CATERPILLAR 3500 SERIES

DIESEL GENERATOR 720KV

SERVICE MANUAL 
  COMPUTER PDF CD !!

650 PLUS PAGES

Note:  Computer CD, Not Printed Material !!


Caterpillar 3500 Series Engines


3508,   3512,   3516,   8,  12,  16  Cylinders !!


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 :

3500 INDUSTRIAL ENGINES,



FOR 3500 INDUSTRIAL

ENGINE ATTACHMENTS

49Y1-UP 65Z1-UP

95Y1-UP 68Z1-UP

27Z1-UP 71Z1-UP

Contents :

Specifications for Engine Attachments, Industrial   General Tightening Torque for Bolts, Nuts, and Taperlock Studs  Torque for Flared and O-Ring Fittings Engine Design   Fuel System Fuel Injection   Fuel Pressure Regulator (Earlier)  Fuel Pressure Regulator (Later)  Manual Shutoff Group   Fuel Injection Control Group   Governor Fastener Group   Governor Drive   Air Induction and Exhaust System Camshafts   Valves   Valve Covers   Valve Rocker Arms, Lifters and Bridges  Cylinder Heads  Turbocharger Impeller Installation  Turbochargers   Exhaust Manifolds   Air Intake Shutoff  Lubrication System Oil Pump   Oil Filter Bypass Valve (Earlier)  Oil Filter Bypass Valve (Later)  Oil Cooler Bypass and Cooling Jet Sequence Valves Cooling System Water Pump  Aftercooler   Water Connection Group - Outlet   Water Temperature Regulators   V-Belt Tension Chart  Basic Engine Components Cylinder Block   Cylinder Liners   Cylinder Liner Projection  Pistons and Rings   Connecting Rods   Connecting Rod and Main Bearing Journals  Crankshaft   Crankshaft Wear Sleeves and Seals   Front Balancer Group   Lower Front Gear Group   Upper Front Gear Group (N)  Rear Gear Group   Flywheel   Flywheel Runout   Flywheel Housing  Flywheel Housing Bore  Flywheel Housing Runout  Alternators and Regulators   Deleted Electrical System Electric Starter Motors   Deleted Starter Solenoids   Delete Air Starter Motors   Deleted Pressure Regulating Valve for Air Starter Motor   Deleted Systems Operation,   Industrial Engines  Engine Design   Fuel System   Fuel Injection Control Linkage  Fuel Injector  Woodward UG Lever Governors  Air Fuel Ratio Control   Air Inlet and Exhaust System  Aftercooler   Turbochargers   Valve System Components   Lubrication System  Cooling System   Basic Block   Cylinder Block, Liners and Heads   Pistons, Rings and Connecting Rods  Crankshaft   Camshafts   Air Starting System  Electrical System  Alternator  Starter Motor   Starter Solenoid  Circuit Breaker  Contactor Switch (Water Temperature)  Testing and Adjusting   Troubleshooting  Fuel System   Fuel System Inspection  Checking Engine Cylinders Separately  Fuel Injector Testing   Injector Tester Preparation   Operation of the Tester   Leak Test for Injector Tester   Injector Test Sequence  Fuel Pressure   Engine Rotation   Finding Top Center Position for No  Piston   Camshaft Timing  Startup Procedure  Crankshaft Positions for Fuel Timing  Fuel Timing   Injector Synchronization  Fuel Setting   Fuel Setting Adjustment  Engine Speed Measurement   Woodward UG Lever Governor   Compensating Adjustment  Low and High Idle Speed Adjustment  Speed Droop Adjustment  Air Fuel Ratio Control  Air Inlet and Exhaust System  Restriction of Air Inlet and Exhaust  Measurement of Pressure in Inlet Manifold  Exhaust Temperature  Crankcase (Crankshaft Compartment) Pressure   Compression   Cylinder Heads  Valves   Bridge Adjustment  Crankshaft Positions for Valve Clearance Setting   Valve Clearance  Lubrication System   Too Much Oil Consumption  Measuring Engine Oil Pressure  Oil Pressure is Low   Oil Pressure is High  Too Much Bearing Wear   Increased Oil Temperature   Cooling System   Visual Inspection of the Cooling System  Testing the Cooling System   Test Tools for Cooling System   Pressure Cap Test   Radiator and Cooling System Leak Tests  Water Temperature Gauge Test   Water Temperature Regulator Test   Basic Block   Connecting Rod Bearings   Main Bearings   Cylinder Block   Projection of Cylinder Liners   Flywheel and Flywheel Housing  Checking Crankshaft Deflection (Bend)  Vibration Damper   Electrical System   Test Tools for Electrical System   Battery   Charging System   Starting System  Air Starting System   Deleted Caterpillar,   Governor  Governor Types   Basic Governor   Governor Components   Operation of the   Governor   Auxiliary Controls   Manual Shutdown   Pressure Shutdown  Electric Shutdown   Manual Mechanical Speed Control  Pneumatic Speed Control  Air Fuel Ratio Control  Speed Adjusting Motor Governor Head  Manual Speed Setting Control  Pneumatic Mid Speed Control   Troubleshooting  Governor Troubleshooting   Air Fuel Ratio Control Troubleshooting  Pneumatic Speed Setting Control Troubleshooting  TESTING AND ADJUSTING   Governor Oil Pump   Governor Preparation  Governor Installation   Governor Adjustments   Auxiliary Controls   HYDRAMECHANICAL PROTECTIVE SYSTEM, SERIES ENGINES  Specifications Shutoff Control Group   Thermostatic Pilot Valve   Accessory (Shutoff) Drive Group   Air Intake Shutoff  Tachometer and Service Meter Drive   Remote Shutoff Valve Group   Electrical Switches   SYSTEMS OPERATION Overspeed   Low Engine Oil Pressure   High Coolant Temperature  System Components  System Hydraulics  Hydraulic Circuits (Earlier)  Hydraulic Circuits (Later)  Hydraulic Circuits, Later with an Alarm System  TESTING AND ADJUSTING Troubleshooting  System Checks  System Tests   Shutoff Speed Setting Adjustment  Wiring Diagrams   INDUSTRIAL ENGINES  Disassembly and Assembly Manual Shutoff   Gauge Panel  Air Intake Shutoff   Tachometer Drive   Crankcase Breather  Water Temperature Regulators   Water Pump  Fuel Filter Housing  Fuel Priming Pump, Fuel Transfer Pump   Oil Pump   Oil Filter Housing   Oil Pan   Oil Sequence Valves  Oil Cooler   Turbochargers   Exhaust Manifolds  Aftercooler   Governor   Governor Drive  Hydramechanical Shutoff Control   Hydramechanical Shutoff Drive   Accessory Drive (Front)   Oil and Water Pump Drive   Crankshaft Vibration Damper  Crankshaft Front Seal and Wear Sleeve   Crankshaft Rear Seal and Wear Sleeve   Front Drive Housing   Flywheel   Flywheel Housing  Valve Covers  Rocker Shafts and Push Rods   Fuel Injectors  Fuel Injection Control Linkage   Cylinder Heads  Valves   Bridge Dowels   Connecting Rod Bearings   Front Balancer Group  Rear Gear Group   Spacer Plates  Crankshaft Main Bearings  Pistons   Cylinder Liners   Camshafts   Crankshaft   Specifications for Engine Attachments Y-UP, Y-UP, Z-UP, Z-UP, Z-UP, Z-UP  Ether Starting Aid  Primary Fuel Filter  Fuel Filter Change Indicator Group  Governor   Oil Pans   Oil Filter Bypass Valve   Duplex Oil Filter   Oil Scavenge Pump   Exhaust Manifolds   Turbochargers  Air Intake Shutoff   Front Gear Groups  Auxiliary Drive   Tachometer Drive   Trunnion (Front)  Engine Front Support Group (Wide)   Vibration Damper Group   Front Mounting Group  Stub Shafts   Time Delay Relay   Heaters, Jacket Water   Magnetic Pickup   Tachometer, Digital   Contactors   Pressure Switches   Temperature Switches   Sending Units, Oil Pressure   Tachometer, Electric   Gauges, Ammeter/Oil Pressure/ Water Temperature   Air Shutoff Solenoids   Air Compressor Group   Air Control Valve Group   Electric Protective System for Engines Equipped with Reversal Protection   Components   Individual Circuit Description   Engine Stopped  Starting Engine Deleted Engine Starts to Run: No Faults   Deleted Engine Runs at Rated Speed: No Faults   Deleted Pressure (At Engine Speeds above Oil Step Speed Setting)  Engine Shutdown Due to Fault: Loss of Engine Oil Deleted Engine Running Below Oil Step Speed Setting: No Faults (or Just Accelerating through Step Speed)   Deleted Engine Shutdown Due to Fault: Low Oil Pressure (At Engine Speeds Below Oil Step Speed Setting)   Deleted Engine Shutdown Due to Fault: Coolant Overheating Deleted Engine Shutdown Due to Fault: Engine Overspeed Deleted Engine Shutdown Due to Fault: Engine Reversal   Deleted Shutdown System with   Electric Governor Control: No Faults Deleted Troubleshooting  Functional Test   System Problem Index  System Troubleshooting Charts, Preliminary Checks  Overspeed, Chart A  Crank Terminate, Chart B   Step Oil Pressure, Chart C   Reversal Detection, Chart D   Troubleshooting Procedures   Overspeed Setting Calibration, Procedure A   Crank Terminate, Speed Adjustment, Procedure B   Oil Step Calibration, Procedure C  Overspeed Verify Test, Procedure D  Reversal Detection, Procedure E  Sensor Assembly Verify, Procedure F  On/Off Time Delay (Relay), Procedure G   WIRING DIAGRAMS  Electric Protective System Schematic   Engine Wiring Diagram  Typical Junction Box Wiring Diagram   Customer Wiring with Electric Protective System   Electrical Protective System for Generator Set, Industrial and Marine Engines  Components  Individual Circuit Description  Engine Stopped  Starting Engine   Engine Starts to Run: No Faults   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)  Engine Shutdown Due to Fault: Low Oil Pressure (At Engine Speeds Below Oil Step Speed Setting)  Engine Shutdown Due to Fault: Coolant Overheating   Engine Shutdown Due to Fault: Engine Overspeed  Shutdown System with   Electric Governor Control: No Faults  Electric Protective System Functional Tests  Speed Specification Chart   Troubleshooting   Problem Identification Index   System Troubleshooting Charts, PRELIMINARY CHECKS   System Arming, Chart A  Overspeed, Chart B  Crank Terminate, Chart C   Step Oil Pressure, Chart D  TROUBLESHOOTING PROCEDURES Overspeed Setting Calibration, Procedure A   Crank Terminate Speed Adjustment, Procedure B   Oil Step Calibration, Procedure C   Overspeed Verify Test, Procedure D   Magnetic Pickup Verify, Procedure E  On/Off Delay (Relay), Procedure F   WIRING DIAGRAMS  Electric Protective System Schematic  Engine Wiring Diagram   Typical Junction Box Wiring Diagram   Customer Wiring with Electric Protective System   Operation and Maintenance,   Industrial Engine Safety   Operation Section  Model Views  Gauges   Shutoff and Alarm System Components  Engine Controls   Before Starting the Engine   Starting the Engine   After Starting the Engine  Stopping the Engine  After Stopping the Engine   Lifting Engine and Attachment  Engine Storage    Maintenance Section   Serial Number Location   Maintenance Recommendations   Fuel, Coolant and Lubricant Specifications   Refill Capacities   Engine Specifications  Recommended Lubricant Viscosities  Lubrication and Maintenance Chart   Troubleshooting Section


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