Caterpillar 3508 Shop Manual

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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

This is the cut pages sample. Download all 661 page(s) at: ManualPlace.com
 FORM NO. SENR2995

IMPORTANT SAFETY NOTICE

Proper repair-is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work
methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge
required to safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word CAUTION or NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F.

a
 SAFETY

4. If an engine must be started to make pressure or

speed checks, be sure all guards and shields are
installed. To help prevent an accident caused by
Improper performance of lubrication or maintenance parts in rotation, work carefully around
machinery that has been put into operation.
procedures is dangerous and could result in injury
or death. Read and understand the lubrication and
5. If an engine has been running and the coolant is
maintenance procedures, recommended by
hot, loosen the filler cap slowly and let the
Caterpillar, that are outlined in the OPERATION pressure out of the cooling system, before any
GUIDE and/or OWNER’S MANUAL for this product caps, plugs or lines are removed or
before performing disconnected.
any lubrication or maintenance.
6. Corrosion inhibitor contains alkali. Avoid contact
Do not operate this product unless you have read with eyes. Avoid prolonged or repeated contact
and understood the instructions. Improper with skin. Do not take internally. In case of
operation is dangerous and could result in injury or contact, immediately wash skin with soap and
death. water. For eyes, flush with large amounts of
water for at least 15 minutes. CALL
The servicemen or mechanic may be unfamiliar with PHYSICIAN. KEEP OUT OF REACH OF
many of the components and systems of this product. CHILDREN.
This makes it important to use caution when performing
service work. A knowledge of the system and/or 7. Do not smoke when an inspection of the battery
components is important before the removal or electrolyte level is made. Never disconnect any
disassembly of any component. charging unit circuit or battery circuit cable from
the battery when the charging unit is operating.
Because of the size of some components, the A spark can cause an explosion from the
serviceman or mechanic should check the weights noted flammable vapor mixture of hydrogen and
in this Manual. Use proper lifting procedures when oxygen that is released from the electrolyte
removing any components. through the battery outlets. Do not let electrolyte
solution make contact with skin or eyes.
Following is a list of basic precautions that should Electrolyte solution is an acid. In case of
always be observed. contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of
1. Read and understand all Warning plates and water for at least 15 minutes. CALL
decals before operating, lubricating or repairing PHYSICIAN. KEEP OUT OF REACH OF
this product. CHILDREN.

2. Make sure the work area around the product is 8. Disconnect battery and discharge any capacitors
made safe and be aware of hazardous before starting any repair work. Hang “Do Not
conditions that may exist. Operate” tag in the Operator’s compartment or
on the controls.
3. Always wear protective glasses and protective
shoes when working. In particular, wear 9. Do not work on anything that is supported only
protective glasses when a hammer or sledge is by lift jacks or a hoist. Always use blocks or
used for pounding to make repairs. Use welders proper stands to support the product before
gloves, hood/goggles, apron and other protective performing any service work.
clothing appropriate to the welding job being
performed. Do not wear loose-fitting or torn 10. Relieve all pressure in air, oil or water systems
clothing. Remove all rings from fingers when before any lines, fittings or related items are
working on machinery. disconnected or removed. Be alert for possible
pressure when disconnecting any device from a
system that utilizes pressure. Do not check for
pressure leaks with your hand. High pressure oil
or fuel can pierce the skin.

b
11. Never bend a fuel injection line, or install a line 18. Always use tools that are in good condition and
which has been bent. Keep the fuel injection be sure you understand how to use them before
lines and connections clean. Be sure to install performing any service work. Use only
caps and covers anytime a line is removed or Caterpillar replacement parts.
disconnected.
19. Reinstall all fasteners with same part number.
12. During service work, do not hit the fuel injection Do not use a lesser quality fastener if
lines with wrenches or other tools. When lines replacements are necessary.
are installed, use the correct torque to tighten
connections and be sure all clamps and 20. Repairs which require welding should be
dampers are correctly installed. performed only with the benefit of the
appropriate reference information and by
13. Make sure all fuel injection lines and pressure oil personnel adequately trained and
lines have enough clearance to prevent contact knowledgeable in welding procedures. Make
with any other component. Do not put any fuel reference to “Techniques of Structural Repair
or oil lines close to a hot component. Course” form number JEG03719. Determine
type of metal being welded and select correct
14. To avoid back injury use a hoist or get help when welding procedure and electrodes, rods or wire
lifting components which weigh 50 lb. (23 kg) or to provide a weld metal strength equivalent at
more. Make sure all chains, hooks, slings, etc., least to that of parent metal.
are in good condition and are of the correct
capacity. Be sure hooks are positioned 21. Before doing electrical work, disconnect battery.
correctly. Lifting eyes are not to be side loaded Do not damage wiring during removal
during a lifting operation. operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
15. To avoid burns, be alert for hot parts on products contacting sharp corners, or by rubbing against
which have just been stopped and hot fluids in some object or hot surface. Do not connect
lines, tubes and compartments. wiring to a line containing fluid.

16. Be careful when removing cover plates. 22. Be sure all protective devices including guards
Gradually back off the last two bolts or nuts and shields are properly installed and functioning
located at opposite ends of the cover or device correctly before starting a repair. If a guard or
and pry cover loose to relieve any spring or other shield must be removed to perform the repair
pressure, before removing them completely. work, use extra caution. After the repair is
completed, reinstall any guard or shield that was
17. Be careful when removing filler caps, breathers removed.
and plugs on the product. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the product has recently been stopped
because fluids can be hot.
A83266X2

c
 IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work
methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge
required to safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard.
The warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI 139F.

A83264X2

d
 IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1 139F.

A83264 X2

e
 IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are
many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI 139F.

A83264 X2

f
3500 ENGINES DISASSEMBLY AND ASSEMBLY

IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of a machine. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on the machine to
provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to
you or other persons. These labels identify hazards which may not be apparent to a trained mechanic.
There are many potential hazards during repair for an untrained mechanic and there is no way to label. the
machine against all such hazards. These warnings in the Service Manual and on the machine are
identified by this symbol:

Operations that may result only in machine damage are identified by labels on the machine and in
the Service Manual by the word NOTICE.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings, in this Manual are therefore not all inclusive. If a procedure, tool, device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the machine will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torques, pressures of operation, measurements,
adjustments, illustrations and other items can change at any time. These changes can effect the service
given to the product. Get the complete and most current information before you start any job. Caterpillar
Dealers have the most current information which is available. For a list of the most current modules and
form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE
REG1 139F.

67200-1 X1

g
3500 ENGINES DISASSEMBLY AND ASSEMBLY

IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of a machine. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on the machine to
provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to
you or other persons. These labels identify hazards which may not be apparent to a trained mechanic.
There are many potential hazards during repair for an untrained mechanic and there is no way to label ,the
machine against all such hazards. These warnings in the Service Manual and on the machine are
identified by this symbol:

Operations that may result only in machine damage are identified by labels on the machine and in
the Service Manual by the word NOTICE.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings, in this Manual are therefore not all inclusive. If a procedure, tool, device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the machine will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torques, pressures of operation, measurements,
adjustments, illustrations and other items can change at any time. These changes can effect the service
given to the product. Get the complete and most current information before you start any job. Caterpillar
Dealers have the most current information which is available. For a list of the most current modules and
form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE
REG1139F.

67200-1 X1

h
3500 ENGINES DIASSEMBLY AND ASSEMBLY

SAFETY

machinery that has been put into operation.

Improper performance of lubrication or maintenance 5. If an engine has been running and the coolant is
hot, loosen the filler cap slowly and let the
procedures is dangerous and could result in injury
pressure out of the cooling system, before any
or death. Read and understand the lubrication and
caps, plugs or lines are removed or
maintenance procedures, recommended by
disconnected.
Caterpillar, that are outlined in the OPERATION
GUIDE and/or OWNER’S MANUAL for this product 6. Corrosion inhibitor contains alkali. Avoid contact
before performing any lubrication or maintenance. with eyes. Avoid prolonged or repeated contact
with skin. Do not take internally. In case of
Do not operate this product unless you have read contact, immediately wash skin with soap and
and understood the instructions. Improper water. For eyes, flush with large amounts of
operation is dangerous and could result in injury or water for at least 15 minutes. CALL
death. PHYSICIAN. KEEP OUT OF REACH OF
CHILDREN.
The servicemen or mechanic may be unfamiliar with
many of the components and systems of this product. 7. Do not smoke when an inspection of the battery
This makes it important to use caution when performing electrolyte level is made. Never disconnect any
service work. A knowledge of the system and/or charging unit circuit or battery circuit cable from
components is important before the removal or the battery when the charging unit is operating.
disassembly of any component. A spark can cause an explosion from the
flammable vapor mixture of hydrogen and
Because of the size of some components, the oxygen that is released from the electrolyte
serviceman or mechanic should check the weights noted through the battery outlets. Do not let electrolyte
in this Manual. Use proper lifting procedures when solution make contact with skin or eyes.
removing any components. Electrolyte solution is an acid. In case of
contact, immediately wash skin with soap and
Following is a list of basic precautions that should water. For eyes, flush with large amounts of
always be observed. water for at least 15 minutes. CALL
PHYSICIAN. KEEP OUT OF REACH OF
1. Read and understand all Warning plates and CHILDREN.
decals before operating, lubricating or repairing
this product. 8. Disconnect battery and discharge any capacitors
before starting any repair work. Hang "Do Not
2. Make sure the work area around the product is Operate" tag in the Operator’s compartment or
made safe and be aware of hazardous on the controls.
conditions that may exist.
9. Do not work on anything that is supported only
3. Always wear protective glasses and protective shoes by lift jacks or a hoist. Always use blocks or
when working. In particular, wear protective glasses proper stands to support the product before
when a hammer or sledge is used for pounding to performing any service work.
make repairs. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to the 10. Relieve all pressure in air, oil or water systems
welding job being performed. Do not wear loose- before any lines, fittings or related items are
fitting or torn clothing. Remove all rings from fingers disconnected or removed. Be alert for possible
when working on machinery. pressure when disconnecting any device from a
4. system that utilizes pressure. Do not check for
4. If an engine must be started to make pressure or pressure leaks with your hand. High pressure oil
speed checks, be sure all guards and shields are or fuel can pierce the skin.
installed. To help prevent an accident caused by
parts in rotation, work carefully around

i
3500 ENGINES DISASSEMBLY AND ASSEMBLY

11. Never bend a fuel injection line, or install a line 18. Always use tools that are in good condition and
which has been bent. Keep the fuel injection be sure you understand how to use them before
lines and connections clean. Be sure to install performing any service work. Use only
caps and covers anytime a line is removed or Caterpilla, replacement parts.
disconnected.
19. Reinstall all fasteners with same part number.
12. During service work, do not hit the fuel injection Do not use a lesser quality fastener if
lines with wrenches or other tools. When lines replacements are necessary.
are installed, use the correct torque to tighten
connections and be sure all clamps and 20. Repairs which require welding should be
dampers are correctly installed. performed only with the benefit of the
appropriate reference information and by
13. Make sure all fuel injection lines and pressure oil personnel adequately trained and
lines have enough clearance to prevent contact knowledgeable in welding procedures. Make
with any other component. Do not put any fuel reference to "Techniques of Structural Repair
or oil lines close to a hot component. Course" form number JEG03719. Determine
type of metal being welded and select correct
14. To avoid back injury use a hoist or get help when welding procedure and electrodes, rods or wire
lifting components which weigh 50 lb. (23 kg) or to provide a weld metal strength equivalent at
more. Make sure all chains, hooks, slings, etc., least to that of parent metal.
are in good condition and are of the correct
capacity. Be sure hooks are positioned 21. Before doing electrical work, disconnect battery.
correctly. Lifting eyes are not to be side loaded Do not damage wiring during removal
during a lifting operation. operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
15. To avoid burns, be alert for hot parts on products contacting sharp corners, or by rubbing against
which have just been stopped and hot fluids in some object or hot surface. Do not connect
lines, tubes and compartments. wiring to a line containing, fluid.

16. Be careful when removing cover plates. 22. Be sure all protective devices including guards
Gradually back off the last two bolts or nuts and shields are properly installed and functioning
located at opposite ends of the cover or device correctly before starting a repair. If a guard or
and pry cover loose to relieve any spring or other shield must be removed to perform the repair
pressure, before removing them completely. work, use extra caution. After the repair is
completed, reinstall any guard or shield that was
17. Be careful when removing filler caps, breathers removed.
and plugs on the product. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the product has recently been stopped
because fluids can be hot.
A83266X2

j
 IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1 139F.

A83264 X2
k
 IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:

Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG 139F.

A83264 X2

l
 IMPORTANT SAFETY INFORMATION

Most accidents involving engine operation and maintenance are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident
occurs.

Read and understand all safety precautions and warnings before operating or performing
lubrication and maintenance on this engine.

Basic safety precautions are outlined in the "Safety" section of this guide and in the description of
operations where hazards exist. WARNING labels have also been put on the engine to provide
instructions and to identify specific hazards which if not heeded could cause bodily injury or
death to you or other persons. These warnings in the guide and on the engine labels are identified
by the symbol

Operations that may cause only engine damage are identified by NOTICE labels on the engine and
in the guide.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this guide and on the engine are therefore not all inclusive. If a procedure, tool or
work method or operating technique not specifically recommended by Caterpillar is used, you
must satisfy yourself that it is safe for you and others. You should also ensure that the engine will
not be damaged or made unsafe by the method of operation or maintenance procedures you
choose.

Improper operation, lubrication or maintenance of this engine can be dangerous and could result
in injury or death.

Do not operate this engine until you read and understand the instructions in the "Operation"
section of the Operation and Maintenance Guide or the Owner’s Manual.

Do not perform any lubrication and maintenance on this engine until you read and understand the
instructions in the "Maintenance" section of the Operation and Maintenance Guide or the Owner’s
Manual.

m/(n Blank)
 TM 5-2815-232-14
Table of Contents
WHERE TITLE SHOWS DELETED TEXT DOES NOT PERTAIN TO THE 3508 ENGINE.

Page Page
Specifications for Engine Attachments, Cooling System
3500 Industrial ............................................. 1
Water Pump .............................................. 31
General Tightening Torque for Bolts, Nuts, Aftercooler .............................................. 32
and Taperlock Studs .............................. 3
Water Connection Group - Outlet ............. 32
Torque for Flared and O-Ring Fittings 4
Engine Design ........................................ 5 Water Temperature Regulators ................ 33

Fuel System V-Belt Tension Chart................................. 33

Fuel Injection ....................................... 8
Fuel Pressure Regulator (Earlier)........ 8 Basic Engine Components

Fuel Pressure Regulator (Later).......... 9 Cylinder Block ........................................... 34

Manual Shutoff Group ......................... 9 Cylinder Liners .......................................... 35
Fuel Injection Control Group ............... 10 Cylinder Liner Projection........................... 35
Governor Fastener Group ................... 11 Pistons and Rings ..................................... 36
Governor Drive .................................... 11 Connecting Rods ...................................... 37
Connecting Rod and Main Bearing Journals 38
Air Induction and Exhaust System
Crankshaft .............................................. 39
Camshafts ........................................... 12
Crankshaft Wear Sleeves and Seals ........ 40
Valves ............................................. 14
Front Balancer Group (3508) .................... 41
Valve Covers ....................................... 15
Lower Front Gear Group .......................... 42
Valve Rocker Arms, Lifters and Bridges 15
Upper Front Gear Group (7N4871)........... 44
Cylinder Heads.................................... 16
Rear Gear Group ...................................... 45
Turbocharger Impeller Installation....... 17
Flywheel .............................................. 47
Turbochargers ..................................... 18
Flywheel Runout ....................................... 48
Exhaust Manifolds ............................... 22
Flywheel Housing...................................... 50
Air Intake Shutoff................................. 23
Flywheel Housing Bore ............................. 52

Lubrication System Flywheel Housing Runout ......................... 53

Alternators and Regulators ....................... Deleted
Oil Pump ............................................. 26
Oil Filter Bypass Valve (Earlier)........... 28
Electrical System
Oil Filter Bypass Valve (Later)............. 29
Electric Starter Motors ............................. Deleted
Oil Cooler Bypass and Cooling Jet Starter Solenoids ..................................... Deleted
Sequence Valves................................. 30

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 Table of Contents (Continued)

Page Page
Air Starter Motors ................................ Deleted Troubleshooting.............................................. 91
Pressure Regulating Valve for Fuel System .............................................. 107
Air Starter Motor ............................................. Deleted
Fuel System Inspection............................. 107
Systems Operation, 3500 Industrial Engines 61
Checking Engine Cylinders Separately..... 107
Engine Design ........................................ 63 Fuel Injector Testing ................................. 107
Fuel System ............................................ 65 Injector Tester Preparation ....................... 108
Fuel Injection Control Linkage............. 67 Operation of the Tester ............................. 108
Fuel Injector......................................... 68 Leak Test for Injector Tester ..................... 109
Woodward UG8 Lever Governors ....... 71 Injector Test Sequence ............................. 110
Air Fuel Ratio Control .......................... 73 Fuel Pressure ........................................... 116
Engine Rotation ........................................ 117
Air Inlet and Exhaust System................ 75 Finding Top Center Position for No. 1
Aftercooler ........................................... 77 Piston .............................................. 117
Turbochargers ..................................... 78 Camshaft Timing....................................... 118
Valve System Components ................. 78 Startup Procedure..................................... 120
Lubrication System ................................ 80 Crankshaft Positions for Fuel Timing ........ 121
Cooling System ........................................ 82 Fuel Timing .............................................. 122
Basic Block ............................................. 84 Injector Synchronization............................ 123
Cylinder Block, Liners and Heads ....... 84 Fuel Setting .............................................. 125
Pistons, Rings and Connecting Rods.. 84 Fuel Setting Adjustment............................ 126
Crankshaft ........................................... 84 Engine Speed Measurement .................... 127
Camshafts ........................................... 85 Woodward UG8 Lever Governor ................... 128
Air Starting System ................................ 86 Compensating Adjustment........................ 128
Electrical System...................................... 88 Low and High Idle Speed Adjustment....... 129
Alternator............................................. 88 Speed Droop Adjustment.......................... 129
Starter Motor ....................................... 88 Air Fuel Ratio Control ..................................... 132
Starter Solenoid................................... 89 Air Inlet and Exhaust System.................... 133
Circuit Breaker..................................... 89 Restriction of Air Inlet and Exhaust........... 133
Contactor Switch (Water Temperature) 90 Measurement of Pressure in Inlet Manifold 133
Testing and Adjusting ........................... 91

ii
 Table of Contents (Continued)

Page Page
Exhaust Temperature............................... 134 Projection of Cylinder Liners ..................... 145
Crankcase (Crankshaft Compartment) Flywheel and Flywheel Housing................ 146
Pressure ............................................. 134 Checking Crankshaft Deflection (Bend).... 148
Compression ............................................ 134 Vibration Damper ...................................... 149
Cylinder Heads......................................... 134 Electrical System ............................................ 150
Valves ............................................. 134 Test Tools for Electrical System ............... 150
Bridge Adjustment .................................... 135 Battery .............................................. 151
Crankshaft Positions for Valve Charging System ...................................... 151
Clearance Setting .................................... 136 Starting System......................................... 152
Valve Clearance ....................................... 137 Air Starting System ................................... Deleted
Lubrication System ........................................ 139 Caterpillar, 3161 Governor........................ 155
Too Much Oil Consumption...................... 139 Governor Types ........................................ 157
Measuring Engine Oil Pressure................ 139 Basic Governor ......................................... 159
Oil Pressure is Low ................................. 140 Governor Components ............................. 159
Oil Pressure is High.................................. 140 Operation of the 3161 Governor ............... 161
Too Much Bearing Wear .......................... 140 Auxiliary Controls ........................................... 164
Increased Oil Temperature ...................... 140 Manual Shutdown ..................................... 164
Cooling System ............................................. 141 Pressure Shutdown................................... 164
Visual Inspection of the Cooling System.. 141 Electric Shutdown .................................... 164
Testing the Cooling System ..................... 141 Manual Mechanical Speed Control ........... 164
Test Tools for Cooling System ................. 141 Pneumatic Speed Control ......................... 165
Pressure Cap Test ................................... 142 Air Fuel Ratio Control................................ 167
Radiator and Cooling System Leak Tests 143 Speed Adjusting Motor Governor Head.... 169
Water Temperature Gauge Test .............. 143 Manual Speed Setting Control .................. 169
Water Temperature Regulator Test ......... 144 Pneumatic Mid Speed Control .................. 170
Basic Block ............................................. 145 Troubleshooting.............................................. 172
Connecting Rod Bearings ........................ 145 Governor Troubleshooting ........................ 172
Main Bearings .......................................... 145 Air Fuel Ratio Control Troubleshooting..... 176
Cylinder Block .......................................... 145

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 Table of Contents (Continued)

Page Page
Pneumatic Speed Setting System Checks ......................................... 243
Control Troubleshooting ........................... 178 System Tests ............................................ 245
Testing and Adjusting ................................... 180 Shutoff Speed Setting Adjustment ............ 245
Governor Oil Pump ................................. 180 Wiring Diagrams ....................................... 247
Governor Preparation............................... 181
Governor Installation ................................ 182 3500 Industrial Engines .................................. 253
Governor Adjustments ............................. 187 Disassembly and Assembly
Auxiliary Controls ..................................... 192 Manual Shutoff ......................................... 257
Hydramechanical Protective System, Gauge Panel ............................................. 259
3500 Series Engines....................................... 197
Air Intake Shutoff ...................................... 262
Specifications Tachometer Drive ..................................... 269
Shutoff Control Group .............................. 199 Crankcase Breather .................................. 270
Thermostatic Pilot Valve .......................... 202 Water Temperature Regulators ................ 272
Accessory (Shutoff) Drive Group ............. 202 Water Pump .............................................. 275
Air Intake Shutoff...................................... 206 Fuel Filter Housing.................................... 279
Tachometer and Service Meter Drive ...... 209 Fuel Priming Pump, Fuel Transfer Pump . 283
Remote Shutoff Valve Group ................... 209 Oil Pump .............................................. 288
Electrical Switches ................................... 210 Oil Filter Housing ...................................... 293
Systems Operation Oil Pan .............................................. 300
Overspeed ............................................. 211 Oil Sequence Valves................................. 304
Low Engine Oil Pressure ......................... 211 Oil Cooler .............................................. 305
High Coolant Temperature....................... 211 Turbochargers .......................................... 312
System Components ................................ 211 Exhaust Manifolds..................................... 321
System Hydraulics.................................... 214 Aftercooler .............................................. 322
Hydraulic Circuits (Earlier)........................ 214 Governor .............................................. 326
Hydraulic Circuits (Later).......................... 228 Governor Drive.......................................... 328
Hydraulic Circuits, Later with an Hydramechanical Shutoff Control ............. 332
Alarm System ........................................... 232
Hydramechanical Shutoff Drive ................ 345
Testing and Adjusting
Accessory Drive (Front) ............................ 347
Troubleshooting........................................ 239

iv
 Table of Contents (Continued)

Page Page
Oil and Water Pump Drive ....................... 350 Oil Pans .............................................. 421
Crankshaft Vibration Damper................... 353 Oil Filter Bypass Valve ........................... 422
Crankshaft Front Seal and Wear Sleeve . 354 Duplex Oil Filter ..................................... 423
Crankshaft Rear Seal and Wear Sleeve .. 356 Oil Scavenge Pump ................................ 424
Front Drive Housing ................................. 358 Exhaust Manifolds .................................. 426
Flywheel ............................................. 362 Turbochargers......................................... 427
Flywheel Housing ..................................... 363 Air Intake Shutoff .................................... 436
Valve Covers ............................................ 365
Front Gear Groups.................................. 437
Rocker Shafts and Push Rods ................. 366
Auxiliary Drive ........................................ 440
Fuel Injectors............................................ 369
Tachometer Drive ................................... 441
Fuel Injection Control Linkage ................. 371
Trunnion (Front)...................................... 443
Cylinder Heads......................................... 377
Engine Front Support Group (Wide) ..... 443
Valves ............................................. 381
Vibration Damper Group ........................ 444
Bridge Dowels .......................................... 382
Front Mounting Group............................ 447
Connecting Rod Bearings ........................ 384
Stub Shafts .............................................. 447
Front Balancer Group............................... 385
Time Delay Relay .................................... 449
Rear Gear Group ..................................... 387
Heaters, Jacket Water ............................ 449
Spacer Plates ........................................... 391
Crankshaft Main Bearings........................ 393 Magnetic Pickup ..................................... 449

Pistons ............................................. 396 Tachometer, Digital ............................... 450

Cylinder Liners ......................................... 398 Contactors .............................................. 451

Camshafts ............................................. 400 Pressure Switches ................................. 452

Crankshaft ............................................. 407 Temperature Switches .......................... 453
Specifications for Engine Attachments Sending Units, Oil Pressure .................. 454
49Y1-UP, 95Y1-UP, 27Z1-UP, 65Z1-UP, Tachometer, Electric .............................. 454
68Z1-UP, 71Z1-UP................................... 411
Gauges, Ammeter/Oil Pressure/
Ether Starting Aid................................... 416 Water Temperature ................................ 455
Primary Fuel Filter.................................. 416 Air Shutoff Solenoids ............................. 456
Fuel Filter Change Indicator Group...... 416 Air Compressor Group .......................... 457
Governor ............................................. 417 Air Control Valve Group ........................ 458

v
Caterpillar 3508 Shop Manual
Full download: http://manualplace.com/download/caterpillar-3508-shop-manual/
Table of Contents (Continued)

Page Page
Electric Protective System for Engines Step Oil Pressure, Chart C ....................... 492
Equipped with Reversal Protection .............. 459 Reversal Detection, Chart D .................... 494
Components ........................................... 460 Troubleshooting Procedures ........................ 496
Individual Circuit Description .............. 462 Overspeed Setting Calibration,
Engine Stopped ...................................... 462 Procedure A .............................................. 496
Starting Engine....................................... Deleted Crank Terminate, Speed Adjustment,
Engine Starts to Run: No Faults ........... Deleted Procedure B .............................................. 497

Engine Runs at Rated Speed: Oil Step Calibration, Procedure C............. 498
No Faults ............................................. Deleted Overspeed Verify Test, Procedure D ........ 499
Pressure (At Engine Speeds above Oil Step Reversal Detection, Procedure E.............. 500
Speed Setting) ........................................ Deleted
Sensor Assembly Verify, Procedure F ...... 501
Engine Shutdown Due to Fault:
On/Off Time Delay (Relay), Procedure G . 503
Loss of Engine Oil.................................. Deleted
Wiring Diagrams.............................................. 504
Engine Running Below Oil Step
Speed Setting: No Faults (or Just Electric Protective System Schematic ..... 505
Accelerating through Step Speed) ....... Deleted Engine Wiring Diagram ............................. 506
Engine Shutdown Due to Fault: Low Oil Typical Junction Box Wiring Diagram ....... 507
Pressure (At Engine Speeds Below Oil
Step Speed Setting) ............................... Deleted Customer Wiring with Electric
Protective System .................................... 510
Engine Shutdown Due to Fault:
Coolant Overheating .............................. Deleted Electrical Protective System for Generator Set,
Industrial and Marine Engines............... 513
Engine Shutdown Due to Fault:
Engine Overspeed.................................. Deleted Components ............................................ 514

Engine Shutdown Due to Fault: Individual Circuit Description ................ 516

Engine Reversal .................................... Deleted Engine Stopped....................................... 516
Shutdown System with 2301 Electric Starting Engine ...................................... 518
Governor Control: No Faults................. Deleted
Engine Starts to Run: No Faults ........... 520
Troubleshooting ..................................... 484
Engine Runs at Rated Speed: No Faults 522
Functional Test ....................................... 485
Engine Shutdown Due to Fault:
System Problem Index........................... 486 Loss of Engine Oil Pressure (At Engine
System Troubleshooting Charts, Speeds Above Oil Step Speed Setting) 524
Preliminary Checks ................................ 487 Engine Shutdown Due to Fault: Low Oil
Overspeed, Chart A........................... 488 Pressure (At Engine Speeds Below Oil
Step Speed Setting) ................................ 528
Crank Terminate, Chart B ................. 490

vi

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