Complete workshop repair & service manual with electrical wiring diagrams for Caterpillar 3500B Series Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Caterpillar 3500B Series Engines service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MANUAL LIST:
RENR1242 - Schematic (3500B Engine for Electrical Power Generation (EPG) with Electronic Modular Control Panel (EMCP))
RENR1243 - Schematic (3500B Engine for Electrical Power Generation (EPG) with Switchgear Conversion)
RENR5057 - Specifications (3500B Generator Set Engines)
RENR5058 - Systems Operation (3500B and 3500C Generator Set Engines)
RENR5058 - Testing & Adjusting (3500B and 3500C Generator Set Engines)
RENR5059 - Troubleshooting (3500B and 3500C Generator Set Engines)
RENR7678 - Schematic (3500B & 3500C Generator Set Electrical System Engines & Industrial Engines)
RENR7885 - Electrical System (3500B and 3500C Generator Set Engine)
RENR9845 - Electrical Schematic (3500B Generator with EMCP 3)
SENR1122 - Specifications (3500B Engines for 776D, 777D, 784C, 785C, 789C, 793C & 793D Off-Highway Truck_Tractors)
SENR1123 - Systems Operation (3500B Engines for Caterpillar Built Machines)
SENR1123 - Testing & Adjusting (3500B Engines for Caterpillar Built Machines)
SENR1126 - Disassembly & Assembly (3500 & 3500B High Displacement Engines for Caterpillar Built Machines)
SENR6562 - Specifications (3500B Engines)
SENR6563 - Systems Operation (3500B Engines)
SENR6563 - Testing & Adjusting (3500B Engines)
SENR6564 - Disassembly & Assembly (3500B Engines)
SENR6587 - Systems Operation (3508, 3508B, 3508C, 3512, 3512B, 3512C, 3516, 3516B & 3516C Engines Caterpillar Monitoring System)
SENR6587 - Testing & Adjusting (3508, 3508B, 3508C, 3512, 3512B, 3512C, 3516, 3516B & 3516C Engines Caterpillar Monitoring System)

RENR1242 - Schematic (3500B Engine for Electrical Power Generation (EPG) with Electronic Modular Control Panel (EMCP))...1
  Collage...2
  Main...12
    Features...12
    Cover Page...13
    Information...0
      Component Location...14
      Plugs And Connectors...0
        Page 1 of 2...15
        Page 2 of 2...16
    Schematic...17
    Machine Views...0
      Component Locations - Standy Power Applications...18
      Component Locations - Prime Power Applications...19
RENR1243 - Schematic (3500B Engine for Electrical Power Generation (EPG) with Switchgear Conversion)...20
  Collage...21
  Main...36
    Features...36
    Cover Page...37
    Information...0
      Component Location...38
      Plugs and Connectors...0
        Page 1 of 2...39
        Page 2 of 2...40
    Schematic...41
    Machine Views...0
      Component Locations - Prime Power Applications...42
      Component locations - Standby Power Applications...43
RENR2207 - Specifications (3500B and 3500B High Displacement Generator Set Engines)...44
  Engine Design...46
  Fuel Pressure Regulator...48
  Fuel Transfer Pump...49
  Fuel Injector Mechanism...50
  Fuel Injector...52
  Camshaft...53
  Valve Mechanism...55
  Cylinder Head...57
  Cylinder Head Valves...61
  Turbocharger...66
  Exhaust Manifold...68
  Air Inlet and Exhaust Lines...69
  Air Shutoff...71
  Prelube Pump...74
  Engine Oil Pump...76
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves...81
  Engine Oil Filter...83
  Crankcase Breather...85
  Engine Oil Pan...86
  Water Temperature Regulator...88
  Fan Drive...89
  Water Pump...91
  Auxiliary Water Pump...96
  Cylinder Block...100
  Cylinder Liner...103
  Piston and Rings - One-Piece Piston...104
  Piston and Rings - Two-Piece Piston...107
  Connecting Rod...110
  Connecting Rod and Main Bearing Journals...113
  Crankshaft...114
  Crankshaft Wear Sleeves and Seals...116
  Housing (Front)...118
  Gear Group (Front)...120
  Gear Group (Rear)...122
  Balancer Group (Front)...125
  Accessory Drive (Lower Left Hand)...127
  Accessory Drive (Upper Right Hand)...130
  Flywheel...132
  Flywheel Housing...134
  Flywheel Housing Cover...137
  Vibration Damper...138
  Belt Tension Chart...140
  Alternator and Regulator...142
  Alternator Mounting...145
  Electric Starting Motor...147
  Cooling System Pressure Cap...149
  Coolant Level Switch...150
  Fuel Pressure Sensor...151
  Coolant Level Sensor...153
  Engine Oil Pressure Sensor...155
  Turbocharger Inlet Pressure Sensor...156
  Turbocharger Outlet Pressure Sensor...157
  Engine Coolant Temperature Sensor...158
  Turbocharger Exhaust Temperature Sensor...159
  Engine Speed_Timing Sensor...160
  Crankcase Pressure Sensor...161
  Atmospheric Pressure Sensor...162
RENR2208 - Systems Operation (3500B and 3500B High Displacement Generator Set Engines)...163
  Engine Design...165
  General Information...167
  Starting the Engine...168
  Ether Control System...169
  Cold Cylinder Cutout...170
  Electronic Control Terms...172
  Electronic Control System Components...177
  Electronic Control System Operation...178
  Cat Data Link...179
  Secondary Cat Data Link...181
  Electronic Control Module (ECM)...182
  System Configuration Parameters...184
  100 Hour Free Configuration on Engine Start-up...185
  Engine Monitoring System...186
  Histogramming...187
  Fuel Rate Scaling (Fuel Correction Factor) - Diesel Fuel...188
  ECM Total Fuel Consumption Adjustment - Diesel Fuel...189
  ECM Hour Increment Adjustment...190
  Fuel System Operation...191
  Fuel Injector Mechanism...193
  Fuel Injector...195
  Air Inlet and Exhaust System Operation...197
  Aftercooler...199
  Air Shutoff...200
  Valve Mechanism...202
  Turbocharger...206
  Lubrication System Operation...210
  Separate Circuit Cooling System...214
  Cylinder Block; Liners and Heads...215
  Pistons; Rings and Connecting Rods...217
  Pistons; Rings and Connecting Rods - Two-Piece Piston...219
  Crankshaft...221
  Camshaft...223
  Electrical System Operation...224
  Grounding Practices...225
  Alternator...226
  Starting Solenoid...228
  Starting Motor...230
  Engine Speed Sensor...232
  Circuit Breaker...233
RENR2208 - Testing and Adjusting (3500B and 3500B High Displacement Generator Set Engines)...234
  General Information (Electronic Control System)...236
  Calibration...237
  Configuration Parameters...238
  Monitoring System Parameters...239
  Engine Speed_Timing Sensor - Remove and Install...240
  General Information (Fuel System) - Diesel...242
  Fuel System Inspection...243
  Checking Engine Cylinders...244
  Fuel Pressure...245
  Fuel Injector Trim Code...247
  Engine Rotation...248
  Finding the Top Center Position for the No. 1 Piston...249
  Camshaft Timing...252
  Fuel Injector Adjustment...259
  Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting...270
  Restriction of Air Inlet and Exhaust...271
  Measuring Inlet Manifold Pressure...272
  Measuring Exhaust Temperature...273
  Crankcase Pressure...274
  Compression...275
  Cylinder Heads...276
  Valve Lash Check...278
  Valve Lash and Valve Bridge Adjustment...280
  General Information (Lubrication System)...287
  Engine Oil Pressure - Test...288
  Excessive Bearing Wear - Inspect...289
  Excessive Engine Oil Consumption - Inspect...290
  Increased Engine Oil Temperature - Inspect...291
  Engine Oil Pressure is Low...292
  Engine Oil Pressure is High...294
  Indicators for Engine Oil Pressure...295
  General Information (Cooling System)...296
  Visual Inspection...297
  Test Tools for the Cooling System...298
  Testing the Cooling System...302
  Radiator and Cooling System - Test...303
  Coolant Temperature Sensor - Test...312
  Water Temperature Regulator - Test...315
  Connecting Rod Bearings...317
  Main Bearings...318
  Cylinder Block...319
  Cylinder Liner Projection...320
  Flywheel - Inspect...325
  Flywheel Housing - Inspect...329
  Vibration Damper...334
  Test Tools for the Electrical System...335
  Battery...340
  Charging System...341
  Alternator Regulator...342
  Electric Starting System...344
  Pinion Clearance Adjustment...346
RENR2209 - Troubleshooting (3500B and 3500B High Displacement Generator Set Engines)...348
  System Overview...354
  Self-Diagnostics...365
  Electronic Service Tools...366
  Electronic Display Module...372
  Engine Monitoring System...380
  Programming Parameters...386
  Factory Passwords...387
  Factory Passwords Worksheet...389
  Flash Programming...391
  System Configuration Parameters...395
  Customer Parameters Worksheet...400
  Replacing the ECM...404
  Symptoms...408
  Alternator...410
  Can Not Reach Top Engine RPM...411
  Oil Contains Coolant...414
  Coolant Temperature Is Too High...427
  ECM Will Not Accept Factory Passwords...429
  ECM Will Not Communicate with Other Systems or Display Modules...431
  Electronic Service Tool Will Not Communicate with ECM...432
  Engine Cranks but Will Not Start...434
  Engine Has Early Wear...437
  Engine Misfires; Runs Rough or Is Unstable...440
  Engine Oil in Cooling System...444
  Engine Stalls at Low RPM...446
  Engine Will Not Crank...448
  Excessive Engine Oil Consumption...451
  Excessive Black Smoke...453
  Excessive White Smoke...456
  Exhaust Temperature Is Too High...459
  Fuel Dilution of Engine Oil...461
  Fuel in Cooling System...463
  Intermittent Engine Shutdown...465
  Intermittent Low Power or Power Cutout...467
  Low Engine Oil Pressure...470
  Low Power_Poor or No Response to Throttle...472
  Mechanical Noise (Knock) in Engine...475
  Noise Coming from Cylinder...476
  Poor Fuel Consumption...478
  Too Much Valve Lash...480
  Too Much Vibration...482
  Valve Rotocoil or Spring Lock Is Free...484
  Diagnostic Codes...485
  MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open circuit...488
  MID 036 - CID 0001 - FMI 06 Injector Cylinder 1 short...489
  MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open circuit...490
  MID 036 - CID 0002 - FMI 06 Injector Cylinder 2 short...491
  MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open circuit...492
  MID 036 - CID 0003 - FMI 06 Injector Cylinder 3 short...493
  MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open circuit...494
  MID 036 - CID 0004 - FMI 06 Injector Cylinder 4 short...495
  MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open circuit...496
  MID 036 - CID 0005 - FMI 06 Injector Cylinder 5 short...497
  MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open circuit...498
  MID 036 - CID 0006 - FMI 06 Injector Cylinder 6 short...499
  MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open circuit...500
  MID 036 - CID 0007 - FMI 06 Injector Cylinder 7 short...501
  MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open circuit...502
  MID 036 - CID 0008 - FMI 06 Injector Cylinder 8 short...503
  MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open circuit...504
  MID 036 - CID 0009 - FMI 06 Injector Cylinder 9 short...505
  MID 036 - CID 0010 - FMI 05 Injector Cylinder 10 open circuit...506
  MID 036 - CID 0010 - FMI 06 Injector Cylinder 10 short...507
  MID 036 - CID 0011 - FMI 05 Injector Cylinder 11 open circuit...508
  MID 036 - CID 0011 - FMI 06 Injector Cylinder 11 short...509
  MID 036 - CID 0012 - FMI 05 Injector Cylinder 12 open circuit...510
  MID 036 - CID 0012 - FMI 06 Injector Cylinder 12 short...511
  MID 036 - CID 0013 - FMI 05 Injector Cylinder 13 open circuit...512
  MID 036 - CID 0013 - FMI 06 Injector Cylinder 13 short...513
  MID 036 - CID 0014 - FMI 05 Injector Cylinder 14 open circuit...514
  MID 036 - CID 0014 - FMI 06 Injector Cylinder 14 short...515
  MID 036 - CID 0015 - FMI 05 Injector Cylinder 15 open circuit...516
  MID 036 - CID 0015 - FMI 06 Injector Cylinder 15 short...517
  MID 036 - CID 0016 - FMI 05 Injector Cylinder 16 open circuit...518
  MID 036 - CID 0016 - FMI 06 Injector Cylinder 16 short...519
  MID 036 - CID 0091 - FMI 08 Throttle Position signal abnormal...520
  MID 036 - CID 0094 - FMI 02 Fuel Pressure misinstalled...521
  MID 036 - CID 0094 - FMI 03 Fuel Pressure open_short to +batt...522
  MID 036 - CID 0094 - FMI 04 Fuel Pressure short to ground...523
  MID 036 - CID 0094 - FMI 13 Fuel Pressure calibration required...524
  MID 036 - CID 0100 - FMI 02 Engine Oil Pressure out of range...525
  MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open_short to +batt...526
  MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground...527
  MID 036 - CID 0100 - FMI 13 Engine Oil Pressure calibration required...528
  MID 036 - CID 0101 - FMI 03 Crankcase Pressure open_short to +batt...529
  MID 036 - CID 0101 - FMI 04 Crankcase Pressure short to ground...530
  MID 036 - CID 0101 - FMI 13 Crankcase Pressure calibration required...532
  MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open_short to +batt...533
  MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground...534
  MID 036 - CID 0168 - FMI 00 System Voltage High...535
  MID 036 - CID 0168 - FMI 01 System Voltage Low...536
  MID 036 - CID 0168 - FMI 02 System Voltage intermittent_erratic...537
  MID 036 - CID 0190 - FMI 02 Loss of Engine Speed signal...538
  MID 036 - CID 0190 - FMI 03 Engine Speed open_short to +batt...539
  MID 036 - CID 0190 - FMI 08 Engine Speed signal abnormal...540
  MID 036 - CID 0248 - FMI 09 Cat Data Link not communicating...541
  MID 036 - CID 0253 - FMI 02 Personality Module mismatch...543
  MID 036 - CID 0254 - FMI 12 Electronic Control Module Error...544
  MID 036 - CID 0261 - FMI 13 Engine Timing calibration required...545
  MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt...546
  MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground...547
  MID 036 - CID 0263 - FMI 03 Digital Sensor Supply short to +batt...548
  MID 036 - CID 0263 - FMI 04 Digital Sensor Supply short to ground...549
  MID 036 - CID 0268 - FMI 02 Check Programmable Parameters...550
  MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure above normal...551
  MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure open_short to +batt...552
  MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure short to ground...553
  MID 036 - CID 0273 - FMI 13 Turbo Outlet Pressure calibration required...554
  MID 036 - CID 0274 - FMI 03 Atmospheric Pressure open_short to +batt...555
  MID 036 - CID 0274 - FMI 04 Atmospheric Pressure short to ground...556
  MID 036 - CID 0274 - FMI 13 Atmospheric Pressure calibration required...557
  MID 036 - CID 0275 - FMI 03 Right Turbo Inlet Pressure open_short to +batt...558
  MID 036 - CID 0275 - FMI 04 Right Turbo Inlet Pressure short to ground...559
  MID 036 - CID 0275 - FMI 13 Right Turbo Inlet Pressure calibration required...560
  MID 036 - CID 0276 - FMI 03 Left Turbo Inlet Pressure open_short to +batt...561
  MID 036 - CID 0276 - FMI 04 Left Turbo Inlet Pressure short to ground...562
  MID 036 - CID 0276 - FMI 13 Left Turbo Inlet Pressure calibration required...563
  MID 036 - CID 0279 - FMI 03 Aftercooler Temperature open_short to +batt...564
  MID 036 - CID 0279 - FMI 04 Aftercooler Temperature short to ground...565
  MID 036 - CID 0289 - FMI 02 Unfiltered Fuel Pressure misinstalled...566
  MID 036 - CID 0289 - FMI 03 Unfiltered Fuel Pressure open_short to +batt...567
  MID 036 - CID 0289 - FMI 04 Unfiltered Fuel Pressure short to ground...568
  MID 036 - CID 0289 - FMI 13 Unfiltered Fuel Pressure calibration required...569
  MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs...570
  MID 036 - CID 0337 - FMI 02 Incorrect Remote E-Stop Switch inputs...571
  MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open circuit...572
  MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to ground...573
  MID 036 - CID 0444 - FMI 05 Start Relay open circuit...574
  MID 036 - CID 0444 - FMI 06 Start Relay short to ground...575
  MID 036 - CID 0446 - FMI 05 Air Shutoff Relay open...576
  MID 036 - CID 0446 - FMI 06 Air Shutoff Relay short...577
  MID 036 - CID 0542 - FMI 02 Unfiltered Engine Oil Pressure misinstalled...578
  MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open_short to +batt...579
  MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground...580
  MID 036 - CID 0542 - FMI 13 Unfiltered Engine Oil Pressure cal required...581
  MID 036 - CID 0545 - FMI 05 Ether Start Relay open_short to +batt...582
  MID 036 - CID 0545 - FMI 06 Ether Start Relay short to ground...583
  MID 036 - CID 0546 - FMI 05 Ether Hold Relay open_short to ground...584
  MID 036 - CID 0546 - FMI 06 Ether Hold Relay short to +batt...585
  MID 036 - CID 0827 - FMI 08 Left Exhaust Temperature signal abnormal...586
  MID 036 - CID 0828 - FMI 08 Right Exhaust Temperature signal abnormal...587
  E017 High Engine Coolant Temperature Warning...588
  E100 Low Engine Oil Pressure Warning...590
  E190 Engine Overspeed Warning...592
  E272 Inlet Air Restriction Warning...593
  Air Shutoff System...595
  Analog Sensor Supply...601
  CAT Data Link...608
  Digital Sensor Supply...614
  Direct Fuel Control Mode...619
  ECM_Personality Module...624
  Electrical Power Supply (EMCP II)...627
  Electrical Power Supply (EMS II)...633
  Emergency Stop Switch (EMCP II)...640
  Emergency Stop Switch (EMS II)...645
  Engine Control Switch (ECS) (EMCP II)...651
  Engine Control Switch (ECS) (EMS II)...656
  Engine Sensor Open_Short Test...659
  Engine Speed_Timing Sensor...673
  Ether Injection System...681
  Injector Solenoids...696
  Inspecting Electrical Connectors...705
  Prelubrication System...716
  Speed Control...724
  Starting Motor System (EMCP II)...732
  Starting Motor System (EMS II)...738
  Analog Sensor - Calibrate...745
  Engine Speed_Timing Sensor - Calibrate...748
RENR5057 - Specifications (3500B Generator Set Engines)...751
  Accessory Drive (Lower Left Hand)...761
  Accessory Drive (Upper Right Hand) 1...765
  Accessory Drive (Upper Right Hand) 2...769
  Accessory Drive (Upper Right Hand) 3...772
  Accessory Drive...775
  Aftercooler Coolant Temperature Sensor...778
  Air Cleaner 1...780
  Air Cleaner 2...782
  Air Cleaner 3...784
  Air Cleaner 4...786
  Air Cleaner Adapter...788
  Air Inlet and Exhaust Lines 1...789
  Air Inlet and Exhaust Lines 2...792
  Air Inlet and Exhaust Lines 3...795
  Air Inlet and Exhaust Lines 4...799
  Air Inlet and Exhaust Lines 5...803
  Air Inlet and Exhaust Lines 6...806
  Air Lines - Air Starting Lines...810
  Air Lines 1...812
  Air Lines 2...814
  Air Lines 3...817
  Air Lines...819
  Air Shutoff 1...822
  Air Shutoff 2...825
  Air Shutoff 3...827
  Air Shutoff 4...830
  Air Shutoff 5...833
  Air Starting Motor 1...836
  Air Starting Motor 2...839
  Air Starting Motor 3...842
  Air Starting Motor Pressure Regulating Valve...844
  Alternator Mounting 1...846
  Alternator Mounting 2...849
  Alternator and Regulator 1...852
  Alternator and Regulator 2...855
  Alternator and Regulator 3...857
  Alternator and Regulator 4...859
  Atmospheric Pressure Sensor 1...861
  Atmospheric Pressure Sensor 2...863
  Auxiliary Drive Pulley 1...865
  Auxiliary Drive Pulley 2...867
  Auxiliary Drive Pulley 3...869
  Auxiliary Drive Shaft...871
  Auxiliary Water Pump - Sea Water...873
  Auxiliary Water Pump 1...877
  Auxiliary Water Pump 2...880
  Auxiliary Water Pump 3...883
  Belt Tension Chart 1...886
  Belt Tension Chart 2...889
  Camshaft 1...891
  Camshaft 2...895
  Camshaft 3...898
  Camshaft 4...901
  Connecting Rod 1...904
  Connecting Rod 2...908
  Connecting Rod 3...912
  Connecting Rod 4...915
  Connecting Rod and Main Bearing Journals 1...919
  Connecting Rod and Main Bearing Journals 2...922
  Coolant Level Sensor 1...924
  Coolant Level Sensor 2...927
  Coolant Level Switch...929
  Coolant Temperature Switch...931
  Cooling System Pressure Cap...933
  Cover Group (Front Housing)...936
  Crankcase Breather 1...938
  Crankcase Breather 2...940
  Crankcase Breather 3...942
  Crankcase Breather 4...944
  Crankcase Breather 5...946
  Crankcase Pressure Sensor 1...948
  Crankcase Pressure Sensor 2...950
  Crankshaft 1...952
  Crankshaft 2...954
  Crankshaft 3...957
  Crankshaft 4...959
  Crankshaft 5...961
  Crankshaft 6...963
  Crankshaft Wear Sleeves and Seals...966
  Cylinder Block 1...969
  Cylinder Block 2...975
  Cylinder Block 3...979
  Cylinder Block 4...984
  Cylinder Head 1...989
  Cylinder Head 2...993
  Cylinder Head 3...997
  Cylinder Head Valves 1...1002
  Cylinder Head Valves 2...1005
  Cylinder Liner...1008
  Disconnect Switch...1011
  Duplex Engine Oil Filters 1...1013
  Duplex Engine Oil Filters 2...1016
  Duplex Engine Oil Filters 3...1020
  Duplex Engine Oil Filters 4...1024
  Duplex Engine Oil Filters 5...1027
  Electric Starting Motor 1...1030
  Electric Starting Motor 2...1033
  Engine Oil Pan 1...1036
  Electric Starting Motor 3...1039
  Electric Starting Motor 4...1042
  Electric Starting Motor 5...1045
  Electric Starting Motor 6...1047
  Electronic Control Module...1049
  Engine Air Cleaner Service Indicator 1...1051
  Engine Air Cleaner Service Indicator 2...1053
  Engine Air Cleaner Service Indicator 3...1055
  Engine Coolant Temperature Sensor 1...1057
  Engine Coolant Temperature Sensor 2...1059
  Engine Coolant Temperature Sensor 3...1061
  Engine Design - SN - JM31-UP...1063
  Engine Design - SN - JM41-UP...1065
  Engine Design SN - GD31-UP; SN - JCH1-UP...1067
  Engine Design SN - JCN1-UP...1069
  Engine Design SN - JCY1-UP; SN - PBR1-UP; SN - PDR1-UP; SN - YAP1-UP; SN - YAT1-UP; SN - YBT1-UP; SN - ZAP1-UP; SN - ZBP1-UP...1071
  Engine Design SN - JDE1-UP; SN - YAR1-UP; SN - YAW1-UP; SN - YBW1-UP; SN - ZAR1-UP; SN - ZBR1-UP...1073
  Engine Design SN - YAM1-UP; SN - YAY1-UP; SN - YBB1-UP; SN - ZAH1-UP...1075
  Engine Design SN - YAN1-UP; SN - YAZ1-UP; SN - YBC1-UP; SN - ZAJ1-UP...1077
  Engine Design SN - ZAD1-UP...1079
  Engine Oil Cooler 1...1081
  Engine Oil Cooler 2...1083
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 1...1085
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 2...1088
  Engine Oil Filter 1...1091
  Engine Oil Filter 2...1094
  Engine Oil Filter 3...1097
  Engine Oil Filter 4...1101
  Engine Oil Filter 5...1104
  Engine Oil Lines 1...1107
  Engine Oil Lines 2...1110
  Engine Oil Pan 10...1113
  Engine Oil Pan 11...1115
  Engine Oil Pan 12...1118
  Engine Oil Pan 2...1121
  Engine Oil Pan 3...1123
  Engine Oil Pan 4...1126
  Engine Oil Pan 5...1129
  Engine Oil Pan 6...1132
  Engine Oil Pan 7...1135
  Engine Oil Pan 8...1138
  Engine Oil Pan 9...1141
  Engine Oil Pressure Sensor 1...1143
  Engine Oil Pressure Sensor 2...1145
  Engine Oil Pump 1...1147
  Engine Oil Pump 2...1150
  Engine Oil Pump 3...1155
  Engine Oil Pump 4...1161
  Engine Oil Sump Pump...1166
  Engine Oil Temperature Sensor 1...1168
  Engine Oil Temperature Sensor 2...1170
  Engine Speed Sensor 1...1172
  Engine Speed Sensor 2...1174
  Engine SpeedTiming Sensor 1...1177
  Engine SpeedTiming Sensor 2...1179
  Exhaust Fitting 1...1181
  Exhaust Fitting 2...1183
  Exhaust Fitting 3...1185
  Exhaust Fitting 4...1187
  Exhaust Flange 1...1189
  Exhaust Flange 2...1191
  Exhaust Flange 3...1192
  Exhaust Flange 4...1194
  Exhaust Manifold 1...1196
  Exhaust Manifold 2...1199
  Exhaust Manifold 3...1201
  Exhaust Manifold 4...1203
  Exhaust Manifold 5...1205
  Exhaust Manifold 6...1207
  Exhaust Manifold 7...1209
  Fan Drive 1...1211
  Fan Drive 2...1214
  Fan Drive 3...1217
  Fan Drive 4...1219
  Flexible Coupling 1...1221
  Flexible Coupling 2...1224
  Flywheel Housing Cover 1...1226
  Flywheel Housing Cover 2...1228
  Flywheel Housing...1230
  Flywheel...1234
  Fuel Filter (Primary) SMCS - 1260; SN - JCH1-UP; SN - JCN1-UP; SN - JM31-UP; SN - JM41-UP...1237
  Fuel Filter (Primary) SN - JCH1-UP; SN - JCN1-UP; SN - JCY1-UP; SN - JDE1-UP...1239
  Fuel Filter 1...1241
  Fuel Filter 2...1244
  Fuel Filter 3...1246
  Fuel Filter 4...1248
  Fuel Injector 1...1250
  Fuel Injector 2...1252
  Fuel Injector 3...1254
  Fuel Injector 4...1256
  Fuel Injector Mechanism 1...1258
  Fuel Injector Mechanism 2...1261
  Fuel Pressure Regulator...1264
  Fuel Pressure Sensor 1...1266
  Fuel Pressure Sensor 2...1268
  Fuel Priming Pump...1270
  Fuel Transfer Pump...1272
  Gear Group (Front) 1...1275
  Gear Group (Front) 2...1278
  Gear Group (Rear) 1...1281
  Gear Group (Rear) 2...1284
  Gear Group (Rear) 3...1287
  Gear Group (Rear) 4...1290
  Gear Group (Rear)...1293
  Generator Coupling 1...1295
  Generator Coupling 2...1297
  Generator Coupling 3...1299
  Generator Coupling 4...1301
  Generator Coupling 5...1303
  Generator Coupling 6...1305
  Governor - Woodward 2301A Speed Control...1307
  Housing (Front) 1...1309
  Housing (Front) 2...1312
  Magnetic Switch...1314
  Piston and Rings - One-Piece Piston 1...1316
  Piston and Rings - One-Piece Piston 2...1320
  Piston and Rings - One-Piece Piston 3...1323
  Piston and Rings - One-Piece Piston 4...1327
  Prelube Pressure Switch...1330
  Prelube Pump - Air...1332
  Prelube Pump 1...1334
  Prelube Pump 2...1337
  Prelube Pump 3...1339
  Radiator 1...1341
  Radiator 2...1344
  Radiator 3...1346
  Radiator 4...1348
  Radiator 5...1350
  Radiator 6...1352
  Radiator 7...1354
  Stub Shaft (Front) 1...1357
  Stub Shaft (Front) 2...1359
  Stub Shaft (Front) 3...1361
  Thermocouple 1...1363
  Thermocouple 2...1366
  Thermostatic Valve...1368
  Turbocharger 1...1371
  Turbocharger 10...1374
  Turbocharger 2...1376
  Turbocharger 3...1378
  Turbocharger 4...1381
  Turbocharger 5...1383
  Turbocharger 6...1385
  Turbocharger 7...1387
  Turbocharger 8...1389
  Turbocharger 9...1391
  Turbocharger Exhaust Temperature Sensor 1...1393
  Turbocharger Exhaust Temperature Sensor 2...1396
  Turbocharger Inlet Pressure Sensor 1...1398
  Turbocharger Inlet Pressure Sensor 2...1400
  Turbocharger Oil Lines 1...1402
  Turbocharger Oil Lines 2...1404
  Turbocharger Oil Lines 3...1406
  Turbocharger Oil Lines 4...1408
  Turbocharger Oil Lines 5...1410
  Turbocharger Outlet Pressure Sensor 1...1412
  Turbocharger Outlet Pressure Sensor 2...1415
  Valve Mechanism 1...1417
  Valve Mechanism 2...1420
  Vibration Damper 1...1423
  Vibration Damper 2...1425
  Vibration Damper 3...1428
  Vibration Damper 4...1431
  Vibration Damper 5...1433
  Vibration Damper 6...1435
  Vibration Damper Guard 1...1437
  Vibration Damper Guard 2...1439
  Vibration Damper Guard 3...1441
  Vibration Damper Guard 4...1443
  Water Lines...1445
  Water Pump 1...1447
  Water Pump 2...1449
  Water Pump 3...1452
  Water Temperature Regulator 1...1456
  Water Temperature Regulator 2...1458
  Water Temperature Regulator 3...1460
RENR5058 - Testing & Adjusting (3500B and 3500C Generator Set Engines)...1463
  Alternator Regulator...1465
  Battery...1467
  Calibration...1468
  Camshaft Timing...1469
  Charging System...1477
  Checking Engine Cylinders with an Electronic Service Tool...1478
  Checking Engine Cylinders...1480
  Configuration Parameters...1481
  Connecting Rod Bearings...1482
  Coolant Temperature Sensor - Test...1483
  Cooling System Pressure Cap - Test...1485
  Crankcase Pressure...1488
  Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting...1489
  Cylinder Block...1491
  Cylinder Liner Projection...1492
  Electric Starting System...1497
  Engine Oil Pressure - Test...1499
  Engine Oil Pressure is High...1503
  Engine Oil Pressure is Low...1504
  Engine Rotation...1506
  Excessive Bearing Wear - Inspect...1507
  Excessive Engine Oil Consumption - Inspect...1508
  Finding the Top Center Position for the No. 1 Piston...1510
  Flywheel - Inspect...1513
  Flywheel Housing - Inspect...1517
  Fuel Injector Adjustment...1522
  Fuel Pressure...1527
  Fuel System Inspection...1529
  General Information (AirElectric Starting System)...1530
  General Information (Cooling System)...1533
  General Information (Lubrication System)...1535
  Increased Engine Oil Temperature - Inspect...1536
  Indicators for Engine Oil Pressure...1537
  Main Bearings...1538
  Measuring Exhaust Temperature...1539
  Measuring Inlet Manifold Pressure...1540
  Monitoring System Parameters...1541
  Pinion Clearance Adjustment...1543
  Restriction of Air Inlet and Exhaust...1545
  Test Tools for the Cooling System...1546
  Test Tools for the Electrical System...1550
  Testing the Cooling System...1555
  Valve Lash - Adjust...1559
  Vibration Damper...1563
  Visual Inspection...1564
RENR5059 - Troubleshooting (3500B and 3500C Generator Set Engines)...1567
  Electrical Connectors and Functions...1568
  Electronic Service Tools...1571
  Self-Diagnostics...1582
  System Overview...1584
RENR7678 - Schematic (3500B & 3500C Generator Set Electrical System Engines & Industrial Engines)...1595
  Main...1596
  Collage...1598
RENR7885 - Electrical System (3500B and 3500C Generator Set Engine)...1623
  Main Schematic...1624
  Collage Schematic...1626
RENR9845 - Electrcial Schematic (3500B Generator with EMCP 3)...1634
  Main Schematic...1635
  Collage Schematic...1639
SENR1122 - Specifications (3500B Engines for 776D; 777D; 784C; 785C; 789C; 793C & 793D Off-Highway Truck_Tractors)...1713
  Accessory Drive (Lower Left Hand)...1716
  Accessory Drive (Upper Left Hand)...1735
  Accessory Drive (Upper Right Hand)...1737
  Accessory Drive...1742
  Aftercooler Coolant Temperature Sensor...1744
  Air Inlet and Exhaust Lines...1745
  Air Starting Motor...1762
  Alternator Mounting...1765
  Alternator and Regulator...1769
  Atmospheric Pressure Sensor...1773
  Auxiliary Drive (Lower Left Hand)...1776
  Auxiliary Water Pump...1783
  Balancer Group (Front)...1795
  Belt Tension Chart - Refrigerant Compressor...1797
  Belt Tension Chart...1799
  Camshaft Bearing Position...1801
  Camshaft...1804
  Connecting Rod and Main Bearing Journals...1810
  Connecting Rod...1812
  Coolant Flow Switch...1823
  Crankcase Breather...1825
  Crankcase Pressure Sensor...1833
  Crankshaft Wear Sleeves and Seals...1837
  Crankshaft...1839
  Cylinder Block...1847
  Cylinder Head Valves...1862
  Cylinder Head...1865
  Cylinder Liner...1868
  Electric Starting Motor...1869
  Engine Coolant Temperature Sensor...1873
  Engine Design...1874
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves...1882
  Engine Oil Filter Base...1888
  Engine Oil Level Switch...1890
  Engine Oil Pan...1891
  Engine Oil Pressure Sensor...1903
  Engine Oil Pump...1905
  Engine Oil Scavenge Pump...1918
  Engine Speed Sensor...1930
  Engine Speed_Timing Sensor...1933
  Engine Support...1936
  Engine Trunnion...1940
  Exhaust Bypass Valve...1944
  Exhaust Manifold...1947
  Fan Drive...1958
  Flywheel Housing Adapter...1968
  Flywheel Housing Cover...1970
  Flywheel Housing...1974
  Flywheel...1976
  Fuel Filter (Primary)...1980
  Fuel Filter Base...1982
  Fuel Filter Differential Pressure Switch...1983
  Fuel Injector Mechanism...1986
  Fuel Injector...1991
  Fuel Pressure Regulator...1993
  Fuel Transfer Pump...1994
  Gear Group (Front)...1996
  Gear Group (Rear)...1998
  Housing (Front)...2008
  Jacket Water Heater...2010
  Lines (Air Compressor)...2014
  Piston and Rings - One-Piece Piston...2016
  Piston and Rings - Two-Piece Piston...2023
  Pressure Sensor - Coolant...2033
  Refrigerant Compressor Pressure Switch...2034
  Refrigerant Compressor...2035
  Turbocharger Exhaust Temperature Sensor...2040
  Turbocharger Inlet Pressure Sensor...2041
  Turbocharger Outlet Pressure Sensor...2045
  Turbocharger...2049
  Valve Mechanism...2066
  Vibration Damper...2070
  Water Pump...2074
  Water Temperature Regulator...2084
SENR1123 - Systems Operation (3500B Engines for Caterpillar Built Machines)...2087
  Aftercooler...2089
  Air Cleaner and Precleaner...2090
  Air Inlet and Exhaust System Operation - 793C...2092
  Air Inlet and Exhaust System Operation...2094
  Alternator...2097
  Camshaft...2099
  Cat Data Link...2100
  Circuit Breaker...2103
  Cold Cylinder Cutout...2104
  Cold Mode Operation...2108
  Cooling System Operation - 793C...2109
  Cooling System Operation...2114
  Crankshaft...2117
  Cylinder Block; Liners and Heads...2118
  Electrical System Operation...2120
  Electronic Circuits...2121
  Electronic Control Module (ECM)...2125
  Electronic Control System Components...2127
  Electronic Control System Operation...2129
  Elevated Low Idle Operation...2131
  Engine Monitoring System...2134
  Engine Speed Controlled by the Transmission ECM...2138
  Ether Control System...2140
  Exhaust Bypass Valve - Wastegate...2142
  Fuel Injector Mechanism...2144
  Fuel Injector...2146
  Fuel System Operation...2148
  Grounding Practices...2151
  Lubrication System Operation...2153
  Pistons; Rings and Connecting Rods - One-Piece Piston...2158
  Pistons; Rings and Connecting Rods - Two-Piece Piston...2160
  Starting Motor...2162
  Starting Solenoid...2164
  Throttle Position Sensor...2166
  Turbocharger - Series Turbocharger System for High Altitude Arrangements (HAA)...2167
  Turbocharger...2169
  Valve Mechanism...2171
SENR1123 - Testing & Adjusting (3500B Engines for Caterpillar Built Machines)...2176
  Alternator Regulator...2178
  Battery...2180
  Camshaft Timing...2181
  Checking Engine Cylinders with an Electronic Service Tool...2189
  Checking Engine Cylinders...2190
  Checking and Calibrating Electronic Injection Timing with the Electronic Service Tool...2191
  Compression...2192
  Connecting Rod Bearings...2193
  Coolant Temperature Sensor - Test...2194
  Crankcase Pressure...2196
  Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting...2197
  Cylinder Block...2199
  Cylinder Liner Projection...2200
  Electric Starting System...2205
  Engine Oil Pressure - Test...2207
  Engine Oil Pressure is High...2212
  Engine Oil Pressure is Low...2213
  Engine Rotation...2215
  Engine Speed Measurement...2216
  Excessive Bearing Wear - Inspect...2217
  Excessive Engine Oil Consumption - Inspect...2218
  Exhaust Bypass Valve...2219
  Finding the Top Center Position for the No. 1 Piston...2220
  Flywheel - Inspect...2223
  Flywheel Housing - Inspect...2226
  Fuel Injector Adjustment...2231
  Fuel Injector Trim Code...2240
  Fuel Pressure...2241
  Fuel Ratio Control...2244
  Fuel System Inspection...2246
  General Information (Air_Electric Starting System)...2247
  General Information (Cooling System)...2248
  General Information (Electronic Control System)...2251
  General Information (Fuel System) - Diesel...2252
  Increased Engine Oil Temperature - Inspect...2253
  Indicators for Engine Oil Pressure...2254
  Main Bearings...2255
  Measuring Exhaust Temperature 01_10_2010...2256
  Measuring Exhaust Temperature...2260
  Measuring Inlet Manifold Pressure...2261
  Pinion Clearance Adjustment...2262
  Radiator and Cooling System - Test...2264
  Test Tools for the Cooling System...2268
  Test Tools for the Electrical System...2272
  Valve Lash Check...2277
  Valve Lash and Valve Bridge Adjustment...2278
  Vibration Damper...2286
  Visual Inspection...2287
  Water Temperature Regulator - Test...2290
SENR1126 - Disassembly & Assembly (3500 & 3500B High Displacement Engines for Caterpillar Built Machines)...2292
  Accessory Drive (Front) - Assemble...2296
  Accessory Drive (Front) - Disassemble...2300
  Accessory Drive (Front) - Install...2304
  Accessory Drive (Front) - Remove...2306
  Accessory Drive (Rear) - Install...2308
  Accessory Drive (Rear) - Remove...2316
  Aftercooler - Remove and Install - Aftercooler Housing with 12 bolts...2321
  Aftercooler - Remove and Install - High Altitude Arrangement...2331
  Air Compressor - Remove and Install...2347
  Air Conditioner Compressor - Remove and Install...2351
  Air Inlet Manifold - Remove and Install...2355
  Air Starting Motor - Assemble...2359
  Air Starting Motor - Disassemble...2373
  Air Starting Motor - Install...2385
  Air Starting Motor - Remove...2388
  Alternator - Remove and Install...2391
  Auxiliary Water Pump - Assemble...2394
  Auxiliary Water Pump - Disassemble...2420
  Auxiliary Water Pump - Install...2444
  Auxiliary Water Pump - Remove...2453
  Bearing Clearance - Check...2464
  Belt Tightener - Assemble...2467
  Belt Tightener - Disassemble...2478
  Belt Tightener - Install...2487
  Belt Tightener - Remove...2491
  Camshaft - Install...2495
  Camshaft - Remove...2505
  Camshaft Bearings - Install...2511
  Camshaft Bearings - Remove...2514
  Connecting Rod Bearings - Remove and Install...2517
  Crankshaft - Install...2527
  Crankshaft - Remove...2534
  Crankshaft Front Seal and Wear Sleeve - Install...2538
  Crankshaft Front Seal and Wear Sleeve - Remove...2544
  Crankshaft Main Bearings - Install...2547
  Crankshaft Main Bearings - Remove...2552
  Crankshaft Rear Seal and Wear Sleeve - Install...2556
  Crankshaft Rear Seal and Wear Sleeve - Remove...2562
  Cylinder Head - Assemble...2565
  Cylinder Head - Disassemble...2571
  Cylinder Head - Install...2577
  Cylinder Head - Remove...2584
  Cylinder Liner - Install...2589
  Cylinder Liner - Remove...2597
  Electric Starting Motor - Remove and Install...2599
  Electronic Control Module (ECM) and Personality Module (PM) - Remove and Install...2601
  Electronic Control Module (Engine) - Remove and Install...2605
  Electronic Unit Injector - Install...2607
  Electronic Unit Injector - Remove...2611
  Engine Oil Cooler - Install...2613
  Engine Oil Cooler - Remove...2617
  Engine Oil Cooler Bypass Valve - Remove and Install...2621
  Engine Oil Filter Base - Assemble...2626
  Engine Oil Filter Base - Disassemble...2629
  Engine Oil Filter Base - Install...2632
  Engine Oil Filter Base - Remove...2635
  Engine Oil Level Gauge (Dipstick) - Remove and Install...2639
  Engine Oil Pan - Assemble...2643
  Engine Oil Pan - Disassemble...2646
  Engine Oil Pan - Install...2649
  Engine Oil Pan - Remove...2653
  Engine Oil Pump - Assemble...2657
  Engine Oil Pump - Disassemble...2661
  Engine Oil Pump - Install...2666
  Engine Oil Pump - Remove...2670
  Engine Oil Scavenge Pump - Assemble...2674
  Engine Oil Scavenge Pump - Disassemble...2679
  Engine Oil Scavenge Pump - Install...2682
  Engine Oil Scavenge Pump - Remove...2688
  Engine Oil Sequence Valves - Remove and Install...2694
  Engine Oil and Water Pump Drive - Assemble...2699
  Engine Oil and Water Pump Drive - Disassemble...2702
  Engine Oil and Water Pump Drive - Install...2705
  Engine Oil and Water Pump Drive - Remove...2707
  Engine Trunnion - Remove and Install...2709
  Exhaust Manifold - Remove and Install...2713
  Fan Drive (Hydraulic) - Assemble...2720
  Fan Drive (Hydraulic) - Disassemble...2738
  Fan Drive - Assemble...2750
  Fan Drive - Disassemble...2767
  Fan Drive - Remove...2782
  Flywheel - Remove and Install...2785
  Flywheel Housing - Install...2788
  Flywheel Housing - Remove...2795
  Front Drive Housing - Remove and Install...2798
  Fuel Filter Base - Remove and Install...2805
  Fuel Manifold - Remove and Install...2810
  Fuel Priming Pump - Remove and Install...2812
  Fuel Transfer Pump - Assemble...2815
  Fuel Transfer Pump - Disassemble...2821
  Fuel Transfer Pump - Install...2826
  Fuel Transfer Pump - Remove...2827
  Gear Group (Rear) - Install...2829
  Gear Group (Rear) - Remove...2835
  Installation Procedure...2839
  Piston Cooling Jets - Remove and Install...2849
  Pistons and Connecting Rods - Install...2852
  Pistons and Connecting Rods - Remove...2858
  Rocker Shaft - Assemble...2862
  Rocker Shaft - Disassemble...2865
  Rocker Shaft and Push Rods - Remove...2868
  Rocker Shaft and Pushrod - Install...2870
  Transmission Oil Cooler - Remove and Install...2875
  Turbocharger - Assemble...2879
  Turbocharger - Disassemble...2881
  Turbocharger - Install...2883
  Turbocharger - Remove...2890
  Valve Mechanism Cover - Remove and Install...2897
  Valve Mechanism Cover Base - Remove and Install...2900
  Vibration Damper - Remove and Install...2902
  Water Pump - Assemble...2915
  Water Pump - Disassemble...2948
  Water Pump - Install...2975
  Water Pump - Remove...2983
  Water Temperature Regulators - Install...2988
  Water Temperature Regulators - Remove...2991
SENR6562 - Specifications (3500B Engines)...2995
  Air Starting Motor Pressure Regulating Valve...3000
  Flexible Coupling (1)...3002
  Engine Mount...3004
  Cylinder Head...3006
  Coolant Level Sensor (1)...3012
  Engine Oil Filter...3014
  Fuel Transfer Pump...3017
  Electric Starting Motor (4)...3020
  Air Inlet and Exhaust Lines (1)...3023
  Accessory Drive (Lower Left Hand; Reverse Rotation)...3028
  Auxiliary Water Pump (1)...3031
  Water Temperature Regulator...3036
  Turbocharger (2)...3039
  Turbocharger (3)...3041
  Fuel Filter (Primary)...3043
  Alternator Mounting...3046
  Turbocharger Outlet Pressure Sensor...3049
  Cylinder Block...3051
  Vibration Damper Guard (2)...3055
  Engine Oil Pump (1)...3058
  Alternator and Regulator (1)...3065
  Fuel Pressure Regulator...3068
  Gear Group (Front) (1)...3071
  Water Pump...3074
  Camshaft (4)...3080
  Crankshaft (1)...3083
  Thermostatic Valve (2)...3086
  Engine Oil Filter Base...3088
  Engine Trunnion...3091
  Vibration Damper (1)...3093
  Electric Starting Motor (2)...3095
  Accessory Drive (Upper Left Hand; Reverse Rotation)...3098
  Accessory Drive (Upper Right Hand) (2)...3101
  Turbocharger (4)...3102
  Engine Design (1)...3105
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves (2)...3107
  Engine Oil Lines - Front Mounted Engine Oil Filter...3110
  Air Cleaner...3113
  Coolant Level Switch...3116
  Camshaft (3)...3118
  Crankcase Breather...3121
  Exhaust Manifold (1)...3123
  Camshaft (2)...3125
  Auxiliary Water Pump - Sea Water (1)...3128
  Piston and Rings - Two-Piece Piston...3132
  Housing (Front) (1)...3136
  Valve Mechanism...3139
  Balancer Group (Front)...3142
  Connecting Rod...3144
  Cylinder Head Valves...3148
  Air Starting Motor...3155
  Turbocharger (5)...3158
  Flywheel Housing (1)...3161
  Flywheel...3164
  Crankcase Pressure Sensor...3167
  Electric Starting Motor (3)...3169
  Accessory Drive (Lower Left Hand) (1)...3172
  Engine Design (3)...3175
  Turbocharger (6)...3177
  Flywheel Housing (2)...3179
  Connecting Rod and Main Bearing Journals...3183
  Engine Oil Sump Pump...3186
  Accessory Drive (Upper Left Hand)...3190
  Stub Shaft (Rear)...3193
  Fuel Pressure Sensor...3195
  Accessory Drive (Lower Left Hand) (2)...3197
  Piston and Rings - One-Piece Piston...3200
  Vibration Damper (3)...3204
  Exhaust Flange...3207
  Fuel Injector Mechanism...3210
  Atmospheric Pressure Sensor...3212
  Auxiliary Water Pump - Sea Water (2)...3215
  Camshaft (1)...3219
  Auxiliary Drive Shaft...3222
  Housing (Front) (2)...3225
  Duplex Engine Oil Filters...3228
  Fuel Injector...3231
  Engine Oil Pressure Sensor...3234
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves (1)...3236
  Exhaust Manifold (2)...3238
  Vibration Damper (2)...3240
  Cylinder Liner...3242
  Coolant Temperature Switch...3245
  Accessory Drive (Lower Left Hand) (3)...3248
  Air Cleaner Adapter...3252
  Electric Starting Motor (1)...3254
  Engine SpeedTiming Sensor...3257
  Fan Drive...3260
  Air Shutoff...3262
  Accessory Drive (Upper Right Hand) (1)...3266
  Engine Design (2)...3269
  Turbocharger (7)...3271
  Belt Tension Chart...3273
  Radiator Mounting...3276
  Crankshaft (2)...3279
  Thermostatic Valve (1)...3281
  Vibration Damper Guard (1)...3283
  Engine Oil Pump (2)...3285
  Accessory Drive (Lower Left Hand) (4)...3292
  Fuel Filter Base...3295
  Alternator and Regulator (2)...3297
  Stub Shaft (Front)...3301
  Gear Group (Front) (2)...3304
  Vibration Damper (4)...3307
  Coolant Level Sensor (2)...3310
  Gear Group (Front) (3)...3312
  Alternator and Regulator (3)...3317
  Engine Oil Pump (3)...3321
  Air Inlet and Exhaust Lines (2)...3324
  Fuel Filter...3328
  Engine Speed Sensor...3331
  Crankshaft Wear Sleeves and Seals...3334
  Auxiliary Water Pump (2)...3337
  Turbocharger (1)...3343
  Engine Coolant Temperature Sensor...3345
  Engine Oil Level Switch...3347
  Auxiliary Drive Pulley...3350
  Turbocharger Inlet Pressure Sensor...3355
  Engine Oil Scavenge Pump...3357
  Flexible Coupling (2)...3362
  Engine Oil Pan...3365
SENR6563 - Systems Operation (3500B Engines)...3367
  Charging System...3369
  System Configuration Parameters...3371
  Jacket Water Cooling Circuit...3372
  Separate Circuit Cooling System...3374
  Cold Cylinder Cutout...3376
  Electronic Control System Components...3378
  Electronic Control Module (ECM)...3379
  Crankshaft...3382
  Secondary Cat Data Link...3383
  Ether Control System...3384
  Electronic Circuits...3387
  Valve Mechanism...3388
  ECM Total Fuel Consumption Adjustment - Diesel Fuel...3393
  Pistons; Rings and Connecting Rods - Two-Piece Piston...3394
  Circuit Breaker...3396
  Starting System ...3397
  100 Hour Free Configuration on Engine Start-up...3400
  Fuel Injector Mechanism...3401
  Air Starting System...3404
  Camshaft...3407
  ECM Hour Increment Adjustment...3408
  Turbocharger...3409
  Cat Data Link...3414
  Pistons; Rings and Connecting Rods - One-Piece Piston...3416
  Electrical System Operation...3418
  Fuel Injector...3419
  Air Inlet and Exhaust System Operation...3422
  Electronic Control System Operation...3424
  Fuel Rate Scaling (Fuel Correction Factor) - Diesel Fuel...3427
  Cylinder Block; Liners and Heads...3428
  Grounding Practices...3430
  Engine Monitoring System...3432
  Fuel System Operation...3433
  Lubrication System Operation...3435
  Histogramming...3440
  Aftercooler - Jacket Water Aftercooler...3441
SENR6563 - Testing & Adjusting (3500B Engines)...3443
  Cylinder Head...3445
  Fuel Injector Adjustment...3447
  Battery...3452
  Charging System...3454
  Vibration Damper...3456
  General Information (AirElectric Starting System)...3457
  Engine Oil Pressure is High...3460
  Cylinder Block...3461
  Flywheel - Inspect...3463
  Alternator Regulator...3467
  General Information (Lubrication System)...3469
  General Information (Cooling System)...3470
  Coolant Temperature Sensor - Test...3473
  Indicators for Engine Oil Pressure...3475
  Valve Lash and Valve Bridge Adjustment...3476
  Pinion Clearance Adjustment...3485
  Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting...3487
  Fuel Pressure...3489
  Radiator and Cooling System - Test...3492
  Connecting Rod Bearings...3496
  Excessive Engine Oil Consumption - Inspect...3497
  Crankcase Pressure...3499
  General Information (Fuel System) - Diesel...3500
  Measuring Inlet Manifold Pressure...3501
  Engine Oil Pressure is Low...3503
  Excessive Bearing Wear - Inspect...3505
  Test Tools for the Electrical System...3506
  Water Temperature Regulator - Test...3511
  Monitoring System Parameters...3514
  Test Tools for the Cooling System...3516
  Visual Inspection...3520
  Main Bearings...3523
  Engine Rotation...3524
  Finding the Top Center Position for the No. 1 Piston...3525
  Flywheel Housing - Inspect...3528
  Checking Engine Cylinders...3533
  Restriction of Air Inlet and Exhaust...3534
  Engine Oil Pressure - Test...3535
  Increased Engine Oil Temperature - Inspect...3537
  Checking Engine Cylinders with an Electronic Service Tool...3538
  Testing the Cooling System...3539
  Fuel System Inspection...3544
  Cylinder Liner Projection...3545
  Electric Starting System...3550
  Camshaft Timing...3552
  Measuring Exhaust Temperature...3560
SENR6564 - Disassembly & Assembly (3500B Engines)...3561
  Accessory Drive (Front) - Remove...3566
  Air Starting Motor - Install...3568
  Engine Oil Sequence Valves - Remove and Install...3571
  Camshaft - Remove...3576
  Turbocharger - Install - Rear Mounted Turbocharger (1)...3582
  Gear Group (Rear) - Remove...3587
  Auxiliary Water Pump - Remove - Auxiliary Sea Water Pump...3591
  Fuel Transfer Pump - Assemble...3593
  Exhaust Elbow - Remove and Install...3602
  Flywheel Housing - Remove...3607
  Fuel Filter Housing - Disassemble - Spin-on Filters...3610
  Engine Oil Cooler - Install...3613
  Engine Oil Cooler - Remove...3616
  Auxiliary Water Pump - Disassemble - Auxiliary Pump (Type 1)...3619
  Auxiliary Water Pump - Remove - Auxiliary Pump...3635
  Camshaft Bearings - Remove...3638
  Turbocharger - Remove - Rear Mounted Turbocharger (1)...3641
  Engine Oil Filter Housing - Remove...3645
  Engine Oil Scavenge Pump - Install...3648
  Cylinder Liner - Install...3651
  Fuel Transfer Pump - Remove...3659
  Crankshaft Rear Seal and Wear Sleeve - Remove ...3661
  Electronic Unit Injector - Remove...3664
  Fuel Filter Housing - Install (2)...3666
  Radiator Group - Remove...3668
  Electronic Unit Injector - Install...3673
  Engine Oil Pan - Remove ...3677
  Air Inlet Manifold - Remove and Install...3681
  Water Pump - Assemble...3685
  Expansion Tank - Remove and Install...3693
  Pistons and Connecting Rods - Install...3700
  Auxiliary Water Pump - Assemble - Auxiliary Pump (Type 1)...3706
  Engine Oil Pan - Assemble...3723
  Turbocharger - Install - Center Mounted Turbocharger...3726
  Fan - Remove and Install...3731
  Engine Oil Pump - Remove...3738
  Water Pump (Separate Circuit Aftercooler) - Install...3741
  Auxiliary Water Pump - Install - Auxiliary Sea Water Pump...3743
  Fuel Cooler - Remove and Install...3746
  Fuel Filter Housing - Remove (1)...3749
  Engine Oil Filter Base - Remove - Spin-on Filters...3751
  Connecting Rod Bearings - Remove and Install...3753
  Engine Oil and Water Pump Drive - Install...3758
  Radiator Core - Install...3760
  Vibration Damper - Remove and Install ...3766
  Pistons and Connecting Rods - Remove...3777
  Cylinder Head - Install...3781
  Turbocharger - Assemble...3788
  Crankshaft Main Bearings - Install...3791
  Rocker Shaft - Disassemble...3796
  Crankshaft - Install...3799
  Fuel Transfer Pump - Install...3806
  Engine Oil and Water Pump Drive - Disassemble...3808
  Air Shutoff - Remove and Install...3811
  Engine Oil Filter Housing - Install...3816
  Water Pump - Install...3819
  Auxiliary Water Pump - Install - Auxiliary Pump...3822
  Engine Oil Pan - Install ...3826
  Cylinder Liner - Remove...3830
  Camshaft - Install...3832
  Engine Oil Filter Base - Assemble - Spin-on Filters...3842
  Valve Cover - Remove and Install...3844
  Crankcase Breather - Remove and Install...3847
  Crankshaft Front Seal and Wear Sleeve - Install...3852
  Water Temperature Regulators - Remove...3858
  Fuel Priming Pump - Remove and Install...3862
  Radiator Group - Install...3865
  Crankshaft Rear Seal and Wear Sleeve - Install...3869
  Exhaust Manifold - Remove and Install...3875
  Auxiliary Water Pump - Assemble - Auxiliary Sea Water Pump...3881
  Bearing Clearance - Check...3894
  Air Shutoff - Assemble...3897
  Radiator Core - Remove...3900
  Cylinder Head - Disassemble...3906
  Water Pump - Disassemble...3913
  Water Temperature Regulators - Install...3920
  Engine Oil Cooler - Disassemble...3925
  Auxiliary Water Pump - Disassemble - Auxiliary Sea Water Pump...3930
  Air Starting Motor - Remove...3940
  Engine Oil and Water Pump Drive - Assemble...3946
  Rocker Shaft and Push Rods - Remove ...3950
  Fuel Filter Housing - Remove (2)...3953
  Electric Starting Motor - Remove and Install...3956
  Engine Oil Filter Housing - Disassemble...3958
  Water Pump - Remove...3964
  Engine Oil Pump - Assemble...3968
  Fuel Filter Housing - Install...3973
  Accessory Drive (Front) - Install...3975
  Accessory Drive (Front) - Disassemble...3977
  Water Pump (Separate Circuit Aftercooler) - Disassemble...3981
  Engine Oil Filter Housing - Assemble...3986
  Rocker Shaft - Assemble...3992
  Auxiliary Water Pump - Assemble - Auxiliary Pump (Type 2)...3996
  Cylinder Head - Assemble...4013
  Fuel Filter Housing - Remove - Spin-on Filter...4019
  Turbocharger - Disassemble...4021
  Rocker Shaft and Pushrod - Install...4024
  Air Cleaner - Remove and Install...4029
  Gear Group (Rear) - Install...4032
  Flywheel - Remove and Install...4038
  Water Pump (Separate Circuit Aftercooler) - Remove...4041
  Engine Oil Pump - Disassemble...4043
  Electronic Control Module (Engine) - Remove and Install...4047
  Engine Oil Pump - Install...4049
  Engine Oil Scavenge Pump - Assemble...4052
  Engine Oil Scavenge Pump - Disassemble...4058
  Front Drive Housing - Remove and Install ...4061
  Engine Oil and Water Pump Drive - Remove...4068
  Fuel Transfer Pump - Disassemble...4070
  Turbocharger - Remove - Rear Mounted Turbocharger (2)...4079
  Camshaft Bearings - Install...4083
  Air Shutoff - Disassemble...4086
  Fuel Filter Housing - Install - Spin-on Filters (1)...4089
  Air Starting Motor - Assemble...4091
  Engine Oil Filter Base - Install - Spin-on Filters...4109
  Crankshaft - Remove...4111
  Engine Oil Pan - Disassemble...4115
  Piston Cooling Jets - Remove and Install...4118
  Crankshaft Front Seal and Wear Sleeve - Remove...4121
  Fuel Filter Housing - Assemble - Spin-on Filters...4124
  Valve Cover Base - Remove and Install...4127
  Engine Oil Cooler - Assemble...4129
  Engine Oil Filter Base - Disassemble - Spin-on Filters...4136
  Engine Oil Scavenge Pump - Remove...4138
  Auxiliary Water Pump - Disassemble - Auxiliary Pump (Type 2)...4141
  Air Starting Motor - Disassemble...4156
  Aftercooler - Remove and Install...4171
  Cylinder Head - Remove...4178
  Accessory Drive (Front) - Assemble...4183
  Water Pump (Separate Circuit Aftercooler) - Assemble...4187
  Turbocharger - Remove - Center Mounted Turbocharger...4193
  Alternator - Remove and Install...4198
  Crankshaft Main Bearings - Remove...4201
  Flywheel Housing - Install...4205
  Turbocharger - Install - Rear Mounted Turbocharger (2)...4212
SENR6587 - Systems Operation (3508; 3508B; 3508C; 3512; 3512B; 3512C; 3516; 3516B & 3516C Engines Caterpillar Monitoring System)...4216
  Sensors...4217
  Warning Operation...4220
  Instrument Modules for Locomotive Applications...4222
  Normal Mode...4225
  Modes Of Operation...4227
  Quad Gauge Module...4228
  Alert Indicator Description...4236
  Electronic Control Module (Engine)...4240
  Harness Code Mode...4242
  Action Alarm and Alarm Silence Switch...4244
  Instrument Modules for Marine Applications...4246
  Senders...4249
  Instrument Modules for Generator Set Applications...4252
  Tattletale Mode...4255
  Panel Components...4257
  Units Mode...4271
  Numeric Readout Mode...4273
  Internal Panel Components...4284
  Service Mode...4288
SENR6587 - Testing & Adjusting (3508; 3508B; 3508C; 3512; 3512B; 3512C; 3516; 3516B & 3516C Engines Caterpillar Monitoring System)...4292
  Connector Contact Description of Main Display Module...4294
  CID 0172 FMI 04 Temperature Sender (Inlet Air) Voltage Below Normal - Test...4302
  Alarm Silence Switch - Troubleshoot...4305
  CID 0175 FMI 08 Temperature Sender (Engine Oil) Abnormal Signal - Test...4308
  CID 0248 FMI 02 Cat Data Link Incorrect - Test...4312
  ClearMode Switch - Troubleshoot...4315
  Level Switch (Coolant) - Troubleshoot...4319
  Main Display Module Initialization - Adjust...4323
  CID 0263 FMI 03 Sensor Power Supply Voltage Above Normal - Test...4325
  CID 0175 FMI 04 Temperature Sender (Engine Oil) Voltage Below Normal - Test...4328
  Glossary of Terms...4331
  Service Tools...4334
  CID 0096 FMI 03 Level Switch (Fuel) Voltage Above Normal - Test...4336
  Electrical Components And Connector Locations...4339
  Accessing Diagnostic Information...4340
  CID 0271 FMI 06 Alarm (Action) Current Above Normal - Test...4342
  CID 0263 FMI 04 Sensor Power Supply Voltage Below Normal - Test...4345
  Scroll Switch - Troubleshoot...4348
  Troubleshooting Diagnostic Codes...4351
  CID 0819 FMI 02 Display Data Link Incorrect - Test...4353
  LHRH Switch - Troubleshoot...4354
  CID 0127 FMI 08 Pressure Sensor (Transmission Oil) Abnormal Signal - Test...4356
  System Schematic...4360
  CID 0271 FMI 05 Alarm (Action) Current Below Normal - Test...4364
  CID 0821 FMI 04 Display Power Supply Voltage Below Normal - Test...4367
  CID 0177 FMI 08 Temperature Sensor (Transmission Oil) Abnormal Signal - Test...4370
  Alert Indicator - Troubleshoot...4374
  Initial Troubleshooting Procedure...4377
  General Information...4380
  CID 0271 FMI 03 Alarm (Action) Voltage Above Normal - Test...4382
  Module - Replace...4384
  Harness Code - Troubleshoot...4385
  CID 0821 FMI 03 Display Power Supply Voltage Above Normal - Test...4389
  System Self Test...4392
UENR0181 - Disassembly and Assembly (3500B Engines)...4395
  Air Starting Motor - Remove...4400
  Air Starting Motor - Disassemble...4403
  Air Starting Motor - Assemble...4415
  Air Starting Motor - Install...4428
  Electric Starting Motor - Remove and Install...4431
  Alternator - Remove and Install...4433
  Electronic Control Module (Engine) - Remove and Install...4436
  Fuel Filter Housing - Remove - Spin-on Filter...4438
  Fuel Filter Housing - Remove...4443
  Fuel Filter Housing - Disassemble - Spin-on Filters...4448
  Fuel Filter Housing - Assemble - Spin-on Filters...4451
  Fuel Filter Housing - Install - Spin-on Filters...4454
  Fuel Filter Housing - Install...4456
  Fuel Priming Pump - Remove and Install...4460
  Fuel Transfer Pump - Remove...4463
  Fuel Transfer Pump - Disassemble...4465
  Fuel Transfer Pump - Assemble...4474
  Fuel Transfer Pump - Install...4483
  Fuel Cooler - Remove and Install...4485
  Air Cleaner - Remove and Install...4487
  Turbocharger - Remove - Center Mounted Turbocharger...4490
  Turbocharger - Remove - Rear Mounted Turbocharger...4494
  Turbocharger - Disassemble...4501
  Turbocharger - Assemble...4503
  Turbocharger - Install - Center Mounted Turbocharger...4505
  Turbocharger - Install - Rear Mounted Turbocharger...4509
  Aftercooler - Remove and Install...4516
  Air Inlet Manifold - Remove and Install...4523
  Exhaust Elbow - Remove and Install...4526
  Exhaust Manifold - Remove and Install...4530
  Expansion Tank - Remove and Install...4538
  Water Temperature Regulators - Remove...4544
  Water Temperature Regulators - Install...4547
  Water Pump - Remove...4552
  Water Pump - Disassemble...4556
  Water Pump - Assemble...4562
  Water Pump - Install...4569
  Water Pump (Separate Circuit Aftercooler) - Remove...4572
  Water Pump (Separate Circuit Aftercooler) - Disassemble...4574
  Water Pump (Separate Circuit Aftercooler) - Assemble...4579
  Water Pump (Separate Circuit Aftercooler) - Install...4584
  Auxiliary Water Pump - Remove - Auxiliary Sea Water Pump...4586
  Auxiliary Water Pump - Remove - Auxiliary Pump...4588
  Auxiliary Water Pump - Disassemble - Auxiliary Sea Water Pump...4591
  Auxiliary Water Pump - Disassemble - Auxiliary Pump (Type 2)...4600
  Auxiliary Water Pump - Disassemble - Auxiliary Pump (Type 1)...4615
  Auxiliary Water Pump - Assemble - Auxiliary Sea Water Pump...4629
  Auxiliary Water Pump - Assemble - Auxiliary Pump (Type 1)...4640
  Auxiliary Water Pump - Assemble - Auxiliary Pump (Type 2)...4655
  Auxiliary Water Pump - Install - Auxiliary Sea Water Pump...4670
  Auxiliary Water Pump - Install - Auxiliary Pump...4672
  Engine Oil Cooler - Remove...4676
  Engine Oil Cooler - Disassemble...4679
  Engine Oil Cooler - Assemble...4683
  Engine Oil Cooler - Install...4688
  Engine Oil Pump - Remove...4691
  Engine Oil Pump - Disassemble...4694
  Engine Oil Pump - Assemble...4698
  Engine Oil Pump - Install...4702
  Engine Oil Filter Housing - Remove...4705
  Engine Oil Filter Housing - Disassemble...4708
  Engine Oil Filter Housing - Assemble...4713
  Engine Oil Filter Housing - Install...4718
  Engine Oil Filter Base - Remove - Spin-on Filters...4721
  Engine Oil Filter Base - Disassemble - Spin-on Filters...4722
  Engine Oil Filter Base - Assemble - Spin-on Filters...4724
  Engine Oil Filter Base - Install - Spin-on Filters...4726
  Engine Oil and Water Pump Drive - Remove...4728
  Engine Oil and Water Pump Drive - Disassemble...4730
  Engine Oil and Water Pump Drive - Assemble...4733
  Engine Oil and Water Pump Drive - Install...4736
  Engine Oil Pan - Remove...4738
  Engine Oil Pan - Disassemble...4742
  Engine Oil Pan - Assemble...4745
  Engine Oil Pan - Install...4748
  Engine Oil Scavenge Pump - Remove...4752
  Engine Oil Scavenge Pump - Disassemble...4754
  Engine Oil Scavenge Pump - Assemble...4757
  Engine Oil Scavenge Pump - Install...4762
  Crankcase Breather - Remove and Install...4764
  Valve Cover - Remove and Install...4768
  Valve Cover Base - Remove and Install...4771
  Rocker Shaft and Push Rods - Remove...4773
  Rocker Shaft - Disassemble...4775
  Rocker Shaft - Assemble...4778
  Rocker Shaft and Pushrod - Install...4782
  Electronic Unit Injector - Remove...4788
  Electronic Unit Injector - Install...4790
  Cylinder Head - Remove...4794
  Cylinder Head - Disassemble...4798
  Cylinder Head - Assemble...4804
  Cylinder Head - Install...4810
  Accessory Drive (Front) - Remove...4819
  Accessory Drive (Front) - Disassemble...4821
  Accessory Drive (Front) - Assemble...4824
  Accessory Drive (Front) - Install...4828
  Front Drive Housing - Remove and Install...4830
  Vibration Damper - Remove and Install...4836
  Crankshaft Front Seal and Wear Sleeve - Remove...4846
  Crankshaft Front Seal and Wear Sleeve - Install...4848
  Flywheel - Remove and Install...4855
  Crankshaft Rear Seal and Wear Sleeve - Remove...4858
  Crankshaft Rear Seal and Wear Sleeve - Install...4860
  Flywheel Housing - Remove...4866
  Flywheel Housing - Install...4868
  Engine Oil Sequence Valves - Remove and Install...4874
  Gear Group (Rear) - Remove...4879
  Gear Group (Rear) - Install...4882
  Piston Cooling Jets - Remove and Install...4888
  Bearing Clearance - Check...4891
  Connecting Rod Bearings - Remove and Install...4894
  Crankshaft Main Bearings - Remove...4899
  Crankshaft Main Bearings - Install...4903
  Pistons and Connecting Rods - Remove...4907
  Pistons and Connecting Rods - Install...4911
  Cylinder Liner - Remove...4917
  Cylinder Liner - Install...4919
  Camshaft - Remove...4923
  Camshaft Bearings - Remove...4929
  Camshaft Bearings - Install...4931
  Camshaft - Install...4934
  Crankshaft - Remove...4943
  Crankshaft - Install...4947
  Radiator Group - Remove...4953
  Radiator Group - Install...4957
  Radiator Core - Remove...4961
  Radiator Core - Install...4967
  Fan - Remove and Install...4972
UENR3905 - Schematic (3500 and 3500B Generator with MUI and EUI Engines Electrical System; MUI EMCP2E 242-2242; EMCP2 242-2241; EUI EMCP2E 242-2245; EMCP2 242-2244)...4980
  Main...4981
  Collage...4985

EXCERPT:
Valve Mechanism
Type 1
The valve system components control the flow of the inlet air and the exhaust gases into the cylinders and out of the cylinders during engine operation.
The crankshaft gear drives the camshaft gears through idlers. Both camshafts must be timed to the crankshaft in order to get the correct relation between the piston and the valve movement.
The camshafts have three lobes for each cylinder. Two lobes operate the valves and one operates the fuel injector.
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Caterpillar 3500B Series Engines Factory Service & Shop Manual