Caterpillar 3500 Series Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 3500 Series Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 3500 Series Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
RENR9363 - Systems Operation (3500 Engines).pdf
RENR9363 - Testing And Adjusting (3500 Engines).pdf
RENR9364 - Troubleshooting (3500 Engines).pdf
RENR9365 - Disassembly and Assembly (3500 Engines).pdf
LEBW0013 - Project Guide CM25 (6; 8; 9 Cylinder - Project Guide - Generator Set for Petroleum Applications).pdf
SENR2351 - Specifications (3500 Industrial Engines).pdf
SENR2352 - Systems Operation (3500 Industrial Engines).pdf
SENR2352 - Testing and Adjusting (3500 Industrial Engines).pdf
SENR2354 - Systems Operation (3500 Industrial Engine Attachments).pdf
SENR2354 - Testing and Adjusting (3500 Industrial Engine Attachments).pdf
SENR2355 - Disassembly and Assembly (3500 INDUSTRIAL ENGINE).pdf
SENR2361 - Specifications (3500 Generator Set Engines).pdf
SENR2362 - Systems Operation (3500 Engines).pdf
SENR2362 - Testing and Adjusting (3500 Engines).pdf
SENR2370 - Disassembly and Assembly (3500 GENERATOR SET ENGINES).pdf
SENR2995 - Technical Manual (Introduction; Systems & Maintenance for 3500 Series Diesel Engines).pdf
SENR3078 - Specifications (3500 Series Engines Hydramechanical Protective System).pdf
SENR3078 - Specifications (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM).pdf
SENR3078 - Systems Operation (3500 Series Engines Hydramechanical Protective System).pdf
SENR3078 - Systems Operation (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM).pdf
SENR3078 - Testing & Adjusting - Troubleshooting (3500 Series Engines Hydramechanical Protective System).pdf
SENR3078 - Testing And Adjusting (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM).pdf
SENR3108 - Specifications (SUPPLEMENT FOR UPRATED 3500 ENGINES).pdf
SENR3878 - Specifications (3500 Generator Set Engines).pdf
SENR3879 - Testing and Adjusting (3500 Generator Set Engines).pdf
SENR3882 - Disassembly and Assembly (3500 Generator Set Engines).pdf
SENR6581 - Systems Operation (Ether Aid Starting System for 3500 Mui Engines).pdf
SENR6581 - Testing & Adjusting (Ether Aid Starting System for 3500 Mui Engines).pdf
PRODUCT DETAILS:
Total Pages: 3,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENT...
LEBW0013 - Project Guide CM25 (6; 8; 9 Cylinder - Project Guide - Generator Set for Petroleum Applications)........277
SENR2351 - Specifications (3500 Industrial Engines)........383
Accessory Drive (Upper Right Hand)........386
Accumulator........388
Aftercooler........390
Air Cleaner Adapter........392
Air Cleaner........393
Air Compressor........395
Air Starting Motor Pressure Regulating Valve........397
Air Starting Motor........399
Alternator Mounting........401
Alternator and Regulator........403
Ammeter........409
Auxiliary Drive Housing........413
Auxiliary Drive Pulley........415
Auxiliary Water Pump - Sea Water........419
Auxiliary Water Pump........431
Belt Tension Chart........434
Camshaft........437
Connecting Rod and Main Bearing Journals........440
Connecting Rod........442
Coolant Level Switch........445
Coolant Temperature Switch........447
Crankcase Breather........453
Crankshaft Wear Sleeves and Seals........456
Crankshaft........458
Cylinder Block........464
Cylinder Head Valves........473
Cylinder Head........475
Cylinder Liner........481
Differential Pressure Gauge........483
Duplex Engine Oil Filters........485
Electric Starting Motor........488
Engine Air Cleaner Service Indicator........503
Engine Design........505
Engine Mount (Front) - Hydraulic Pump Drive or PTO Clutch........507
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves........509
Engine Oil Pan........512
Engine Oil Pump........514
Engine Oil Scavenge Pump........519
Engine Speed Sensor........522
Engine Trunnion........524
Ether Starting Aid........528
Exhaust Flange........530
Exhaust Manifold........535
Flexible Coupling........537
Flywheel Housing........542
Flywheel........545
Fuel Filter (Primary)........547
Fuel Filter Service Indicator........549
Fuel Filter........551
Fuel Injection Control Linkage........553
Fuel Injector Mechanism........556
Fuel Pressure Regulator........566
Fuel Transfer Pump........568
Gear Group (Front)........570
Gear Group (Rear)........573
Governor Drive........576
Governor Linkage........579
Jacket Water Heater........582
Magnetic Switch........588
Manual Shutoff........590
Piston and Rings - One-Piece Piston........592
Piston and Rings - Two-Piece Piston........598
Piston and Rings........601
Power Take-Off Clutch - Front........604
Power Take-Off Clutch........606
Pressure Contactor........611
Pressure Gauge - Engine Oil........615
Pressure Gauge - Hydraulic Oil........621
Pressure Gauge........623
Pressure Switch - Prelube........625
Pressure Switch........627
Sending Unit - Engine Oil Pressure........641
Sending Unit - Water Temperature........643
Service Meter........645
Shutoff (Energize to Shutdown)........647
Signal Generator........650
Stub Shaft (Front)........652
Stub Shaft (Rear)........654
Tachometer Drive........656
Tachometer........658
Temperature Contactor........664
Temperature Gauge........668
Temperature Switch........673
Time Delay Relay........683
Turbocharger 1........685
Turbocharger 2........687
Vacuum Gauge........691
Valve Mechanism........693
Vibration Damper........703
Water Pump........705
SENR2352 - Systems Operation (3500 Industrial Engines)........707
Accumulator........708
Aftercooler........711
Air Inlet and Exhaust System Operation........712
Air Starting System Operation........714
Alternator........716
Camshaft........718
Circuit Breaker........719
Coolant Temperature Switch........720
Cooling System Operation - Jacket Water Aftercooled........722
Crankshaft........724
Cylinder Block, Liners and Heads........725
Electrical System Operation........727
Engine Speed Sensor........728
Fuel Injection Control Linkage........729
Fuel Injection Cycle........731
Fuel Injector........734
Fuel System Operation 01_04_2014........737
Fuel System Operation........739
Governor - 3161........747
Lubrication System Operation........752
Pistons, Rings and Connecting Rods - Two-Piece Piston........756
Starting Motor........758
Starting Solenoid........760
Turbocharger........762
Valve System Components........765
SENR2352 - Testing and Adjusting (3500 Industrial Engines)........769
Accumulator Pressure - Test........771
Alternator Regulator........776
Battery........778
Camshaft Timing........779
Charging System........786
Checking Engine Cylinders........787
Compression........788
Connecting Rod Bearings........789
Crankcase Pressure........790
Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting........791
Cylinder Block........793
Cylinder Heads........795
Cylinder Liner Projection........797
Electric Starting System........802
Engine Oil Pressure - Test........803
Engine Oil Pressure is High........807
Engine Oil Pressure is Low........808
Engine Rotation........810
Engine Speed Measurement........811
Excessive Bearing Wear - Inspect........812
Excessive Engine Oil Consumption - Inspect........813
Finding the Top Center Position for the No. 1 Piston........814
Flywheel - Inspect........817
Flywheel Housing - Inspect........820
Fuel Injector Synchronization........824
Fuel Injector Timing........827
Fuel Pressure........832
Fuel Setting........834
Fuel System Inspection........839
General Information (Cooling System)........840
General Information (Fuel System) - Diesel........842
General Information (Lubrication System)........843
Increased Engine Oil Temperature - Inspect........844
Indicators for Engine Oil Pressure........845
Lubrication........846
Main Bearings........847
Measuring Exhaust Temperature........848
Measuring Inlet Manifold Pressure........849
Pinion Clearance Adjustment........851
Pressure Regulating Valve........853
Start-Up Procedure........855
Test Tools for the Cooling System........856
Test Tools for the Electrical System........859
Testing the Cooling System........862
Troubleshooting........866
Valve Lash Check........873
Valve Lash and Valve Bridge Adjustment........874
Vibration Damper........881
Visual Inspection........882
Water Temperature Regulator - Test........884
Woodward UG8 Governor........885
SENR2354 - Systems Operation (3500 Industrial Engine Attachments)........897
Cooling System........898
Duplex Oil Filter........900
Electrical System........902
Fuel System........906
Power Take-Off Clutch........909
SENR2354 - Testing and Adjusting (3500 Industrial Engine Attachments)........911
Duplex Oil Filter - Adjust........912
Electrical Gauge - Test - Engine Oil Pressure........914
Electrical Gauge - Test - Water Temperature........916
Mechanical Gauge - Test - Water Temperature........918
Mechanical Gauge - Test........919
Power Take-Off Clutch - Adjust........920
Sending Unit - Test - Engine Oil Pressure........923
Sending Unit - Test - Water Temperature........925
Temperature Contactor - Test........927
Troubleshooting........929
SENR2355 - Disassembly and Assembly (3500 INDUSTRIAL ENGINE)........936
ACCESSORY DRIVE (FRONT)........938
AFTERCOOLER........943
AIR CLEANER HOUSINGS........948
AIR INTAKE SHUTOFF (3508)........951
AIR INTAKE SHUTOFF (3512)........958
AIR STARTER (AN ATTACHMENT)........963
ALTERNATOR (AN ATTACHMENT)........981
CAMSHAFT BEARINGS, CRANKSHAFT........983
CAMSHAFTS........991
CONNECTING ROD BEARINGS........999
CRANKCASE BREATHER........1002
CRANKSHAFT FRONT SEAL AND WEAR SLEEVE........1005
CRANKSHAFT MAIN BEARINGS........1009
CRANKSHAFT REAR SEAL AND WEAR SLEEVE........1015
CRANKSHAFT VIBRATION DAMPER........1019
CYLINDER HEADS........1021
CYLINDER LINERS........1028
EXHAUST ELBOW........1032
EXHAUST MANIFOLDS........1034
FLYWHEEL HOUSING........1036
FLYWHEEL........1041
FRONT BALANCER GROUP (3508)........1043
FRONT DRIVE HOUSING........1047
FUEL FILTER HOUSING........1053
FUEL INJECTION CONTROL LINKAGE........1058
FUEL INJECTORS........1066
FUEL PRIMING PUMP, FUEL TRANSFER PUMP........1070
GAUGE PANEL........1076
GOVERNOR DRIVE........1080
GOVERNOR........1086
HYDRAMECHANICAL SHUTOFF CONTROL........1089
HYDRAMECHANICAL SHUTOFF DRIVE........1106
MANUAL SHUTOFF........1110
OIL AND WATER PUMP DRIVE........1113
OIL COOLER........1118
OIL FILTER HOUSING........1127
OIL PAN........1139
OIL PUMP........1144
OIL SEQUENCE VALVES........1151
PISTON COOLING JETS, SERVICE METER........1153
PISTONS........1155
REAR GEAR GROUP........1159
ROCKER SHAFT ASSEMBLIES........1164
SPACER PLATES........1167
TACHOMETER DRIVE........1170
TURBOCHARGERS (3508)........1172
TURBOCHARGERS (3512)........1181
TURBOCHARGERS........1190
VALVE COVERS, ROCKER SHAFTS AND PUSH RODS........1193
VALVE LIFTERS, BRIDGE DOWELS........1196
VALVE SEAT INSERTS, VALVE GUIDES........1198
VALVES........1201
WATER PUMP........1204
WATER TEMPERATURE REGULATORS........1211
SENR2361 - Specifications (3500 Generator Set Engines)........1215
Fuel Filter (Primary)........1218
Fuel Filter Service Indicator........1220
Fuel Pressure Regulator........1222
Fuel Injector Mechanism........1224
Fuel Injection Control Linkage........1227
Governor Linkage........1230
Manual Shutoff........1233
Aftercooler........1235
Camshaft........1237
Valve Mechanism........1241
Cylinder Head........1248
Cylinder Head Valves........1254
Turbocharger........1263
Exhaust Manifold........1265
Exhaust Flange........1267
Air Cleaner........1269
Engine Air Cleaner Service Indicator........1271
Ether Starting Aid........1273
Engine Oil Pump........1275
Engine Oil Scavenge Pump........1280
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves........1283
Engine Oil Filter........1286
Duplex Engine Oil Filters........1288
Engine Oil Pan........1291
Water Temperature Regulator........1293
Water Connection Group........1295
Water Pump........1296
Auxiliary Water Pump - Sea Water........1302
Auxiliary Water Pump........1314
Cooling System Pressure Cap........1326
Cylinder Block........1334
Cylinder Liner........1338
Piston and Rings........1340
Piston and Rings - Two-Piece Piston........1343
Piston and Rings - One-Piece Piston........1346
Connecting Rod........1349
Connecting Rod and Main Bearing Journals........1352
Crankshaft........1354
Crankshaft Wear Sleeves and Seals........1356
Gear Group (Front)........1358
Gear Group (Rear)........1361
Accessory Drive (Upper Right Hand)........1365
Flywheel........1367
Flywheel Housing........1369
Flexible Coupling........1375
Power Take-Off Clutch - Front........1380
Engine Mount........1382
Engine Mount (Front) - Hydraulic Pump Drive or PTO Clutch........1383
Engine Trunnion........1385
Vibration Damper........1387
Stub Shaft (Front)........1392
Stub Shaft (Rear)........1394
Auxiliary Drive Pulley........1396
Auxiliary Drive Shaft........1398
Auxiliary Drive Housing........1400
Belt Tension Chart........1402
Alternator and Regulator........1404
Electric Starting Motor........1408
Air Starting Motor........1412
Air Starting Motor Pressure Regulating Valve........1414
Jacket Water Heater........1416
Air Shutoff Solenoid........1420
Coolant Temperature Switch........1424
Fuel Shutoff Solenoid........1426
Magnetic Switch........1429
Engine Speed Sensor........1431
Pressure Contactor........1435
Temperature Contactor........1437
Temperature Switch........1439
Pressure Switch........1443
Ammeter........1447
Pressure Gauge........1451
Pressure Gauge - Hydraulic Oil........1453
Temperature Gauge........1455
Sending Unit - Engine Oil Pressure........1457
Sending Unit........1459
Tachometer........1461
Tachometer Drive........1463
Time Delay Relay........1465
SENR2362 - Systems Operation (3500 Engines)........1467
Fuel System Operation........1468
Fuel Injection Control Linkage........1472
Fuel Injector........1474
Fuel Injection Cycle........1477
Governor - 3161........1480
Duplex Fuel Filter........1485
Air Inlet and Exhaust System Operation........1488
Aftercooler........1490
Valve System Components........1491
Turbocharger........1495
Lubrication System Operation........1498
Duplex Oil Filter........1502
Centrifugal Oil Filters........1504
Cooling System Operation........1506
Cylinder Block; Liners and Heads........1508
Pistons; Rings and Connecting Rods - Two-Piece Piston........1510
Crankshaft........1512
Camshaft........1513
Power Take-Off Clutch........1514
Air Starting System Operation........1516
Electrical System Operation........1518
Alternator........1519
Starting Solenoid........1521
Starting Motor........1523
Engine Speed Sensor........1525
Coolant Temperature Switch........1526
Circuit Breaker........1528
SENR2362 - Testing and Adjusting (3500 Engines)........1529
Troubleshooting........1531
General Information (Fuel System) - Diesel........1561
Fuel System Inspection........1562
Checking Engine Cylinders........1563
Fuel Pressure - Diesel System........1564
Engine Rotation........1570
Finding the Top Center Position for the No. 1 Piston........1571
Camshaft Timing........1574
Engine Speed Measurement........1578
Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting........1579
Fuel Injector Timing........1581
Fuel Injector Synchronization........1586
Fuel Setting........1590
Start-Up Procedure........1595
Restriction of Air Inlet and Exhaust........1596
Measuring Inlet Manifold Pressure........1597
Measuring Exhaust Temperature........1599
Crankcase Pressure........1600
Compression........1601
Cylinder Heads........1602
Valve Lash Check........1604
Valve Lash and Valve Bridge Adjustment........1606
General Information (Lubrication System)........1613
Engine Oil Pressure - Test........1614
Excessive Bearing Wear - Inspect........1618
Excessive Engine Oil Consumption - Inspect........1619
Increased Engine Oil Temperature - Inspect........1620
Engine Oil Pressure is Low........1621
Engine Oil Pressure is High........1623
Indicators for Engine Oil Pressure........1624
Duplex Oil Filter - Adjust........1625
General Information (Cooling System)........1627
Visual Inspection........1629
Test Tools for the Cooling System........1631
Testing the Cooling System........1635
Coolant Temperature Sensor - Test........1639
Water Temperature Regulator - Test........1642
Connecting Rod Bearings........1644
Main Bearings........1645
Cylinder Block........1646
Cylinder Liner Projection........1647
Flywheel - Inspect........1652
Flywheel Housing - Inspect........1656
Vibration Damper........1661
Power Take-Off Clutch - Adjust........1662
Pressure Regulating Valve........1665
Lubrication........1667
Test Tools for the Electrical System........1668
Battery........1673
Charging System........1674
Alternator Regulator........1675
Electric Starting System........1677
Pinion Clearance Adjustment........1679
Temperature Contactor - Test........1681
Electrical Gauge - Test - Water Temperature........1683
Mechanical Gauge - Test........1685
Mechanical Gauge - Test - Water Temperature........1686
Sending Unit - Test - Engine Oil Pressure........1687
SENR2370 - Disassembly and Assembly (3500 GENERATOR SET ENGINES)........1689
Introduction........1692
Alternator........1693
Accessory Drive (Front)........1695
Manual Shutoff........1701
Air Cleaner Housings........1704
Gauge Panel........1707
Contactor Group........1711
Air Inlet Shutoff (3508)........1713
Air Inlet Shutoff (3512)........1721
Air Inlet Shutoff (3516)........1727
Service Meter........1735
Tachometer Drive........1736
Crankcase Breather........1740
Water Temperature Regulators........1743
Water Pump........1747
Fuel Filter Housing........1754
Fuel Priming Pump........1759
Fuel Transfer Pump........1761
Engine Oil Pump........1768
Engine Oil Filter Housing........1776
Engine Oil Pan........1785
Engine Oil Sequence Valve........1791
Engine Oil Cooler........1793
Turbochargers........1803
Aftercooler........1836
Exhaust Elbow........1843
Exhaust Manifolds........1845
Oil & Water Pump Drive........1847
Crankshaft Vibration Damper........1852
Crankshaft Front Seal & Wear Sleeve........1854
Crankshaft Rear Seal & Wear Sleeve........1858
Front Drive Housing........1862
Air Starting Motor (An Attachment)........1868
Governor Actuator........1887
Governor Drive........1889
Governor Fastener Group........1891
Hydra Mechanical Shutoff Control (An Attachment)........1895
Hydra Mechanical Shutoff Drive........1912
Flywheel........1916
Flywheel Housing........1918
Valve Covers........1922
Rocker Shafts & Push Rods........1923
Fuel Injectors........1928
Fuel Injection Control Linkage........1932
Cylinder Heads........1939
Valves........1946
Valve Lifters........1949
Bridge Dowels........1951
Valve Seat Inserts........1953
Valve Guides........1955
Connecting Rod Bearings........1957
Front Balancer Group (3508)........1960
Rear Gear Group........1964
Spacer Plates........1970
Crankshaft Main Bearings........1973
Piston Cooling Jets........1979
Pistons........1980
Cylinder Liners........1984
Camshafts........1988
Camshaft Bearings........1997
Crankshaft........2000
SENR2995 - Technical Manual (Introduction; Systems & Maintenance for 3500 Series Diesel Engines)........2006
TOC........2022
WARNING........2009
CHARTS........0
CHART_PART1 A........2507
CHART_PART1 B........2509
CHART_PART1 C........2511
CHART_PART1 D........2513
CHART_PART2 A........2559
CHART_PART2 B........2560
CHART_PART2 C........2562
CHART_PART2 D........2564
FIGURES........0
FIGURE 1........2535
FIGURE 2........2537
FIGURE 3........2539
FIGURE 4........2541
FIGURE 5........2543
FIGURE 6........2545
FIGURE 7........2547
FIGURE 8........2549
FIGURE 9........2551
FIGURE 10........2553
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PAGE 624........2642
PAGE 628........2646
SENR3078 - Specifications (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM)........2670
Accessory (Shutoff) Drive Group........2671
Air Intake Shutoff........2673
Electrical Switches........2678
Remote Shutoff Valve Group........2680
Shutoff Control Group Identification........2681
Shutoff Control Group........2682
Tachometer And Service Meter Drive........2690
Thermostatic Pilot Valve........2692
SENR3078 - Specifications (3500 Series Engines Hydramechanical Protective System)........2693
Accessory (Shutoff) Drive Group........2694
Air Intake Shutoff........2696
Electrical Switches........2701
Remote Shutoff Valve Group........2703
Shutoff Control Group Identification........2705
Shutoff Control Group........2706
Tachometer And Service Meter Drive........2714
Thermostatic Pilot Valve........2716
SENR3078 - Systems Operation (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM)........2717
SENR3078 - Systems Operation (3500 Series Engines Hydramechanical Protective System)........2744
SENR3078 - Testing & Adjusting - Troubleshooting (3500 Series Engines Hydramechanical Protective System)........2770
SENR3078 - Testing And Adjusting (3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM)........2786
SENR3108 - Specifications (SUPPLEMENT FOR UPRATED 3500 ENGINES)........2802
Camshafts........2803
Crankshaft Wear Sleeves And Seals........2805
Magnetic Pickup........2807
Oil Cooler Bypass And Cooling Jet Sequence Valves........2808
Oil Filter Bypass Valve........2810
Rear Gear Group........2812
Turbocharger Impeller Installation........2816
Turbochargers........2817
Valve Rocker Arms, Lifters, And Bridges........2823
Vibration Damper Groups........2825
SENR3878 - Specifications (3500 Generator Set Engines)........2828
Accessory Drive (Upper Right Hand)........2831
Air Shutoff 1........2833
Air Shutoff 2........2835
Air Starting Motor 1........2838
Air Starting Motor Pressure Regulating Valve 2........2840
Alternator and Regulator 1........2842
Alternator and Regulator 2........2844
Alternator and Regulator 3........2847
Balancer Group (Front)........2850
Belt Tension Chart........2852
Camshaft SN - 1ZF1-UP........2855
Camshaft SN - 3YF1-UP, SN - 4XF1-UP........2858
Connecting Rod and Main Bearing Journals........2862
Connecting Rod........2864
Coolant Level Switch........2867
Coolant Temperature Switch........2868
Crankcase Breather........2870
Crankshaft SN - 1ZF1-UP........2871
Crankshaft SN - 3YF1-UP, SN - 4XF1-UP........2873
Crankshaft Wear Sleeves and Seals........2875
Cylinder Block........2877
Cylinder Head Valves........2881
Cylinder Head........2886
Cylinder Liner........2890
Electric Starting Motor 1........2892
Electric Starting Motor 2........2894
Engine Design SN - 1ZF1-UP........2896
Engine Design SN - 3YF1-UP........2898
Engine Design SN - 4XF1-UP........2900
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves SN - 1ZF1-UP, SN - 3YF1-UP, SN - 4XF1-UP........2902
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves SN - 4XF1-UP........2904
Engine Oil Filter Base........2906
Engine Oil Filter........2909
Engine Oil Pan........2911
Engine Oil Pump (SN - 1ZF1-UP)........2913
Engine Oil Pump SN - 3YF1-UP........2918
Engine Oil Pump SN - 4XF1-UP........2923
Engine Speed Sensor........2926
Exhaust Manifold SN - 1ZF1-UP........2928
Exhaust Manifold SN - 3YF1-UP, SN - 4XF1-UP........2930
Fan Drive........2932
Flexible Coupling........2934
Flywheel Housing........2936
Flywheel........2939
Fuel Filter Base........2941
Fuel Injection Control Linkage........2943
Fuel Injector Mechanism........2946
Fuel Pressure Regulator........2948
Fuel Shutoff........2950
Fuel Transfer Pump........2953
Gear Group (Front)........2955
Gear Group (Rear)........2957
Governor Drive........2962
Governor Linkage........2964
Jacket Water Heater........2966
Magnetic Switch 1........2969
Magnetic Switch 2........2971
Manual Shutoff........2972
Piston and Rings - Two-Piece Piston........2974
Pressure Contactor 1........2977
Pressure Contactor 2........2979
Pressure Gauge - Engine Oil........2981
Pressure Switch 1........2983
Pressure Switch 2........2985
Radiator Mounting........2987
Sending Unit - Engine Oil Pressure 1........2989
Sending Unit - Engine Oil Pressure 2........2991
Sending Unit - Water Temperature........2993
Sending Unit........2995
Service Meter........2997
Tachometer........2998
Temperature Contactor 1........3000
Temperature Contactor 2........3002
Temperature Gauge........3004
Temperature Switch........3006
Turbocharger........3008
Valve Mechanism........3010
Vibration Damper 1........3015
Vibration Damper 2........3017
Vibration Damper 3........3018
Vibration Damper Guard........3020
Water Pump........3022
Water Temperature Regulator........3027
SENR3879 - Testing and Adjusting (3500 Generator Set Engines)........3029
Alternator Regulator........3031
Battery........3033
Camshaft Timing........3034
Charging System........3038
Checking Engine Cylinders........3040
Compression........3041
Connecting Rod Bearings........3042
Crankcase Pressure........3043
Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting........3044
Cylinder Block........3046
Cylinder Heads........3047
Cylinder Liner Projection........3049
Electric Starting System........3054
Engine Oil Pressure - Test........3056
Engine Oil Pressure is High........3061
Engine Oil Pressure is Low........3062
Engine Rotation........3064
Engine Speed Measurement........3065
Excessive Bearing Wear - Inspect........3067
Excessive Engine Oil Consumption - Inspect........3068
Finding the Top Center Position for the No. 1 Piston........3070
Flywheel - Inspect........3073
Flywheel Housing - Inspect........3077
Fuel Injector Synchronization........3082
Fuel Injector Testing........3086
Fuel Injector Timing........3088
Fuel Pressure........3093
Fuel Setting........3096
Fuel System Inspection........3101
Increased Engine Oil Temperature - Inspect........3102
Lubrication........3103
Main Bearings........3104
Measuring Exhaust Temperature........3105
Measuring Inlet Manifold Pressure........3106
Pinion Clearance Adjustment........3109
Pressure Regulating Valve........3111
Restriction of Air Inlet and Exhaust........3113
Test Tools for the Electrical System........3114
Testing the Cooling System........3119
Valve Lash Check........3123
Valve Lash and Valve Bridge Adjustment........3124
Vibration Damper........3133
Visual Inspection........3134
Water Temperature Regulator - Test........3137
SENR3882 - Disassembly and Assembly (3500 Generator Set Engines)........3139
Accessory Drive (Front)........3141
Aftercooler........3144
Air Inlet Manifold........3146
Bridge Dowels........3148
Camshaft Bearings........3150
Camshafts........3153
Connecting Rod Bearings........3162
Contactor Group........3166
Crankshaft Front Seal And Wear Sleeve........3167
Crankshaft Main Bearings........3171
Crankshaft Rear Seal And Wear Sleeve........3177
Crankshaft Vibration Damper........3180
Crankshaft........3182
Cylinder Head Assemblies........3190
Cylinder Liners........3194
Exhaust Elbow........3199
Exhaust Manifold........3201
Flywheel Housing........3203
Flywheel........3207
Front Balancer Group (3508)........3209
Front Drive Housing........3212
Fuel Filter Base........3216
Fuel Injection Control Linkage........3217
Fuel Injectors........3225
Fuel Transfer Pump........3229
Governor Actuator Drive........3235
Governor Actuator........3237
Governor Fastener Group........3239
Manual Shutoff........3242
Oil And Water Pump Drive........3244
Oil Cooler........3247
Oil Filter Base........3252
Oil Pan........3254
Oil Pump........3258
Oil Sequence Valves........3264
Piston Cooling Jets........3266
Pistons And Connecting Rod Assemblies........3268
Rear Gear Group........3275
Rocker Shaft Assemblies And Push Rods........3279
Rocker Shaft Assemblies........3282
Spacer Plates........3285
Turbochargers........3288
Valve Covers........3295
Valve Guides........3296
Valve Lifters........3298
Valve Seat Inserts........3300
Valves........3302
Water Pump........3304
Water Temperature Regulators........3310
SENR6581 - Systems Operation (Ether Aid Starting System for 3500 Mui Engines)........3313
SENR6581 - Testing & Adjusting (Ether Aid Starting System for 3500 Mui Engines)........3322
Caterpillar 3500 Series Engines Repair Service Manual
