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G330607YComplete digital official shop manual contains service, maintenance, and troubleshooting information for the Caterpillar 3304, 3306 Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Engine like a professional mechanic in local service/repair workshop. This service manual is a guide to servicing of Cat Lift Trucks for 3.5 thru 7.0 ton models. The instructions are grouped by systems to serve the convenience of your ready reference. Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing consistent with what you will learn from this service manual.
Magneto
Tools Needed | Quantity | |
9U-6958 | Magneto Test Module | 1 |
The following components of the instrument panel can affect the output of the magneto: magnetic switch, stop switch, engine oil pressure gauge and water temperature gauge. Determine if the components are working properly. There may be a problem with an overspeed contactor or an activated overspeed contactor rather than the magneto. Also, make sure that the gas shutoff valve is OK.
Use the 9U-6958 Magneto Test Module for measuring the voltage that is supplied to the spark plug by the magneto. The Operating Manual, NEHS0588 is provided with the tool.
Bench testing of the magneto is performed by the manufacturer.
Ignition Timing
- Determine the correct ignition timing for the fuel.
- Obtain a fuel analysis.
- Enter the data from the fuel analysis into the Caterpillar Software Program, LEKQ6378, 'Methane Number Program'.
- Refer to Engine Performance, LEBH9529, 'G3300 Industrial', 'Fuel Usage Guide' or Engine Performance, LEBX9532, 'G3300 Generator Set', 'Fuel Usage Guide' or consult with your Caterpillar dealer in order to determine the desired ignition timing.
Caterpillar G3304 Service Manual Download
Timing of Magneto to Engine (Solid State Altronic)
Show/hide table
Tools Needed | Quantity | |
9U-5358 | Timing Light Gp | 1 |
- Turn the crankshaft in the direction of engine rotation until the No. 1 piston is coming up on the compression stroke. Refer to Testing and Adjusting, 'Finding Top Center Position for No. 1 Piston'. Also observe the direction that the pointer on the magneto moves. Note: The magneto has two marks that indicate the rotation of the magneto ('CW' and 'CCW'). The magneto also has a pointer that moves clockwise or counterclockwise when the crankshaft is rotated. When you time the magneto to the engine, the pointer must indicate the correct timing mark.
Illustration 1 g00743172 Marks for the direction of rotation and pointer on the magneto Show/hide tableIllustration 2 g00735090 Flywheel timing marks - Observe the timing marks on the flywheel. Turn the crankshaft until the desired timing mark on the flywheel is directly under the pointer for the timing marks on the flywheel.
- Observe the pointer on the magneto. When the desired timing mark on the flywheel is obtained, the pointer on the magneto must be aligned with the appropriate mark.If the pointer on the magneto is not aligned with the appropriate mark, remove the magneto from the engine.
- Align the pointer on the magneto with the appropriate mark for the direction of rotation.
Illustration 3 g00743728 Lugs on the magneto drive tang - Pull the magneto drive away from the magneto drive housing. Align the slots of the magneto drive with the lugs on the magneto drive tang. Push the magneto drive back into the housing.
- Keep the pointer on the magneto aligned with the appropriate mark and install the magneto.
- Align the pointer on the magneto with the appropriate mark for the direction of rotation.
- Start the engine. Operate the engine at high idle speed. Note: Do not adjust the timing at low idle because of the timing advance in the magneto.
- Attach a timing light to the secondary lead for the spark plug of the number 1 cylinder. Use the timing light to observe the timing marks on the flywheel. If necessary, loosen the bolts for the magneto and rotate the magneto in order to gain the desired timing. When the timing is correct, tighten the bolts for the magneto.
- Install the covers for the flywheel housing.
Solid State Altronic Canadial Standards Association (CSA) and ATEX Applications
The ignition harnesses for engines in potentially explosive atmospheres are protected by thick braided covers. The ignition pulses in the harnesses might not be detected by many timing lights because of the braided covers.
A fabricated jumper cable will enable the timing light to detect ignition pulses. The fabricated cable is installed between the ignition harness connector and the ignition transformer of the number 1 cylinder.
Show/hide table
Tools Needed | Quantity | |
Fabricated jumper cable | 1 | |
Description | Part No. | |
Amphenol three-pin connector | MS3101A-10SL-3P | 1 |
Amphenol three-socket connector | MS3101A-10SL-3S | 1 |
16 AWG Red wire | Approximately | 1 |
16 AWG Black wire | Approximately | 1 |
16 AWG Green wire | Approximately | 1 |
- Assemble the materials listed in Table 2 according to the Illustration 4 schematic. Show/hide tableDo not disconnect equipment unless power has been disconnected or the area is known to be non-hazardous
- Disconnect the ignition harness from the number 1 cylinder. Connect the fabricated jumper harness between the ignition number 1 cylinder connector and the number 1 cylinder ignition transformer.
- Follow the procedure that is described above in 'Timing of Magneto to Engine (Solid State Altronic)'. When you perform the procedure, attach the timing light to the wiring for the fabricated jumper cable.
- After the procedure is completed, stop the engine. Remove the fabricated jumper cable. Reconnect the ignition harness to the ignition transformer for the number 1 cylinder.
Illustration 4 | g02725233 |
(1) Three-pin connector (2) Three-socket connector |
Timing of Magneto to Engine (Solid State Fairbanks Morse)
Tools Needed | Quantity | |
9U-5358 | Timing Light Gp | 1 |
- Turn the crankshaft in the direction of engine rotation until the No. 1 piston is coming up on the compression stroke. Refer to Testing and Adjusting, 'Finding Top Center Position for No. 1 Piston'. Show/hide table
Illustration 5 g00735090 Flywheel timing marks - Observe the timing marks on the flywheel. Turn the crankshaft until the desired timing mark on the flywheel is directly under the pointer for the timing marks on the flywheel.
- Remove the magneto from the engine.
Illustration 6 g00812376 (1) Timing bolt - Remove timing bolt (1) and turn magneto drive until the yellow mark on the gear is in the center of the hole. Show/hide table
Illustration 7 g00814081 G3304 Engine magneto
(1) 30 degree angle of the drive coupling from the vertical positionIllustration 8 g00814077 G3306 Engine magneto
(1) 45 degree angle of the drive coupling from the vertical position - Place the magneto drive coupling in the proper position. To rotate the drive coupling, pull out the coupling and rotate the coupling to the correct position. When the coupling is in the correct position, push in the coupling in order to engage the gear teeth.
- Install the magneto in order to engage the drive tang and the drive slot.
- Start the engine. Operate the engine at high idle speed. Note: Do not adjust the timing at low idle because of the timing advance in the magneto.
- Attach a timing light to the secondary lead for the spark plug of the number 1 cylinder. Use the timing light to observe the timing marks on the flywheel. If necessary, loosen the bolts for the magneto and rotate the magneto in order to gain the desired timing. When the timing is correct, tighten the bolts for the magneto.
Timing of the Spark Gap Magneto to the Engine
Show/hide table
Tools Needed | Quantity | |
9U-5358 | Timing Light Gp | 1 |
- Turn the flywheel in direction of engine rotation until the No. 1 piston is coming up on the compression stroke. Refer to Testing and Adjusting, 'Finding Top Center Position for No. 1 Piston'.
Illustration 9 g00735090 Flywheel timing marks - Observe the timing marks on the flywheel. Turn the crankshaft until the desired timing mark on the flywheel is directly under the pointer for the timing marks on the flywheel.
- Remove the magneto from the engine. Show/hide table
Illustration 10 g00812380 Position of the magneto drive
(1) Timing bolt
(2) Drive coupling and drive slot - Remove timing bolt (1). Turn the magneto drive in order to position the yellow mark that is on the distributor disc in the center of the hole. Install the timing bolt.
- Place drive coupling (2) in the vertical position. To rotate the drive coupling, pull out the coupling and rotate the coupling. When the coupling is in the correct position, push in the coupling in order to engage the gear teeth.
- Install the magneto in order to engage the drive tang and the drive slot.
- Start the engine. Operate the engine at high idle speed. Note: Do not adjust the timing at low idle because of the timing advance in the magneto.
- Attach a timing light to the secondary lead for the spark plug of the number 1 cylinder. Use the timing light to observe the timing marks on the flywheel. If necessary, loosen the bolts for the magneto and rotate the magneto in order to gain the desired timing. When the timing is correct, tighten the bolts for the magneto.
- Install the covers for the flywheel housing.
Adjustment of the Brush Spring
Illustration 11 | g00812377 |
(1) End cap assembly (2) Gasket for end cap assembly (3) Distributor block (4) Dowel rod (5) Distributor disc (6) Brush and spring assembly |
Measure the distance between distributor block (3) and the face of the distributor disc (5). The correct clearance indicates the correct pressure on the brush and spring assembly (6).
- Remove the timing bolt and install dowel rod (4) between distributor block (3) and distributor disc (5). The correct clearance is
3.96 to 5.56 mm (0.156 to 0.219 inch) . - To increase the clearance, add additional gaskets (2) for the end cap assembly. To reduce the clearance, add number 10 washers between distributor block (3) and end cap assembly (1).
Ignition Transformers
Check the transformer resistance. Refer to Specifications, 'Transformer'.
Spark Plugs and Adapters
Show/hide table
Tools Needed | Quantity | |
1F-0479 | Wrench | 1 |
9U-6695 | Spark Plug Firing Indicator Gp | 1 |
2P-5481 | Deep Well Socket | 1 |
154-9521 | Spark Plug Seat Cleaner | 1 |
Illustration 12 | g00803420 |
(1) Gasket (2) O-ring seal (3) Adapter |
Use the 1F-0479 Wrench for removal and installation of the spark plug adapter. When you install the adapter, make sure that gasket (1) is in place. Apply liquid soap to O-ring seal (2) and the bore for the seal in the cylinder head. Apply 5P-3931 Anti-Seize Compound on the threads of the adapter and on the threads in the cylinder head. Tighten the adapter to a torque of 95 ± 8 N·m (70 ± 6 lb ft) .
The 9U-6695 Spark Plug Firing Indicator Gp is an aid for determining ignition problems. Refer to the instructions that are included with the tool.
The condition of the spark plug and the changes in engine load will vary the voltage that is needed to create a spark. A new spark plug in an engine at low idle requires approximately 3,000 to 6,000 V. At full load, 8,000 to 10,000 V are required. If the spark plug gap needs adjustment, more than 10,000 V are required. If the spark plug gap is too great, the requirement for voltage will increase. When the voltage for the spark plug is greater than 10,000 V, the engine will run rough.
Refer to the engine Operation and Maintenance Manual for instructions on inspection and installation of the spark plug.
Altronic Integral Transformer
- Install new 108-6561 Gasket (5) on the spark plug. The gasket is copper. Whenever the transformer is removed, always install a new gasket.
- Ensure that transformer (4) is clean and free from dirt and oil. Screw the transformer by hand onto the spark plug. Tighten the transformer until the transformer bottoms out on the copper gasket. Tighten the transformer for an additional 1/8 of a turn (45 degrees). Do not overtighten the transformer.
- Inspect boot (3) for cleanliness and good condition. Install the boot.
- Tighten clamp (2).
- Inspect connector (1) for cleanliness and good condition. Reconnect the connector. Align the threads properly. For a correctly fastened connector, little thread or no thread is visible.
Show/hide table
Illustration 13 | g00803356 |
(1) Connector (2) Clamp (3) Boot (4) Transformer (5) Gasket |
Adjustment of the Contact Points for the Gauges
The adjustment of the contact for the engine oil pressure gauge is correct when the engine is stopped at 55 kPa (8 psi) of engine oil pressure. The adjustment of the contact for the temperature gauge for water is correct when the engine is stopped at 99 °C (210 °F) .
Adjustment of the gauges is made with a small hex head wrench. Turn the adjustment screw on the gauge until the correct point is achieved.
Illustration 14 | g00675751 |
Water temperature gauge (1) Adjustment screw |
Show/hide table
Illustration 15 | g00675777 |
Engine oil pressure gauge (1) Adjustment screw |
Catalog:
Model:
Price:$59.00
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Caterpillar 3208 Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for Caterpillar3208 Engine is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
MANAUL LIST:
SENR3581 - Specifications (3208 Marine Engine).pdf
SEBR0541 - Service Manual (3208 Diesel Truck Engine)
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
SENR2131 - Specifications (3208 Marine Engine)
SENR2133 - Specifications (3208 Marine Engine Attachments)
SENR2135 - Disassembly and Assembly (3208 Marine Engine)
SENR3130 - Torque Specifications
SENR3581 - Disassembly and Assembly (3208 Marine Engine)
SENR3581 - Systems Operation (3208 Marine Engine)
SENR3581 - Testing and Adjusting (3208 Marine Engine)
SENR3581 - Troubleshooting (3208 Marine Engine)
SEBU6090 - Engine Safety (3208 Marine Engine).pdf
SEBU6090 - Maintenance Intervals (3208 Marine Engine).pdf
SENR2132 - Systems Operation (3208 Marine Engine).pdf
SENR2132 - Testing & Adjusting (3208 Marine Engine).pdf
SENR2134 - Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 - Testing & Adjusting (3208 Marine Engine Attachments).pdf
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols
UENR3262 - Disassembly & Assembly - Seal Installation
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes{1100, 1105}.pdf
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display).pdf
SENR2995 - Product Safety.pdf
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
…
SENR3581 - Specifications (3208 Marine Engine).pdf
SEBR0541 - Service Manual (3208 Diesel Truck Engine)
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
SENR2131 - Specifications (3208 Marine Engine)
SENR2133 - Specifications (3208 Marine Engine Attachments)
SENR2135 - Disassembly and Assembly (3208 Marine Engine)
SENR3130 - Torque Specifications
SENR3581 - Disassembly and Assembly (3208 Marine Engine)
SENR3581 - Systems Operation (3208 Marine Engine)
SENR3581 - Testing and Adjusting (3208 Marine Engine)
SENR3581 - Troubleshooting (3208 Marine Engine)
SEBU6090 - Engine Safety (3208 Marine Engine).pdf
SEBU6090 - Maintenance Intervals (3208 Marine Engine).pdf
SENR2132 - Systems Operation (3208 Marine Engine).pdf
SENR2132 - Testing & Adjusting (3208 Marine Engine).pdf
SENR2134 - Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 - Testing & Adjusting (3208 Marine Engine Attachments).pdf
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols
UENR3262 - Disassembly & Assembly - Seal Installation
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes{1100, 1105}.pdf
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display).pdf
SENR2995 - Product Safety.pdf
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
…
![Pdf Pdf](/uploads/1/2/6/6/126667453/971805543.jpg)
ENGINE - GENERATOR SET
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF
ENGINE - INDUSTRIAL
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC
ENGINE - MACHINE
Model Prefix
3208 ENGINE - MACHINE 03Z
3208 ENGINE - MACHINE 79V
3208 ENGINE - MACHINE 90N
3208 ENGINE - MACHINE 93Z
Model Prefix
3208 ENGINE - MACHINE 03Z
3208 ENGINE - MACHINE 79V
3208 ENGINE - MACHINE 90N
3208 ENGINE - MACHINE 93Z
ENGINE - TRUCK
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z
MARINE PRODUCTS
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V
EXCERPT:
Fuel Injection Pump Housing And Governor
SMCS - 1286-11; 1286-12
SMCS - 1286-11; 1286-12
Remove Fuel Injection Pump Housing And Governor
View Image
start by:
a) remove air cleaner
![Caterpillar G3304 Service Manual Caterpillar G3304 Service Manual](/uploads/1/2/6/6/126667453/206488955.png)
b) remove fuel injection lines
c) Remove air inlet manifold
View Image
1. Remove plug from cover in fuel injection pump housing and install tool (A). Turn the crankshaft (clockwise) until the timing pin drops into the groove (slot) in the fuel injection pump camshaft.
View Image
2. Remove two nuts (2) and the tachometer drive housing (1).
3. Remove tachometer drive shaft (3).
View Image
4. Install tooling (B) into the camshaft drive gear for the fuel injection pump. Turn bolts (4) evenly until the drive gear is free of the shaft. Remove tooling (B).
View Image
5. Remove the plug from the timing hole in the front cover and install a 5/16'-18 NC bolt (5) 2 1/2 in. long. The cover bolt from hole (6) can be used. Turn the crankshaft (clockwise) until bolt can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time to the engine.
View Image
Service Manual Bmw
6. Remove line (7). Remove bolts (8) from base of the fuel injection pump housing.
View Image
7. Remove the fuel injection pump housing and governor as a unit.
Install Fuel Injection Pump Housing And Governor
1. Put the fuel injection pump housing and governor in position on the engine. Install the bolts and lines.
2. Install the tachometer drive shaft and tighten it to a torque of 110 ± 10 lb. ft. (149 ± 14 N·m).
3. To check the timing, remove the timing pin and the bolt. Turn the crankshaft (clockwise) two revolutions and install the timing pin and bolt back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be put into time again before Step 4 is done.
4. Remove the bolt from the timing gear. Install the plug into the timing hole.
Caterpillar G3304 Service Manual Pdf
5. Remove the timing pin from the timing groove (slot) in the fuel injection pump camshaft.
6. Install the tachometer drive housing.
end by:
a) install air inlet manifold
Caterpillar G3304 Service Manual Transmissions
b) install fuel injection lines
Caterpillar G3304 Service Manuals
c) install air cleaner
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