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CAT Caterpillar 3500 3508 3512 3516 Engines
Service Repair Operator’s Manual TM 5-2815-232-14

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TECHNICAL MANUAL

OPERATOR’ S, UNIT, INTERMEDIATE

(DS) AND INTERMEDIATE (GS)

MAINTENANCE MANUAL

FOR ENGINE, DIESEL,

CATERPILLAR, MODEL 3508

NSN 2815-01-216-0938

 

FOR USE IN SERVICE MANUALS:

3500 INDUSTRIAL ENGINES,

SENR2573

VOLUME I SPECIFICATIONS,

REGO1312
FOR USE IN SERVICE MANUALS:

3500 INDUSTRIAL ENGINES,

SENR2573

VOLUME I SPECIFICATIONS,

REGO1312

SPECIFICATIONS

FOR 3500 INDUSTRIAL

ENGINE ATTACHMENTS

49Y1-UP 65Z1-UP

95Y1-UP 68Z1-UP

27Z1-UP 71Z1-UP
Tech Manual Contents

Specs for Engine Attachments, 3500 Industrial

Cat: REGO1312

SN: 49Y1-Up, 95Y1-Up, 27Z1-Up, 65Z1-Up, 68Z1-Up, 71Z1-Up

General Tightening Torque for Bolts, Nuts, and Taperlock Studs

Fuel System

Air Induction and Exhaust System

Lubrication system

Cooling System

Basic Engine Components

Electrical System

Systems Operation Testing & Adjusting, 3500 Industrial Engines

Cat: SENR2573

SN: 49Y1-Up, 95Y1-Up, 27Z1-Up, 65Z1-Up, 68Z1-Up, 71Z1-Up

Engine Design

Fuel System

Air Inlet and Exhaust System

Lubrication system

Air Starting System

Testing and Adjusting

Troubleshooting

Fuel System

Woodward UG8 Lever Governor, 3161 Governor

Cat: SENR3028

Air Fuel Ratio Control

Lubrication System

Cooling System

Basic Block

Electrical System

Auxiliary Controls

Troubleshooting

Testing and Adjusting

Hydramechanical Protective system, 3500 Series Engine

Specifications

Systems Operation

Testing and Adjusting

Disassembly and Assembly, 3500 Engines

Cat: SENR2573

SN: 68Z1-Up, 65Z1-Up

Engine Attachments Specifications, 3500 Series

Cat: REGO1312 – Form: SENR2353-01

SN: 49Y1-Up, 95Y1-Up, 27Z1-Up, 65Z1-Up, 68Z1-Up, 71Z1-Up

Electric Protective System for Engines with Reversal Protection

Cat: SENR2984

Components

Troubleshooting Procedures

Wiring Diagrams

Electric Protective System for Generator Set, Industrial & Marine

Cat: SENR2985

Components

Troubleshooting Procedures

Wiring Diagrams

Operation & Maintenance Manual

Cat: SEBU5853

SN: 23Z1-Up, 24Z1-Up, 25Z1-Up, 27Z1-Up, 65Z1-Up, 67Z1-Up,
 68Z1-Up, 70Z1-Up, 71Z1-Up, 73Z1-Up, 49Y1-Up, 95Y1-Up

Safety

Operation  Maintenance
For More Detail Please See the TOC

 

Specifications for Engine Attachments,

3500 Industrial ............................................. 1

General Tightening Torque for Bolts, Nuts,
and Taperlock Studs.............................. 3

Torque for Flared and O-Ring Fittings4

Engine Design ........................................ 5

Fuel System

Fuel Injection ....................................... 8

Fuel Pressure Regulator (Earlier)........ 8

Fuel Pressure Regulator (Later).......... 9

Manual Shutoff Group ......................... 9

Fuel Injection Control Group ............... 10

Governor Fastener Group ................... 11

Governor Drive .................................... 11

Air Induction and Exhaust System

Camshafts ........................................... 12

Valves ............................................. 14

Valve Covers ....................................... 15

Valve Rocker Arms, Lifters and Bridges 15

Cylinder Heads.................................... 16

Turbocharger Impeller Installation....... 17

Turbochargers ..................................... 18

Exhaust Manifolds ............................... 22

Air Intake Shutoff................................. 23

Lubrication System

Oil Pump ............................................. 26

Oil Filter Bypass Valve (Earlier)........... 28

Oil Filter Bypass Valve (Later)............. 29

Oil Cooler Bypass and Cooling Jet

Sequence Valves................................. 30

 

Cooling System

Water Pump.............................................. 31

Aftercooler .............................................. 32

Water Connection Group - Outlet ............. 32

Water Temperature Regulators ................ 33

V-Belt Tension Chart................................. 33

Basic Engine Components

Cylinder Block ........................................... 34

Cylinder Liners .......................................... 35

Cylinder Liner Projection........................... 35

Pistons and Rings ..................................... 36

Connecting Rods ...................................... 37

Connecting Rod and Main Bearing Journals 38

Crankshaft .............................................. 39

Crankshaft Wear Sleeves and Seals ........ 40

Front Balancer Group (3508).................... 41

Lower Front Gear Group .......................... 42

Upper Front Gear Group (7N4871)........... 44

Rear Gear Group ...................................... 45

Flywheel .............................................. 47

Flywheel Runout ....................................... 48

Flywheel Housing...................................... 50

Flywheel Housing Bore............................. 52

Flywheel Housing Runout......................... 53

 

Air Starter Motors ................................ Deleted

Pressure Regulating Valve for

Air Starter Motor ............................................. Deleted

Systems Operation, 3500 Industrial Engines 61

Engine Design ........................................ 63

Fuel System ............................................ 65

Fuel Injection Control Linkage............. 67

Fuel Injector......................................... 68

Woodward UG8 Lever Governors....... 71

Air Fuel Ratio Control .......................... 73

Air Inlet and Exhaust System................ 75

Aftercooler ........................................... 77

Turbochargers ..................................... 78

Valve System Components ................. 78

Lubrication System................................ 80

Cooling System ........................................ 82

Basic Block ............................................. 84

Cylinder Block, Liners and Heads ....... 84

Pistons, Rings and Connecting Rods.. 84

Crankshaft ........................................... 84

Camshafts ........................................... 85

Air Starting System................................ 86

Electrical System...................................... 88

Alternator............................................. 88

Starter Motor ....................................... 88

Starter Solenoid................................... 89

Circuit Breaker..................................... 89

Contactor Switch (Water Temperature) 90

Testing and Adjusting ........................... 91


Troubleshooting.............................................. 91

Fuel System .............................................. 107

Fuel System Inspection............................. 107

Checking Engine Cylinders Separately..... 107

Fuel Injector Testing ................................. 107

Injector Tester Preparation ....................... 108

Operation of the Tester ............................. 108

Leak Test for Injector Tester ..................... 109

Injector Test Sequence............................. 110

Fuel Pressure ........................................... 116

Engine Rotation ........................................ 117

Finding Top Center Position for No. 1

Piston .............................................. 117

Camshaft Timing....................................... 118

Startup Procedure..................................... 120

Crankshaft Positions for Fuel Timing........ 121

Fuel Timing .............................................. 122

Injector Synchronization............................ 123

Fuel Setting .............................................. 125

Fuel Setting Adjustment............................ 126

Engine Speed Measurement .................... 127

Woodward UG8 Lever Governor ................... 128

Compensating Adjustment........................ 128

Low and High Idle Speed Adjustment....... 129

Speed Droop Adjustment.......................... 129

Air Fuel Ratio Control..................................... 132

Air Inlet and Exhaust System.................... 133

Restriction of Air Inlet and Exhaust........... 133

Measurement of Pressure in Inlet Manifold 133
Exhaust Temperature............................... 134

Crankcase (Crankshaft Compartment)

Pressure ............................................. 134

Compression ............................................ 134

Cylinder Heads......................................... 134

Valves ............................................. 134

Bridge Adjustment.................................... 135

Crankshaft Positions for Valve

Clearance Setting .................................... 136

Valve Clearance....................................... 137

Lubrication System ........................................ 139

Too Much Oil Consumption...................... 139

Measuring Engine Oil Pressure................ 139

Oil Pressure is Low ................................. 140

Oil Pressure is High.................................. 140

Too Much Bearing Wear .......................... 140

Increased Oil Temperature ...................... 140

Cooling System ............................................. 141

Visual Inspection of the Cooling System.. 141

Testing the Cooling System ..................... 141

Test Tools for Cooling System ................. 141

Pressure Cap Test ................................... 142

Radiator and Cooling System Leak Tests 143

Water Temperature Gauge Test .............. 143

Water Temperature Regulator Test ......... 144

Basic Block ............................................. 145

Connecting Rod Bearings ........................ 145

Main Bearings .......................................... 145

Cylinder Block .......................................... 145
Projection of Cylinder Liners ..................... 145

Flywheel and Flywheel Housing................ 146

Checking Crankshaft Deflection (Bend).... 148

Vibration Damper ...................................... 149

Electrical System ............................................ 150

Test Tools for Electrical System ............... 150

Battery .............................................. 151

Charging System ...................................... 151

Starting System......................................... 152

Air Starting System ................................... Deleted

Caterpillar, 3161 Governor........................ 155

Governor Types ........................................ 157

Basic Governor ......................................... 159

Governor Components ............................. 159

Operation of the 3161 Governor ............... 161

Auxiliary Controls ........................................... 164

Manual Shutdown ..................................... 164

Pressure Shutdown................................... 164

Electric Shutdown .................................... 164

Manual Mechanical Speed Control........... 164

Pneumatic Speed Control......................... 165

Air Fuel Ratio Control................................ 167

Speed Adjusting Motor Governor Head.... 169

Manual Speed Setting Control.................. 169

Pneumatic Mid Speed Control .................. 170

Troubleshooting.............................................. 172

Governor Troubleshooting ........................ 172

Air Fuel Ratio Control Troubleshooting..... 176
Pneumatic Speed Setting

Control Troubleshooting........................... 178

Testing and Adjusting ................................... 180

Governor Oil Pump ................................. 180

Governor Preparation............................... 181

Governor Installation ................................ 182

Governor Adjustments ............................. 187

Auxiliary Controls ..................................... 192

Hydramechanical Protective System,

3500 Series Engines....................................... 197

Specifications

Shutoff Control Group .............................. 199

Thermostatic Pilot Valve .......................... 202

Accessory (Shutoff) Drive Group ............. 202

Air Intake Shutoff...................................... 206

Tachometer and Service Meter Drive ...... 209

Remote Shutoff Valve Group ................... 209

Electrical Switches ................................... 210

Systems Operation

Overspeed ............................................. 211

Low Engine Oil Pressure ......................... 211

High Coolant Temperature....................... 211

System Components................................ 211

System Hydraulics.................................... 214

Hydraulic Circuits (Earlier)........................ 214

Hydraulic Circuits (Later).......................... 228

Hydraulic Circuits, Later with an

Alarm System........................................... 232

Testing and Adjusting

Troubleshooting........................................ 239


System Checks......................................... 243

System Tests ............................................ 245

Shutoff Speed Setting Adjustment............ 245

Wiring Diagrams ....................................... 247

3500 Industrial Engines.................................. 253

Disassembly and Assembly

Manual Shutoff ......................................... 257

Gauge Panel............................................. 259

Air Intake Shutoff ...................................... 262

Tachometer Drive ..................................... 269

Crankcase Breather.................................. 270

Water Temperature Regulators ................ 272

Water Pump.............................................. 275

Fuel Filter Housing.................................... 279

Fuel Priming Pump, Fuel Transfer Pump . 283

Oil Pump .............................................. 288

Oil Filter Housing ...................................... 293

Oil Pan .............................................. 300

Oil Sequence Valves................................. 304

Oil Cooler .............................................. 305

Turbochargers .......................................... 312

Exhaust Manifolds..................................... 321

Aftercooler .............................................. 322

Governor .............................................. 326

Governor Drive.......................................... 328

Hydramechanical Shutoff Control ............. 332

Hydramechanical Shutoff Drive ................ 345

Accessory Drive (Front) ............................ 347
Oil and Water Pump Drive ....................... 350

Crankshaft Vibration Damper................... 353

Crankshaft Front Seal and Wear Sleeve . 354

Crankshaft Rear Seal and Wear Sleeve .. 356

Front Drive Housing ................................. 358

Flywheel ............................................. 362

Flywheel Housing..................................... 363

Valve Covers............................................ 365

Rocker Shafts and Push Rods ................. 366

Fuel Injectors............................................ 369

Fuel Injection Control Linkage ................. 371

Cylinder Heads......................................... 377

Valves ............................................. 381

Bridge Dowels .......................................... 382

Connecting Rod Bearings ........................ 384

Front Balancer Group............................... 385

Rear Gear Group ..................................... 387

Spacer Plates........................................... 391

Crankshaft Main Bearings........................ 393

Pistons ............................................. 396

Cylinder Liners ......................................... 398

Camshafts ............................................. 400

Crankshaft ............................................. 407

Specifications for Engine Attachments

49Y1-UP, 95Y1-UP, 27Z1-UP, 65Z1-UP,

68Z1-UP, 71Z1-UP................................... 411

Ether Starting Aid................................... 416

Primary Fuel Filter.................................. 416

Fuel Filter Change Indicator Group...... 416

Governor ............................................. 417
Pans .............................................. 421

Oil Filter Bypass Valve ........................... 422

Duplex Oil Filter ..................................... 423

Oil Scavenge Pump ................................ 424

Exhaust Manifolds .................................. 426

Turbochargers......................................... 427

Air Intake Shutoff .................................... 436

Front Gear Groups.................................. 437

Auxiliary Drive ........................................ 440

Tachometer Drive ................................... 441

Trunnion (Front)...................................... 443

Engine Front Support Group (Wide) ..... 443

Vibration Damper Group ........................ 444

Front Mounting Group............................ 447

Stub Shafts .............................................. 447

Time Delay Relay .................................... 449

Heaters, Jacket Water ............................ 449

Magnetic Pickup ..................................... 449

Tachometer, Digital ............................... 450

Contactors .............................................. 451

Pressure Switches ................................. 452

Temperature Switches .......................... 453

Sending Units, Oil Pressure .................. 454

Tachometer, Electric .............................. 454

Gauges, Ammeter/Oil Pressure/

Water Temperature ................................ 455

Air Shutoff Solenoids ............................. 456

Air Compressor Group .......................... 457

Air Control Valve Group ........................ 458
Electric Protective System for Engines

Equipped with Reversal Protection .............. 459

Components ........................................... 460

Individual Circuit Description .............. 462

Engine Stopped...................................... 462

Troubleshooting..................................... 484

Functional Test ....................................... 485

System Problem Index........................... 486

System Troubleshooting Charts,

Preliminary Checks................................ 487

Overspeed, Chart A........................... 488

Crank Terminate, Chart B ................. 490
Step Oil Pressure, Chart C ....................... 492

Reversal Detection, Chart D .................... 494

Troubleshooting Procedures ........................ 496

Overspeed Setting Calibration,

Procedure A .............................................. 496

Crank Terminate, Speed Adjustment,

Procedure B .............................................. 497

Oil Step Calibration, Procedure C............. 498

Overspeed Verify Test, Procedure D........ 499

Reversal Detection, Procedure E.............. 500

Sensor Assembly Verify, Procedure F...... 501

On/Off Time Delay (Relay), Procedure G . 503

Wiring Diagrams.............................................. 504

Electric Protective System Schematic ..... 505

Engine Wiring Diagram............................. 506

Typical Junction Box Wiring Diagram ....... 507

Customer Wiring with Electric

Protective System .................................... 510

Electrical Protective System for Generator Set,

Industrial and Marine Engines............... 513

Components............................................ 514

Individual Circuit Description................ 516

Engine Stopped....................................... 516

Starting Engine ...................................... 518

Engine Starts to Run: No Faults ........... 520

Engine Runs at Rated Speed: No Faults 522

Engine Shutdown Due to Fault:

Loss of Engine Oil Pressure (At Engine

Speeds Above Oil Step Speed Setting) 524

Engine Shutdown Due to Fault: Low Oil

Pressure (At Engine Speeds Below Oil

Step Speed Setting)................................ 528
Engine Shutdown Due to Fault:

Coolant Overheating ...................................... 530

Engine Shutdown Due to Fault:

Engine Overspeed.......................................... 532

Shutdown System with 2301 Electric

Governor Control: No Faults......................... 534

Electric Protective System

Functional Tests............................................. 536

Speed Specification Chart ............................ 537

Troubleshooting ............................................ 538

Problem Identification Index ......................... 539

System Troubleshooting Charts,

Preliminary Checks ........................................ 540

System Arming, Chart A........................... 541

Overspeed, Chart B.................................. 542

Crank Terminate, Chart C ........................ 544

Step Oil Pressure, Chart D....................... 546

Troubleshooting Procedures

Overspeed Setting Calibration,

Procedure A ............................................. 548

Crank Terminate Speed Adjustment,

Procedure B ............................................ 549

Oil Step Calibration, Procedure C ............ 550

Overspeed Verify Test, Procedure D ....... 551

Magnetic Pickup Verify, Procedure E....... 552

On/Off Delay (Relay), Procedure F .......... 553

Wiring Diagrams............................................. 554

Electric Protective System Schematic...... 555

Engine Wiring Diagram ............................ 556

Typical Junction Box Wiring Diagram ...... 557

Customer Wiring with Electric

Protective System ................................... 560

 

Operation and Maintenance, 3508 Industrial Engine

Safety .............................................. 565

Operation Section................................... 568

Model Views.............................................. 569

Gauges .............................................. 571

Shutoff and Alarm System Components... 573

Engine Controls ........................................ 575

Before Starting the Engine ....................... 578

Starting the Engine ................................... 579

After Starting the Engine........................... 582

Stopping the Engine.................................. 583

After Stopping the Engine ......................... 584

Lifting Engine and Attachment.................. 584

Engine Storage ........................................ 585

Maintenance Section ...................................... 586

Serial Number Location ............................ 587

Maintenance Recommendations .............. 587

Fuel, Coolant and Lubricant

Specifications ......................................... 590

Refill Capacities ........................................ 592

Engine Specifications................................ 592

Recommended Lubricant Viscosities........ 593

Lubrication and Maintenance Chart ......... 594

When Required......................................... 596

Every 10 Service Hours or Daily............... 597

Every 50 Service Hours or Weekly .......... 609

Every 100 Service Hours or 2 Weeks....... 611

Every 250 Service Hours or Monthly......... 612

Every 500 Service Hours or 3 Months ...... 617

Every 1000 Service Hours or 6 Months .... 618

Every 2000 Service Hours or 1 Year......... 624

Troubleshooting Section ....................... 628

 
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