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TM-5-2815-232-14
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
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TM-5-2815-232-14
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RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
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DISTRIBUTION
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