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CATERPILLAR 3500 3508 3512 3516 Diesel Engines pdf Operators Service Manual CD
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View full item details »
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Estimated to arrive by Mon, Apr 8th.
Details
FREE via USPS Ground Advantage (2 to 3 business days) to United States
Offer policy
OBO - Seller accepts offers on this item.
Details
Return policy
Purchase protection
Payment options
PayPal accepted
PayPal Credit accepted
Venmo accepted
PayPal, MasterCard, Visa, Discover, and American Express accepted
Maestro accepted
Amazon Pay accepted
Item traits
Category: | |
---|---|
Quantity Available: |
82 in stock |
Condition: |
New other (see details) |
Equipment Make: |
Caterpillar |
MPN: |
TM 5-2815-232-14, NSN 2815-01-216-0938 |
Model: |
3500 Series TM 5-2815-232-14 NSN 2815-01-216-0938 |
Country of Manufacture: |
United States |
Type: |
SERVICE MANUAL Operator MAINTENANCE MANUAL |
Format: |
This Manual is PDF File Format on a CD |
Equipment Type: |
Caterpillar 3500 3508 3512 3516 Engines |
Listing details
Shipping discount: |
Seller pays shipping for this item. |
---|---|
Posted for sale: |
More than a week ago |
Item number: |
262031500 |
Item description
CATERPILLAR 3500 3508 3512
3516 Engines pdf Service Manual on a CD
CAT Caterpillar 3500 3508 3512 3516 Engines
* LANGUAGE: English
*
FORMAT: PDF
*
COMPATIBLE: Win/ Mac
*
SEARCHABLE - BOOKMARKED - INDEXED
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 SERVICE MANUALS:
3500 INDUSTRIAL ENGINES,
SENR2573
VOLUME I SPECIFICATIONS,
REGO 1312 FOR USE IN SERVICE
MANUALS:
3500 INDUSTRIAL ENGINES,
SENR2573
VOLUME I SPECIFICATIONS,
REGO1312
SPECIFICATIONS
FOR 3500 INDUSTRIAL
ENGINE ATTACHMENTS
49Y1-UP 65Z1-UP
95Y1-UP 68Z1-UP
27Z1-UP 71Z1-UP
Numerous illustrations - Lots of Information.
661 total pages,
CD-ROM.
Published by the Department of the Army.
TM
5-2815-232-14
TABLE OF
CONTENTS:
(Please Note: 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 Fittings4
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 .....................................
Delete
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
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
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
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
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
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 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
Engine Shutdown Due to Fault:
Loss of Engine Oil Pressure (At Engine
Speeds Above Oil Step Speed Setting) 524
Engine Shutdown Due to Fault: Low Oil
Pressure (At Engine Speeds Below Oil
Step Speed Setting)................................ 528
Engine Shutdown Due to Fault:
Coolant Overheating ...................................... 530
Engine Shutdown Due to Fault:
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
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