTEM

5 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL FUEL SYSTEM INDEX SYSTEMS OPERATION Air Inlet and Exhaust System Air Inlet and Exhaust System Cylinder Head and Valves Turbocharger Valve Mechanism Basic Block Crankshaft Cylinder Block Pistons, Rings and Connecting Rods Vibration Damper Cooling System Cooling System..., 16 Cooling System Components Electrical System Charging System Components Other Components Starting System Components Engine Design Fuel System Fuel Flow... 5 Fuel Injection Nozzle Fuel Injection Pump Fuel Transfer Pump Governor... 8 Oil Flow for Fuel Pump and Governor Lubrication System System Oil Flow TESTING AND ADJUSTING Air Inlet and Exhaust System Crankcase (Crankshaft Compartment) Pressure 54 Cylinder Head Measurement of Exhaust Temperatures Measurement of Pressure in Inlet Manifold Procedure for Measuring Camshaft Lobes.... Restriction of Air Inlet and Exhaust.... Valve Clearance Basic Block Connecting Rod and Main Bearings Connecting Rods and Pistons Cylinder Block Cylinder Liner Projection Flywheel and Flywheel Housing Piston Ring Groove Gauge Cooling System Testing the Cooling System Checking Filter Cap and Relief Valve Test Tools for Cooling System Testing Radiator and Cooling System for Leaks Water Temperature Regulator V-Belt Tension Chart..., 60 Visual Inspection of the Cooling System Electrical System Battery Charging System Starting System Test Tools for Electrical System Fuel System Checking Engine Cylinders Separately Checking Engine Timing With 6V3100 Diesel Engine Timing Indicator Group Checking the Plunger and Lifter of an Injection Pump.. 38 Checking Timing by Timing Pin Method Fuel Injection Lines Fuel Setting Procedure Fuel System Inspection Governor Adjustments Locating Top Center Compression Position for No. 1 Piston Measuring Engine Speed Removal and Installation of Fuel Injection Pumps Testing Fuel Injection Nozzles Lubrication System Oil Pressure is High Oil Pressure is Low Too Much Bearing Wear Too Much Oil Consumption Troubleshooting SPECIFICATIONS NOTE: For Specifications with illustrations, make reference to SPECIFICA TIONS for 3306 DIRECT INJECTION VEHICULAR ENGINE WITH NEW SCROLL FUEL SYSTEM, Form No. SENR2147. If the Specifications in Form SENR2147 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. 3

6 ENGINE DISASSEMBLY AND ASSEMBLY INDEX Air Cleaner Elements and Housing ,20 Air Compressor... :... 64,65 Air Conditioner Compressor Air Compressor Governor Air Compressor Governor, Disassemble & Assemble ,68 Alternator... : Camshaft... :... : Camshaft Bearings Connecting Rod Bearings Crankshaft Crankshaft Front Seal and Wear Sleeve Crankshaft Main 'Bearings... :... _ ,129 Crankshaft Rear Seal and Wear Sleeve Cylinder Head... : Cylinder Liners... : ,126 Electric Starting Motor Engine '" Engine Oil Cooler...::..._ '-"" Exhaust Manifold... 60,61'" Fan...,... 13,14 Fan Drive '5 Fan Drive, Disassemble & Assemble Flywheel Flywheel Housing... : Fuel Injection Lines Fuel Injection Nozzles... :... 69,70 Fuel Injection Pumps ,82 Fuel Injection Pumps, Disassemble & ASSemble... _ Fuel Injection Pump Housings ana Governor Fuel Injection Pump Housing, Disassemble & Assemble Fuel Priming and Primary Filter Pump Group Fuel Priming and Primary Filter Pump Group, Disassemble & Assemble ,64 Fuel Shutoff Solenoid... _ Fuel Transfer Pump Fuel Transfer Pump, Disassemble & Assemble Governor, Disassemble & Assemble... :... : Hood... :... 8,9 Muffler... 39,40 Oil Filter Base... 49,50 Oil Filter Base, Disassemble & Assemble Oil Pan... : Oil Pan Plate... : ' Oil Pump Oil Pump, Disassemble & Assemble

7 ENGINE DISASSEMBLY AND ASSEMBLY Pistons ,122 Pistons, Disassemble & Assemble... ::..., ,124 Radiator and' Guard..., Radiator and Hydraulic Oil Cooler Rocker Shaft and Pushrods ,104 Rocker Shaft, Disassemble & Assemble ,105 Spacer Plate Timing Gear Cover ,56 Timing Gears and Plate... _ Torque Converter Oil Cooler Turbocharger Turbocharger, Disassemble & Assemble Valves... :... : Valve Cover ,102 Valve Guides Valve Lifters Valve Seat Inserts Vibration Damper and Pulley... 52,53 Water Directors Water Pump... 20,21 Water Pump, Disassemble & Assemble... : Water Temperature Regulator In. WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 7

8 ENGINE DISASSEMBLY AND ASSEMBLY REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR AIR CONDITIONER COMPRESSOR ~WARNING. Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2-Dichlorodifluoromethane) which is not toxic or flammable. But there is a reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CI GARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See AIR CON DITIONING AND HEATING SERVICE MANUAL Form No. SENR7454 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.. l. Remove plate (3) and disconnect hose assemblies (4) from the air conditioner compressor. 2. Put plate (3) back in position on the compressor to keep out foreign material. 3. Loosen adjusting bolt (1) and remove vee belt (2). 4. Disconnect the wires from the compressor. 5. Remove bolts (6) and remove compressor (5). NOTE: The following steps ardor installation of the. air conditioning compressor. 6. Put the air conditioner compressor in position and install the bolts. 7. Connect wires (7) to the compressor. 8. Install the belt on the compressor. Make an adjustment of the belt. See MAINTENANCE GUIDE.. 9. Put hose assemblies (4) in position and install plate (3). 10. See AIR CONDITIONING AND HEAT ING SERVICE MANUAL Form No. SENR for correct procedure for evacuating and charging the system. 12

9 ENGINE DISASSEMBLY AND ASSEMBLY 19. Remove bolts (39) and governor servo (38) from the fuel injection pump. GOVERNOR 20. Remove lockring (44), seat (43), spring (broken link spring) (42) and sleeve (41) from valve (40). Remove the other lockring (44) from the groove in the center of valve (40). 21. Remove valve (40), sleeve (45) and piston (47) from the governor servo. Remove the O-ring seal from sleeve (45). 22. Remove pin (46) and lever (48) from the governor servo. 23. Use tool (B) to hold spring (50) in compression so ring (49) can be removed. Spring (50) is used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing. 24. Remove ring (49) then remove tool (B). 25. Remove bearing (51), sleeves (52) and spring (50) from the governor shaft. 87

10 ENGINE DISASSEMBLY AND ASSEMBLY 1'1. Put bracket (14) in position and install the bolts. ENGINE 12. Connect control linkage (13) to the governor. 13. Put tube (15) in position and install the hose clamp. 14. Put tubes (16) and (18) in position and install hose clamps '( 17) Put the water temperature regulator, the gasket and tube (I 9) in position and install the bolts.' - <;"~~,

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