- OPERATOR' S, UNIT,
INTERMEDIATE (DS) AND INTERMEDIATE (GS) MAINTENANCE MANUAL FOR
ENGINE, DIESEL, CATERPILLAR, MODEL 3508
- WARNING
- SAFETY
- SAFETY-continued
- IMPORTANT SAFETY NOTICE
- IMPORTANT SAFETY
NOTICE-continued
- IMPORTANT SAFETY
NOTICE-continued
- IMPORTANT SAFETY
NOTICE-continued
- IMPORTANT SAFETY
NOTICE-continued
- SAFETY
- SAFETY-continued
- IMPORTANT SAFETY NOTICE
- IMPORTANT SAFETY
NOTICE-continued
- IMPORTANT SAFETY INFORMATION
- Table of Contents
- Table of Contents-continued
- Table of Contents-continued
- Table of Contents-continued
- Table of Contents-continued
- Table of Contents-continued
- Table of Contents-continued
- SPECIFICATIONS FOR 3500
INDUSTRIAL ENGINE ATTACHMENTS
- GENERAL TIGHTENING TORQUE FOR
BOLTS, NUTS AND TAPERLOCK STUDS
- TORQUE FOR FLARED AND O-RING
FITTINGS
- ENGINE DESIGN CYLINDER AND
VALVE LOCATION
- FIRING ORDER (INJECTION
SEQUENCE)
- INTRODUCTION
- FUEL INJECTION
- FUEL PRESSURE REGULATOR
(Later)
- FUEL INJECTION CONTROL GROUP
- GOVERNOR FASTENER GROUP (UG8L
& 3161 Governors)
- CAMSHAFTS
- CAMSHAFTS (3512 and 3516)
- 7N1904 Spring (outer) for
valve
- VALVE COVERS
- CYLINDER HEADS
- TURBOCHARGER IMPELLER
INSTALLATION
- TURBOCHARGER TV61
- TURBOCHARGER TV81
- TURBOCHARGER TV91
- TURBOCHARGER C153
- EXHAUST MANIFOLDS
- AIR INTAKE SHUTOFF (5N9060)
- AIR INTAKE SHUTOFF (2W7163)
- AIR INTAKE SHUTOFF (2WS216)
- OIL PUMP (2W5474)
- OIL PUMP (2W5477)
- OIL FILTER BYPASS VALVE
- OIL FILTER BYPASS
VALVE-continued
- OIL COOLER BYPASS AND COOLING
JET SEQUENCE VALVES
- WATER PUMP
- WATER CONNECTION GROUP -
OUTLET
- WATER TEMPERATURE REGULATORS
- CYLINDER BLOCK
- CYLINDER LINERS
- PISTONS AND RINGS
- CONNECTING RODS
- CONNECTING ROD AND MAIN
BEARING JOURNALS
- CRANKSHAFT
- CRANKSHAFT WEAR SLEEVES AND
SEALS
- FRONT BALANCER GROUP (3508)
- LOWER FRONT GEAR GROUP
(8N7174)
- LOWER FRONT GEAR GROUP
(8N5620)
- UPPER FRONT GEAR GROUP
(7N4871)
- 2REAR GEAR GROUP (3508)
- REAR GEAR GROUP (3512 & 3516)
- FLYWHEEL (1N3770 & 7N7732)
- FLYWHEEL (1N3565 & 7N5014)
- Flywheel Runout-continued
- FLYWHEEL HOUSING (SAE "00")
- FLYWHEEL HOUSING (SAE "0")
- FLYWHEEL HOUSING BORE
- FLYWHEEL HOUSING RUNOUT
- ALTERNATORS AND REGULATORS
Deleted
- Alternators and
Regulators-continued
- ELECTRIC STARTER MOTORS
- STARTER SOLENOIDS
- AIR STARTER MOTORS
- SYSTEMS OPERATION TESTING AND
ADJUSTING 3500 INDUSTRIAL ENGINES
- CYLINDER AND VALVE LOCATION
- Illustration
- FIRING ORDER (INJECTION
SEQUENCE)
- FUEL SYSTEM
- FUEL FLOW THRU INJECTOR
- FUEL INJECTION CONTROL
LINKAGE
- FUEL INJECTOR
- FUEL INJECTOR OPERATION
- The spray tip of the injector
- WOODWARD UG8 LEVER GOIVERNORS
- WOODWARD UG8 LEVER
GOIVERNORS-continued
- AIR FUEL RATIO CONTROL
- SCHEMATIC OF AIR FUEL RATIO
CONTROL SYSTEM
- AIR INLET AND EXHAUST SYSTEM
- AIR FLOW SCHEMATIC
- AIR INLET AND EXHAUST SYSTEM
- TURBOCHARGERS
- VALVE SYSTEM COMPONENTS
- LUBRICATION SYSTEM
- PISTON COOLING AND
LUBRICATION
- COOLING SYSTEM
- RIGHT SIDE OF ENGINE
- BASIC BLOCK
- CAMSHAFTS
- AIR STARTING SYSTEM
- AIR STARTING SYSTEM-continued
- ELECTRICAL SYSTEM
- OTHER COMPONENTS
- Water Temperature Contactor
Switch
- TROUBLESHOOTING
- ENGINE CRANKSHAFT WILL NOT
TURN
- ENGINE WILL NOT START
- ENGINE OVERSPEEDS ON START
- ENGINE HIGH IDLE SPEED TOO
LOW
- ENGINE LOSES HIGH IDLE AFTER
START UP
- ENGINE MISFIRING OR RUNNING
ROUGH
- ENGINE STALL AT LOW RPM
- TOO MUCH VIBRATION
- LOUD COMBUSTION NOISE (SOUND)
- FUEL CONSUMPTION TOO HIGH
- VALVE ROTOCOIL OR SPRING LOCK
IS FREE
- COOLANT IN LUBRICATION OIL
- ENGINE HAS LOW OIL PRESSURE
- ENGINE COOLANT IS TOO HOT
- EXHAUST TEMPERATURE IS TOO
HIGH
- FUEL SYSTEM
- 6V4022 INJECTOR TESTER
- TESTER NOMENCLATURE
- TEST SEQUENCE
- INJECTOR INSTALLED
- Orifice Inspection
- Valve Opening Pressure (VOP)
- External Leakage
- Leakdown Rate
- FUEL PRESSURE
- ENGINE ROTATION
- CAMSHAFT TIMING
- REMOVE COVER (LH SIDE)
- START UP PROCEDURE
- CRANKSHAFT POSITIONS FOR FUEL
TIMING AND VALVE CLEARANCE SETTING
- FUEL TIMING
- INJECTOR SYNCHRONIZATION
- LOCATION OF FUEL SETTING
COVER AND SYNCHRONIZING PIN
- FUEL SETTING
- Fuel Setting Adjustment
- ENGINE SPEED MEASUREMENT
- WOODWARD UG8 LEVER GOVERNOR
- LOW AND HIGH IDLE SPEED
ADJUSTMENT
- OIL PRESSURE LINE TO AIR FUEL
RATIO CONTROL
- Adjustment for Positive Droop
- AIR FUEL RATIO CONTROL
- AIR INLET AND EXHAUST SYSTEM
- EXHAUST TEMPERATURE
- BRIDGE ADJUSTMENT
- CRANKSHAFT POSITIONS FOR FUEL
TIMING AND VALVE CLEARANCE SETTING
- VALVE CLEARANCE
- Valve Clearance
Adjustment-continued
- LUBRICATION SYSTEM
- OIL PRESSURE IS LOW
- COOLING SYSTEM
- Pressure Cap Test
- Water Temperature Gauge Test
- Water Temperature Regulator
Test.
- BASIC BLOCK
- FLYWHEEL AND FLYWHEEL HOUSING
- 8S2328 DIAL INDICATOR GROUP
INSTALLED
- Face Runout (axial
eccentricity) of the Flywheel
- VIBRATION DAMPER
- ELECTRICAL SYSTEM
- BATTERY
- STARTING SYSTEM
- Pinion Clearance Adjustment
- SERVICE MANUAL CATERPILLAR
3161 GOVERNOR
- GOVERNOR TYPES
- 3161 GENERATOR SET GOVERNOR
- BASIC GOVERNOR
- Ballhead Assembly
- Limit/Shutdown Pilot Valve
- SCHEMATIC OF THE 3161
GOVERNOR 16 2(Increased Fuel Position)
- Decrease In Speed Setting
- AUXILIARY CONTROLS
- PNEUMATIC SPEED SETTING
CONTROL
- PNEUMATIC SPEED SETTING
CONTROL SCHEMATIC
- AIR FUEL RATIO CONTROL
- SCHEMATIC OF AIR FUEL RATIO
CONTROL ON THE 3161 GOVERNOR
- SPEED ADJUSTING MOTOR
GOVERNOR HEAD
- MANUAL MECHANICAL SPEED
CONTROL
- PNEUMATIC MID SPEED CONTROL
- GOVERNOR TROUBLESHOOTING
- GOVERNOR
TROUBLESHOOTING-continued
- GOVERNOR
TROUBLESHOOTING-continued
- GOVERNOR
TROUBLESHOOTING-continued
- AIR FUEL RATIO CONTROL
TROUBLESHOOTING
- AIR FUEL RATIO CONTROL
TROUBLESHOOTING-continued
- PNEUMATIC SPEED SETTING
CONTROL TROUBLESHOOTING
- PNEUMATIC SPEED SETTING
CONTROL TROUBLESHOOTING-continued
- GOVERNORS FOR 3500 SERIES
ENGINES
- GOVERNOR PREPARATION
- GOVERNOR INSTALLATION
- 3161 Standard and Generator
Set Governors
- 3161 Governor With Torque
Rise
- ENGAGE GOVERNOR ZEROING PIN
- RELEASE GOVERNOR ZEROING PIN
- GOVERNOR ADJUSTMENTS
- LOW AND HIGH IDLE ADJUSTMENTS
- TORQUE RISE SETTING (ON 3500
SERIES ENGINES)
- INSTALL DIAL INDICATOR
- TORQUE RISE CAM ADJUSTMENT
- AUXILIARY CONTROLS
- FEEDBACK SPRING AND SPEED
SETTING PISTON POSITION
- SPEED SETTING BELLOWS AND
LEVER
- ADJUST AIR PRESSURE
- AIR FUEL RATIO CONTROL
ADJUSTMENTS (ON 3500 SERIES ENGINES)
- SPECIFICATIONS SYSTEMS
OPERATION TESTING AND ADJUSTING HYDRAMECHANICAL PROTECTIVE SYSTEM
FOR 3500 SERIES ENGINES
- HYDRAMECHANICAL PROTECTIVE
SYSTEM
- GENERAL TIGHTENING TORQUE FOR
BOLTS, NUTS AND TAPERLOCK STUDS
- TORQUE FOR FLARED AND O-RING
FITTINGS
- THERMOSTATIC PILOT VALVE
(4L7108)
- SHUTOFF CONTROL GROUP
- SPEEDER SPRING CHART
- ACTUATOR VALVE
- AIR INTAKE SHUTOFF (5N9060)
- AIR INTAKE SHUTOFF (2W7163)
- AIR INTAKE SHUTOFF (2W5216)
- TACHOMETER AND SERVICE METER
DRIVE
- ELECTRICAL SWITCHES
- HYDRAMECHANICAL PROTECTIVE
SYSTEM
- Emergency Manual Shutoff
- Air Inlet Shutoff
- SYSTEM HYDRAULICS
- SCHEMATIC NO. 1 (COMPLETE
HYDRAMECHANICAL PROTECTIVE SYSTEM)
- LOW SPEED RANGE (NORMAL
ENGINE OIL PRESSURE)
- SCHEMATIC NO. 3 (LOW ENGINE
OIL PRESSURE FAULT) (Low Speed Range)
- SCHEMATIC NO. 4 (LOW ENGINE
OIL PRESSURE CIRCUIT) (High Speed Range)
- SCHEMATIC NO. 5 (LOW ENGINE
OIL PRESSURE FAULT) (High Speed Range)
- SCHEMATIC NO. 6 (ENGINE
COOLANT TEMPERATURE CIRCUIT) (Low Speed Range Shown)
- HIGH ENGINE COOLANT
TEMPERATURE CIRCUIT (FAULT CONDITION)
- OVERSPEED CIRCUIT (NORMAL
CONDITIONS)
- SCHEMATIC NO.8 (OVERSPEED
CIRCUIT)
- OVERSPEED CIRCUIT (OVERSPEED
FAULT)
- EMERGENCY MANUAL SHUTOFF
- START-UP OVERRIDE OF LOW
ENGINE OIL PRESSURE
- REMOTE NORMAL SHUTOFF
- HYDRAULIC CIRCUITS (LATER)
- SCHEMATIC NO. 13 (START-UP
OVERRIDE)
- LOW SPEED RANGE (LOW ENGINE
OIL PRESSURE FAULT)
- REMOTE NORMAL SHUTOFF
- LATER HYDRAULIC CIRCUITS WITH
AN ALARM SYSTEM
- SCHEMATIC NO. 16 (OVERSPEED
CIRCUIT)
- OVERSPEED CIRCUIT (OVERSPEED
FAULT)
- SCHEMATIC NO. 17 (OVERSPEED
FAULT)
- LOW OIL PRESSURE OR HIGH
COOLANT TEMPERATURE FAULT
- SCHEMATIC NO. 18 (LOW OIL
PRESSURE OR HIGH COOLANT TEMPERAFAULT)
- REMOTE NORMAL SHUTOFF
- TROUBLESHOOTING
- ENGINE WILL NOT START
- ENGINE WILL ONLY RUN BELOW
70% OF RATED SPEED
- SHUTOFF CONTROL UNIT DOES NOT
OPERATE
- HYDRAMECHANICAL PROTECTIVE
SYSTEM
- START-UP OVERRIDE VALVE CHECK
- FUEL SHUTOFF TEST
- UG-8L GOVERNOR
- HYDRAMECHANICAL PROTECTIVE
SYSTEM WIRING DIAGRAMS
- 3500 ENGINE WIRING DIAGRAM
(REF. 5N8944) (Earlier Systems With 5N9310 Pressure Switch Assembly)
- 3500 ENGINE WIRING DIAGRAM
(REF. 5N8944) (Later Systems With 4W2188 Pressure Switch Assembly)
- CUSTOMER WIRING WITH
HYDRA-MECHANICAL SHUT-OFF GROUPS
- NOTES
- DISASSEMBLY AND ASSEMBLY 3500
INDUSTRIAL ENGINES
- GENERAL TIGHTENING TORQUE FOR
BOLTS AND NUTS
- ALTERNATOR
- MANUAL SHUTOFF
- INSTALL MANUAL SHUTOFF
- GAUGE PANEL
- INSTALL GAUGE PANEL
- INSTALL GAUGE PANEL-continued
- AIR INTAKE SHUTOFF (3508)
- DISASSEMBLE AIR INTAKE
SHUTOFF 1078-15
- DISASSEMBLE AIR INTAKE
SHUTOFF 1078-15-continued
- ASSEMBLE AIR INTAKE SHUTOFF
- ASSEMBLE AIR INTAKE
SHUTOFF-continued
- AIR INTAKE SHUTOFF (3508)
- AIR INTAKE SHUTOFF (3512)
- TACHOMETER DRIVE
- CRANKCASE BREATHER
- INSTALL CRANKCASE BREATHER
- WATER TEMPERATURE REGULATORS
- INSTALL WATER TEMPERATURE
REGULATORS
- WATER PUMP
- INSTALL WATER PUMP
- DISASSEMBLE WATER PUMP
- ASSEMBLE WATER PUMP
- ASSEMBLE WATER PUMP-continued
- FUEL FILTER HOUSING
- DISASSEMBLE FUEL FILTER
HOUSING
- ASSEMBLE FUEL FILTER HOUSING
1262-16
- ASSEMBLE FUEL FILTER HOUSING
1262-16-continued
- FUEL PRIMING PUMP, FUEL
TRANSFER PUMP
- FUEL TRANSFER PUMP
- ASSEMBLE FUEL TRANSFER PUMP
1256-16
- ASSEMBLE FUEL TRANSFER PUMP
1256-16-continued
- ASSEMBLE FUEL TRANSFER PUMP
1256-16-continued
- OIL PUMP
- DISASSEMBLE OIL PUMP
- DISASSEMBLE OIL
PUMP-continued
- ASSEMBLE OIL PUMP
- ASSEMBLE OIL PUMP-continued
- OIL FILTER HOUSING
- DISASSEMBLE OIL FILTER
HOUSING
- DISASSEMBLE OIL FILTER
HOUSING-continued
- DISASSEMBLE OIL FILTER
HOUSING-continued
- OIL FILTER HOUSING
- ASSEMBLE OIL FILTER
HOUSING-continued
- ASSEMBLE OIL FILTER
HOUSING-continued
- OIL PAN
- DISASSEMBLE OIL PAN
- Assemble Oil Pan
- Assemble Oil Pan-continued
- OIL SEQUENCE VALVES
- OIL COOLER
- INSTALL OIL COOLER 1378-12
- INSTALL OIL COOLER
1378-12-continued
- DISASSEMBLE OIL COOLER
1378-15
- DISASSEMBLE OIL COOLER
1378-15-continued
- ASSEMBLE OIL COOLER 1378-16
- ASSEMBLE OIL COOLER
1378-16-continued
- TURBOCHARGERS
- Install Turbochargers 1052-12
- Install Turbochargers
1052-12-continued
- TURBOCHARGERS (3508)
- DISASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61)-continued
- DISASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61)-continued
- ASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61) 1052-16
- ASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61) 1052-16-continued
- ASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61) 1052-16-continued
- EXHAUST MANIFOLDS
- AFTERCOOLER
- REMOVE AFTERCOOLER
1063-11-continued
- INSTALL AFTERCOOLER 1063-12
- INSTALL AFTERCOOLER
1063-12-continued
- GOVERNOR
- INSTALL GOVERNOR 1264-12
- GOVERNOR DRIVE
- DISASSEMBLE GOVERNOR DRIVE
1288-15-continued
- ASSEMBLE GOVERNOR DRIVE
1288-16
- ASSEMBLE GOVERNOR DRIVE
1288-16-continued
- HYDRAMECHANICAL SHUTOFF
CONTROL
- INSTALL HYDRAMECHANICAL
SHUTOFF CONTROL
- DISASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL
- DISASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- DISASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- DISASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- DISASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- HYDRAMECHANICAL SHUTOFF
CONTROL
- ASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL
- ASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- ASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- ASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- ASSEMBLE HYDRAMECHANICAL
SHUTOFF CONTROL-continued
- HYDRAMECHANICAL SHUTOFF DRIVE
- INSTALL HYDRAMECHANICAL
SHUTOFF DRIVE
- ACCESSORY DRIVE (FRONT)
- DISASSEMBLE ACCESSORY DRIVE
(FRONT) 1207-15
- ASSEMBLE ACCESSORY DRIVE
1207-16
- OIL AND WATER PUMP DRIVE
- DISASSEMBLE OIL AND WATER
PUMP DRIVE 1313-15
- ASSEMBLE OIL AND WATER PUMP
DRIVE 1313-16
- CRANKSHAFT VIBRATION DAMPER
- CRANKSHAFT FRONT SEAL AND
WEAR SLEEVE
- INSTALL CRANKSHAFT FRONT SEAL
AND WEAR SLEEVE 1160-12-continued
- CRANKSHAFT REAR SEAL AND WEAR
SLEEVE
- INSTALL CRANKSHAFT REAR SEAL
AND WEAR SLEEVE 1161-12-continued
- FRONT DRIVE HOUSING
- REMOVE FRONT DRIVE HOUSING
11zit-continued
- INSTALL FRONT DRIVE HOUSING
1157-12
- INSTALL FRONT DRIVE HOUSING
1157-12-continued
- FLYWHEEL
- REMOVE FLYWHEEL HOUSING
1157-11
- INSTALL FLYWHEEL
HOUSING1157-12
- VALVE COVERS, ROCKER SHAFTS
AND PUSH RODS
- ROCKER SHAFTS AND PUSH RODS
- DISASSEMBLE ROCKER SHAFT
ASSEMBLIES 1102-15
- ASSEMBLE ROCKER SHAFT
ASSEMBLIES 1102-16
- FUEL INJECTORS
- INSTALL FUEL INJECTORS
1251-12
- FUEL INJECTION CONTROL
LINKAGE
- REMOVE FUEL INJECTION CONTROL
LINKAGE 1269-continued
- REMOVE FUEL INJECTION CONTROL
LINKAGE 1269-continued
- INSTALL FUEL INJECTION
CONTROL LINKAGE 1269-12
- INSTALL FUEL INJECTION
CONTROL LINKAGE 1269-12-continued
- INSTALL FUEL INJECTION
CONTROL LINKAGE 1269-12-continued
- CYLINDER HEADS
- REMOVE CYLINDER HEADS
1101-11-continued
- INSTALL CYLINDER HEADS
1101-12
- INSTALL CYLINDER HEADS
1101-12-continued
- VALVES
- VALVE LIFTERS, BRIDGE DOWELS
- VALVE SEAT INSERTS, VALVE
GUIDES
- CONNECTING ROD BEARINGS
- FRONT BALANCER GROUP (3508)
- FRONT BALANCER GROUP (3508)
- REAR GEAR GROUP
- INSTALL REAR GEAR GROUP
1212-12
- INSTALL REAR GEAR GROUP
1212-12-continued
- INSTALL REAR GEAR GROUP
1212-12-continued
- SPACER PLATES
- INSTALL SPACER PLATES 1221-12
- CRANKSHAFT MAIN BEARINGS
- INSTALL CRANKSHAFT MAIN
BEARINGS 1203-12
- INSTALL CRANKSHAFT MAIN
BEARINGS 1203-12-continued
- PISTONS
- INSTALL PISTONS 1214-12
- CYLINDER LINERS
- INSTALL CYLINDER LINERS
1216-12-continued
- CAMSHAFTS
- REMOVE CAMSHAFTS
1210-11-continued
- REMOVE CAMSHAFTS
1210-11-continued
- INSTALL CAMSHAFTS 1210-11
- INSTALL CAMSHAFTS
1210-11-continued
- INSTALL CAMSHAFTS
1210-11-continued
- CAMSHAFT BEARINGS
- REMOVE CRANKSHAFT 1202-11
- INSTALL CRANKSHAFT1202-12
- INSTALL
CRANKSHAFT1202-12-continued
- SPECIFICATIONS FOR 3500
INDUSTRIAL ENGINE ATTACHMENTS
- GENERAL TIGHTENING TORQUE FOR
BOLTS, NUTS AND TAPERLOCK STUDS
- TORQUE FOR FLARED AND O-RING
FITTINGS
- INTRODUCTION
- ETHER STARTING AID
- GOVERNOR FASTENER GROUP (2301
Governor with EG3P Actuators)
- GOVERNOR FASTENER GROUP (2301
Governors With EG10P Actuators)
- GOVERNOR FASTENER GROUP (UG8L
& 3161 Governors)
- GOVERNOR ALIGNMENT PROCEDURE
(UG8L & 3161 Governors)
- OIL PANS
- OIL FILTER BYPASS VALVE (L.H.
- DUPLEX OIL FILTER
- Schematic Drawing
- OIL SCAVENGE PUMP (1W8505)
- EXHAUST MANIFOLDS (WATER
COOLED)
- TURBOCHARGER IMPELLER
INSTALLATION
- TURBOCHARGER TW61
- TURBOCHARGER TW81
- TURBOCHARGER TW91
- TURBOCHARGER W153
- TURBOCHARGER INSTALLATION
(Watercooled Exhaust Elbow) (3508 - 95Y & 68Z)
- TURBOCHARGER INSTALLATION
(Watercooled Exhaust Elbow) (3512 - 49Y & 65Z, 3516 - 71Z)
- TURBOCHARGER INSTALLATION
(Watercooled Turbochargers) (3516 - 27Z)
- TURBOCHARGER INSTALLATION
(Watercooled Turbochargers) (3508 - 95Y & 68Z, 3512 - 49Y & 65Z,
3516 - 71Z)
- AIR INTAKE SHUTOFF (5N9060)
- (UPPER) FRONT GEAR GROUPS
- LOWER FRONT GEAR GROUPS
- LOWER FRONT GEAR GROUPS
- AUXILIARY DRIVE PULLEY GROUPS
- AUXILIARY DRIVE SHAFT GROUP
- TRUNNION
- FRONT TRUNNION SUPPORT
- VIBRATION DAMPER GROUP (FOR
HIGH INERTIA DRIVEN EQUIPMENT)
- VIBRATION DAMPER GROUP (3508
& 3512)
- VIBRATION DAMPER GROUPS
(3516)
- 8N339 Damper Group
- FRONT MOUNTING GROUP (For
Hydraulic Pump or PTO Clutch)
- FRONT STUB SHAFT
- TIME DELAY RELAY
- DIGITAL TACHOMETER
- TEMPERATURE CONTACTOR
- PRESSURE SWITCHES
- TEMPERATURE SWITCHES
- SENDING UNITS
- OIL PRESSURE GAUGE (ELECTRIC)
- AIR SHUTOFF SOLENOIDS
- AIR COMPRESSOR GROUP (8N8360)
- AIR CONTROL VALVE GROUPS
- SYSTEMS OPERATION
TROUBLESHOOTING INDIVIDUAL CIRCUIT DESCRIPTION ELECTRIC PROTECTIVE
SYSTEM FOR ENGINES EQUIPPED WITH REVERSAL PROTECTION
- INTRODUCTION
- COMPONENT LOCATIONS ON ENGINE
- INDIVIDUAL CIRCUIT
DESCRIPTION
- ENGINE STOPPED
- INTRODUCTION TO THE
TROUBLESHOOTING GUIDE
- ELECTRIC PROTECTIVE SYSTEM
FUNCTIONAL TEST
- SYSTEM PROBLEM INDEX
- SYSTEM TROUBLESHOOTING CHARTS
- TROUBLESHOOTING (OVERSPEED)
- TROUBLESHOOTING
(OVERSPEED)-continued
- TROUBLESHOOTING (CRANK
TERMINATE)
- TROUBLESHOOTING (CRANK
TERMINATE)-continued
- TROUBLESHOOTING (STEP OIL
PRESSURE)
- TROUBLESHOOTING (STEP OIL
PRESSURE)-continued
- TROUBLESHOOTING (REVERSAL
DETECTION)
- TROUBLESHOOTING (REVERSAL
DETECTION)-continued
- 5N1955 ELECTRONIC SPEED
SWITCH
- CRANK TERMINATE SPEED
ADJUSTMENT
- OIL STEP CALIBRATION
- OVERSPEED VERIFY TEST
- REVERSAL DETECTION
- 7N7412 SENSOR ASSEMBLY VERIFY
- SW3 CHECK
- ON/OFF TIME DELAY (RELAY)
- ELECTRIC PROTECTIVE SYSTEM
WIRING DIAGRAMS
- ELECTRIC PROTECTIVE SYSTEM
SCHEMATIC
- 3500 ENGINE WIRING DIAGRAM
(REF 5N8944) (All Possible Combinations)
- TYPICAL JUNCTION BOX WIRING
DIAGRAM (REF 5N8944)
- JUNCTION BOX (REF 5N8513)
- JUNCTION BOX WIRING HARNESS
(REF 5N8511)
- CUSTOMER WIRING WITH ELECTRIC
PROTECTIVE SYSTEM (NOTE A)
- NOTES
- SYSTEMS OPERATION
TROUBLESHOOTING INDIVIDUAL CIRCUIT DESCRIPTION ELECTRIC PROTECTIVE
SYSTEM FOR GENERATOR SET, INDUSTRIAL AND MARINE ENGINES
- ELECTRIC PROTECTIVE SYSTEM
- COMPONENT LOCATIONS ON ENGINE
- INDIVIDUAL CIRCUIT
DESCRIPTION
- Fig. 1. ENGINE STOPPED
- MANUAL START
- Fig. 2. STARTING ENGINE WITH
ELECTRIC STARTER MOTORS
- ENGINE STARTS TO RUN: NO
FAULTS
- Fig. 3. ENGINE STARTS TO RUN:
NO FAULTS
- ENGINE RUNS AT RATED SPEED:
NO FAULTS
- Fig. 4. ENGINE RUNS AT RATED
SPEED: NO FAULTS
- ENGINE SHUTDOWN DUE TO FAULT:
LOSS OF ENGINE OIL PRESSURE (AT ENGINE SPEEDS ABOVE OIL STEP SPEED
SETTING)
- Fig. 5. ENGINE SHUTDOWN DUE
TO FAULT: LOSS OF ENGINE OIL PRESSURE (AT ENGINE SPEEDS ABOVE OIL
STEP SPEED SETTING)
- ENGINE RUNNING BELOW OIL STEP
SPEED SETTING: NO FAULTS (OR JUST ACCELERATING THROUGH STEP SPEED)
- Fig. 6. ENGINE RUNNING BELOW
OIL STEP SPEED SETTING: NO FAULTS OR JUST ACCELERATING THROUGH STEP
SPEED)
- ENGINE SHUTDOWN DUE TO FAULT:
LOW OIL PRESSURE (AT ENGINE SPEEDS BELOW OIL STEP SPEED SETTING)
- Fig. 7. ENGINE SHUTDOWN DUE
TO FAULT: LOW OIL PRESSURE (AT ENGINE SPEEDS BELOW OIL STEP SPEED
SETTING)
- ENGINE SHUTDOWN DUE TO FAULT:
COOLANT OVERHEATING
- Fig. 8. ENGINE SHUTDOWN DUE
TO FAULT: COOLANT OVERHEATING
- ENGINE SHUTDOWN DUE TO FAULT:
ENGINE OVERSPEED
- Fig. 9. ENGINE SHUTDOWN DUE
TO FAULT: ENGINE OVERSPEED
- SHUTDOWN SYSTEM WITH 2301
ELECTRIC GOVERNOR CONTROL: NO FAULTS
- Fig. 10. SHUTDOWN SYSTEM WITH
2301 ELECTRIC GOVERNOR CONTROL: NO FAULTS (CIRCUIT SHOWN AT RATED
SPEED)
- ELECTRIC PROTECTIVE SYSTEM
FUNCTIONAL TEST
- SPEED SPECIFICATION CHART
- INTRODUCTION TO THE
TROUBLESHOOTING GUIDE
- PROBLEM IDENTIFICATION INDEX
- SYSTEM TROUBLESHOOTING CHARTS
AND PROCEDURES
- TROUBLESHOOTING (SYSTEM
ARMING)
- TROUBLESHOOTING (OVERSPEED)
- TROUBLESHOOTING (OVERSPEED)-continued
- TROUBLESHOOTING (CRANK
TERMINATE)
- TROUBLESHOOTING (CRANK
TERMINATE)-continued
- OIL STEP FUNCTION
- CHART D-continued
- 4W2218 ELECTRONIC SPEED
SWITCH (ESS)
- CRANK TERMINATE SPEED
ADJUSTMENT
- OIL STEP CALIBRATION
- OVERSPEED VERIFY TEST
- MAGNETIC PICKUP VERIFY
- ON/OFF TIME DELAY (RELAY)
- ELECTRIC SHUT-OFF WIRING
DIAGRAMS
- ELECTRIC PROTECTIVE SYSTEM
SCHEMATIC
- NOTE C
- 3500 ENGINE WIRING DIAGRAM
(REF 5N8944) (All Possible Combinations)
- TYPICAL JUNCTION BOX WIRING
DIAGRAM (REF 5N8944)
- JUNCTION BOX (REF 4W2635)
- JUNCTION BOX WIRING HARNESS
(REF 4W2636)
- CUSTOMER WIRING WITH ELECTRIC
PROTECTIVE SYSTEM (NOTE A)
- NOTES
- Operations & Maintenance
3508, 3512 and 3516 Industrial Engines
- Foreword
- Safety
- Burns
- Preparing to Start
- Operation Section
- Model Views
- Model Views-continued
- Gauges
- Oil Filter Differential
Pressure
- Shutoff and Alarm System
Components
- Electrical High Water
Temperature Shutoff
- Engine Controls
- Mechanical Governor Control
- UG8D Governor (3508/3512 Gen.
Set Engines)
- Before Starting the Engine
- Direct Electric Starting
- Air Starting
- Starting From External
Electrical Source
- After Starting the Engine
- Stopping the Engine
- Lifting Engine and Attachment
- Engine Storage
- Maintenance Section
- Serial Number Locations
- Maintenance Recommendations
- Scheduled Oil Sampling
- Fuel, Coolant and Lubricant
Specifications
- Lubricant Specifications
- Refill Capacities-Approximate
- Recommended Lubricant
Viscosities
- Lubrication and Maintenance
Chart
- Lubrication and Maintenance
Chart-continued
- Air Starter
- Walk-Around Inspection
- Cleaning the Primary Fuel
Filter
- Changing Final Fuel
Filters-continued
- Duplex Fuel Filters
- Changing Auxiliary Final Fuel
Filters
- Changing Auxiliary Final Fuel
Filters-continued
- Air Cleaners
- Cleaning Air Cleaner Elements
- Inspecting Elements
- Lubricate Fittings
- Woodward UG8L Governor
- Fuel Tank
- Zinc Rods
- Batteries
- Clutch Bearing
- Alternator Belts
- Cooling System
- Engine Crankcase
- Change Oil and Filters -
Clean Suction Screen-continued
- Change Oil and Filters -
Clean Suction Screen-continued
- Emergency Shutoff Controls
- Shutoff Controls
- Bleed Air From the Governor
- Bleed Air From the
Governor-continued
- Bleed Air From the
Governor-continued
- Governor Air Actuator
- 3512 Engines With 613 Liter
(162 Gal.) Capacity Oil Sump
- Engine Valve Lash
- Change Coolant-continued
- Clean the Cooling System
- Troubleshooting Section
- Troubleshooting
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Troubleshooting-continued
- Caterpillar Warranty
- 3508 DIESEL ENGINE
CATERPILLAR SECTION II.MAINTENANCE ALLOCATION CHART
- 3508 DIESEL ENGINE
CATERPILLAR SECTION II.MAINTENANCE ALLOCATION CHART-continued
- 3508 DIESEL ENGINE
CATERPILLAR SECTION II.MAINTENANCE ALLOCATION CHART-continued
- 3508 DIESEL ENGINE
CATERPILLAR SECTION II.MAINTENANCE ALLOCATION CHART-continued
- 3508 DIESEL ENGINE
CATERPILLAR SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS
- THE METRIC SYSTEM AND
EQUIVALENTS
- Blank Page
- TM-5-2815-232-14
- Blank Page
- RECOMMENDED CHANGES TO
EQUIPMENT TECHNICAL PUBLICATIONS
- Blank Page
- Blank Page
- Blank Page
- DISTRIBUTION
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
- Blank Page
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