TM 5-2815-232-14 TECHNICAL MANUAL OPERATOR S, UNIT, INTERMEDIATE (DS) AND INTERMEDIATE (GS) MAINTENANCE MANUAL FOR ENGINE, DIESEL, CATERPILLAR, MODEL 3508 NSN 2815-01-216-0938 HEADQUARTERS, DEPARTMENT OF THE ARMY 25 JULY 1986
TM 5-2815-232-14 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... 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 Alternators and Regulators... Deleted Electrical System Electric Starter Motors... Deleted Starter Solenoids... Deleted i
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 ii
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 iii
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 iv
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 Oil 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 v
Electric Protective System for Engines Equipped with Reversal Protection... 459 Components... 460 Individual Circuit Description... 462 Engine Stopped... 462 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... 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 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)... 528 vi
Coolant Overheating... 530 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 vii/(viii Blank) FORM NO. SENR235341
3500 ENGINE SPECIFICATIONS 3