Caterpillar G3304 Service Manual

Usage:

Magneto

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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.

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

1. Determine the correct ignition timing for the fuel.
   1. Obtain a fuel analysis.
   2. Enter the data from the fuel analysis into the Caterpillar Software Program, LEKQ6378, 'Methane Number Program'.
   3. 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.

Timing of Magneto to Engine (Solid State Altronic)

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

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   Illustration 2	g00735090
   Flywheel timing marks

2. 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.
3. 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.

   1. Align the pointer on the magneto with the appropriate mark for the direction of rotation.

      Illustration 3	g00743728
      Lugs on the magneto drive tang

   2. 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.
   3. Keep the pointer on the magneto aligned with the appropriate mark and install the magneto.
4. 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.

5. 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.
6. 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.

Manual Car Service Manuals

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.

Illustration 4	g02725233
(1) Three-pin connector (2) Three-socket connector

1. Assemble the materials listed in Table 2 according to the Illustration 4 schematic.
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   Do not disconnect equipment unless power has been disconnected or the area is known to be non-hazardous

2. 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.
3. 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.
4. 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.

Timing of Magneto to Engine (Solid State Fairbanks Morse)

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'.
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   Illustration 5	g00735090
   Flywheel timing marks

2. 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.
3. Remove the magneto from the engine.

   Illustration 6	g00812376
   (1) Timing bolt

4. Remove timing bolt (1) and turn magneto drive until the yellow mark on the gear is in the center of the hole.
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   Illustration 7	g00814081
   G3304 Engine magneto (1) 30 degree angle of the drive coupling from the vertical position

   Illustration 8	g00814077
   G3306 Engine magneto (1) 45 degree angle of the drive coupling from the vertical position

5. 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.
6. Install the magneto in order to engage the drive tang and the drive slot.
7. 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.

8. 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

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

2. 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.
3. Remove the magneto from the engine.
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   Illustration 10	g00812380
   Position of the magneto drive (1) Timing bolt (2) Drive coupling and drive slot

4. 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.
5. 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.
6. Install the magneto in order to engage the drive tang and the drive slot.
7. 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.

8. 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.
9. Install the covers for the flywheel housing.

Adjustment of the Brush Spring

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).

1. 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).
2. 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

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

Caterpillar G3304 Service Manual Pdf

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Illustration 13	g00803356
(1) Connector (2) Clamp (3) Boot (4) Transformer (5) Gasket

1. Install new 108-6561 Gasket (5) on the spark plug.

   The gasket is copper. Whenever the transformer is removed, always install a new gasket.

2. 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.

3. Inspect boot (3) for cleanliness and good condition. Install the boot.
4. Tighten clamp (2).
5. 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.

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.

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Caterpillar G3304 Service Manual Transmission

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