Beruflich Dokumente
Kultur Dokumente
SENR2364
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3500 Generator Set
Engine Attachments
23Z1-UP 67Z1-UP
24Z1-UP 7QZ1-UP
25Z1-UP 73Z1-UP
,&WARNING
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 perforrn
repairs is provided in the SAFETY section of this Manual.
Improper repair procedures can be dangerous and could result in injury or death.
Basic safety precautions, skills and knowledge are Iisted in the SAFETY section
of this Manual and in the descriptions of operations where hazards exist. Warning
labels have also been pur 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 rnay 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 syrnbol:
A WARNING
Operations that rnay 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 wamings in this Manual are therefore not all inclusive. If a
procedure, tool device or work method not specificalIy recommended by Caterpil-
lar is used, you must saftisfy 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, pres-
sures 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 befare you start any jobo 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 REGl139F.
A83264X2
2
".,UU \:U:Nt:.HA rOR
SET ENGINE ATTACHMENTS INDEX
SYSTEMS OPERATION
Cooling System " 9, 10
Power Take-Off Clutches " 19
Electrical System 11, 12
Air Shutoff Solenoid 12 Wiring Diagrams . 13-18
Electrical Gauges and Sending Units. . . . . . . . . . . . . . . . . .. 11 Air Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
Electric Hour Meter '.' " 11 Charging System 14
Sending Unit tor Oil Pressure. . . . . . . . . . . . . . . . . . . . . . .. 11 Converter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Sending Unit tor Water Temperature . . . . . . . . . . . . . . . .. 11 Instrument Panel................................. ..... 13
Pyrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
Fuel System '" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tachometer 18
Duplex Fuel Filter System 4
Woodward UG8 Governor 5-7
Lubrication System 8 Woodward UG8 Dial Governor. . . . . . . . . . . . . . . . . . . . . . . . . 5
Duplex Oil Filter System 8
SPECIFICATIONS
NOTE: For Specifications with illustrations, make reference to SPECIFI-
CATIONS for 3500 GENERATOR SET ENGINE ATTACHMENTS,
Form No. SENR2363. lf the Specifications in Form SENR2363 are not the
same as in the Systems Operation and the Testing and Adjusting, look at the
printing date on the back cover of each book. Use the Specifications given
in the book with the latest date.
3
FUEL SYSTEM
SYSTEMS OPERATION
FUEL SVSTEM
DUPLEX FUEL FIL TER SYSTEM
When the control valve is moved to the "AUXI-
The duplex fuel filter system makes it possible to LIAR Y RUN" position, the fuel will be cleaned by
change filter elements while the engine is running at the filter elements in the auxiliary filter housing. The
a ny speed. main filter elements can be changed, at this time,
B55638Xl
after the main filter housing is drained and the fuel
_ UNFILTERED
FUEL
pressure is released.
líWhtDFILTEREDFUEL
After the filter elements in either housing have
been changed, the housing must be filIed with fuel to
keep the engine speed and fuel pressure constant
when the fuel is directed from one filter housing to
another. To filI either filter housing with fuel, move
fiJl vulve (2) to the open position for a minimum of 5
minutes. This will direct a small flow of fuel to the
empty filter housing. Some air will remain in the
filter housing until the control valve directs fuel flow
through the housing. The remainder of air in the
system is then directed back to the fuel tank by the
pressure regulating valve on front of the right fuel
manifold.
TO ENGINE
B55640Xl
_UNFILTERED
¡:UEL
&X%lP]FILTERED
FUEL
TO ENGINE
4
... VVLlYV,","U UüU liUVERNOR
SYSTEMS OPERATION
SPEED . A90203X1
SETTING
o MOTOR ~ HIGH PRESS OIL
SPEED
DROOP
r'_I-~ 1111111111111 COMPENSATION OIL
o
SPEEDER SLIDING
SYN. TURNS
PLUG ~1[SI.1ITTJD FULCRUM INDICATOR
.-q:::============~ r., C:::=::=BJ
SYNCHRONIZER
(SPEED)
ADJ.
FLYWEIGHT
PISTON
(SMALU
CHECK VALVE CHECK VALVE
(CLOSEO) (OPEN)
s
WOODWARD UG8 GOVERNOR
SYSTEMS OPERATION
6
VYUUDWARD UG8 GOVERNOR
SYSTEMS OPERATION
NOTICE
Do not move Ihe governor linkage in Ihe in-
crease fuel direction until the load limU control
is moved to the maximum position.
ference in rpm divided by the full load rpm and 1. Speed droop knob. 2. Synchronizer knob. 3. Load lirnlt
knob. 4. Synchronizer indicator.
multiplied by 100 is the percent of speed droop.
Zero speed droop is used on 'a single system en-
No Load Speed - FuI! Load Speed % of gine, such as a standby generator set. Speed droop
Full Load Speed x 100 = Speed Droop higher than zero permits a load to be divided be-
tween two or more engines connected to the same
load.
'.,
7
LUBRICA nON SYSTEM
SYSTEMS OPERATION
LUBRICATION SYSTEM
DUPLEX OIL FILTER SVSTEM
/
.>.'/
r".'/ ~-,-_/
1\ -, 5
\ /
885191X1 /
/-~
\
1
- _j
6
DUPLEX OIL FILTER
(Control Valve Shown in Main Run Position)
1. Main filter housing. 2. Bypass valve. 3. Auxiliary filter housing. 4. Handle. 5. Fill valve. 6. Linkage. 7. Control valve shafts.
COOLING SYSTEM
b 7
13
IZIIA 10
TOP VIEW
B38951Xl
SCHEMATICOF COOLlNGSYSTEM
(3512SHOWN)
1.Waterpump. 2. Tube (to aftercooler). 3. Oil cooler. 4. Cylinder block. 5. Cylinder head. 6. Watercooled exhaustmanifold.
7. Aftercooler. 8. Regulatorhousing. 9. Tubes (to expansiontank). 10.Tube (to water pump). 11.lnlerfrom heat exchanger.
12.Outlet to heat exchanger. 13.Expansiontank. 14.Tube (to water cooled turbocharger and exhaust elbów).
ELECTRICAL SYSTEM
SYSTEMS OPERATlON
ELECTRICAL SYSTEM
ELECTRICAL GAUGES ANO
SENOING UNITS or beca use the level is too low before starting the
engine, the sending unit will not work correctly.
The electrical gauges and sending units operate
in electrical balance. Because of t his, the voltage Sendíng Unít for Oil Pressure
and resistance ratings are important to get the
corree: indications on the gauges. The chart shows
components that operate together.
COOLlNG SYSTEM
SYSTEMS OPERATION
lO
ELECTRICAL SYSTEM
SYSTEMS OPERATION
WIRING DIAGRAMS
INSTRUMENT PANEL
.\. 1
:y
,\,
1
1
} 1 1 I
I I
( I
r--------J I I
R I R W¡B I W/B
8 ? ~ I W/B 1
I I I
1 I I
TSl
--.-+-02_,__ -? O ? b b ~ ~
~ q 99 Q ?~~
I I I \ I I I 1...
1 1 1 l ..... ,
) L_~~~~~-~~~---~:~~ .,:f-~:;:::!J..----
AI7333Xl
9 10 ~11 12
13
WIRING DIAGRAM FOR INSTRUMENTPANEL
1.Light switch. 2. Panellights. 3. Instrument panel. 4. Ammeter. 5. Oil pressuregauge. 6. Watertemperaturegauge. 7. Gear
oil pressuregauge. 8. Terminal strip. 9. Wire to battery. 10.Oil pressureswitch with time delay. 11.Sending unit for oll pres-
sure. 12. Sending unit for water temperature. 13. Sending unit for gear oil pressure.
1~ 2 3 4 5 6
/~\rr---j_-{;¿J~
,~~.~ ,/ I~ I
TS2-4 :-.( I :,' I ~, 1
I I I
II I I
I I I
I I
TS~5
OR
TS2-5
A17555Xl
IJ
WIRING DIAGRAMS
SYSTEMS OPERATION
CHARGING SYSTEM
TSj-l : TS:1-3
I TSl-21
I I
I
I
I
/2 . TABLE OF CALlBRATEO LEAOS
LENGTH OF EACH LEAO WIRE SIZE
I I I~--o l·' (AMMETER TO SHUNT) (AWG NO.)
: \IStt~1 2.3
3.7
5.9
m
m
m
( 7.7
( 12.2
( 19.4
ft)
ft)
tt)
18
16
14
j 9.5
14.9
m
m
( 31.0
( 49.0
tt)
ft)
12
10
23.8 m ( 78.0 ft)
8
37.8 m (124.0 ft)
6
IF LENGTHS OTHER THAN THOSE GIVEN ON THIS
TABLE ARE REQUIRED THE TOTAL RESISTANCE OF
A 17554XI 3 4 BOTH LEADS TO BE .100 OHM.
CHARGING SYSTEM
1. Shunt. 2. Regulator. 3. Battery. 4. Alternator.
PYROMETERS
RED
NEGATIVE
PYROMETER
THERMOCOUPLES
IN EACH EXHAUST
STACK
ENGINE CENTER LlNE
EXHAUST MANIFOLD
A99258X 1
14
SYSTEMS OPERATION
SELECTORSWITCH
----
ENGINE CENTER UNE
A99257Xl
SELECTORSWITCH
A99256Xl
15
WIRING DIAGRAMS
SYSTEMS OPERATION
AIR START
1
r----~- __ - --- UNE
I
I
I r-------- -.- NEUTRAL
,I ,I 120 VAC
I I
2
885193X1
AC AIR STARTERWIRING DIAGRAM
1. Start pushbutton. 2. Air solenoid valve.
'----1'-
L_
... -____ __J
I 240VAC
,-- _ _J
4 5 885194X1
AC AIR STARTERWITH AC PRELUBEPUMPWIRING DIAGRAMS
1. Prelube pump. 2. Relay. 3. Start pushbutton. 4. Air solenoid valve. 5. Pressureswitch.
16
WIRING DIAGRAMS
SYSTEMS OPERATION
CONVERTER ASSEMBL y
(AC Source lo DC Output)
2 B85195Xl
SPEED
RAISES ..... -----l~ LOWERS
5
WIRING DIAGRAM FOR 115 VOLT SOURCE
1. Voltage source. 2. Converter assembly. 3. Jumpers. 4. Toggle switch (momentary). 5. Synchronizing motor.
2 B85196Xl
SPEED
RAISES LOWERS
r-----l
[¡
_ _1
OFF RED
POSITION
3 4 5
WIRING DIAGRAM FOR 230 VOLT SOURCE
1. Voltage source. 2. Converter assembly. 3. Jumper. 4. Toggle switch (momentary). 5. Synchronizing motor.
17
WIRING DIAGRAMS
SYSTEMS OPERATION
TACHOMETER
885197X1
WIRING DIAGRAM FOR TACHOMETERCIRCUIT ONLY
1. Magnetic pickup. 2. Tachometer. 3. Second tachometer (jf used). 4. Ground connection (ground to engine). 5. Wiring
connections tor second tachometer, If used (all wires must be 22 AWG shielded cable or larger).
IX
POWER T AKE-OFF. CLUTCHES
SYSTEMS OPERATION
~.. _-------------------
10
B25057~2
The spline teeth on the ring engage with the spline When lever (4) is moved to the NOT ENGAGED
teeth on the outside diameter of driven plate assem- position, fork (7) moves collar assembly '(5) away
blies (2). When lever (4) is moved to the ENGAG ED from the engine. The movement of the collar assern-
position, fork (7) moves collar assembly (5) in the bly will reIease levers (3). With the levers released
direction of the engine. The collar assembly is con- there will not be enough friction between the faces of
nected to four levers (3). The action of the Ievers will the clutch assembly to permit a flow of torque.
19
TROUBLESHOOTING
TESTING ANO AOJUSTING
TROUBLESHOOTING
This list of problems, causes, and corrections, wilI only give an indication of
where a possible problem can be, and what repairs are needed. NormalIy,
more or other repair work is needed beyond the recommendations in the list.
Remember that a problem is no! normally caused only by one part. bu! by
the relation of one part with other parts. This list can not give all possible
problems and corrections. The serviceman must find the problem and its
source, then make the necessary repairs.
Item Problem
l. Shutoff Solenoid Prevents Engine Start.
2. Shutoff Solenoid Fails to Stop Engine.
3. Contactor Switch For Water Temperture Ooes
Not Activate Shutoff Solenoid.
4. Contactor Switch For Water Ternperature
Activates Shutoff Solenoid at Wrong Tern-
perature.
5. Contactor Switch for Oil Pressure Fails to
Activate Shutoff Solenoid.
6. Electrical Gauges Give Wrong Readings.
7. Clutch Will Not Engage (Slips), Heats or Lever
M oves to Released Position.
8. Clutch Shaft Has Too Much End Play.
9. Clutch Bearings Have Short Service Life.
10. Woodward UG-8 Governor.
a. No Output From Governor.
b. Engine Has Slow Response To A Change
In Speed Setting or Load.
c. Engine Ooes Not Have Stability.
d. Engine WilI N ot Orive Full Rated Load.
e. Load S haring Between Paralleled Units
Is Not Correct (One unir on zero Droop, all
others on Droop).
f. Load Sharing Between Paralleled Units
Is Not Correct (AII units on Oroop).
For information on the 230 I Electric Governors
(see module 2301 ELECTRIC GOVERNORS,
Form No. SENR2928).
For information on the 3161 Governor (See
module CATERPILLAR 3161 GOVERNOR,
Form No. SENR3028).
20
I HUUBLESHOOTlNG
J. SOLENOIO
CONTACTOR SWITCH FOR WATER TEMPERATURE DOES NOT ACTlVATE SHUTOFF
Cause
Correction
Wrong Connections
Connect battery to C and shutoff solenoid to NO connections.
Check connections to other components or make installation of new
WIfIng .:
Failure of Shutoff Solenoid
Check the shutoff solenoid.
Low Water Level in Cooling
System Fill the cooling system.
4. AT
CONTACTOR SWITCH FOR WATER
WRONG TEMPERATURE TEMPERATURE ACTlVATES SHUTOF¡'.· SOLENOID
Cause
Correction
Wrong Setting of Switch
Make a test 01' temperature setting a nd if necessary install new
contactor switch with correct setting. See specifications.
21
TROUBLESHOOTI~G
TESTING ANO AOJUSTING
7. CLUTCH WILL NOT ENGAGE (SLIPS). HEATS OR LEVER MOVES TO RELEASED POSITION.
Cause
Correction
Wrong Adjustment
Make adjustment to clutch engagement lever pullo
Alignment of Flywheel and
Check and make adjustment to alignment.
Flywheel H ousing M ounting
Face and Bores
Overload on Clutch
Reduce load or reduce engine speed when engaging clutch.
22
I HUUBLESHOOTlNG
TESTING ANO AOJUSTING
Engine Misfiring
Make reference to FUEL SYSTEMS in ENGINE TESTING AND
ADJUSTlNG.
24
I HUUBLESHOOTlNG
lOe. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (one unit on zero droop
and all the others on droop)
Cause
Correction
Droop Setting is Too Low on
Sorne Units Increase droop setting on these units until the load is constant on
each droop unit.
Different Speed Settings on the
Units Adjust speed settings on droop units. No load speed on all droop
units should be the same.
IOr. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (all units on droop)
Cause
Correction
Speed Droop Setting on One or
M ore Units is N ot Correct Adjust droop on each unit to get the desired division of load.
25
FUEL SYSTEM
TESTING ANO AOJUSTING
FUEL SYSTEM
INJECTOR SYNCHRONIZAT~ON
l. The top bolt that holds cover (3) in position is
i
Tools Needed: synchronizing pin (2). Remove synchronizing
6V3119 Rack Synchronizing Gauge. pin (2) and plug (1) from the front drive hous-
ing. DO NOT destroy seal or remove cover (3).
Injector synchronization is the setting of all in- 2. Remove the washer from synchronizing pin (2)
jector racks to a reference position so each injector and install it into the threaded hole where plug
gives the same amount of fuel to each cylinder. This (1) was removed. Tighten synchronizing pin (2).
is done by setting each injector rack to the same
position while the control linkage is in a fixed posi- NOTICE
tion (called the synchronizing position). The pro-
cedure for adjustment of injector synchronization Do not force the governor linkage toward in-
is as follows: creased fuel unless the load limit knob is
turned to TEN. The result will be damage to
the governor.
26
I-UEL SYSTEM
TESTING ANO ADJUSTING
Tools Needed:
6V3139 Timing and Fuel Setting Tool Group.
5P4814 Collet. l. Put 6V3075 ~ial Indicator (2) with 5P7263
6V3075 Dial Indicator (metric). Contact Point (4) in 5P4814 Collet (3). Remove
5P7263 Contact Poínt, 76.2 mm (3.00 in.) long. the plug from the right side of fuel setting cover
6V3119 Rack Synchronizing Gauge 12.7 mm (.50 in.). (8).
2. Move the governor or actuator terminal shaft l. Cut the seal wire and remove fuel setting cover
in the fuel HON" direction until the flat face of (8) and the gasket. Loosen locknut (7) and (with
fuel stop lever (6) contacts synchronizing pin fuel stop lever still held against end of the fuel
(5). Hold the linkage in this position. setting screw) turn the fuel setting screw in or
out until the correct reading is on the dial
3. Install the dial indicator and collet (3) in the indicator.
threaded hole as shown. When the contact point
seats against fuel stop lever (6), slide the dial
indicator in or out until the indicator reads zero.
Now tighten collet (3) just enough to hold in-
dicator at this position.
4. Turn synchronizing pin (5) back out a mínimum
of 25 mm (1 in.) (or remove it cornpletely), and
then slowly move the governor or actuator ter-
minal shaft in the fuel HON" direction until the
flat face of the fuel stop lever is against the end
of the fuel setting screw. With the linkage held
in this position, the dial indicator reading will
be the present fuel setting.
ADJUSTMENT OF THE FUEL SETTING SCREW
2X
r-UEL SYSTEM
TESTING ANO AOJUSTING
INSTALL COVER
7. Locknut. 8. Fuel setting cover.
~-
B19988X2
CJ -JI
,
.:~r'"
!U1 "¡
er and move the pointer up two rnarks on the
.,
'"
SPEEO OIiOQp
I •
SYNCHRCNllfR pointer scale.
2. Remove the plug fmm rhe base of the governor. If the engine does not surge, and the needle valve is
1/2 to 3/4 of a tum open, the govemor adjustment is
J. U se a wide blade screwdriver and engage lhe wide correcto Install the plug in the base. If the needle valve
screwdriver slot in the needle valve. Turn the is more than 3/4 of a turn open do Steps 10 thru 16
needle val ve three or more tums in a counterclock- again.
wise direction.
A needle valve that is opened less than 1/2 tllrn will
4-. Let the engi ne surge for approxímarely 30 seconds cause the engine to be slow to retum to normal speed
to help remove air from the govemor. after a load change.
5. Loasen rhe nur rhat holds the compensation point- If the compensation pointer is too far toward the
er and move the pointer down as far as it will go. maximum position, the engine speed change wiIl be too
Tighren rhe .nut.
great when the load changes.
6. Slowly turn rhe needle valve in a clockwise direc-
tion until the engine does nor surge.
~o
VVUUUWARO UG8 DIAL GOVERNOR
TESTING ANO AOJUSTING
GOVERNORADJUSTMENTS
(Example Only)
1. Terminal lever. 2. Idler gear. 3. Load limit con-
trol. 4. Linkage. 5. Synchronizer control knob. 6. Gear.
7. Synchronizer indicator knob.
JI
LUBRICATION SYSTEM
TESTING ANO AOJUSTING
LUBRICATION SYSTEM
DUPLEX OIL FIL TER
DUPLEXOIL FILTER
1. Selector valve shaft. 2. Handle. 3. Plunger assembly. 4. Linkage. 5. Lever.
Linkage Adjustment
corners of nut) until the selector valve shaft (1)
l. Disconnect linkage (4) from lever (5) andj or
handle (2). has an axial movement of 0.22 ± 0.08 mm (.OOX
± .003 in.).
2. Rotate lever (5) to move selector valve to Main
3. Hold adjustment nut (6) with a wrench. and
Run position (countercIockwise direction) until tighten ja m nut (7) to a torque of 45 ± 7 N-n:
valve is against stop pin inside cover assembly (35 ±. 5 lb. ft.).
(8 ).
4. Now rotate selector va lvc. Va lve should m ove
3. Push handle (2) to Main Run position untiI ball
freely with no binding. Ir valvc does not m ovo
of plunger assembIy (3) seats into hole of freely, more adjustment is necessary.
mounting bracket.
4. Now adjust Iinkage to fit between Iever (5) and
handle (2). Install linkage back to Iever (5)
and o r handle (2).
32
In., I HUMENTS ANO GAUGES
TESTING ANO AOJUSTING
ELECTRIC GAUGES
2. Put a thermometer in the water to measure the 3. Let the gauge heat at the middle resistance for 5
temperature. minutes, then check the pointer position for all 01'
the resistanees given.
33
INSTRUMENTS ANO GAUGES
TESTING ANO AOJUSTING
48735X 1
95584Xl
34
INSTRUMENTS ANO GAUGES
TESTING ANO ADJUSTING
X3974
35
C.ATERPILLAR®
SENR2364
Printed In U.S.A. (7/84)