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TECHNICAL PRESENTATION
3512 ENGINE
LESVO509
3512 ENGINE
LEVEL II
This presentation tells about procedures and shows the special tools needed to make
adjustments and minor repairs to the 3512 Engine. Reference must be made to the
Service Manual for complete instruction.
The 3512 Engine has different arrangements for different applications (Industrial,
Generator Set, Marine, Marine Auxiliary, and Vehicular Engines). The slides in this
presentation show the 3512 and 3516 Engines.
PREREQUISITES
The serviceman must have completed LESV0508, 3500 Series Engines Introduction,
Systems and Maintenance, LESV0508. Serviceman must know the construction and
operation of diesel engines and have experiences with the adjustment and minor repair
of these engines.
OBJECTIVES
After learning the information in this Meeting Guide, the serviceman can tell the
procedures and special tools needed to do the following jobs:
1.
2.
3.
4.
5.
NOTE: This presentation gives Level II knowledge of the 3500 Engine. The instructor
can give skill training after this presentation skill training will give each serviceman the
ability to do the different jobs that are needed to make adjustments and minor repairs to
the 3500 engine.
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3512 ENGINE
REFERENCES
The following material will be used for instructor and serviceman references:
1.
2.
3.
4.
SEBR0548
SEBP1292
SEBV5854
SEBDO506-01
Engine Literature is a list of different service information and training materials which
are available. This list is used by the instructor to find materials which can be used to teach
servicemen to do the different jobs expected of them.
DIRECTIONS TO THE INSTRUCTOR
When you get ready to teach this STMG, do as follows:
1. Read all of the information (script) for each slide in the presentation.
2. Read the recommendation for FOLLOW-UP TRAINING.
3. Show the presentation. Make sure you know exactly what points are to be seen on each
slide and to be learned by the serviceman.
4. Read the script again and add any notes that you will need to teach the presentation.
5. Read service literature (reference) as necessary.
6. Look at a 3500 Engine and learn what you need to teach.
7. ORDER copies of references for use by servicemen.
8. Make a plan for FOLLOW-UP TRAINING.
Estimated Time: 8 hours
Visuals: 144 slides
Form: LESV0509
Date: 8/80 Revised: 8/86
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INTRODUCTION TO REPAIR
This presentation is about adjustment and minor
repair of the 3500 Engine. It gives the
important steps and shows the special tools
needed to do these jobs.
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INTRODUCTION TO REPAIR
We will show those adjustments and repairs that are
special to the 3500 Engines and different from
other Caterpillar Engines. These adjustments
and repairs are:
1.
2.
3.
4.
5.
6.
7.
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INJECTOR SYNCHRONIZATION
The power setting screw is under the cover on the
governor side (right front side shown) of the
engine on the front gear housing. The top bolt
in the cover is the synchronization pin.
Injector synchronization is the setting of all injector
racks to a reference position so that each
injector sends the same amount of fuel to each
combustion chamber. This is done by setting
each injector rack to the reference position
while the control linkage is held in a fixed
position called the synchronizing position.
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INJECTOR SYNCHRONIZATION
Remove the cover and gasket of the power setting
screw by taking out the two bolts. The power
setting screw is in the opening in the gasket.
It is not necessary to remove the cover or break the
fuel setting seal to set synchronization.
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INJECTOR SYNCHRONIZATION
The top bolt is the synchronizing pin. The bottom
bolt is a standard bolt.
NOTE: Cover can be installed either way so long
bolt can be installed in the upper or lower
location.
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INJECTOR SYNCHRONIZATION
Remove the washer from the synchronizing pin and
put it in the threaded hole to the left of the
power setting screw.
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REVIEW
Let us review the control linkage of the unit injectors
and the power setting screw arrangement by
looking at this illustration.
We can see the power setting screw (2) in contact with
the fuel stop lever. The synchronization pin,
when installed, will also be in contact with the
fuel stop lever.
The synchronization pin sets the fuel stop lever at the
reference position for rack synchronization of
the fuel injectors. To make this adjustment, the
synchronization gauge is put on the rack (6) (see
slides 19,20, and 21).
The synchronization pin is also the ZERO reference
point for the dial indicator which is installed in
the hole to the right of the power setting screw.
When a check of the power setting is made, the
dial indicator is installed, put at ZERO, and then
used to measure the power setting: the setting of
the power setting screw.
NOTE: This illustration is not correct. The seal goes
through the cover bolt, not the synchronizing pin.
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unit injector;
rack extending from injector;
bellcrank;
screw slot on end of the control rod;
nut and bolt that holds the control rod to
the bellcrank.
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22
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ENGINE TIMING
Remove the plug (5M2613) from the front face of
the flywheel housing and the two (2) bolts
from the cover plate of the bore for the engine
turning tool. The longer bolt (L1352) is used
as the timing bolt to find the location of No. 1
piston on top center of the compression
stroke.
NOTE: LESV0508 3512 Engine Introduction,
Systems and Maintenance, the instruction
which starts with slide No. 92 gives an
explanation of the steps used to find top
center, compression stroke. Teach or review
this procedure, if needed.
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ENGINE TIMING
Remove the right and left rear camshaft
compartment cover. There is a timing pin
(7N3370) stored under the right rear and left
rear camshaft compartment covers. Each
timing pin has a bolt which holds it on the
side of the block when it is not in use.
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ENGINE TIMING
Look at the camshaft and see where the slot in the
camshaft is in relation to the timing pin hole
in the block. If you cant see the slot because
it is on the top side away from you, feel on
the back side of the camshaft for the slot.
Finding the position of the slot in the camshaft to
the timing pin hole in the block will give an
indication where No. 1 piston is in relation to
top center, compression stroke. When the slot
in the camshaft is in alignment with the
timing pin hole, No. 1 piston is at top center
on the compression stroke. The timing bolt
hole in the flywheel will also be in alignment
with the timing hole in the flywheel housing.
The timing bolt will turn into the timing hole
in the flywheel.
Now, put the engine at No. 1 piston at top center,
compression stroke.
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ENGINE TIMING
Remove the bolt from the camshaft timing pin. Put
the pin in the timing hole in the block and
push the pin in the slot in the camshaft. When
the pin is in the slot, the camshaft is in time
with the crankshaft. When the pin will not go
in and the slot is not in alignment, the
camshaft will have to be put in time.
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ENGINE TIMING
NOTICE: When a camshaft is out of time as much
as 20, the valves will contact the pistons and
cause damage to the valve system parts.
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ENGINE TIMING
We will use only the left camshaft to demonstrate
the timing procedure. When the right
camshaft is not in time, the same procedure is
followed.
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ENGINE TIMING
Remove each of the valve covers on the left bank of
the engine. Loosen the rocker arm shaft bolts
on each of the six cylinder heads until the
push rods are not engaged. With the rocker
arm shaft bolts loose, the valves and injectors
are released from the camshaft.
NOTICE:WHEN THE ENGINE IS TURNED,
there is only a small clearance between the
pistons and the valves at top center, exhaust
stroke, etc. If the engine is NOT timed
correctly and the crankshaft is turned, it is
possible for the pistons to contact (strike) the
valves and cause damage.
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ENGINE TIMING
Remove the cam drive gear retaining bolt.
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ENGINE TIMING
Use a crossbar puller arrangement to pull the
camshaft drive gear from the tapered end of
the camshaft.
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ENGINE TIMING
The tooling and drive gear are removed from the
camshaft. Put a bolt in the end of the
camshaft and turn the camshaft until the
timing pin can be installed through the timing
hole into the groove in the camshaft.
Turn the gear and hold in the direction of normal
engine rotation to remove backlash. Install the
bolt and plate.
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ENGINE TIMING
Tighten the bolt to specified torque, then hit the gear
and tighten it to specified torque again.
Repeat this procedure a second time.
With the timing bolt in the flywheel and timing pin
in the camshaft, the timing is now correct.
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ENGINE TIMING
Make sure the push rods are engaged correctly with
the rocker arms. Tighten the rocker arm shaft
bolts.
Valve clearance (lash) and injector timing must be
checked and adjusted after the rocker arm
shaft bolts have been loosened and tightened.
Valve adjustment procedure was explained in
LESC0508. Also look in the Service Manual
for the specifications and procedures for your
engine. Injector timing will be covered later in
slides 42-47 of this meeting guide.
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ENGINE TIMING
When the right camshaft is not in time, and the left
camshaft is in time, do the same procedure for
putting the right camshaft in time with the
crankshaft.
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REVIEW OF
CAMSHAFT TIMING PROCEDURE
Follow these procedures to change the timing of a
camshaft:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
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INJECTOR TIMING
These are the special tools used to check or adjust the
injector pump plunger timing.
1. Timing Fixture (Bracket, Collet Extension
Rod) [6V7881]
2. Set gauge (6V3117)
3. Dial Indicator (6V3075)
4. 3.048mm (.12 inch) Contact Point (8S3675)
5. Extension Rod (Part of the Timing Fixture)
This is the other part of the Timing and Fuel Tool
Group (6V7880).
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TIMING FIXTURE
Assemble and set indicator. Assemble the timing fixture
assembly and zero the dial indicator to check or
make an adjustment to the injector pump longer
timing.
1. Turn a 3.1mm (.12 inch) Contact Point
[8S3675 in the stem of the dial indicator.
2. Put the dial indicator in the collet of the
fixture and tighten the collet just enough to
hold the dial indicator.
3. Move the extension rod and watch the dials
on the indicator. Make sure the extension rod
is free.
4. Position the fixture assembly on the set gauge
with the magnetic base of the fixture on the
top surface and the extension rod on the
bottom step.
5. Move the dial indicator in the collet until the
pointers indicate zero. Now move the dial
indicator in the collet until the large pointer
indicates the setting shown in the Dial
Indicator Setting Chart* (if other than zero
setting) and tighten the collet.
The Dial Indicator Setting Chart is Serviceman
Handout 1.
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88.28
+ 1.28
88.07
+ 1.07
87.85
+ 0.85
87.64
+ 0.64
87.43
+ 0.43
87.21
+ 0.21
87.00
0.00
86.79
0.21
86.57
0.43
86.36
0.64
86.15
0.84
85.93
1.07
85.72
1.28
*See Fuel Setting Information for the
correct fuel timing dimension to use.
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