TECHNICAL MANUAL OPERATOR S, UNIT, INTERMEDIATE (DS) AND INTERMEDIATE (GS) MAINTENANCE MANUAL FOR

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1 TM TECHNICAL MANUAL OPERATOR S, UNIT, INTERMEDIATE (DS) AND INTERMEDIATE (GS) MAINTENANCE MANUAL FOR ENGINE, DIESEL, CATERPILLAR, MODEL 3508 NSN HEADQUARTERS, DEPARTMENT OF THE ARMY 25 JULY 1986

2 TM Table of Contents WHERE TITLE SHOWS DELETED TEXT DOES NOT PERTAIN TO THE 3508 ENGINE. Specifications for Engine Attachments, 3500 Industrial... 1 General Tightening Torque for Bolts, Nuts, and Taperlock Studs... 3 Torque for Flared and O-Ring Fittings 4 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 Governor Fastener Group Governor Drive Air Induction and Exhaust System Camshafts Valves Valve Covers Valve Rocker Arms, Lifters and Bridges 15 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 38 Crankshaft Crankshaft Wear Sleeves and Seals Front Balancer Group (3508) Lower Front Gear Group Upper Front Gear Group (7N4871) 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... Deleted i

3 Air Starter Motors... Deleted Pressure Regulating Valve for Air Starter Motor... Deleted Systems Operation, 3500 Industrial Engines 61 Engine Design Fuel System Fuel Injection Control Linkage Fuel Injector Woodward UG8 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.. 84 Crankshaft Camshafts Air Starting System Electrical System Alternator Starter Motor Starter Solenoid Circuit Breaker Contactor Switch (Water Temperature) 90 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. 1 Piston Camshaft Timing Startup Procedure Crankshaft Positions for Fuel Timing Fuel Timing Injector Synchronization Fuel Setting Fuel Setting Adjustment Engine Speed Measurement Woodward UG8 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 133 ii

4 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 143 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, 3161 Governor Governor Types Basic Governor Governor Components Operation of the 3161 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 iii

5 Pneumatic Speed Setting Control Troubleshooting Testing and Adjusting Governor Oil Pump Governor Preparation Governor Installation Governor Adjustments Auxiliary Controls Hydramechanical Protective System, 3500 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. 283 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) iv

6 Oil and Water Pump Drive Crankshaft Vibration Damper Crankshaft Front Seal and Wear Sleeve. 354 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 49Y1-UP, 95Y1-UP, 27Z1-UP, 65Z1-UP, 68Z1-UP, 71Z1-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 v

7 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)... Deleted Loss of Engine Oil... Deleted Engine Running Below Oil Step Speed Setting: No Faults (or Just Accelerating through Step Speed)... Deleted Low Oil Pressure (At Engine Speeds Below Oil Step Speed Setting)... Deleted Coolant Overheating... Deleted Engine Overspeed... Deleted Engine Reversal... Deleted Shutdown System with 2301 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. 503 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 522 Loss of Engine Oil Pressure (At Engine Speeds Above Oil Step Speed Setting) 524 Low Oil Pressure (At Engine Speeds Below Oil Step Speed Setting) vi

8 Coolant Overheating Engine Overspeed Shutdown System with 2301 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, 3508 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 When Required Every 10 Service Hours or Daily Every 50 Service Hours or Weekly Every 100 Service Hours or 2 Weeks Every 250 Service Hours or Monthly Every 500 Service Hours or 3 Months Every 1000 Service Hours or 6 Months Every 2000 Service Hours or 1 Year Troubleshooting Section vii/(viii Blank) FORM NO. SENR235341

9 3500 ENGINE SPECIFICATIONS 3

3304 Engine S/n 43V, 46V, 48V, 78P, 9Z, 7Z & 12Z

Caterpillar Service Manual 3304 Engine S/n 43V, 46V, 48V, 78P, 9Z, 7Z & 12Z Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR