3500

TECHNICAL PRESENTATION

3512 ENGINE

3500 SERIES ENGINES

ENGINE SERVICE TRAINING 1998

ADJUSTMENTS AND MINOR REPAIRS

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3512 ENGINE


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LEVEL II

This presentation tells about procedures and shows the special tools needed to makeadjustments and minor repairs to the 3512 Engine. Reference must be made to theService 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 thispresentation 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 andoperation of diesel engines and have experiences with the adjustment and minor repairof these engines.

OBJECTIVES

After learning the information in this Meeting Guide, the serviceman can tell theprocedures and special tools needed to do the following jobs:

1. remove and install a unit injector;2. check and adjust injector synchronization;3. check and adjust power settings;4. check and adjust injector pump plunger timing; and5. remove and install the water pump water seals.

NOTE: This presentation gives Level II knowledge of the 3500 Engine. The instructorcan give skill training after this presentation skill training will give each serviceman theability to do the different jobs that are needed to make adjustments and minor repairs tothe 3500 engine.

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3512 ENGINE


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REFERENCES

The following material will be used for instructor and serviceman references:

1. 3512 Engine Service Manual SEBR05482. 3512 Engine Parts Book SEBP12923. 3512 Engine Operation and Maintenance Guide SEBV58544. Engine Literature SEBDO506-01

Engine Literature is a list of different service information and training materials whichare available. This list is used by the instructor to find materials which can be used to teachservicemen 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 hoursVisuals: 144 slidesForm: LESV0509

Date: 8/80 Revised: 8/86

INTRODUCTION TO REPAIR

This presentation is about adjustment and minorrepair of the 3500 Engine. It gives theimportant steps and shows the special toolsneeded to do these jobs.

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INTRODUCTION TO REPAIR

3500 SERIES ENGINES


We will show those adjustments and repairs that arespecial to the 3500 Engines and different fromother Caterpillar Engines. These adjustmentsand repairs are:

1. unit injector replacement2. injector synchronization3. check power setting4. adjust power setting5. timing camshafts to crankshaft6. injector pump plunger timing, and7. water pump seal replacement


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UNIT INJECTOR REPLACEMENT

Follow these procedures to replace a unit injector:

1. Remove the valve cover.2. Remove the bolts from the rocker arm shaft.

Lift the rocker arms and shaft from the valvecover base.

3. Remove the valve bridge from the dowels.4. Remove the locknut and washer from the

control rod bolt. Disconnect the control rodfrom the bellcrank.

5. Remove the bolts from the brackets of thebellcrank lever assembly.

6. Slide the bellcrank from the rack of theinjector and remove the bellcrank leverassembly from the cylinder head.

7. Remove the bolt from the injector clamp andremove the clamp.

8. Pull the unit injector up and out of the bore ofthe cylinder head and remove it from theengine.

CAUTION: DO NOT pry on rack or locationdowels or points that will cause damage.


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9. Clean the injector bore of the cylinder head.10. Put new O-ring seals (3) on the unit injector and

put clean engine oil on the O-ring seals.11. Put the unit injector in position with the bore of the

cylinder head. Make sure the two (2) dowels in theinjectors body are in alignment with each side ofthe bridge dowel.

12. Push the unit injector down into the bore of thecylinder head.

13. Install the clamp and bolt. Tighten the bolt toService Manual specifications.

14. put the bellcrank lever assembly in position on thecylinder head. Make sure the bellcrank isconnected correctly to the rack.

15. Install the two bolts in the brackets and tighteneach bolt to Service Manual specifications.

16. Connect the control rod bolt to the bellcrank, puton the washer and locknut and tighten each toService Manual specifications.

17. Move the control rod, linkage and rack and see thatall controls move freely.

18. Check the synchronization of all injectors andadjust.

19. Install rocker arm shafts and rocker arms and checkand adjust the valve clearance and injector timing.

20. Put on the valve covers and install the bolts.Tighten the bolts to Service Manual specifications.


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The valve cover, rocker arms and shaft have beenremoved so that you can see better. You cansee the injector and rack, the bellcrank leverassembly and the control rod, and valvebridges.

NOTICE: Place a clean shop towel below thebellcrank and control rod bolt. The shoptowel can stop any parts that drop so they willnot fall into the cylinder head and the oil pan.

Remove the locknut and washer from the control rodbolt, and the two bolts from the bellcranklever assembly bracket. Then remove thevalve bridges from the dowels and the boltfrom the injector clamp, and the clamp.


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With the bellcrank lever assembly, the valve bridgesand the injector clamp and bolt removed, theinjector is ready to be removed.

You can see the two injector body location dowelson the right side of the valve bridge dowel.These two location dowels make it necessaryto remove the valve bridges to remove aninjector. The injector body location dowelsposition the injector rack to the bellcrank.


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With the injector removed, make sure the injectorbore in the cylinder head is clean.

Install new O-ring seals (3) on the injector housing(nut) and put clean engine oil on the O-ringseals.

Make sure the plug is installed in the top of thecylinder head. Then install the injector body...


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...into the bore of the cylinder head. Make sure theinjector location dowels are in position on thevalve bridge dowel. Push the injector down intothe cylinder head. Install the clamp and bolt.Tighten the bolt to Service Manualspecifications. Check the injector rack to see thatit moves freely.

NOTICE: DO NOT hit the unit injector to make it gointo the cylinder head.

Connect the bellcrank lever to the rack and install thebolts in the bracket. Put the control rod bolt inthe bellcrank and install the washer and locknut.Tighten the bolts in the bracket and the locknuton the control rod bolt.

The shop towel can now be removed from below thebellcrank assembly. Move the control rod up anddown and make sure the rack and linage movesfreely. The injectors must be synchronized.Injector synchronization is shown and explainedin slides 8 through 21 of this meeting guide. Theinjectors can be synchronized with the rockerarms and shaft in place, but it is easier tosynchronize the injectors before the rocker armsand shaft are installed. Now install the rockerarms and shaft.


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Valve clearance (lash) and injector timing must bechecked and adjusted after the rocker armshafts have been loosened and tightened.Valve adjustment procedure was explained inSTMG 398. Also look in the Service Manualfor the specifications and procedures for yourengine. Injector timing will be covered later inthis meeting guide.

Put on the valve covers and install the bolts. Tightenthe bolts to Service Manual specifications.


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INJECTOR SYNCHRONIZATION

The power setting screw is under the cover on thegovernor side (right front side shown) of theengine on the front gear housing. The top boltin the cover is the synchronization pin.

Injector synchronization is the setting of all injectorracks to a reference position so that eachinjector sends the same amount of fuel to eachcombustion chamber. This is done by settingeach injector rack to the reference positionwhile the control linkage is held in a fixedposition called the synchronizing position.


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Remove the cover and gasket of the power settingscrew by taking out the two bolts. The powersetting screw is in the opening in the gasket.

It is not necessary to remove the cover or break thefuel setting seal to set synchronization.


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The top bolt is the synchronizing pin. The bottombolt is a standard bolt.

NOTE: Cover can be installed either way so long bolt can be installed in the upper or lowerlocation.


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Remove the washer from the synchronizing pin andput it in the threaded hole to the left of thepower setting screw.


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REVIEW

Let us review the control linkage of the unit injectorsand the power setting screw arrangement bylooking at this illustration.

We can see the power setting screw (2) in contact withthe fuel stop lever. The synchronization pin,when installed, will also be in contact with thefuel stop lever.

The synchronization pin sets the fuel stop lever at thereference position for rack synchronization ofthe fuel injectors. To make this adjustment, thesynchronization gauge is put on the rack (6) (seeslides 19,20, and 21).

The synchronization pin is also the ZERO referencepoint for the dial indicator which is installed inthe hole to the right of the power setting screw.When a check of the power setting is made, thedial indicator is installed, put at ZERO, and thenused to measure the power setting: the setting ofthe power setting screw.

NOTE: This illustration is not correct. The seal goesthrough the cover bolt, not the synchronizing pin.


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The five holes are:

1. top cover bolt / synchronizing pin storage hole;

2. bottom cover bolt hole;3. center is power screw with locknut;4. hole to left of power screw is synchronizing

pin hole;5. hole to right of power screw is for collet and

dial indicator.

Turn the synchronizing pin in the threaded hole onthe left side of the power screw.


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Turn the synchronizing pin all the way in against thehousing and tighten it.


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This is the fuel control linkage with the fronthousing off the engine. We can see the flatface of the fuel stop lever which contacts thesynchronizing pin and the power screw.


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Here we see the synchronizing pin installed andtightened against the face of the fuel stoplever. The front housing is installed but thehousing adapter cover has been removed.

Turn the governor speed control lever clockwise inthe fuel ON direction until the flat face ofthe fuel stop lever contacts the synchronizingpin. This is the synchronizing position forinjector rack synchronization. It is also thezero reference point for zeroing the dialindicator for making a power settingadjustment.

Hold the governor linkage in this position all thetime while each injector rack is being adjustedand while the power setting adjustment ismade.


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This is the tool group used when synchronizing theinjectors and for making a power setting.

1. Synchronizing Gauge 12.7 mm (.500 inch)[6VV3119].

2. Dial Indicator [6V3075]3. Collet [5P4814] (Course threads)4. Contact Point 76.2mm (3.0 inch)

[5P7263]

This is part of the Timing and Fuel Setting ToolGroup. (6V7880).


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The valve and injector rocker arms have beenremoved so that you can see the:

1. unit injector;2. rack extending from injector;3. bellcrank;4. screw slot on end of the control rod;5. nut and bolt that holds the control rod to

the bellcrank.

The synchronizing gauge goes on the round part ofthe rack between the end of the rack and thebody of the unit injector.


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With the synchronizing pin against the face of thefuel stop lever, put the 12.7mm (.500 inch)synchronizing gauge on the rack between theinjector body and the end of the rack assembly.


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Put a screwdriver in the screw slot on the end of thecontrol rod and turn it one click at a timeuntil the 12.7mm synchronizing gauge just fitsbetween the end of the rack assembly and theinjector body. To get the setting correct, youmust get the correct feel with the gauge.This feel is similar to the feel of aclearance gauge when you check enginevalves.

DO NOT attempt to use the synchronizing gauge asa stop because deflection of the linkage willcause an incorrect adjustment.


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Remove the screwdriver from the slot so that NOpressure is on the linkage while checking thesetting with the synchronizing gauge. Anypressure on the linkage with the screwdriverwill cause the setting (adjustment) to bewrong. To make sure the linkage is free andpositioned normally, move (flip) the linkageby placing the box end of a combinationwrench (9/16 or 5/8) over the nut and boltthat holds the control rod to the bellcrank.Pull up the control rod a little and release ittwo or three times; then check the settingagain. Make the adjustment to all injectors.


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CHECK POWER SETTING

Power setting is the adjustment of the power screw to ameasurement given in the specifications. Thepower screw is adjusted to set the maximumpower output of the engine by limiting themaximum travel of the torsion shafts and,therefore, the movement of all injector racks.Before the power setting is checked, make surethat all injectors are correctly synchronized.Leave the synchronizing pin tightened in place.Move the governor linkage in the fuel ONdirection until the face of the fuel stop levercontacts the synchronizing pin. Hold the linkagein this position.

NOTE: For increased accuracy, use an FT1819Governor Torque Arm (shown in the followingslide). The FT 1819 cant be used on trucks.

For all power settings, torque rise cam settings, andsynchronization, the governor to engine linkagemust be completely free. If need be,k it can befreed by loosening the governor mounting boltsand repositioning the governor slightly. If thegovernor linkage is few, THE FT1819 ARMISNT REALLY NEEDED.


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CHECK POWER SETTING

Turn the collet (5P4814) for the dial indicator intothe threaded hole to the right of the powerscrew. Put the 76.2mm (3.0 inch) contactpoint on the dial indicator and install it in thecollet. With the contact point against the fuelstop lever face, move the indicator until theindicator reads or is set on zero. Tighten thenut on the collet.

NOTE: The dust cover on the top of the dial indicator must be removed to give clearance with the alternator mount bracket.

Remove the synchronizing pin.

NOTE: The 3161 Governor was used for illustration of these procedures.


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CHECK POWER SETTING

With the governor and adapter cover removed, wesee the power setting screw and the contactpoint of the dial indicator against the face ofthe fuel stop lever. Move the governor linkagein the fuel ON direction until the face of thefuel stop lever contacts the end of the powerscrew. With the linkage held against the powersetting screw, the dial indicator reading willbe the power setting.


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CHANGE POWER SETTING

To change the power setting, loosen the locknut andturn the power screw (while holding thelinkage against the power setting screw) in orout to the correct specifications. The powersetting is on the engine information plate andin the rack setting charge (RACK SETTINGINFORMATION). When the correctadjustment is made, tighten the locknut on thepower screw. Make sure the setting does notchange. Remove the collet and dial indicator.


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CHANGE POWER SETTING

With the injectors synchronized and the adjustmentmade to the power setting, install the powersetting screw cover and gasket.


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ENGINE TIMING

Remove the plug (5M2613) from the front face ofthe flywheel housing and the two (2) boltsfrom the cover plate of the bore for the engineturning tool. The longer bolt (L1352) is usedas the timing bolt to find the location of No. 1piston on top center of the compressionstroke.

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 camshaftcompartment cover. There is a timing pin(7N3370) stored under the right rear and leftrear camshaft compartment covers. Eachtiming pin has a bolt which holds it on theside 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 thecamshaft is in relation to the timing pin holein the block. If you cant see the slot becauseit is on the top side away from you, feel onthe back side of the camshaft for the slot.

Finding the position of the slot in the camshaft tothe timing pin hole in the block will give anindication where No. 1 piston is in relation totop center, compression stroke. When the slotin the camshaft is in alignment with thetiming pin hole, No. 1 piston is at top centeron the compression stroke. The timing bolthole in the flywheel will also be in alignmentwith the timing hole in the flywheel housing.The timing bolt will turn into the timing holein 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. Putthe pin in the timing hole in the block andpush the pin in the slot in the camshaft. Whenthe pin is in the slot, the camshaft is in timewith the crankshaft. When the pin will not goin and the slot is not in alignment, thecamshaft will have to be put in time.


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ENGINE TIMING

NOTICE: When a camshaft is out of time as muchas 20, the valves will contact the pistons andcause damage to the valve system parts.


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ENGINE TIMING

We will use only the left camshaft to demonstratethe timing procedure. When the rightcamshaft is not in time, the same procedure isfollowed.


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ENGINE TIMING

Remove each of the valve covers on the left bank ofthe engine. Loosen the rocker arm shaft boltson each of the six cylinder heads until thepush rods are not engaged. With the rockerarm shaft bolts loose, the valves and injectorsare released from the camshaft.

NOTICE:WHEN THE ENGINE IS TURNED,there is only a small clearance between thepistons and the valves at top center, exhauststroke, etc. If the engine is NOT timedcorrectly and the crankshaft is turned, it ispossible for the pistons to contact (strike) thevalves and cause damage.

NOTE: Loosen the rocker arm shaft bolts first, thenforce the cam drive gear from the camshaft taper. The injectors put a large force on each of the cam lobes and can cause rotation of the camshaft when the drive gear is loosened from the taper.


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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 thecamshaft drive gear from the tapered end ofthe camshaft.


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ENGINE TIMING

The tooling and drive gear are removed from thecamshaft. Put a bolt in the end of thecamshaft and turn the camshaft until thetiming pin can be installed through the timinghole into the groove in the camshaft.

Turn the gear and hold in the direction of normalengine rotation to remove backlash. Install thebolt and plate.


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ENGINE TIMING

Tighten the bolt to specified torque, then hit the gearand tighten it to specified torque again.Repeat this procedure a second time.

With the timing bolt in the flywheel and timing pinin the camshaft, the timing is now correct.


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ENGINE TIMING

Make sure the push rods are engaged correctly withthe rocker arms. Tighten the rocker arm shaftbolts.

Valve clearance (lash) and injector timing must bechecked and adjusted after the rocker armshaft bolts have been loosened and tightened.Valve adjustment procedure was explained inLESC0508. Also look in the Service Manualfor the specifications and procedures for yourengine. Injector timing will be covered later inslides 42-47 of this meeting guide.


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ENGINE TIMING

When the right camshaft is not in time, and the leftcamshaft is in time, do the same procedure forputting the right camshaft in time with thecrankshaft.


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REVIEW OFCAMSHAFT TIMING PROCEDURE

Follow these procedures to change the timing of acamshaft:

1. Put the timing bolt in the flywheel.2. Put the timing pin the camshaft that is in time.3. Remove each of the valve comers on the bank that

needs timing.4. Loosen the rocker arm shaft bolts on each of the

cylinder heads until the push rods are not engaged.5. Remove the cover of the drive gear of the camshaft

that is out of time. 6. Remove the bolt that holds the plate to the cam

drive gear and the end of the camshaft.7. Use a cross block puller arrangement on the cam

drive gear until the gear comes loose from the taperof the camshaft.

8. Remove the puller and leave the drive gear inposition.

9. Install a bolt into the hole in the end of thecamshaft.

10. Use the bolt to turn the camshaft until the timingpin will go into the slot in the camshaft.

11. With the timing pin in the slot of the camshaft,remove the bolt from the threaded hole in the endof the camshaft.

12. Install the plate and bolt in the end of the camshaft.13. Tighten the bolt and torque to Service Manual

specifications. Strike and torque again. Repeat.14. Make sure push rods are engaged correctly with the

rocker arms and then tighten the rocker arm shaftbolts.

15. Remove the timing pin(s) from the camshaft(s) andthe timing bolt from the flywheel.

16. Check and adjust valve clearance and injectortiming.

17. If the other camshaft is not in time with thecrankshaft, do steps 1 through 16.


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INJECTOR TIMING

These are the special tools used to check or adjust theinjector 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 ToolGroup (6V7880).


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TIMING FIXTURE

Assemble and set indicator. Assemble the timing fixtureassembly and zero the dial indicator to check ormake an adjustment to the injector pump longertiming.

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 tohold 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 gaugewith 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 ServicemanHandout 1.


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UNIT INJECTOR TIMING

The dial indicator measures the distance from thetop of the injector follower to the injectorbody surface. This measurement gives therelation of the scroll on the plunger with theports in the barrel. Injector pump plungertiming is a standard that permits the setting ofall unit injectors the same so that thebeginning of injection takes place in eachcombustion chamber a specific number ofcrankshaft degrees before top center.


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Injector pump plunger timing can be checked oradjusted during the twocrank positionsequence for valve clearance setting, orturning the crankshaft in the direction ofnormal rotation until the injector is atmaximum height and the push rod is at itslowest point (the lifter assembly is at itslowers point on the base circle of the cam).Use a wrench (3/4 inch) and loosen theadjustment screw locknut of the rocker arm.


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With the timing fixture in position, turn theadjustment screw clockwise until the dialindicator is on zero*. Hold the adjustmentscrew with the screwdriver and tighten thelocknut to Service Manual specifications.

*On-Engine settings are always zero.


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Check the setting again to see that the adjustmenthas not changed and the dial indicator readszero.


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INSTALL WATER PUMP WATER SEAL

The water pump water seal can be changed (anewseal installed) without removing the pumpfrom the engine. Remove cover. Removeimpeller. The seal is behind the impeller.

You can find a bad seal by looking at the weep holeof the water pump. When the seal is bad,coolant will leak out the weep hole.

NOTE: Service Training Video Tape 6.25 InchBore Vee Engines-Cooling System, alsoshows the installation of the jacket waterpump water seal. Video Tape 72Reconditioning Water Pumps, can be usedto supplement this training.


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SERVICEMAN HANDOUT 1


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*DIAL INDICATOR SETTING CHART

Fuel Timing Dimension mm Dial Indicator Setting mm

88.28

87.85

87.64

87.43

87.21

87.00

86.79

86.57

86.36

86.15

85.93

85.72

88.07

+ 1.28

+ 0.85

+ 0.64

+ 0.43

+ 0.21

0.00

0.21

0.43

0.64

0.84

1.07

1.28

+ 1.07

*See Fuel Setting Information for thecorrect fuel timing dimension to use.

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LESVO509 54

INTRODUCTIONINTRO TO REPAIRUNIT INJ REPLACEINJ. SYNCHRON.REVIEWCHECK PWR SET.ENGINE TIMINGCAMSHFT TIM. PROC.INJECTOR TIMINGTIMING FIXTUREUNIT INJ. TIMINGWATER PUMP SEAL

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