- Caterpillar G3304 Service Manual Pdf
- Caterpillar G3304 Service Manual Transmission
- Bike Service Manual
CATERPILLAR SERVICE MANUALS Everybody knows that Caterpillar produces the finest machinery in the world! But even the finest piece of equipment will need service, repair, and regular maintenance. A factory Caterpillar service manual is the only real choice. The free Caterpillar operators manual is helpful for becoming familiar with the operation and minor maintenance of Continue reading. Gas engine Caterpillar G399 Service manual: CAT40-028: G3304: Gas engine Caterpillar G3304 Spare parts catalog: CAT40-029: G3304: Gas engine Caterpillar G3304 Operation and maintenance manual: CAT40-030: G3304: Gas engine Caterpillar G3304 Service manual: CAT40-031: G3304B.
Usage:
G330607YThe ignition system has five basic components: magneto, ignition transformers for each cylinder, wiring harness, spark plugs and instrument panel.
Solid State Magneto (Altronic)
| Illustration 1 | g00743710 |
| Magneto (1) Alternator (2) Stator | |
The main components of the Altronic magneto are alternator (1) and stator (2). The alternator generates electricity. The stator distributes the electricity. There are no brushes or distributor contacts.
| Illustration 2 | g00579848 |
| Cross section of an Altronic magneto (3) Rotor (4) Vent (5) Speed reduction gears (6) Pickup coil (7) Drive tang (8) Storage capacitor (9) Rotating timer (10) Silicon controlled rectifier (SCR) (11) Output connector | |
The magneto's drive tang (7) is driven by the engine. The drive tang is attached to a shaft which turns the alternator's rotor (3). Rotation of the rotor causes rotation of speed reduction gears (5) and rotating timer (9). The power from the alternator charges storage capacitor (8). There is a separate pickup coil (6) and a separate silicon controlled rectifier (SCR) (10) for each cylinder. As the rotating timer passes over the pickup coils, a pulse from each coil activates each corresponding SCR in sequence. Each SCR releases the energy that is stored in capacitor (8). This energy leaves the magneto through output connector (11) and the ignition wiring harness to the ignition transformers. The transformers increase the voltage to the level that is needed to fire the spark plugs.
Solid State Magneto (Fairbanks Morse)
| Illustration 3 | g00662676 |
| Cross section of a solid state Fairbanks Morse magneto (1) Plug (2) Coil (3) Plate and power board assembly (4) Distribution board (5) Capacitor (6) Alternator housing (7) Coil (8) Rotor (9) Silicon controlled rectifier (SCR) (10) Connector plug | |
Rotor (8) is driven by the engine through a drive coupling. The rotor moves by each coil (7) in order to produce voltage. The alternating current is sent through a rectifier which converts alternating current into direct current. The voltage is sent to the silicon controlled rectifier (SCR) (9) for the cylinder that will fire. Energizing the SCR enables the voltage that is stored in capacitor (5) to be released. The voltage goes through distribution board (4) to the transformer. As the rotor moves past each coil, the same electrical impulse is developed.
Spark Gap Magneto
| Illustration 4 | g00662340 |
| Cross section of a spark gap magneto (1) Distributor's disc (2) Cam (3) Distributor's gear and shaft assembly (4) Transformer (5) Coupling (6) Rotor (7) Condenser (8) Contact points (9) Rotor (10) Brush and spring assembly | |
Transformer (4) has a primary coil that is made of a heavy wire. One end of the primary coil is connected to ground on the transformer's core. The other end of the primary coil is connected to contact points (8).
Rotor (6) is a permanent magnet. When the rotor turns, electrical energy is produced in transformer (4). This will produce electricity in the wires.
When the voltage in the primary coil is at the highest peak in the alternating current's cycle, cam (2) opens contact points (8).
The contact points open in order to break the electric circuit. The flux around the wires of the primary coil will suddenly collapse through the primary coil. This produces peak voltage in the primary coil.
At peak voltage, the position of the distributor's disc (1) completes the circuit through the brush and spring assembly (4). The voltage travels to the distributor's block and through the low tension leads to the ignition transformers.
Condenser (7) prevents a spark that can cause damage to contact points (8). The electrical energy which normally makes a spark across the gap in the contact points goes into the condenser. When the contact points close, the electrical energy in the condenser moves back into the primary coil in order to provide voltage.
Impulse coupling (5) is used to cause an increase in the rpm of the rotor. When you start the engine the coupling is engaged. This will produce a stronger spark while the engine is started. The coupling is not engaged during normal engine operation.
Ignition Transformer
| Illustration 5 | g00679230 |
| Standard transformer | |
| Illustration 6 | g00663208 |
| Integral Altronic transformer | |
An ignition transformer for each cylinder enables the ignition system to use low tension (voltage). Low voltage is sent to the transformers. The transformers increase the voltage to the high tension that is needed to fire the spark plugs.
In an ignition system that uses high tension, the loss of current through the wiring can be substantial. Routing of several wires that conduct high tension increases the chance of an insulation failure which can result in grounding of the current. Also, the current in the wiring can be affected in a manner that is similar to the current in a transformer. This can result in a crossover of the current between the leads. The crossover can cause a loss of power and misfire. An ignition system that uses low tension has these advantages over a system that uses high tension:
- Line loss through the wiring is reduced.
- The possibility of insulation failure and grounding of the current is reduced.
- The possibility of crossover is reduced.
For proper operation, the terminals of the transformer must be clean and tight. The negative transformer terminals have a '−' mark. These terminals are connected together and the circuit is grounded.
Spark Plugs And Adapters
| Illustration 7 | g00663105 |
| Spark plug and adapter (1) Cover (2) Spark plug wire (3) Seal (4) Spark plug adapter (5) Spark plug | |
Cover (1) keeps water, dirt and other foreign material out of spark plug adapter (4). Spark plug wire (2) goes through the cover to the terminal of spark plug (5). Seal (3) prevents leaks between the adapter and the cylinder head.
Instrument Panel
| Illustration 8 | g00662973 |
| Instrument panel (1) Stop switch (2) Reset switch (3) Oil pressure gauge (4) Water temperature gauge (5) Start switch | |
The instrument panel is connected to the magneto and the gas shutoff valve.
A magnetic switch connects the magneto to ground. The engine oil pressure gauge and the water temperature gauge have switches that are connected to the magnetic switch. If the water temperature gets too high or if the engine oil pressure gets too low the magnetic switch is activated. The water temperature gauge prevents an overheated engine from running and/or being started. The engine oil pressure gauge prevents engine operation with low oil pressure.
The engine oil pressure gauge and the water temperature gauge will not make a connection to the magneto ground when reset switch (2) is pushed in and held. When you start the engine, press start switch (5) and the reset switch. The reset switch prevents the connection of the magneto to ground because of low engine oil pressure. Once the engine starts, normal engine oil pressure allows the switch to be released. The gauge is then ready to stop the engine when the engine oil pressure is low.
For normal stopping, press stop switch (1). The gas shutoff valve must be manually reset.
Wiring Diagrams
| Illustration 9 | g00664281 |
| Ignition system diagram for the solid state Altronic magneto (G3304) (1) Spark plug (2) Ignition transformer (3) Ground for the magneto's case (4) Magneto (5) Instrument panel (6) Magnetic switch (7) Stop switch (8) Engine oil pressure gauge (9) Water temperature gauge | |
| Illustration 10 | g00664366 |
| Ignition system diagram for the solid state Altronic magneto (G3306) (1) Spark plug (2) Ignition transformer (3) Ground for the magneto's case (4) Magneto (5) Instrument panel (6) Magnetic switch (7) Stop switch (8) Engine oil pressure gauge (9) Water temperature gauge | |
| Illustration 11 | g00669020 |
| Ignition system diagram for the solid state Fairbanks Morse magneto (G3304) (1) Spark plug (2) Ignition transformer (3) Magneto (4) Instrument panel (5) Magnetic switch (6) Stop switch (7) Engine oil pressure gauge (8) Water temperature gauge | |
| Illustration 12 | g00669031 |
| Ignition system diagram for the solid state Fairbanks Morse magneto (G3306) (1) Spark plug (2) Ignition transformer (3) Magneto (4) Instrument panel (5) Magnetic switch (6) Stop switch (7) Engine oil pressure gauge (8) Water temperature gauge | |
| Illustration 13 | g00664212 |
| Ignition system diagram for the spark gap magneto (G3304) (1) Magneto (2) Spark plugs (3) Ignition transformers (4) Magnetic switch (5) Stop switch (6) Engine oil pressure gauge (7) Water temperature gauge (8) Instrument panel | |
| Illustration 14 | g00668991 |
| Ignition system diagram for the spark gap magneto (G3306) (1) Magneto (2) Spark plugs (3) Ignition transformers (4) Magnetic switch (5) Stop switch (6) Engine oil pressure gauge (7) Water temperature gauge (8) Instrument panel | |
| Illustration 15 | g00664384 |
| Wiring diagram with overspeed contactor and gas valve (1) Solenoid (2) Gas shutoff valve (3) Overspeed contactor (4) Shut off stud for spark gap magneto or pin H for Fairbanks Morse magneto or pin G for Altronic magneto (5) Magnetic switch (6) Stop switch (7) Engine oil pressure gauge (8) Water temperature gauge (9) Instrument panel | |
INSTANT DOWNLOAD
Complete 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 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 Caterpillar 3304, 3306 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.
FILELIST:
UEG0797S – Parts Book (3304 Vehicular Engine).pdf
REG00974 – Disassembly & Assembly (3304 Vehicular Engine for 920 & 930 Wheel Loaders)
SENR2149 – Disassembly & Assembly (3306 Vehicular Engine for 966D Wheel Loader)
SENR2252 – Specifications (3304 Direct Injection Vehicular Engine with New Scroll Fuel)
SENR2254 – Disassembly & Assembly (3304 Vehicular Engine for 950B Wheel Loader)
SENR2428 – Specifications (3304 Vehicular Engine for 930R Wheel Loader)
SENR2430 – Disassembly & Assembly (3304 Vehicular Engine for 930R Wheel Loader)
SENR3074 – Disassembly & Assembly (3304 Vehicular Engine for 930T & 936 Wheel Loaders)
SENR5559 – Disassembly & Assembly (3304 & 3306 Diesel Engines)
SENR7590 – Specifications (3304 Vehicular Engine)
SENR2147 – Specifications (3306 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2253 – Systems Operation (3304 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2253 – Testing & Adjusting (3304 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2429 – Systems Operation (3304 Vehicular Engine for 930R Wheel Loader).pdf
SENR2429 – Testing & Adjusting (3304 Vehicular Engine for 930R Wheel Loader).pdf
SENR7590 – Specifications (3304 Vehicular Engine).pdf
SENR7591 – Systems Operation (3304 Vehicular Engine).pdf
SENR7591 – Systems Operation + Testing & Adjusting (3304 Vehicular Engine).pdf
SENR7591 – Testing & Adjusting (3304 Vehicular Engine).pdf
…
ENGINE – GENERATOR SET
Model Prefix
3304 GEN SET ENGINE 3TC
3304 GEN SET ENGINE 4PC
3304 GEN SET ENGINE 6YB
3304 GEN SET ENGINE 83Z
3304B GEN SET ENGINE 1YF
3304B GEN SET ENGINE 2KK
3304B GEN SET ENGINE 3TC
3304B GEN SET ENGINE 83Z
3304B GEN SET ENGINE 9HK
3304B GENERATOR SET DED
ENGINE – INDUSTRIAL
Model Prefix
3304 INDUSTRIAL ENGINE 02B
3304 INDUSTRIAL ENGINE 04B
3304 INDUSTRIAL ENGINE 10E
3304B INDUSTRIAL ENGINE 4XB
ENGINE – MACHINE
Model Prefix
3304 ENGINE – MACHINE 07Z
3304 ENGINE – MACHINE 09Z
3304 ENGINE – MACHINE 10E
3304 ENGINE – MACHINE 12Z
3304 ENGINE – MACHINE 43V
3304 ENGINE – MACHINE 46V
3304 ENGINE – MACHINE 48V
3304 ENGINE – MACHINE 4TJ
3304 ENGINE – MACHINE 4XB
3304 ENGINE – MACHINE 4YD
3304 ENGINE – MACHINE 59Z
3304 ENGINE – MACHINE 78P
3304 ENGINE – MACHINE 9CB
3304 ENGINE – MACHINE 9CG
3304 ENGINE – MACHINE H4G
MARINE PRODUCTS
Model Prefix
3304 MARINE ENGINE 05B
3304 MARINE ENGINE 13E
3304B MARINE ENGINE 13E
3304B MARINE ENGINE 1NS
3304B MARINE ENGINE 1PS
3304B MARINE ENGINE 8XL
Caterpillar G3304 Service Manual Pdf
EXCERPT:
Systems Operation
N3 Series Brushless Alternators Media Number -SENR2082-01 Publication Date -01/03/2002 Date Updated -12/03/2002
Normal Operation
SMCS – 1405
The field winding uses DC voltage to create a magnetic field. The magnetic field is used to magnetize the rotor. The stator is a stationary component that surrounds the rotor. When the rotor rotates voltage is produced. The stator will then send the voltage to the rectifier. The rectifier changes the AC voltage into DC voltage. Part of the DC voltage returns to the field winding in order to maintain the magnetic field. The remainder of the DC voltage is supplied to the battery. Electrical components on the machine will then receive the voltage from the battery. The regulator limits the DC voltage at the battery terminals to 28 ± 1 volts by controlling the current in the field winding.
Alternator Operation Schematics
View Image
Illustration 1 g00866883
Electrical schematic of the N3 series alternator (35 amperes)
B- – Frame to battery ground
B+ – Alternator to battery positive terminal
D+ – Output for the excitation circuit and regulator input
D- – Ground for the alternator and regulator
DF – Alternator output and regulator input
G – Field winding
R – Auxiliary terminal
U – Stator winding
V – Stator winding
W – Stator winding
Caterpillar G3304 Service Manual Transmission
View Image
Illustration 2 g00866887
Electrical schematic of the N3 series alternator (50 amperes)
(1) Diodes for protection against load dump
B- – Frame to battery ground
B+ – Alternator to battery positive terminal
D+ – Output for the excitation circuit and regulator input
D- – Ground for the alternator and regulator
DF – Alternator output and regulator input
G – Field winding
R – Auxiliary terminal
U – Stator winding
V – Stator winding
W – Stator winding
Note: The “R” terminal may be used by one of the following components:
Charge indicator
Tachometer
Hour meter
Electronic control module
Illustrations 1 and 2 show the electrical schematics for the N3 series alternators.
The alternator has two circuits: the charging circuit and the excitation circuit. The charging circuit functions during normal operation. The excitation circuit functions during normal operation and during start-up. An independent circuit exists for each phase of the stator. Phases are noted as “U”, “V”, and “W”. The 50 amp alternator has two extra diodes. Diodes are connected to the neutral point of the stator. Diodes also add extra current to the output. However, the 35 ampere alternator lacks the extra diodes.
The descriptions that follow show the N3 series alternator (35 ampere).
Charging Circuit
The charging circuit supplies current to the battery and to the electrical systems during normal operation. Stator windings in the alternator generate three-phase AC voltage. Positive diodes and the negative diodes change the AC voltage into DC voltage. DC voltage allows the current to flow to the battery terminals.
View Image
Illustration 3 g00825118
Charging circuit with phase angle of 120°
Bike Service Manual
The flow of current at a 120° phase angle is shown in Illustration 3. The polarity for the stator winding is described below:
Positive at the output of winding “U”
Zero at the output of winding “V”
Negative at the output of winding “W”
View Image
Illustration 4 g00825120
Charging circuit with phase angle of 150°
The flow of current at a 150° phase angle is shown in Illustration 4. The polarity for the stator winding is described below:
Positive at the output of winding “U”
Positive at the output of winding “V”
Negative at the output of winding “W”
Excitation Circuit (Normal)
The N3 series alternator is self-excited. The excitation circuit supplies current to the field winding (exciter) during normal operation. The rotor contains an iron core that acts as a rotating magnet. The rotating magnetic field induces voltages in the stator windings. Stator windings generate three-phase AC voltage. Exciter diodes and negative diodes change the AC voltage into DC voltage. DC voltage allows current to flow in the field winding. The current induces a stationary magnetic field in the field winding that will keep the rotor core magnetized. This process continues as the rotor operates normally.