3512 Generator Set Engine 67Z00772-UP(SEBP2640 - 53)/Basic Search Page 1 of 18

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Product: GEN SET ENGINE
Model: 3512 GEN SET ENGINE 67Z01618
Configuration: 3512 Generator Set Engine 67Z00772-UP

Testing and Adjusting
3500 SERIES ENGINES HYDRAMECHANICAL PROTECTIVE SYSTEM
Media Number -SENR3078-00 Publication Date -01/06/1986 Date Updated -13/07/2012

SENR30780010

Testing And Adjusting
SMCS - 1000

Troubleshooting
Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make
a repair to a problem, make reference to the cause and correction.

This list of problems, causes, and corrections, will only give an indication of where a possible
problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond
the recommendations in the list.

Remember that a problem is not normally caused only by one part, but 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.

Troubleshooting Index
1. Engine Will Not Start.
2. Engine Will Start, But Shuts Down When Oil Pressure Override is Released.
3. Engine Will Only Run Below 70% of Rated Speed.
4. Air Inlet Shutoff Activates on Load Rejection.
5. Air Inlet Does Not Close.
6. Engine Will Not Restart After Operation of Emergency Manual Shutoff.
7. Engine Will Not Shutdown When Checking Low Engine Oil Pressure Protection Circuit.
8. Shutoff Control Unit Does Not Operate.

https://127.0.0.1:442/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 4/6/2015

2.0. Oil line to thermostatic pilot valve. 5.. Oil drain line from diverter valve. 3.0. 4. PROTECTIVE SYSTEM OIL LINES 2. Plug.53)/Basic Search Page 2 of 18 FIGURE 1.jsp?returnurl=/sisweb/sisw.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . Oil return line from diverter valve. Oil return line from diverter valve. Cover on actuator valve body.. PROTECTIVE SYSTEM OIL LINES 1. FIGURE 2. Engine Will Not Start Engine Will Start. 5. 3. 4. 4/6/2015 . But Shuts Down When Start-Up Override Is Released https://127. Oil supply line to diverter valve. Oil line to thermostatic pilot valve.1:442/sisweb/sisweb/techdoc/techdoc_print_page. 6. Oil drain line from diverter valve. Oil supply line to diverter valve.

.3512 Generator Set Engine 67Z00772-UP(SEBP2640 .0.0. 4/6/2015 .jsp?returnurl=/sisweb/sisw.1:442/sisweb/sisweb/techdoc/techdoc_print_page..53)/Basic Search Page 3 of 18 Engine Will Only Run Below 70% Of Rated Speed Air Inlet Shutoff Activities On Load Rejection Air Inlet Does Not Close https://127.

53)/Basic Search Page 4 of 18 Engine Will Not Restart After Operation Of Emergency Manual Shutoff Engine Will Not Shutdown When Checking Low Engine Oil Pressure PROTECTION CIRCUIT Shutoff Control Unit Does Not Operate https://127.1:442/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...0. 4/6/2015 .0.3512 Generator Set Engine 67Z00772-UP(SEBP2640 .

OS) 1. 2. HWT. Return line from diverter valve. Oil line to diverter valve.jsp?returnurl=/sisweb/sisw. Oil line to air inlet shutoff actuator. 4/6/2015 .1:442/sisweb/sisweb/techdoc/techdoc_print_page... 6.0. 7. 5. 4. https://127. valves and alarms (if so equipped). Many engines run thousands of hours in continuous-duty applications without any operation of the protective system shutoff actuators. Return line from air inlet shutoff actuator.53)/Basic Search Page 5 of 18 Hydramechanical Protective System PROTECTIVE SYSTEM WITH ENGINE SHUTDOWN FOR ALL FUNCTIONS (LOP. From diverter valve to governor (fuel) shutoff actuator. From two-way valve at the diverter valve to drain.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . 3.0. Oil line to thermostatic pilot valve.

1:442/sisweb/sisweb/techdoc/techdoc_print_page.. Use th following procedures to check the system more completely. further inspection of the system is needed.53)/Basic Search Page 6 of 18 Every 500 Service Meter Units. This will check the protective system for correct operation. 5N6411 Valve (palm valve) can be tested while the engine is operating under full load. Tighten the nut. Shake the line to break the paint. the shutoff is being driven through the coupling. the start-up override must be operated to release hydraulic pressure from the fuel shutoff actuator before the engine can be started again. Drive Coupling Check Put a rag around the fitting to prevent oil spray on oil supply line (5) at the diverter valve.jsp?returnurl=/sisweb/sisw. the emergency manual shutoff should be operated.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . If any oil comes out under pressure.. tests of the air inlet shutoff and the (fuel) shutoff are done with the engine at low idle. NOTICE After the emergency manual shutoff has been operated. However. https://127.0. 4/6/2015 . Also. the air inlet shutoff valve must be opened. If no engine shutdown occurs.0. Operate the engine at low idle and loosen the nut on the fitting at the diverter valve one-half to three- quarters of a turn. The drive coupling and the two-way.

Return line from diverter valve.jsp?returnurl=/sisweb/sisw. Oil line to diverter valve. Oil line to thermostatic pilot valve.. the valve has failed and replacement is necessary. 3. 2. 8. Oil line to air inlet shutoff actuator.0. 7. Loosen the drain line from the two-way (palm) valve. Oil line to thermostatic pilot valve. 4/6/2015 . 5. If there is any oil flow. From two-way valve at the diverter valve to drain. Return line from air inlet shutoff actuator. Oil pressure switch for alarms. Oil line to diverter valve.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . start and operate the engine at low idle. PROTECTIVE SYSTEM OIL LINES 3.1:442/sisweb/sisweb/techdoc/techdoc_print_page.53)/Basic Search Page 7 of 18 PROTECTIVE SYSTEM WITH ENGINE SHUTDOWN FOR OVERSPEED ONLY. 6. From two-way valve (at the diverter valve) to drain. 5. https://127. There should be no oil present.. 6.0. ALARMS FOR OTHER FUNCTIONS (LOP. Start-Up Override Valve Check On an engine with an air start system. From diverter valve to governor (fuel) shutoff actuator. 4. HWT) 1.

Fuel Shutoff Test Hold open the air inlet shutoff valve with a length of wire. remove the plug from where line (4) would connect to the shutoff control group. the fuel shutoff actuator should stop the engine. if needed. Also. 4/6/2015 . Close the valve and start the engine and operate it at low idle. if so equipped. Attach a 3N4847 Hose Assembly to the control. Since the air inlet shutoff valve has been held open. https://127. the valve can be held open by hand.0. The fuel shutoff actuator must also move the governor and fuel control linkage to the "SHUTOFF" position.) Pull the red.jsp?returnurl=/sisweb/sisw. high coolant temperature alarms should also be activated. emergency knob. NOTE: If the engine is not equipped with a thermostatic pilot valve. (If another person is present. The low oil pressure. the start-up override valve must be operated to release hydraulic pressure from the governor shutoff actuator before the engine can be started again.. NOTICE After this test has been performed. NOTICE Before starting the engine. if so equipped. emergency knob.. at the control group. Use a 7D5363 Connector to adapt a 3R3837 Shutoff Valve to the end of the hose. The engine will run normally.1:442/sisweb/sisweb/techdoc/techdoc_print_page.0. Low Oil Pressure Test Disconnect the oil supply line that is installed between the thermostatic pilot valve and the shutoff control group. Low oil pressure and high coolant temperature alarms should also be activated.53)/Basic Search Page 8 of 18 Air Inlet Shutoff Check Operate the engine at low idle and pull the red. and to prevent damage to the engine at start up.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . make sure the air inlet shutoff is reset so the protective system can operate. The air inlet shutoff valve must close and stop the engine. the air inlet shutoff valve must be opened.

connector and shutoff valve from the engine..S. the wiring and alarms work correctly to locate and repair parts as needed. pint) of oil to lower the oil pressure. NOTICE A mechanic with training in governor adjustments is the ONLY one that should perform the following procedure. and the shutoff control group for defects. https://127. This will actuate the low oil pressure protection circuit and cause engine shutdown through the fuel shutoff actuator or activate the low oil pressure. when a low oil pressure fault is simulated. FORM NO.0. make sure the pressure switch on the control valve group. All of the above tests are performed at low idle. Make repairs or replacements of parts as needed. if so equipped. Also.jsp?returnurl=/sisweb/sisw..53)/Basic Search Page 9 of 18 Place the end of the hose in a bucket or other container and open the valve to drain approximately one -half liter (one U. Check and make sure the engine fuel settings are correct. Successful shutdowns and alarms at low idle indicate correct operation. check the actuator. Start the engine and operate it at low idle. it is not necessary to perform the tests at high idle.1:442/sisweb/sisweb/techdoc/techdoc_print_page. 4/6/2015 . See FUEL SETTING CHECK in the Engine TESTING AND ADJUSTING section of this Service Manual. Therefore. SEHS7466 for the complete specifications and test bench procedures to use. If th fuel shutoff actuator is not activated by this test. If the alarms fail to activate. NOTE: The fuel shutoff actuator will not be activated in a protective system that gives overspeed protection only. see CATERPILLAR FUEL INJECTION TEST BENCH BOOK. oil lines or electrical connections. high coolant temperature alarms.3512 Generator Set Engine 67Z00772-UP(SEBP2640 .0. 2. The air inlet shutoff should not be activated by this test. check the capabilities of driven equipment to make sure damage will not occur if run at overspeed. Severe engine damage could occur if this procedure is not followed. 1. Shutoff Speed Setting Adjustment NOTE: When major disassembly or adjustment of the shutoff control group is needed. Remove the hose assembly. Connect the oil supply to the thermostatic pilot valve.

Also. 7. 6.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . 2. Remove seal and wire from the bolts and remove the cover from over the high idle adjustment screw on the Caterpillar 3161 Governor. Pull emergency manual shutoff knob (1). the driven equipment must be disconnected from the engine during this test. or the seal wire from high idle screw lock nut on Woodward UG-8L Governor. the start-up override must https://127. this is 2124 ± 25 rpm for an engine rated at 1800 rpm. The air inlet shutoff must close and the fuel must be shut off through the governor and fuel control linkage at 18% ± 25 rpm above full load rpm. the air inlet shutoff valve must be opened. 3. Overspeed setting adjustment bolt. Turn the governor high idle adjustment screw slowly to increase engine rpm.0. NOTICE After the hydramechanical protective system has been activated. check for correct operation of the hydramechanical protective system. can be damaged if operated at 18% above full load speed. Before any adjustment to the shutoff control overspeed setting is made. NOTE: Some types of engine driven equipment. For example.jsp?returnurl=/sisweb/sisw. If this cannot be done. Also. 5. 4/6/2015 . NOTICE After the emergency manual shutoff has been operated. Start the engine again and operate it at high idle with no load. such as generators.1:442/sisweb/sisweb/techdoc/techdoc_print_page.0. adjustment of the shutoff control group can be made on the CATERPILLAR FUEL INJECTION TEST BENCH. See Form No. the start-up override must be operated to release hydraulic pressure from the fuel shutoff actuator before the engine can be started again. 4. Successful shutdown of intake air and fuel indicate correct operation. SEHS7466 for the complete test bench procedures. the air inlet shutoff valve must be opened. pumps or compressors. Emergency manual shutoff. If so.. Connect a tachometer of known accuracy to the engine.53)/Basic Search Page 10 of 18 SHUTOFF CONTROL GROUP 1..

9. Install the seals and lockwires for the shutoff control group and the governor high idle adjustment screw. turn overspeed adjusting bolt (2) clockwise to increase the shutoff control group overspeed setting. 4/6/2015 .0. Again. High idle adjustment screw. https://127..0.53)/Basic Search Page 11 of 18 be operated to release hydraulic pressure from the fuel shutoff actuator before the engine can be started again. ADJUSTMENT OF HIGH IDLE ON 3161 GOVERNOR NOTE: If engine shutdown occurs before 18% ± 25 rpm of full load rpm. If engine shutdown does not occur at 18% ± 25 rpm above full load rpm. decrease the engine rpm and remove the seal and lockwire and turn overspeed adjusting bolt (2) one turn counterclockwise. see the FUEL SETTING AND RELATED INFORMATION FICHE for the correct specifications to use. If engine shutdown still does not occur. slowly increase the engine rpm to check for engine shutdown at 18% ± 25 rpm above full load rpm. this is 2174 rpm for an engine rated at 1800 rpm. Repeat the above procedure until engine shutdown occurs at the correct rpm. If the Engine Information Plate is missing.jsp?returnurl=/sisweb/sisw.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . UG-8L GOVERNOR 3. 10.. 11. slowly increase engine rpm 50 rpm more.1:442/sisweb/sisweb/techdoc/techdoc_print_page. 8. Adjust engine high idle to the specifications shown on the Engine Information Plate which is attached to one of the right side camshaft inspection covers. For example.

3512 Generator Set Engine 67Z00772-UP(SEBP2640 .53)/Basic Search Page 12 of 18 Hydramechanical Protective System Wiring Diagrams ALT ALTERNATOR AMM AMMETER ASOS AIR SHUTOFF SOLENOID ASSV AIR START SOLENOID VALVE B- BATTERY NEGATIVE B+ BATTERY POSITIVE BATT BATTERY CB CIRCUIT BREAKER EGA ELECTRIC GOVERNOR ACTUATOR EGC ELECTRIC GOVERNOR CONTROL ENCL ENCLOSER FSOS FUEL SHUTOFF SOLENOID HM HOUR METER HMMPU HOUR METER MAGNETIC PICK-UP HMOBSV HYDRAMECHANICAL OIL BYPASS SOLENOID VALVE HMOPS HYDRAMECHANICAL OIL PRESSURE SWITCH HMRSSV HYDRAMECHANICAL REMOTE SHUTOFF SOLENOID VALVE HWTAS HIGH WATER TEMPERATURE ALARM SWITCH LOPAS LOW OIL PRESSURE ALARM SWITCH LWTAS LOW WATER TEMPERATURE ALARM SWITCH MGOPG MARINE GEAR OIL PRESSURE GAGE MGOPSU MARINE GEAR OIL PRESSURE SENDING UNIT MGOTAS MARINE GEAR OIL TEMPERATURE ALARM SWITCH https://127.0..0. 4/6/2015 ..jsp?returnurl=/sisweb/sisw.1:442/sisweb/sisweb/techdoc/techdoc_print_page.

.jsp?returnurl=/sisweb/sisw.53)/Basic Search Page 13 of 18 MPU MAGNETIC PICK-UP OPG OIL PRESSURE GAGE OPS OIL PRESSURE SWITCH OPSU OIL PRESSURE SENDING UNIT PB PUSH BUTTON PP PRELUBE PUMP PPMS PRELUBE PUMP MAGNETIC SWITCH PPPS PRELUBE PUMP PRESSURE SWITCH RNS REMOTE NORMAL SHUTOFF SWITCH SM STARTER MOTOR SMMS STARTER MOTOR MAGNETIC SWITCH TM TACHOMETER TMMPU TACHOMETER MAGNETIC PICK-UP TS TERMINAL STRIP WTG WATER TEMPERATURE GAGE WTS WATER TEMPERATURE SWITCH WTSU WATER TEMPERATURE SENDING UNIT B BLACK BR BROWN B/W BLACK WITH WHITE STRIPE CU COPPER (BARE WIRE) DK BL DARK BLUE DK GR DARK GREEN GR GREEN LT BL LIGHT BLUE https://127.0..3512 Generator Set Engine 67Z00772-UP(SEBP2640 . 4/6/2015 .0.1:442/sisweb/sisweb/techdoc/techdoc_print_page.

0.1:442/sisweb/sisweb/techdoc/techdoc_print_page..jsp?returnurl=/sisweb/sisw.0.53)/Basic Search Page 14 of 18 O ORANGE O/B ORANGE WITH BLACK STRIPE P/B PINK WITH BLACK STRIPE PU/W PURPLE WITH WHITE STRIPE R RED W WHITE W/O WHITE WITH ORANGE STRIPE W/R WHITE WITH RED STRIPE Y YELLOW Y/BR YELLOW WITH BROWN STRIPE https://127. 4/6/2015 .3512 Generator Set Engine 67Z00772-UP(SEBP2640 ..

53)/Basic Search Page 15 of 18 3500 ENGINE WIRING DIAGRAM (REF. 4/6/2015 .1:442/sisweb/sisweb/techdoc/techdoc_print_page.0.jsp?returnurl=/sisweb/sisw.3512 Generator Set Engine 67Z00772-UP(SEBP2640 ..0.. 5N8944) (Earlier Systems With 5N9310 Pressure Switch Assembly) https://127.

53)/Basic Search Page 16 of 18 3500 ENGINE WIRING DIAGRAM (REF.jsp?returnurl=/sisweb/sisw.0..3512 Generator Set Engine 67Z00772-UP(SEBP2640 ..1:442/sisweb/sisweb/techdoc/techdoc_print_page. 5N8944) (Later Systems With 4W2188 Pressure Switch Assembly) https://127.0. 4/6/2015 .

53)/Basic Search Page 17 of 18 CUSTOMER WIRING WITH HYDRA-MECHANICAL SHUT-OFF GROUPS NOTE A: Magnetic pick-up and oil pressure switch to be wired to electric governor control (Woodward 2301) with a two conducter shielded cable (Belden Corp.1:442/sisweb/sisweb/techdoc/techdoc_print_page..jsp?returnurl=/sisweb/sisw. Shields are to be grounded at electric governor control grounding stud.0.3512 Generator Set Engine 67Z00772-UP(SEBP2640 . Each shield should not have more than one ground connection. 4/6/2015 ..0. type 8780 or equivalent). NOTE B: Woodward 2301 Electric Governor Control terminal identification chart: https://127.

Mon Apr 6 23:45:02 UTC+0400 2015 All Rights Reserved. Copyright 1993 . https://127.0.. Private Network For SIS Licensees.1:442/sisweb/sisweb/techdoc/techdoc_print_page.0..53)/Basic Search Page 18 of 18 NOTE C: Caterpillar alarm and prealarm contacts are rated for a maximum of 3 amps inductive at the charging system voltage. 4/6/2015 .3512 Generator Set Engine 67Z00772-UP(SEBP2640 .2015 Caterpillar Inc.jsp?returnurl=/sisweb/sisw.