Service Manual

Caterpillar
Service Manual
Engine 3306
Natrual Gas
S/n 7Y1 to 7Y290

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-ENG3306NG
3306 NATURAL GAS ENGINE
SERIAL NUMBERS
7Y1-7Y290

SPECIFICATIONS (Section 1) - - - -

SYSTEMS OPERATION (Section 2) - - - -

TESTING AND ADJUSTING (Section 3) - - - -

GENERAL INSTRUCTIONS (0 & AJ (Section4J - - - -

DISASSEMBLY AND ASSEMBLY (Section 5J - - - -

3306 NATURAL GAS ENGINE INDEX

INTRODUCTION

The specifications given in this book are on the When the word "permissible" is in the description,
basis of information available at the time the book the specification given is the "maximum or mini-
was written. These specifications give the torques, mum" tolerance permitted before adjustment,
operating pressure, measurements of new parts, repair and/or new parts are needed.
adjustments and other items that will affect the A comparison can be made between the measure-
service of the product. ments of a worn part, and the specifications of a
When the words "use again" are in the description, new part to find the amount of wear. A part that is
the specification given can be used to determine if worn can be safe to use if an estimate of the re-
a part can be used again. If the part is equal to or mainder of its service life is good. If a short service
within the specification given, use the part again. life is expected, replace the part.
NOTE: The specifications given for "use again" and "permissible" are in-
tended for guidance only and Caterpillar Tractor Co. hereby expressly denies
and excludes any representation, warranty or implied warranty of the reuse
of any comDonent.

SPECIFICATIONS (Section 1)
Accessory Drive ........ ....... ......... ....... .... ...... ........ ......... ....... ....... ... 1-5 Magneto Drive .............. ........................... ........... ................... ....... 1-5
Aftercooler ..................... ............ .................... ......... ........ ............ 1-15 Magneto Timing ..... .............. ............ ........... ....... ............... ........... 1-4
Air Cleaner ................................................................................. 1-14 Main Bearings and Connecting Rod Bearings .. ........................ 1-28
Air Starting Motor ...................................................... _............... 1-37 Mechanical Governor Linkage Adjustment .................................. 1-6
Alternator ........................... ........................... ..... ...... ................... 1-35
Alternator Regulator ................................................................... 1-35 Oil Breather Cap .............. ............. ..... ................ .......... .............. 1-18
Ammeter ................. ........... ......................... ........ ......... ....... .......... 1-3 Oil Filter ...................................................................................... 1-17
Auxiliary Water Lines ................................................................. 1-19 Oil Pump .................................................................................... 1-17
Bearing Surface (Journal) for Connecting Rod ......................... 1-27
Bearing Surface (Journal) for Main Bearings ............................ 1-26 Pistons and Rings ........ .......... ........................... ...... ................... 1-24
Pressure Regulating Valve for Air Starting Motor ..................... 1-36
Camshaft .................................................................................... 1-12
Connecting Rod ......................................................................... 1-23 Radiator ....... .................................. ..................... ...... ........ .......... 1-20
Contactor Switch for Oil Pressure ............................................... 1-3
Contactor Switch for Water Temperature .................................... 1-3 Spark Plug Adapter .................................................................... 1-13
Cooling System Pressure Cap ................................................... 1-20 Spark Plug ............................. ....... ................ ............................... 1-4
Crankshaft ......... ........ ..... ............ .................. ....... ......... .............. 1-25 Starter Motor ......... .............................................. ........... ............ 1-35
Crankshaft Hub and Damper ...................... ............................... 1-29 Starter Solenoid ...................... ............. ...... ........ ........................ 1-36
Cylinder Block ............................................................................ 1-21
Cylinder Head . ......... ....... .................. ......... ................................ 1-13 Timing Gears ..... ........................... ....... ...... ........ ..... ........... .......... 1-9
Cylinder Liner .. ........... ......... ....... ................. .................... ........... 1-22 Timing Gear Cover .... .............. .......... ...................... ................... 1-29
Cylinder Liner Projection ....... ..... .................. .............. ................ 1-22 Torque for Flared and O-Ring Fittings ............................................ 9
Engine Design ... .......... .......... .......... ....... ........... .... .......... ............. 1-2 Transformer .................. .... ......................... ..................... .............. 1-4
Engine Oil Pressure .................. ........ .................... ..................... 1-18 Turbocharger .............................................................................. 1-16
Engine Timing . ........... ..... ......... ....................... .......... ................... 1-8
Exhaust Elbow......... ..... ...... ....... ............ .... ...... .............. ............ 1-14 Valves ......................................................................................... 1-10
Valve Cover .......... :.................................................................... 1-13
Fan Drive ..... ........................ ....... ........... .................. ....... ........... 1-29 Valve Rocker Arms and Lifters .; ............ :................................... 1-12
Fan Pulley .................................................................................. 1-30 Valve Springs ............................................................................. 1-11
Flywheel Housing Bore ..................... ........ ........... ........ ...... ........ 1-34 V Belt Tension Chart .. ............. ...... ....... ...... ..... ...... ..................... 1-30
Flywheel Housing Runout .. ...... ........................ ............. ...... ....... 1-33
Flywheel Ring Gear ................................................................... 1-31 Water Cooled Exhaust Manifold ................................................ 1-15
Flywheel Runout .. ........ ............... ................ ........ ............ ........... 1-32 Water Pump ............................................................................... 1-19
Gas Pressure Regulator ....... ................... ........ .................. .......... 1-2 Water Temperature Regulator ................................................... 1-19
Gauge for Oil Pressure ................................................................ 1-2 Woodward PSG Governor and Linkage for
Gauge for Water Temperature ..................................................... 1-2 Naturally Aspirated Engines ........ ............ ............................... 1-8
General Tightening Torques ........................................................... 8 Woodward PSG Governor and Linkage for
Governor ...................... ......... .......... ........................ ..................... 1-9 Turbocharged Engines ......................................................... 1-7

2
 3306 NATURAL GAS ENGINE INDEX

SYSTEMS OPERATION (Section 2)

Air Starting System .........................................,... ... ............ ........ 2-23 Gas Pressure Regulator ............................... .......................... 2-8
Oiler ...................................................................................... 2-23 Governors ........ .................. ........ ..... ...... .......... ... ... .... ........ .... 2-10
Mechanical Governor . ........... ............... .......... ... ... ...... .......... 2-10
Basic Block ........ ............. .... ...... .... ... ....... ... ...... ................... .... ... 2-20 Timing Gears ... .... ....... .... .... ....... .... ... .... ...... ..... ... ........ .... ...... 2-1 0
Vibration Damper " ... ............ ... .... ....................... ... .... ............ 2-20 Turbocharger
(Engines so Equipped) ........................................................... 2-7
Cooling System .. ......... .......... .... .......... .......... ... ... ........ ..... ...... .... 2-17 Valves and Valve Mechanism .............................................. 2-10
Cooling System Components ............................................... 2-19 Woodward PSG Governor .. ....... ....... ......... ........ ........ ..... ... ... 2-11
Cooling System Schematic
(Engines with Turbochargers) ......... ..... ... ... ... ... .... ................ 2-18 Ignition System ......... ............. ....... ... .............. ... ...... .... ..... ...... ... ..... 2-3
Cooling System Schematic Ignition Transformers .. .... .... .... ... ...... ..... ...... ....... ........ ....... ...... 2-4
(Engines without Turbochargers) ......................................... 2-17 Instrument Panel ........ .... .... .... ... ... ........ ... ....... ............ ...... ...... 2-4
Spark Gap Magneto ........... .... ......... ... ..... ..... .... .......... ............ 2-3
Electrical System ............................................,... .... ........ .... ....... 2-21 S~~rk PI~gs and Adapters .............................. '" ... ... ............... 2-4
Charging System Components ............................................. 2-21 Wlrrng Diagram ....................................................................;.. 2-5
Starting System Components ............................................... 2-21
Lubrication System ............................................................,....... 2-13
General Information ......... ......... ... ... ... ..... .......... .................. ......... 2-2 Lubrication System Components ..... ..... ....... ..... .......... ..... ..... 2-15
Gas, Air Inlet and Exhaust System .............................................. 2-6 Lubrication System Schematic
Aftercooler .. .......... ........... ......... ........ ........ ...... ....... ........ .... ...... 2-8 (Engines with Turbocharger) ................................................ 2-13
Balance Line ...........................................~ ............................... 2-9 Lubrication System Schematic
Boost Limit Control (Engines without Turbocharger) ........................................... 2-14
(Engines Equipped with a Turbocharger) ., ....... ....... ....... ....... 2-9 Oil Flow in the Engine . ... ........ ........... ............... ....... ............. 2-16
Carburetor ..... ....... .......... ....... ..... .... .... ....... ..... .... ... .... ........ ...... 2-8 Oil Flow Through the Oil Filter and Oil Cooler ..................... 2-15

TESTING AND ADJUSTING (Section 3)

Air Starting System .................................................................... 3-47 Gas Line Pressure ................................................................ 3-21
Governor Adjustments ....... ....... .......... ............ .......... ..... ....... 3-25
Basic Block .... ............. .............. ............... ........... ....................... 3-37 How To Find Gas Leaks ...................................................... 3-22
Connecting Rod and Main Bearings .................................... 3-37 Performance Evaluation .... ................................................... 3-21
Connecting Rods and Pistons .. ...... ..................... ................. 3-37 Procedure for Measuring Camshaft Lobes .... ...................... 3-24
Cylinder Block ........... .............. ................ .............................. 3-38 Restriction of Air Inlet and Exhaust ...................... ................ 3-20
Cylinder Liner Projection ........ ................ ...... ........................ 3-37 Valve Clearance ........ .................................................. ......... 3-23
Flywheel and Flywheel Housing ........ ........ .............. ............. 3-38
Piston Ring Groove Gauge .................... ...... .................. ...... 3-37 Ignition System ........ ............................ .............. ...... .................. 3-15
Vibration Damper ...... ..................... ............... ..... ............ ....... 3-41 Adjustment of Gauge Contact Point ..................................... 3-18
Finding Top Center Compression Position No.1 Piston ..... 3-15
Timing of Magneto to Engine (Spark Gap) .......................... 3-16
Cooling System .......................................................................... 3-33 Ignition Transformers ............................................................ 3-18
Testing The Cooling System ................................................ 3-33 Spark Plugs and Adapters .................................................... 3-18
Visual Inspection of the Cooling System .... .......... ................ 3-33
Lubrication System .................................................................... 3-31
Electrical System . .... .......... ................. ........... ............. ............... 3-42 Oil Pressure is High ........ .......... ................. .................... ....... 3-32
Battery . ... ....... ... ........ ........... .... ...... ...... ...... ... ..... ............ ........ 3-42 Oil Pressure is Low.............................................................. 3-31
Charging System ............ .................... ............................ ...... 3-42 Too Much Bearing Wear ........... :.......................................... 3-32
Starting System ...... ................ ........... ......... .......................... 3-45 Too Much Oil Consumption .................................................. 3-31

Gas, Air Inlet and Exhaust System ............................................ 3-20 Protection Devices ..................................................................... 3-49
Adjustment to Gas Pressure Regulator ................ .......... ..... 3-22 Contactor Switch for Oil Pressure .. .................. ........... ......... 3-49
Boost Limit Control ............................................................... 3-22 Pressure Switch for Time Delay ........................................... 3-51
Carburetor .. ............................. ..... .... .......... .................. ... ...... 3-20
Compression .... ............. ... ............. ...... ..... ......... ... .... ........ ..... 3-20 Woodward PSG Governor ......................................................... 3-28
Crankcase (Crankshaft Compartment) Pressure .. ............... 3-20 Governor Adjustments .............. ......... ........ ...... ..... ........... ..... 3-28
Cylinder Head .. ........... ........... ........ .............. ....... .......... ........ 3-23
Exhaust Temperature ........................................................... 3-23 Troubleshooting ............................................................ 3-2 thru 3-14

3
3306 NATURAL GAS ENGINE INDEX

0& A GENERAL INSTRUCTIONS (Section 4)

Batteries ................. ............ .................. .................... .................... .4-8 Lines and Wires ........................................................................... 4-6
Bearings ....................................................................................... 4-7 Locks ............................................................................................ 4-6
Anti-Friction ............................................................................. 4-7 Lubrication .............................. ...................................................... 4-7
Double Row, Tapered Roller .................................................. 4-7 Lubrication For a Rebuilt Engine .. .............. .......... ...... ...... ........... 4-2
Heating Bearings .................................................................... 4-7 Procedure for Pressure Lubrication ........................................ 4-3
Installation ................................... .................................... ........ 4-7
Preload ............... .................................. ......... .......... ................ 4-7 Pressing Parts .............. ............................ .................................... 4-5
Sleeve Bearings ..................................................................... 4-7
Bolts and Bolt Torque ......................................................... ......... 4-5
Torque Wrench Extension ......... ..................... ........................ 4-6 Removal and Installation .............................................................. 4-2
T-T-T Procedure ..................................................................... 4-5 Rules for Use of Tools ................................................................. 4-5
Rust Preventive Compound ......................................................... 4-7
Cleanliness ........... ........ ....................... ........ ....... ....... ................... 4-2
Conversion Chart (Inches to mm) .. ............................................. 4-8 Seals (Lip-Type) ........................................................................... 4-8
Service Tools ............................................................................... 4-3
Disassembly and Assembly........................... ................. ..... ........ 4-2 Bearing Cup Pulling Attachment ............................................ 4-5
Bearing Pulling Attachment .................................................... 4-5
Gaskets ............ .............................................. ....... ....................... 4-7 Puller Assembly (2 or 3 arm) ................ ......................... ........ 4-3
Push Pullers ........................................................................... 4-4
Initial Operation After Engine Reconditioning ..... ................ ......... 4-3 Shims ........................................................................................... 4-7

DISASSEMBLY AND ASSEMBLY (Section 5)

Accessory Drive ......... ............. ..... ... ... ..... ... .......... ........... .... .... ... 5-53 Magneto ..................................................................................... 5-56
Accessory Drive, Disassemble & Assemble .............................. 5-54 Magneto, Disassemble & Assemble .......................................... 5-57
Aftercooler ................................................................................... 5-31 Magneto Drive ............................................................................ 5-70
Air Cleaner ................................................................................... 5-3 ~- Magneto Drive, Disassemble & Assemble .............................. .. 5-72
Auxiliary Pump (Fresh Water) ................ ....................... ............. 5-44
Auxiliary Pump (Fresh Water), Disassemble & Assemble ........ 5-45 Oil Filter Base ... ............... ......... .......................... ........ ............... 5-90
Oil Filter Base, Disassemble & Assemble ................................. 5-92
Boost Control Valve ..................................................................... 5-5 Oil Pan ..................................................................................... 5-104
Boost Control Valve, Disassemble & Assemble .......................... 5-6 Oil Pan Plate ............................................................................ 5-105
Oil Pump ................................................................................... 5-106
Camshaft ........ .......... ............................... ..................... ............ 5-103 Oil Pump, Disassemble & Assemble ....................................... 5-107
Camshaft Bearings ............. .................... ........ .............. ........... 5-138
Carburetor .................................................................................. 5-22 Pistons ............ ...... ......... ....... ......... .......... ................................. 5-127
Carburetor, Disassemble & Assemble ....................................... 5-23 Pistons, Disassemble & Assemble .......................................... 5-129
Connecting Rod Bearings .... ...................... ......... ......... ............ 5-111
Crankshaft ........ ............... ........ ......... ............ ....... ........... .......... 5-139 Rocker Shaft and Push Rods ............................... ......... .......... 5-114
Crankshaft Main Bearings ..... ....... .............. ................... ........... 5-112 Rocker Shaft, Disassembly & Assemble ................................. 5-115
Crankshaft Front Seal and Wear Sleeve ................................... 5-97
Crankshaft Rear Seal and Wear Sleeve ..... ................ ....... ..... 5-137 Service Meter .. .............. ............ .................... ........... ....... ........... 5-53
Cylinder Head Assembly............... ...... ........... ............ ...... ........ 5-120 Spark Plugs and Spark Plug Adapters ...... ............ ......... ...... ..... 5-28
Cylinder Liners ......................................................................... 5-131 Timing Gears ........................................................................... 5-100
Engine Oil Cooler .................. ............ ........... ........... ................... 5-94 Timing Gear Plate .. .................. ............. .......... ............ ............. 5-102
Engine Oil Cooler, Disassemble & Assemble ........................... 5-95 Timing Gear Cover ........... ,......................................................... 5-98
Exhaust Manifold ..................................................................... 5-117 Torque for Flared and O-Ring Fittings ............................................ 9
Turbocharger ... '" ............. ...... ............... ..... ....... ... ............ ....... ...... 5-9
Front Support ..... .................. ................ ...... ................ .......... ...... 5-98 Turbocharger, Disassemble & Assemble .................................. 5-12
Flywheel....... ......... ................ ............. ................. ............ ......... 5-133
Flywheel Housing ..................................................................... 5-135 Valves ....................................................................................... 5-124
Valve Cover ............................................................................. 5-113
Gas Pressure Regulator ............................................................ 5-19 Valve Guides ............................................................................ 5-125
Gas Pressure Regulator, Disassemble & Assemble ................. 5-21 Valve Lifters ............................................................................. 5-116
General Tightening Torques ........................................................... 8 Valve Seat Inserts .................................................................... 5-126
Governor and Governor Drive ........ ................ ....... .............. ...... 5-78 Vibration Damper and Pulley ..................................................... 5-96
Governor and Governor Drive, Separation & Connection ......... 5-79
Governor, Disassemble & Assemble ......................................... 5-82 Water Directors ........................................................................ 5-126
Governor Drive, Disassemble & Assemble ............................... 5-88 Water Pump ......... ...... ................................. ..... ................ .......... 5-36
Water Pump, Disassemble & Assemble .................................... 5-38
Instrument Panel..... ........ ......... ............... ...... ................. ............ 5-29 Water Temperature Regulator ................. .......... ........ ................ 5-35

4
3306 NATURAL GAS ENGINE SPECIFICATIONS

TORQUE FOR FLARED AND O-RING FITTINGS

The torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and
Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.

~ ~ ~ Gl~
INVERTED O-RING
m
45° FLARED 37° FLARED 45° FLARED FITTING - PLUG SWIVEL NUTS

TUBE mm 3.1B 4.7B 6.35 7.92 9.52 TUBE mm 12.70 15.88 19.05 22.22 25.40 31.75 3B.l0 50.BO
SIZE SIZE
(0.0) • in. .125 . 188 .250 .312 .375 (0.0.1 in . .500 .625 .750 .B75 1.000 ;.250 1.500 2.000
THREAD 9116 THREAD 13/16
5/16 3/B 7/16 1/2 3/4 7/B 1 1/16 1 5/16 1 5/8 1 7/B 21/2
SIZE linJ S/B SIZE linJ 1 1/4
TORQUE 5 9 16 18 21 TORQUE 40 55 75 90 110 135 160 310
N'm ±1 ±1 ±2 ±2 ±2 N·m ±7 ±7 ±7 ±7 ±7 ±15 ±15 ±30
TORQUE 45 80 145 155 190 TORQUE
±10 ±10 ±20 30±5 40±5 55 ±5 65±5 BO±S 100 ±10 120 ±10 230±20
Ib.in. ±20 ±20 Ib.ft.

ASSEMBL Y OF FITTINGS WITH

STRAIGHT THREADS AND O-RING SEALS

1. Put locknut (3), backup washer (4) and O-ring

seal (5) as far back on fitting body (2) as possible. ITT 2
Hold these components in this position. Turn the
fitting into the part it is used on, until backup
washer (4) just makes contact with the face of the
part it is used on. 3
4

NOTE: If the fitting is a connector (straight fitting) or

plug, the hex on the body takes the place of the locknut.
To install this type fitting tighten the hex against the 5------__ -J~~~~
face of the part it goes into.
2. To put the fitting assembly in its correct position
turn the fitting body (2) out (counterclockwise) a
maximum of 359°. Tighten locknut (3) to the
torque shown in the chart.
----6
ELBOW BODY ASSEMBLY
1_ End of fitting body (connects to tube). 2. Fitting
body. 3. Locknut. 4. Backup washer. 5. a-ring seal. 6.
A71009Xl End of fitting that goes into other part.