CATERPILLAR 3500 3508 3512 3516 Engines Operators Service Manual -

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 Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the lubrication and maintenance procedures, recommended by Caterpillar, that are outlined in the OPERATION GUIDE and/or OWNER’S MANUAL for this product before performing any lubrication or maintenance. Do not operate this product unless you have read and understood the instructions. Improper operation is dangerous and could result in injury or death. The servicemen or mechanic may be unfamiliar with many of the components and systems of this product. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all Warning plates and decals before operating, lubricating or repairing this product. 2. Make sure the work area around the product is made safe and be aware of hazardous conditions that may exist. 3. Always wear protective glasses and protective shoes when working. In particular, wear protective glasses when a hammer or sledge is used for pounding to make repairs. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 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 parts in rotation, work carefully around machinery that has been put into operation. 5. If an engine has been running and the coolant is hot, loosen the filler cap slowly and let the pressure out of the cooling system, before any caps, plugs or lines are removed or disconnected. 6. Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. 7. Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make contact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. 8. Disconnect battery and discharge any capacitors before starting any repair work. Hang “Do Not Operate” tag in the Operator’s compartment or on the controls. 9. Do not work on anything that is supported only by lift jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. 10. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are 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 which has been bent. Keep the fuel injection lines and connections clean. Be sure to install caps and covers anytime a line is removed or disconnected. 12. During service work, do not hit the fuel injection lines with wrenches or other tools. When lines are installed, use the correct torque to tighten connections and be sure all clamps and dampers are correctly installed. 13. Make sure all fuel injection lines and pressure oil lines have enough clearance to prevent contact with any other component. Do not put any fuel or oil lines close to a hot component. 14. To avoid back injury use a hoist or get help when lifting components which weigh 50 lb. (23 kg) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 15. To avoid burns, be alert for hot parts on products which have just been stopped and hot fluids in lines, tubes and compartments. 16. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing them completely. 17. Be careful when removing filler caps, breathers 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. 18. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. Use only Caterpillar replacement parts. 19. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. 20. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Make reference to “Techniques of Structural Repair Course” form number JEG03719. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 21. Before doing electrical work, disconnect battery. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 22. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. After the repair is completed, reinstall any guard or shield that was removed. 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 Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the lubrication and maintenance procedures, recommended by Caterpillar, that are outlined in the OPERATION GUIDE and/or OWNER’S MANUAL for this product before performing any lubrication or maintenance. Do not operate this product unless you have read and understood the instructions. Improper operation is dangerous and could result in injury or death. The servicemen or mechanic may be unfamiliar with many of the components and systems of this product. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all Warning plates and decals before operating, lubricating or repairing this product. 2. Make sure the work area around the product is made safe and be aware of hazardous conditions that may exist. 3. Always wear protective glasses and protective shoes when working. In particular, wear protective glasses when a hammer or sledge is used for pounding to make repairs. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose- fitting or torn clothing. Remove all rings from fingers when working on machinery. 4. 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 parts in rotation, work carefully around machinery that has been put into operation. 5. If an engine has been running and the coolant is hot, loosen the filler cap slowly and let the pressure out of the cooling system, before any caps, plugs or lines are removed or disconnected. 6. Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. 7. Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make contact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. 8. Disconnect battery and discharge any capacitors before starting any repair work. Hang "Do Not Operate" tag in the Operator’s compartment or on the controls. 9. Do not work on anything that is supported only by lift jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. 10. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are 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. i

CATERPILLAR 3500 3508 3512 3516 Engines Operators Service Manual -

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