Service Manual

Caterpillar
Service Manual

3306 Diesel Engine

S/n 8Z, 10Z, & 13Z

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
3306 DIRECT INJECTION VEHICULAR ENGINE SPECIFICATIONS
WITH NEW SCROLL FUEL SYSTEM

INTRODUCTION

The specifications given in this book are on the basis can be used again. If the part is equal to or within the
of information available at the time it was written. The specification given, use the part again.
specifications torques, pressures of operation, mea-
surements, adjustments and other items can change at When the word "permissible" is in the description,
any time. These changes can effect the service given to the specification given is the' 'maximum or minimum"
the product. Get the complete and most current infor- tolerance permitted before adjustment, repair and/or
mation before you start any job. Caterpillar Dealers new parts are needed.
have the most current information which is available. A comparison can be made between the measure-
For a list of the most current modules and form numbers ments.of a worn part, and the specifications of a new
available for each Service Manual, see the SERVICE part to find the amount of wear. A part that is worn can
MANUAL CONTENTS MICROFICHE REGl139F. be safe to use if an estimate of the remainder of its
When the words "use again" are in the description, service life is good. If a short service life is expected,
the specification given can be used to determine if a part replace the part.
77200X2

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 Cooling System

Air Cleaner........................................... 12 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 V-Belt Tension Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
Cylinder Head ........................................ 11 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
Exhaust Manifold........ .................... .... ..... 13 Water Temperature Regulator ......................... 21
Exhaust Pipe and Muffler. ...................... .. .. ... 13
Muffler ............................................... · 14
Precleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
Turbochargers............................... ...... 16, 17
Turbocharger Impeller Installation.. ....... ..... .. ..... 15 Electrical System
Valves................................................ 9 Alternators ......................................... 36, 37
Valve Cover .......................................... 11 Shutoff Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 41
Valve Rocker Arms and Lifters......................... 10 Solenoids ......................................... 39, 40
Starter Motors ................. '. . . . . . . . . . . . . . . . . . .. 38, 39
Basic Engine Components Engine Design ........'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bearing Surface (Journal) for Connecting Rods ........ 29
Bearing Surface (Journal) for Main Bearings ........... 28
Connecting Rod ...................................... 24
Crankshaft ........................................... 27
Crankshaft Hub and Damper .......................... 31 Fuel System
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 Fuel Injection Equipment ................ '............. . 6
Cylinder Liner ........................................ 23 Fuel Transfer Pump .................................. . 6
Cylinder Liner Projection ...................... '.' . . . . .. 23 Governor ............................................ . 7
Flywheel ............................................. 32 Timing Gears ........................................ . 8
Flywheel Housing ................................... " 32
Flywheel Housing Bore .............................. " 35
Flywheel Housing Runout ....... . . . . . . . . . . . . . . . . . . . . .. 34
Flywheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33 Lubrication System
Main and Connecting Rod Bearings .................. " 30 Engine Oil Pressure .................................. .
Piston and Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25, 26 Oil Breather Cap ...........................•..........
Timing Gear Cover ................................. '" 31 Oil Filter ............................................. .
Trunnion ............................................. 31 Oil Pump ............................................ .

2
3306 DIRECT INJECTION VEHICULAR ENGINE SPECIFICATIONS
WITH NEW SCROLL FUEL SYSTEM

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 ................... 18.6 ± 1.0 mm (.73 ± .04 in.)
(2) 8N9594 Spring for governor:
Color code .......................... two light blue stripes
Put a load on spring of . .. . . . . . .. ... .... .... 22.2 N (5.0 lb.)
Then make spring shorter by ............. 16.0 mm (.63 in.)
Total test force................. 53.70 ± 0.9 N (11.8 ± .2 lb.)
Free length after test. . . . . . . . . . . . . .. . . . .. 59.5 mm (2.34 in.)
Outside diameter. . . . . . . . . . . . . . . . . . . . . .. 34.87 mm (1.37 in.)
(2) 2N2878 Spring for governor:
Color code ................................... 1 end brown
Put a load on spring of . . . . . . . . . . . . . . . . . . . .. 29.0 N (6.5 lb.)
Then make spring shorter by ........... 10.69 mm (.421 in.)
Total test force .............. 46.70 ± 0.45 N (10.50 ± .10 lb.)
Free length after test. . . .. 59.44 ± 0.89 mm (2.340 ± .035 in.)
Outside diameter. . . . . . . . . . . . . . . . . . . . . . .. 34.0 mm (1.34 in.)
(2) 8L9790 Spring for governor:
Color code. . ..... . .. . ... .. ..... .. ....... .... one end pink
Put a load on spring of ....................... 18 N (4.0 lb.)
Then make spring shorter by ........... 22.86 mm (.900 in.)
Total test force. . . . . . . . . . . . . . .. 59.5 ± 1.2 N (13.45 ± .27 lb.)
Free length after test.... .. ... .. .. .. .. ... 59.5 mm (2.34 in.)
Outside diameter. . . . . . . . . . . . . . . . . . . . . . .. 35.0 mm (1.38 in:)
(2) 8M9141 Spring for governor:
Color code .............................. one purple stripe
Put a load on spring of .... .... .... ... .... .... 18 N (4.0 lb.)
Then make spring shorter by ........... 22.86 mm (.900 in.)
Total test force ................... 66.0 ± 2.2 N (14.8 ± .5 lb.) (3) 4N6410 Spring for dash pot:

Free length after test ................... , 59.5 mm (2.34 in.) Color code ................................... 1 pink stripe

Outside diameter. . .. . . . . . . . . . . . . . .. . . . .. 34.8 mm (1.37 in.) Length under test force. . . . . . . . . . . . . . .. 26.16 mm (1.030 in.)
Test force .................... 4.45 ± 0.36 N (1.00 ± .08 lb.)
(2) 8L8234 Spring for governor: Free length after test .................. 31.24 mm (1.230 in.)
Color code .................................. 1 white stripe Outside diameter......................... 14.7 mm (.58 in.)
Put a load on spring of ......................... 13 N (3 lb.) (4) 7N7267 Spring for over-fueling:
Then make spring shorter by ........... 22.86 mm (.900 in.) Length under test force................. 10.75 mm (.423 in.)
Total test force ................ 43.35 ± 1.4 N (9.75 ± .31 lb.) Test force ..................... 2.22 ± 0.11 N (.49 ± .03 lb.)
Free length after test. . . . . . . .. 59.4 ± 0.8 mm (2.34 ± .03 in.) Free length after test.. .. .. .. . . . . . .. . .. .. 32.9 mm (1.30 in.)
Outside diameter. . . . . . . . . . . . . . . . . . . . .. 34.37 mm (1.353 in.) Outside diameter. . . . . . . . . . . . . . . . . . . . . .. 11.00 mm (.433 in.)

7
 FORM NO. SENR2148-01
FOR USE IN SERVICE MANUALS:
9660 WHEEL LOADER SENR2144
528 SKIDDER REG01133
12G MOTOR GRADER REG01544
14G MOTOR GRADER REG01542
130G & 140G MOTOR GRADERS
REG01652

SYSTEMS OPERATION
TESTING AND ADJUSTING

3306 DIRECT INJECTION

VEHICULAR ENGINE
WITH NEW SCROLL FUEL SYSTEM
8Z
( 10Z
L' 13Z
3306 DIRECT INJECTION VEHICULAR ENGINE INDEX
WITH NEW SCROLL FUEL SYSTEM

SYSTEMS OPERATION
Air Inlet and Exhaust System Electrical System
Air Inlet and Exhaust System.......................... 12 Charging System Components........................ 19
Cylinder Head and Valves............................. 13 Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Starting System Components.......................... 19
Valve Mechanism..................................... 13 Engine Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Basic Block Fuel System

Crankshaft........................................... 18 Fuel Flow............................................. 5
Cylinder Block........................................ 18 Fuel Injection Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pistons, Rings and Connecting Rods................... 18 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vibration Damper..................................... 18 . Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Governor............................................. 8
Cooling System Oil Flow for Fuel Pump and Governor. . . . . . . . . . . . . . . . . . 7
Cooling System ...................................... , 16
Cooling System Components.......................... 17 Lubrication System
System Oil Flow ...................................... 14

TESTING AND ADJUSTING

Air Inlet and Exhaust System Charging System ..................................... 67
Crankcase (Crankshaft Compartment) Pressure 54 Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 Test Tools for Electrical System ....................... 66
Measurement of Exhaust Temperatures.. .... .. .. ... ... 53
Measurement of Pressure in Inlet Manifold............. 53 Fuel System
Procedure for Measuring Camshaft Lobes ............. . 55 Checking Engine Cylinders Separately... ......... .. ... 33
Restriction of Air Inlet and Exhaust ................... . 53 Checking Engine Timing With 6V3100 Diesel Engine
Valve Clearance 54 Timing Indicator Group. ..... .... .. .. .. ..... .... .... 41
Checking the Plunger and Lifter of an Injection Pump .. 38
Basic Block Checking Timing by Timing Pin Method ............... 42
Connecting Rod and Main Bearings. . . . . . . . . . . . . . . . . . .. 61 Fuel Injection Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38
Connecting Rods and Pistons ......................... 61 Fuel Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62 Fuel System Inspection ............•.................. 33
Cylinder Liner Projection. .... .. .. .. .. ... ..... .. ... . ... 61 Governor Adjustments ................................ 49
Flywheel and Flywheel Housing ....................... 63 Locating Top Center Compression Position for
Piston Ring Groove Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . .. 61 No. 1 Piston ........................................ 40
Measuring Engine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 48
Cooling System Removal and Installation of Fuel Injection Pumps.. .. ... 38
Testing the Cooling System ........................... 58 Testing Fuel Injection Nozzles......................... 34
Checking Filter Cap and Relief Valve. . . . . . . . . . . . . . . . . .. 59
Test Tools for Cooling System. .... .... ..... ... .. ...... 58 Lubrication System
Testing Radiator and Cooling System for Leaks ........ 59 Oil Pressure is High. . ...... ..... ... ....... .. .......... 57
Water Temperature Regulator ......................... 60 Oil Pressure is Low.. . ... . .. .. ....... .. .. .. ... .. .. .... 56
V-Belt Tension Chart ................................. , 60 Too Much Bearing Wear .............................. 57
Visual Inspection of the Cooling System ............... 58 Too Much Oil Consumption ........................... 56

Electrical System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21

Battery............................................... 67

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
ENGINE DISASSEMBLY AND ASSEMBLY

INDEX

Air Cleaner Elements and Housing .................... ........ ........ ........ ..... ............................... ............. ........ 19,20
Air Compressor ..............................................................................................................: ..................... 64,65
Air Conditioner Compressor .... ... ............ ......... ....... ....... ........ ................................... ................ ............... 12
Air Compressor Governor ..... ............... ........... ...... ...... ....... ................ ...... .... ..... .................. ........... ......... 66
Air Compressor Governor, Disassemble & Assemble ......................................................................... . 67,68
Alternator ...................... :........................................................................................................................ 10
Camshaft ............................................................. : ............................ :.................................................. 120
Camshaft Bearings ........ ........ ............ .......... ....... ..... ......... ........... ...................... ............... ............ ........ 133
Connecting Rod Bearings ..... ................ .............. .............. ............. ........ ........... ................. ............. ...... 127
Crankshaft .................................................................................................................................... 134-136
Crankshaft Front Seal and Wear Sleeve .............. ...... ........ ..................... ............. .................. .......... ....... 54
Crankshaft Main 'Bearings ......................................................................................: .............. _....... 128,129
Crankshaft Rear Seal and Wear Sleeve ............................................................................................... 131
Cylinder Head ................................................................................................................:......... ..... 106-108
Cylinder Liners .................................:.............. ..... ....... ........ ................................ ................. ... ...... 125,126
Electric Starting Motor ........................................................................................................................... 11
Engine ........................................................................................................................................... 137-143-'"
Engine Oil Cooler ......:: ................................................................................................................_.......... 5+-'-""
Exhaust Manifold ............................................................................................................................... 60,61'"
Fan ...............................................................................................................................,................... 13,14
Fan Drive . ................ .................... ........... ....... ..... ...... ........ ........... ... ...... .•........ .................... ........... ........ 1'5
Fan Drive, Disassemble & Assemble ................................................................................................. 16-18
Flywheel .......................... ............... .......... ...... ...... ..... ........ ............................... .... ................. .............. 130
Flywheel Housing ............................ :.................................................................................................... 132
Fuel Injection Lines ................... .......... ........ ...... ....... ..... ....... ........ ............................... ................ ............. 60
Fuel Injection Nozzles ................................. : ...................................................................................... 69,70
Fuel Injection Pumps .... ... ................ .......... ....... ............ ...... ... ............ ......... ..... ... ................ .... ............. 81,82
Fuel Injection Pumps, Disassemble & ASSemble ........................................... _.......................................... 83
Fuel Injection Pump Housings ana Governor .... ..... ............. ............. ..... .... .... ........................ ............... 76-80
Fuel Injection Pump Housing, Disassemble & Assemble .................................................................. 97-100
Fuel Priming and Primary Filter Pump Group ................... ....... ..... .... ................................. ............ ........... 62
Fuel Priming and Primary Filter Pump Group, Disassemble & Assemble ...................... .............. ......... 63,64
Fuel Shutoff Solenoid ... _ ........................................................................................................................ 70
Fuel Transfer Pump . .................... ....... .... ..... ........... ........ .......... ...... ........... ... .......... ........... ........... ........... 71
Fuel Transfer Pump, Disassemble & Assemble .................................................................................. 72-75
Governor, Disassemble & Assemble ............................................................................... : ...... : ........... 84-96
Hood ............................................................................................................: ........................................ 8,9
Muffler .............................................................................................................................................. 39,40
Oil Filter Base ................................................................................................................................... 49,50
Oil Filter Base, Disassemble & Assemble ................................................................................................ 50
Oil Pan ...............................................................................................................:.................................. 113.
Oil Pan Plate ...................................................................:.................................................................... 114'
Oil Pump ............................................................................................................................................... 115
Oil Pump, Disassemble & Assemble . .............................................................................................. 116-119

6
ENGINE DISASSEMBLY AND ASSEMBLY

Pistons .......................................................................................................................................... 121,122

Pistons, Disassemble & Assemble ...................................... :: .............................................,........... 123,124
Radiator and' Guard ......... ,.... ............. ........ ....... ......... ........... ............... ....... ....... .......... ............ .... ...... 29-32
Radiator and Hydraulic Oil Cooler ...... ..... ...... ............ ........... ....... ........ ....... ..... .......... ............. ... ......... 33-38
Rocker Shaft and Pushrods .......................................................................................................... 103,104
Rocker Shaft, Disassemble & Assemble ........................................................................................ 104,105
Spacer Plate ........................................................................................................................................ 112
Timing Gear Cover ... .... ......... ............ ....... ..... ............ ........... ......... ....... ............... ......... ............. ........ 55,56
Timing Gears and Plate .................. _ ................................................................................................. 57-59
Torque Converter Oil Cooler ................................................................................................................... 28
Turbocharger .................................................................................................................................... 40-42
Turbocharger, Disassemble & Assemble ........................................................................................... 43-48
Valves ........................................................................ : ........................ :................................................ 109
Valve Cover .................................................................................................................................... 101,102
Valve Guides ........................................................................................................................................ 111
Valve Lifters ......................................................................................................................................... 112
Valve Seat Inserts ................................................................................................................................ 110
Vibration Damper and Pulley ............................................................................................................. 52,53
Water Directors ................................................................................................................................... 110
Water Pump ....................................................................................................................................... 20,21
Water Pump, Disassemble & Assemble ................................................................... : ......................... 22-26
Water Temperature Regulator ................................................................................................................ 27

In. WARNING
DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK.

7
ENGINE DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

REMOVE AND INSTALL AIR
CONDITIONER COMPRESSOR 1357-10

~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 con-
tact 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, en-
gine 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 remov-
al and installation of lines and refrigerant from
the system. .

l. Remove plate (3) and disconnect hose assem-

blies (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 7454 for correct procedure for evacuat-
ing and charging the system.

12
ENGINE DISASSEMBLY AND ASSEMBLY

GOVERNOR
19. Remove bolts (39) and governor servo (38) from
the fuel injection pump.

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 gover-
nor 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
ENGINE DISASSEMBLY AND ASSEMBLY

ENGINE
1'1. Put bracket (14) in position and install the
bolts.

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).-

15 ... Put the water temperature regulator, the gas-

ket and tube (I 9) in position and install the
bolts.' - <;"~~, -

142