18

Product Information Section

Model Views

Product Information
4
Section

~
Model Views
I

I i01228039

Model View Illustrations

I SMCS Code: 1000

The illustrations show various typical features of

I 3500 Series Engines. The illustrations do not show
I
all of the options that are available.

II

I
I

I I
II
II .

I ;

Illustration 14 900657011

(1) Air shutoff (7) Instrument panel (13) Exhaust

(2) Governor (8) Crankcase breather (14) Oil drain
(3) Fuel priming pump (9) Oil cooler (15) Manual shutoff lever
(4) Junction box (10) Air cleaner (16) Oil filler
(5) Fuel filter (11) Air cleaner service indicator (17) Oil level gauge (dipstick)
(6) Oil filter (12) Jacket water pump

- I
 19
Product Information Section
Model Views

Illustration 15 gO0657276

(1) Generator (5) Oil level gauge (dipstick) (9) Fuel filter
(2) Air cleaner (6) Oil cooler (10) Cooling system filler
(3) Exhaust (7) Crankcase breather (11) Jacket water pump
(4)Oil filler (8) Oil filter

, Engine Description
SMCSCode: 1000
i01228233

The 3500 Series Engines were developed in order

to provide power for industrial applications and
generator set applications. The diesel engines are
rated from 900 rpm to 1800 rpm. The engines can
be equipped with either separate circuit aftercooling
or jacket water aftercooling.

}
 20
Product Information Section
II Model Views

3500 Engine Specifications

Table 1 ~
3500 Engine Specifications
Item 3508 Engine 3512 Engine 3516 Engine
Cylinders and arrangement 60 degree Vee 8 60 degree Vee 12 60 degree Vee 16
Bore 170 mm (6.7 inch)
Stroke 190 mm (7.5 inch)
Type 4 stroke cycle
Compression ratio 13:1
Aspiration Turbocharged
Method of cooling the turbocharged air Jacket water aftercooling
Separate circuit aftercooling (option)
Displacement per cylinder 4.3 L (263 cu in)
Total displacement 34.5 L (2105 cu in) 51.8 L (3158 cu in) 69.1 L (4210 cu in)
Rotation (flywheel end) Counterclockwise rotation is standard.

Clockwise rotation is optional.

Fuel See this Operation and Maintenance Manual, "Fuel Recommendations"
(Maintenance Section).
Method of fuel injection Electronic unit injectors
Method of starting Air starting motor
Electric starting motor
~
Maximum allowable back pressure 6.7 kPa (27 inch of H2O)
Maximum inlet air Restriction 6.2 kPa (25 inches of H2O)
Inlet valve lash 0.50 mm (0.020 inch)
Exhaust valve lash 01.00 mm (0.039 inch)

3500 Engine Design

12-10-8-6-4-2 -
(be" (9f\r6~ (o~ r6~ t6e\ ./

8-6-4-2
r6~r68\(O8\ (6~
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~~~~~~
~~~~

c
~t8O\!8O\~~r8O\
~~~P)~-~~~~~~~9)
11-9-7-5-3-1 '

~~fiO\~
~_O)~-q)
~7-5-3-1 \~gJ ~O) 0---0 CD--
0--0 CD-- Illustration 17 gO0308167
Illustration 16 gO0308097 3512 Engine design
3508 Engine design (A) Inlet valve
(8) Exhaust valve
(A) Inlet valve
(C) Flywheel ~4
(8) Exhaust valve
(C) Flywheel
 ~

25
Operation Section
Gauges and Indicators

~, , Gauges and Indicators

101228302 @
Engine Oil Pressure - This gauge
indicates the pressure of the engine oil.
This pressure will be highest after a cold
engine is started. The pressure will decrease as
Gauges and Indicators the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure
SMCS Code: 7450 will stabilize when the engine rpm and temperature
are stable.
Gauges provide indications of engine performance.
Ensurethat the gauges are in good working order.
If the load is stabilized but the engine oil pressure
Compare the gauge readings to the data that
fluctuates, perform the following procedure:
were recorded during the engine commissioning.
Determinethe normal operating range by observing 1. Remove the load.
the gauges over a period of time.
2. Reduce the engine speed to low idle rpm.
Noticeablechanges in gauge readings can indicate
,potentialgauge or engine problems. Problems may 3. Check the oil level. Maintain the oil level between
also be indicated by gauge readings that change the "ADD" and "FULL" marks on the "LOW IDLE"
even if the readings are within specifications.
side of the oil level gauge (dipstick).
Determineand correct the cause of any significant
change in the readings. Consult your Caterpillar 4. Inspect the lubrication system for leaks.
dealer for assistance.
Jacket Water Temperature - This gauge
@ indicates the temperature of the engine

.oe~
coolant at the outlet for the jacket water.
The temperature may vary according to the load.
Do not allow the temperature to exceed the boiling

} temperature of the pressurized cooling system.

o~ee~"!
e G::::::J ~ oc:=J ~ e
The sensor for jacket water temperature must be
fully submerged in order to detect the temperature
correctly. If the engine is operating above the

O~~~
e" '~~OC=:Je
normal temperature range, perform the following
procedure:

1. Reduce the load and/or the engine rpm.

e
0000
. . e
2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down

immediately or if the engine can be cooled by
reducing the load and/or rpm.
Illustration 24 gO0665930
System Voltage - This gauge indicates
Typical instrument panel

Yourengine may not have the same gauges or all of

@ the amount of charge or discharge in the
battery charging circuit.
the gauges that are described. For more information
about the gauge paCkage, refer to the literature that Fuel Pressure - This gauge indicates fuel
is provided by the OEM of the package. pressure to the fuel injection pump from
@ the fuel filter. A decrease in fuel pressure
NOTICE
usually indicates a dirty fuel filter or a plugged -
fuel filter. As the fuel filter becomes plugged, there
If no oil pressure is indicated, STOP the engine. The will be a noticeable reduction in the engine's
engine will be damaged from operating without oil performance.
pressure.
}
rfII"""'""
26
Operation Section
III Gauges and Indicators

~ Exhaust Temperature - This gauge

indicates the exhaust temperature at the
exhaust inlet to the turbochargers. The
two exhaust temperatures may vary slightly. This
cw
Inlet Air Restriction (Air Cleaner Differential
Pressure) - This gauge indicates the
difference in air pressure between the
inlet side and the engine side of the air filter
may be due to variation of the sensitivity of the two element. The air cleaner differential pressure is
thermocouples. measured from the turbocharger air inlet. As the air
, filter element becomes plugged. the difference in
The exhaust temperatures at the exhaust inlets to pressure between the two sides of the air cleaner
I the turbochargers provide a good indication of
element will increase.
engine performance. For engines with dry exhaust
manifolds, the temperatures are representative of Fuel Filter Differential Pressure

,
the actual temperatures of the valves. Monitor this
parameter frequently. @ (Restriction) - This gauge indicates the
difference in fuel pressure between the
inlet side and the outlet side of the fuel filter. As the
~ I Pyrometer - The pyrometer displays the
temperature of the exhaust for the exhaust port of
fuel filter element becomes plugged, the difference
in pressure between the two sides of the fuel filter
each individual cylinder and for the exhaust stacks. increases.

, The exhaust port temperatures are a good indication Oil Filter Differential Pressure
of the condition of the cylinders. The displayed
temperature is slightly lower than the actual
temperature in the cylinder. This is because of the
@ (Restriction) - This gauge indicates the
difference in pressure between the inlet
I! side and the outlet side of the engine oil filters. As
constant flow of exhaust gas past the thermocouple. the oil filter elements become plugged, oil filter
For engines with dry exhaust manifolds, the exhaust differential pressure will increase.
port temperatures are usually lower than the
temperatures at the inlets to the turbochargers. I
Inlet Manifold Air Pressure (Boost
Guttering of valves can be diagnosed with the
exhaust port temperature. The ability to diagnose
@ Pressure) - This gauge indicates the air
pressure (turbocharger boost pressure) ~
this problem may help to prevent additional damage in the air plenum (air inlet manifold) after the
aftercooler.
that could cause further downtime with a higher
repair cost.
Aftercooler Coolant Temperature - This
During normal operation at rated load, the
temperature of the hottest cylinder and the coldest
cylinder may differ by 38 to 52 °C (100 to 125 OF).
@ gauge indicates the temperature of the
coolant in the aftercooler system. Two
methods of aftercooling are available. The separate
circuit aftercooler operates at a temperature that is
The exhaust stack temperature is not a suitable lower than the jacket water aftercooler. Determine
substitute for the exhaust temperature at the inlet to the method of aftercooling in order to verify the
the turbocharger. However, a comparison of the two gauge reading. "
temperatures can help to assess the performance
of the turbocharger. Inlet Manifold Air Temperature - This
NOTICE @ gauge indicates the inlet manifold air
temperature to the cylinders. The sensor
To help prevent engine damage, never exceed the for inlet manifold air temperature is located after
high idle rpm. An overspeed can result in serious dam- the aftercooler.
age to the engine. The engine can be operated at high
idle without damage, but the engine should never be Engine Oil Temperature - This gauge
allowed to exceed the high idle rpm.
@ indicates the engine oil temperature after
the oil has passed through the oil cooler.
Tachometer - The tachometer displays the engine
rpm. The high idle rpm and the rated rpm are
printed on the engine Information Plate.
Hourmeter - This meter indicates the
cw hours of engine operation.
 43
Operation Section
Engine Operation

Engine Operation iOO165110

~I) Fuel Conservation Practices

iOO817012
SMCS Code: 1000; 1250
Engine Operation
The efficiency of the engine can affect the fuel
SMCS Code: 1000 economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency
Proper operation and maintenance are key factors in all applications. Follow the recommended
in attaining the maximum service life and economy procedures in order to attain optimum performance
for the engine. Follow the instructions in this for the life of the engine.
Operation and Maintenance Manual in order to
minimize operating costs and maximize the service . Avoid spilling fuel.
life of the engine.
Fuel expands when the fuel is warmed up. The fuel
Observe the gauges frequently while the engine is may overflow from the fuel tank. Inspect fuel lines
operating. Record the data from the gauges in a log for leaks. Repair the fuel lines, as needed.
regularly. Compare the data to the specifications
for normal engine operation. Comparing the data . Be aware of the properties of the different fuels.
over time will help to detect changes in engine Use only the recommended fuels.
performance.
. Avoid unnecessary idling.
Investigate any significant change in the gauge
readings. Monitor the engine operation and take Shut off the engine rather than idle for long periods
action when discrepancies are found. of time.

Operating the Engine and the

. Observe the service indicator frequently. Keep
the air cleaner elements clean. .
11; Driven Equipment
. Ensure that the turbochargers are operating
Check the gauges and the driven equipment correctly so that the proper air/fuel ratio is
frequently while the engine is operating under a maintained. Clean exhaust indicates proper
load. The engine can be operated for extended functioning.
periods of time at full load.
. Maintain a good electrical system.
Partial Load Operation One defective battery cell will overwork the
Extended operation at low idle or at reduced load alternator. This will consume excess power and
excess fuel.
may cause increased oil consumption and carbon
buildup in the cylinders. Carbon buildup results in a "
loss of power and/or poor performance. . Ensure that the belts are properly adjusted. The
belts should be in good condition.
When possible, apply a full load at least on an . Ensure that all of the connections of the hoses
hourly basis. This will burn excess carbon from the
cylinders. are tight. The connections should not leak.

Partial Load Operation In Cold Weather

. Ensure that the driven equipment is in good
working order.
Operation of the jacket water heater is . Cold engines consume excess fuel. Utilize heat
recommended if the engine is operating at a low from the jacket water system and the exhaust
load in extreme cold.
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators.
All of these items will help maintain operating
"D temperatures.
 45
Operation Section
Engine Stopping

To reset the air shutoff, turn the reset knob to

Engine Stopping
~II) the "OPEN" position. Ensure that both of the air
shutoffs are reset.
i01232206

Air Shutoffs
Emergency Stopping
SMCS Code: 1000; 7418

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

Ensurethat any components for the external system

that support the engine operation are secured after
the engine is stopped.

Emergency Stop Button gO0429164

Illustration 36
Air shutoffs

. The air shutoffs are activated by oil pressure

~QEMERGENCY STOP when energy to a solenoid is interrupted. Each air
shutoff uses a plate that mtates on a shaft in order
to shut off inlet air to the aftercooler. The engine
stops because of the restricted air supply to the
) combustion chamber. The air shutoffs will actuate
for the following conditions:

Note: A switch may be supplied by the customer in

order to activate the air shutoffs.

Illustration 35 gO0104303
. The emergency stop button is pressed.

Typical emergency stop button . The air shutoff is activated.

The emergency stop button is in the OUT position . An overspeed shutdown occurs.
for normal engine operation. For an emergency
stop, push the emergency stop button. This shuts The air shutoffs must be manually reset before the
off the fuel to the engine. This also activates the engine is restarted. To reset the air shutoffs, turn the
air shutoff (if equipped). reset knobs to the "OPEN" position. Ensure that
the air shutoff is reset. If the engine has two air
NOTICE shutoffs, ensure that both of the air shutoffs are
reset.
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.

The engine control switch, the emergency stop

button, and the air shutoff must be reset before the
engine can be restarted. Reset the engine control
switch before resetting the emergency stop button.

To reset the engine control switch, turn the switch to

the "OFF/RESET"position.
Dll) To reset the emergency stop button, turn the button
clockwise. The spring-loaded button will return to
the OUT position. The button may also be pulled
to the OUT position.
 46
Operation Section
III Engine Stopping

Fuel Shutoff a. Disengage the clutch (if equipped).

~
b. Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.

2. Reduce the engine rpm to low idle. Operate the

engine at low idle rpm for a cooldown period
before stopping the engine.

a. If the cooldown feature is utilized,

turn the engine control switch to the
"COOLDOWN/STOP" position.

The engine will operate for a programmed

gO0429138
period of time. After the cooldown, the timer
Illustration 37
will activate the fuel shutoff. The control panel
Fuel shutoff lever will remain powered until the engine control
switch is turned to the "OFF/RESET"position.
A fuel shutoff lever is located on the right side of
the engine near the front of the engine. To shut off b. If the engine has been operated at a low
the fuel, move the lever. load, operate the engine at low idle for
approximately 30 seconds before stopping
i01232212
the engine.

Manual Stop Procedure c. If the engine has been operated at a high

load, operate the engine at low idle for three
SMCS Code: 1000; 7418 to five minutes before stopping the engine.

NOTICE 3. Turn the engine control switch to the stop ~

position.
Stopping the engine immediately after it has been
working under load can result in overheating and ac- The engine will coast to a stop. Ensure that any
celerated wear of engine components. system that provides external support to the engine
operation is secured after the engine is stopped.
Excessive temperatures in the turbocharger center-
housing will cause oil coking problems.
Generator Set Engines
Allow the engine to gradually cool before stopping the
engine 1. Open the main circuit breaker in order to
disengage the driven equipment.
There may be several methods for shutting off the 2. Operate the engine for a cool down period before
engine. Make sure that the shutoff procedures are stopping the engine.
understood. Use the following general guidelines
for stopping the engine. a. If the cooldown feature is utilized,
turn the engine control switch to the
Automatic Stopping "COOLDOWN/STOP" position.

Automatic stopping will occur when the engine is The engine will operate for a programmed
operating in the automatic mode and the remote period of time. After the cooldown, the timer
start/stop initiate contact opens. If the cooldown will activate the fuel shutoff. The engine
feature is utilized, the engine will operate for a control module will remain powered until
programmed period of time before the engine stops. the engine control switch is turned to the
Otherwise, the engine will immediately shut off. "OFF/RESET" position.

b. If the cooldown feature is not utilized, operate

Industrial Engines the engine at high idle for approximately five
minutes. Then stop the engine. 4
1. Disengage the driven equipment. Unload the
compressor or pump.

I
,..
74
Maintenance Section
Refill Capacities

Refi II Capacities Cooling System

\
To properly maintain the cooling system, the total
101228526 capacity of the cooling system must be determined.
The capacity of the total cooling system will vary
Refill Capacities between individual installations. The external system
can include the following components: expansion
SMCS Code: 1000; 1348; 1395; 7560 tank, radiator, and piping. Refer to the specifications
that are provided by the locomotive OEM. Record
Lubrication System the total cooling system capacity in the appropriate
Table.
The capacity of the lubrication system includes the
For the recommended coolant, see this
capacity of the oil filters that are installed at the
factory. Operation and Maintenance Manual, "Coolant
Recommendations" (Maintenance Section).
Auxiliary oil filter systems (if equipped) will require
additional oil. Refer to the specifications that are Engines with Separate Circuit
provided by the OEM of the auxiliary oil filter system. Aftercooling
For the recommended oil, see this Operation 3508 Engine
and Maintenance Manual, "Engine Oil" topic
(Maintenance Section). Table 33

Approximate Refill Capacities for the 3508 Engine

3508 Engine Cooling System with Separate Circuit Aftercooling
Table 30 Compartment or System Liters US Gallons

ApproximateRefillCapacities for 3508 Engine Jacket water system 86.6 L 21.8 US gal
Lubrication Systems 20.1 L
Separate circuit aftercooler 5.3 US gal
Compartment or System Liters US Gallons
External system
Shallow sump 104 L 27 US gal
Total cooling system
Standard sump 227 L 60 US gal
Deep sump 443 L 117 US gal 3512 Engine
Table34
3512 Engine Approximate Refill Capacities for the 3512 Engine
Table 31 Cooling System with Separate Circuit Aftercooling
Compartment or System Liters US Gallons
ApproximateRefillCapacities for 3512 Engine
Lubrication Systems Jacket water system 134.2 L 35.4 US gal
Compartment or System Liters US Gallons Separate circuit aftercooler 22.8 L 6 US gal
Shallow sump 152 L 40 US gal External system
Standard sump 318 L 84 US gal Total cooling system
Deep sump 625 L 165 US gal

3516 Engine
Table 32

Approximate Refill Capacities for 3516 Engine

Lubrication Systems
Compartment or System Liters US Gallons
Shallow sump 204 L 53 US gal
Standard sump 405 L 107 US gal
Deep sump 807 L 213 US gal
 75
Maintenance Section
Refill Capacities

~ 3516 Engine
Table35
ApproximateRefill Capacities for the 3516 Engine
CoolingSystem with Separate Circuit Aftercooling
Compartmentor System Liters US Gallons

Jacketwater system 205.4 L 54.2 US gal

Separatecircuit aftercooler 28 L 7.4 US gal
Externalsystem
Totalcooling system

Engines with Jacket Water Aftercooling

3508 Engine I~
Table36 I
Approximate Refill Capacities for the 3508 Engine
I I

Cooling System with Jacket Water Aftercooling

Compartment or System Liters US Gallons

Engine only 103 L 27.1 US gal

External system
Totalcooling system

II~ 3512 Engine

Table37

Approximate Refill Capacities for the 3512 Engine

Cooling System with Jacket Water Aftercooling
Compartment or System Liters US Gallons

Engine only 160 L 42.3 US gal

External system
Total cooling system

35168 Engine

Table 38

Approximate Refill Capacities for the 3516 Engine

Cooling System with Jacket Water Aftercooling
Compartment or System Liters US Gallons

Engine only 235 L 62 US gal

External system
Total cooling system

",
 77
Maintenance Section
r
: Maintenance Interval Schedule

Initial 250 Service Hours (or at first oil

change)
~ Maintenance Interval Sche~~~; Engine Valve Lash - Inspect/Adjust 107
SMCS Code: 1000; 7500 Fuel Injector - Inspect/Adjust 108
Magnetic Pickups - Clean/Inspect 114
Before performing any operation or maintenance
procedures, ensure that the Safety Information, Every 250 Service Hours
warnings, and instructions are read and
understood. Alternator and Fan Belts - Inspect/Adjust/
Replace 83
To determine the maintenance intervals, use fuel Battery Electrolyte Level - Check 85
consumption, service hours or calendar time, Cooling System Supplemental Coolant Additive
which ever occurs first. Experience has shown (SCA) - Test/Add 91
that maintenance intervals are most accurately Engine Oil Sample - Obtain 101
scheduled on the basis of fuel consumption. Engine Oil and Filter - Change 102
For information on service hours and fuel Fan Drive Bearing - Lubricate 107
consumption, see this Operation and Maintenance Hoses and Clamps - Inspect/Replace 112
Manual, "Maintenance Recommendations" topic Radiator - Clean 121
(Maintenance Section).
Every 500 Service Hours
Before each consecutive interval is performed, all
of the maintenance requirements from the previous Engine Oil and Filter - Change 102
interval must be performed.
Every 1000 Service Hours
Note: For information on generator maintenance,
Cooling System Coolant Analysis (Level II) -
see the Operation and Maintenance Manual for the Obtain 90
generator.
Engine - Clean 93
Note: For engines with a shallow oil sump, change Engine Crankcase Breather - Clean 99
~
the engine oil and oil filters after 500 hours of Engine Oil and Filter - Change 102
Engine Protective Devices - Check 107
operation. For engines with a standard oil sump,
change the engine oil and oil filters after 500 hours Fuel System Primary Filter - Clean/Inspect/
Replace 109
of operation. For engines with a deep oil sump,
Fuel System Secondary Filter - Replace 109
change the engine oil and oil filters after 1000 hours
of operation.
Every 2000 Service Hours
When Required Actuator Control Linkage - Lubricate 81
Maintenance Recommendations 79 Air Starting Motor Lubricator Bowl - Clean ' 82
Crankshaft Vibration Damper - Inspect 93
Batteries - Replace 84
Engine Mounts - Check 100
Engine Air Cleaner Element (Dual Element) -
Engine Valve Lash - Inspect/Adjust 107
Clean/Replace 94
Fuel Injector - Inspect/Adjust 108
Engine Air Cleaner Element (Single Element) -
Magnetic Pickups - Clean/Inspect 114
Inspect/Replace """"""""""""""""""""""""" 97
Fuel System - Prime 108
Zinc Rods - Inspect/Replace 126 Every 3000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change 86
Daily Cooling System Coolant Extender (ELC) - Add 90
Air Starting Motor Lubricator Oil Level - Check 82
Air Tank Moisture and Sediment - Drain 83 Every 6000 Service Hours or 6 Years
Cooling System Coolant Level - Check 90 Alternator - Inspect """"""""""""""""""""""'" 83
Engine Air Cleaner Service Indicator - Inspect 98 Cooling System Coolant (ELC) - Change 88
Engine Air Precleaner - Clean 99 Cooling System Water Temperature Regulator -
Engine Oil Filter Differential Pressure - Check ... 100 Replace 92
Engine Oil Level- Check 101 Starting Motor - Inspect 123
Fuel System Fuel Filter Differential Pressure - Turbocharger - Inspect 123
~ Check 108
Water Pump - Inspect 126
Fuel Tank Water and Sediment - Drain 112
Instrument Panel - Inspect 113
Walk-Around Inspection 124

"".
I --
"..- 78
Maintenance Section
Maintenance Interval Schedule
1\ I

Between 7500 and 11 000 Service Hours

Overhaul (Top End) 116
Overhaul Considerations 118

Between 15 000 and 22 000 Service Hours

Overhaul (Top End) 116

Overhaul Considerations 118

Between 22 500 and 33 000 Service Hours

Overhaul (Major) 114

Overhaul Considerations 118
 79
Maintenance Section
Maintenance Recommendations

101228599
,'\
Maintenance
Recommendations
SMCS Code: 1000

Service Hours and Fuel

Consumption
Experience has shown that maintenance intervals
are most accurately based on fuel consumption.
Fuel consumption corresponds more accurately to
the engine load. Tables 39, 40, and 41 list average
ranges of fuel consumption and service hours for
a load factor of approximately 60 percent. Use the
range of fuel consumption only as a guideline.
Table39

Maintenance Interval Schedule

Service Hours and Fuel Consumption for 3508 Engines (1)

Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 22 700 L (6000 US gal) 27 700 L (7200 US gal) 32 000 L (8500 US gal)
500 Service Hours 45400 L (12,000 US gal) 54400 L (14,400 US gal) 64000 L (17,000 US gal)
1000 Service Hours 89 OOOL(23,500 US gal) 109 000 L (28,800 US gal) 128 000 L (34,000 US gal)
) 2000 Service Hours 178000 L (47,000 US gal) 218000 L (57,600 US gal) 257 000 L (68,000 US gal)
3000 Service Hours 267 500 L (70,500 US gal) 327 500 L (84,000 US gal) 386500 L (102,000 US gal)
6000 Service Hours 535 000 L (141,000 US gal) 636 000 L (168,000 US gal) 774000 L (204,000 US gal)
Top End Overhaul 11 000 Service Hours 9000 Service Hours 7500 Service Hours
976 000 L (257,500 US gal)
Second Top End 22 000 Service Hours 18 000 Service Hours 15 000 Service Hours
Overhaul
1 952 000 L (515,000 US gal)
Major Overhaul 33 000 Service Hours 27 000 Service Hours 22 500 Service Hours
2 928 000 L (772,500 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
JIIIIII
80
Maintenance Section
Maintenance Recommendations
III
Table 40
Maintenance Interval Schedule ~
Service Hours and Fuel Consumption for 3512 Engines (1)
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 33 400 L (8800 US gal) 41000 L (10,800 US gal) 48500 L (12,800 US gal)
500 Service Hours 66 800 L (17,600 US gal) 82 000 L (21,600 US gal) 97 000 L (25,600 US gal)
1000 Service Hours 133500 L (35,000 US gal) 164000 L (43,200 US gal) 194000 L (51,200 US gal)
2000 Service Hours 267 000 L (70,000 US gal) 328 000 L (86,400 US gal) 388 000 L (102,400 US gal)
3000 Service Hours 398000 L (105,000 US gal) 491 000 L (129,600 US gal) 582000 L (153,600 US gal)
6000 Service Hours 796 000 L (210,000 US gal) 982 000 L (259,200 US gal) 1 164 000 L (307,200 US gal)
Top End Overhaul 11 000 Service Hours 9000 Service Hours 7500 Service Hours

1 460 000 L (385,000 US gal)

Second Top End 22 000 Service Hours 18 000 Service Hours 15 000 Service Hours
Overhaul
2 920 000 L (770,000 US gal)
Major Overhaul 33 000 Service Hours 27 000 Service Hours 22 500 Service Hours

4380000 L (1,155,000 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.

Table 41
Maintenance Interval Schedule
I
Service Hours and Fuel Consumption for 3516 Engines (1)

I~
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 44000 L (11,600 US gal) 53000 L (14,000 US gal) 64500 L (17,000 US gal)
500 Service Hours 88 000 L (23,200 US gal) 106 000 L (28,000 US gal) 129 000 L (34,000 US gal)
1000 Service Hours 176000 L (46,500 US gal) 212000 L (56,000 US gal) 258 000 L (68,000 US gal)
2000 Service Hours 352 000 L (93,000 US gal) 424000 L (112,000 US gal) 516000 L (136,000 US gal)
3000 Service Hours 528700 L (139,500 US gal) 636700 L (168,100 US gal) 773 000 L (204,000 US gal)
6000 Service Hours 1 056 000 L (279,000 US gal) 1 272 000 L (336,000 US gal) 1 548 000 L (408,000 US gal)
Top End Overhaul 11 000 Service Hours 9000 Service Hours 7500 Service Hours

1 942 000 L (512,500 US gal)

Second Top End 22 000 Service Hours 18 000 Service Hours 15 000 Service Hours
Overhaul
3 884 000 L (1,025,000 US gal)
Major Overhaul 33 000 Service Hours 27 000 Service Hours 22 500 Service Hours
5 826 000 L (1,537,500 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.

Severe Operation . Fuel consumption

Severe operation is the use of an engine that . Fuel quality
exceeds current published standards for that
engine. Caterpillar maintains standards for the . Altitude
following engine parameters:
. Maintenance intervals
. Horsepower
. Selection of oil
. Range of rpm

I
.........-

81
Maintenance Section
Actuator Control Linkage - Lubricate

. Minimum cool down periods after high load factor

~ . Selection of coolant operation
. Environmental qualities
. Operating the engine beyond the guidelines for
. Installation the engine rating
I
Referto the standards for your engine or consult . Operating the engine at loads that are greater I
your Caterpillar dealer in order to determine if your than the rated load
engine is operating within the defined parameters.
. Operating the engine at speeds that are greater ~

Severeoperation can accelerate component wear. than the rated speed

Enginesthat are operating under severe conditions
may need more frequent maintenance intervals for . Use of the engine for an application that is not I

the following reasons: approved

~

. Maximum reliability Improper Maintenance Practices

. Retention of full service life . Extension of maintenance intervals I

Because of individual applications, it is not possible . Not using recommended fuel, lubricants, and
I
to identify all of the factors which can contribute to coolant/antifreeze
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
iO0855723
specific engine.

The following factors can contribute to severe Actuator Control Linkage -

operation: environment, improper operating Lubricate
procedures, and improper maintenance practices.
SMCS Code: 1265-086
~ Environmental Factors "0

Extreme Ambient Temperatures

Extended operation in environments that are

extremely cold or hot can damage components.
Valve components can be damaged by carbon
buildup if the engine is frequently started and
stopped in very cold temperatures. Extremely hot
inlet air reduces the performance capabilities of
the engine.

Note: See this Operation and Maintenance Manual,

"Cold Weather Operation" topic (Operation Section),
or see Supplement, SEBU5898, "Cold Weather gO0426785
Illustration 43
Recommendations" .
(1) Grease Fitting
Cleanliness
Apply grease to the grease fittings (1).
Unless the equipment is cleaned regularly, extended
operation in a dirty environment and in a dusty Use a hand grease gun and lubricate the grease
environment can damage components. Built up fittings with MPGM.
mud, dirt, and dust can encase components. This
can make maintenance difficult. The buildup can Check the Linkage
contain corrosive chemicals. Corrosive chemicals
and salt can damage some components. Use the following procedure to check the linkage
for binding.
~
Improper Operating Procedures
1. Stop the engine.
. Extended operation at low idle
2. Move the linkage by hand.
...
82
Maintenance Section
II Air Starting Motor Lubricator Bowl - Clean

If the linkage binds. repair the linkage. iO0691572,Ii

For information on adjustment, removal. and Air Starting Motor Lubricator.

replacement. see the Service Manual. Consult your Oil Level - Check
Caterpillar dealer for assistance.
SMCS Code: 1451-535
iO0691569
NOTICE
Air Starting Motor Lubricator Never allow the lubricator bowl to become empty. The
Bowl - Clean air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
SMCS Code: 1451-070

1. Ensure that the air supply to the lubricator is OFF.

Illustration 45 gO0349048

(1) Dome
(2) Knob
gO0270335 (3) Sight gauge
Illustration 44
(4) Plug ~
(1) Plug
(2) Bowl
(3) Drain
1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator
bowl.
Note: Always dispose of fluids according to local
regulations.
2. Ensure that the air supply to the lubricator is OFF.
2. Open drain (3). Drain the oil into a suitable
container. Dispose of the used oil. 3. Remove plug (4). Pour oil into the lubricator bowl.
Use "1OW" oil for temperatures that are greater
3. Remove bowl (2). Clean the bowl with warm than O°C (32°F). Use air tool oil for temperatures
water. that are below O°C (32°F).

4. Dry the bowl. Inspect the bowl for cracks. If the 4. Install plug (4).
bowl is cracked, replace the damaged bowl with
a new bowl. Adjust the Lubricator
5. Install the bowl. Close drain (3). Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
6. Remove plug (1). Fill bowl (2) with oil. Use oil in proportion to variations of the air flow.
nondetergent "1OW" oil for temperatures that
are greater than O°C (32°F). Use air tool oil for 1. Ensure that the fuel supply to the engine is OFF.
temperatures that are below O°C (32°F). Install
oil filler plug (1). NOTICE
Do not crank the engine continuously for more than
7. If necessary. adjust the lubricator in order to
30 seconds. Allow the starting motor to cool for two
release two drops of oil per 30 seconds. For
minutes before cranking the engine again.
instructions, see this Operation and Maintenance
Manual. "Air Starting Motor lubricator Oil level -
Check" topic (Maintenance Section). 2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1).
 93
Maintenance Section
Crankshaft Vibration Damper - Inspect

A water temperature regulator that fails in the open Inspect the damper for evidence of dents, cracks,
position will cause the engine operating temperature and leaks of the fluid.
to be too low during partial load operation. Low
engine operating temperatures during partial loads If a fluid leak is found, determine the type of fluid.
could cause an excessive carbon buildup inside The fluid in the damper is silicone. Silicone has
the cylinders. This excessive carbon buildup could the following characteristics: transparent, viscous,
result in an accelerated wear of the piston rings and smooth, and difficult to remove from surfaces.
wear of the cylinder liner.
If the fluid leak is oil, inspect the crankshaft seals for
NOTICE leaks. If a leak is observed, replace all of the seals.
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe Inspect the damper and repair or replace the
engine damage. damper for any of the following reasons.

Caterpillar engines incorporate a shunt design cooling . The damper is dented, cracked, or leaking.
system and require operating the engine with a water
temperature regulator installed. . The paint on the damper is discolored from heat.
If the water temperature regulator is installed incor- . The engine has had a failure because of a broken
crankshaft.
rectly,the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that . An analysis of the oil has revealed that the front
the water temperature regulator vent hole is open. bearing of the crankshaft is badly worn.

Do not use liquid gasket material on the gasket or . There is a large amount of gear train wear that is
cylinder head surface. not caused by a lack of oil.

Removal and Installation

Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
consult your Caterpillar dealer. Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
replacement.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system
to a level that is below the water temperature iO1108937
regulator housing.
Engine - Clean
iO1064210 SMCS Code: 1000-070
Crankshaft Vibration Damper
- Inspect A WARNING
SMCS Code: 1205-040 Personal injury or death can result from high volt-
age.
The crankshaft vibration damper limits the torsional
Moisture could create paths of electrical conduc-
vibration of the crankshaft. The visconic damper tivity.
has a weight that is located inside a fluid filled case.
Make sure the unit is off line (disconnected from
Damage to the crankshaft vibration damper or failure utility and/or other generators), locked out and
of the damper can increase torsional vibrations.
tagged "Do Not Operate".
This can result in damage to the crankshaft and to
other engine components. A deteriorating damper
can cause excessive gear train noise at variable NOTICE
points in the speed range. Water or condensation can cause damage to gen-
erator components. Protect all electrical components
\ A damper that is hot may be the result of excessive
friction. This could be due to misalignment. Use an
from exposure to water.

infrared thermometer to monitor the temperature of

the damper during operation. If the temperature
reaches 93 °C (200 OF),consult your Caterpillar
dealer.
 107
Maintenance Section
Engine Protective Devices - Check

iO0626013 Valve Bridge

EngineProtective Devices - Check the valve bridge and adjust the valve bridge,
Check if necessary. Perform the procedure for both valve
bridges for each cylinder. After the valve bridge is
SMCS Code: 7400-535 checked for each cylinder, proceed with the valve
lash adjustment, if necessary.
Alarmsand shutoffs must function properly. Alarms
providetimely warning to the operator. Shutoffs help Engine Valve Lash
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are NOTICE
in good working order during normal operation.
Malfunctionsmust be simulated in order to test the Only qualified service personnel should perform this
engine protective devices. maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
A calibration check of the engine protective devices ment procedure.
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective Operation of Caterpillar engines with improper valve
devices are functioning properly. adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
NOTICE
During testing, abnormal operating conditions must be
simulated. The valve bridge adjustment must be performed
before making a valve lash adjustment. If the valve
The tests must be performed correctly in order to pre- lash is within the tolerance, an adjustment of the
vent possible damage to the engine. valve lash is NOT necessary.

Perform the valve lash setting when the engine is

To prevent damage to the engine, only authorized cold. After the engine has been shut down and the
service personnel or your Caterpillar dealer should valve covers are removed, the engine is considered
perform the tests. cold. Before performing maintenance, prevent the
entry of foreign matter into the top of the cylinder
Visual Inspection head and the valve mechanism. Thoroughly clean
the area around the valve mechanism covers.
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that For the valve lash setting, see this Operation and
are loose, broken, or damaged. Damaged wiring Maintenance Manual, "Engine Description" topic
or components should be repaired or replaced (Product Information Section).
immediately.
i01106228
i01071128
Fan Drive Bearing - Lubricate
Engine Valve Lash - SMCS Code: 1359-086-BD
Inspect/Adjust
Note: Lubricate the bearing more frequently if the
SMCS Code: 1102-025 engine is operated in an environment that is dusty,
hot, or humid.
Note: For procedures on adjusting the valve bridge
and adjusting the engine valve lash, see the
Service Manual, "Systems Operation/Testing and
Adjusting" module. Consult your Caterpillar dealer
for assistance.
 108
Maintenance Section
m Fuel Injector - Inspect/Adjust

, ,

<> <>

0
0

0 0
\
e

Illustration 72 gO0583459 Illustration 73 gO0662495

Grease fitting (1) Fuel priming pump plunger

Fill the grease fitting for the fan drive bearing with 2. Turn fuel priming pump plunger (1)
Caterpillar Bearing Lubricant. Alternatively, use a counterclockwise in order to release the lock
multipurpose grease that has three to five percent plate from the retainer.
of molybdenum and a grade of NLGI No.2.
3. Operate the fuel priming pump until the air in the
fuel system has been pumped through the fuel
i01225410 return line back to the fuel tank.
Fuel Injector - Inspect! Adjust 4. Press the fuel priming pump plunger to the
i

I
SMCS Code: 1290-025 locking position. Turn the fuel priming pump
plunger clockwise in order to engage the lock
plate in the retainer.
Note: Perform this procedure when the engine valve
lash is inspected.
,
Note: Enable the starting system only after all
maintenance has been completed.
NOTICE
The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in- i01076701
jector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam- Fuel System Fuel FiIter
age to the cylinder block will be the result. Differential Pressure - Check
SMCS Code: 1261-535
Inspect the adjustment of the lash for the fuel
injector according to the Systems OperationfTesting
Observe the fuel filter differential pressure frequently
And Adjusting, "Fuel System" topic. Adjust the lash
for the fuel injector, if necessary. during engine operation.

Fuel Filter Differential Pressure

i01239545
@ (Restriction) - This gauge indicates the
difference in fuel pressure between the
Fuel System - Prime inlet side and the outlet side of the fuel filter. As the
fuel filter element becomes plugged, the difference
SMCS Code: 1250-548; 1258-548 in pressure between the two sides of the fuel filter
increases.
1. Open the fuel supply valve. Ensure that
the engine will not start during the priming
The nominal fuel filter differential pressure during
procedure. Turn the start switch to the OFF
normal engine operation is approximately 60 kPa
position.
(9 psi).

Replace the secondary fuel filter elements when

the fuel filter differential pressure reaches 103 kPa
,
(15 psi).

-
 109
Maintenance Section
Fuel System Primary Filter - Clean/Inspect/Replace

4. Remove the element and wash the element in

, ' For instructions on replacement of the secondary
) fuel filter elements, see this Operation and
Maintenance Manual, "Fuel System Secondary Filter
clean, nonflammable solvent. Allow the element
to dry. Inspect the element. Install a new element
- Replace" topic. if the old element is damaged or deteriorated.
5. Clean the inside of the filter case. Allow the filter
i01239630
case to dry.
Fuel System Primary Filter - 6. Inspect the O-ring seals. Obtain new seal rings if
Clean/Inspect/Replace the old seal rings are damaged or deteriorated.
Ensure that the sealing surfaces for the seals are
SMCS Code: 1260-510; 1260-571 clean. Install the seals.

NOTICE
A WARNING
Do notfill the fuel filters with fuel before installing them.
Fuel leaked or spilled onto hot surfaces or elec- The fuel would not be filtered and could be contami-
trical components can cause a fire. To help pre- nated. Contaminated fuel will cause accelerated wear
vent possible injury, turn the start switch off when to fuel system parts.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 7. Place the element in the filter case. Slide the
filter case over the mounting bolt.
1. Stop the engine. Ensure that the engine will not
start during this procedure. 8. Install the nut.

2. Shut off the fuel supply valve to the engine. 9. Open the fuel supply valve.

NOTICE 10. Prime the fuel system. See this Operation and
Maintenance Manual, "Fuel System - Prime"
Do not allow dirt to enter the fuel system. Thoroughly
h clean the area around a fuel system component that
topic.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. i01229595

Fuel System Secondary Filter -

NOTICE
Use a suitable container to catch any fuel that might Replace
spill. Clean up any spilled fuel immediately. SMCS Code: 1261-510-SE

A WARNING
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Replace the secondary fuel filter elements whenever

the following conditions occur:

. The fuel filter differential pressure gauge registers

gO0330404
103 kPa (15 psi).
Illustration 74
(1) Filter case . The fuel filters have been used for 1000 service
(2) Nut hours.

~~ 3. Loosen nut (2). Hold filter case (1) and remove

nut (2). Prepare to catch the fuel that is inside of
the filter case with a suitable container. Remove
the filter case from the mounting bolt.

-
....
110
Maintenance Section
I
Fuel System Secondary Filter - Replace

Replacing the Fuel Filter Elements A WARNING

with the Engine Stopped (j
Personal injury can result from parts and/or cov-
Canister ers under spring pressure.

1. Stop the engine. Ensure that the engine will not Spring force will be released when covers are re-
start during this procedure.
moved.

2. Shut off the fuel supply valve to the engine. Be prepared to hold spring loaded covers as the
bolts are loosened.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 5. Be alert to the spring force. Gradually loosen but
clean the area around a fuel system component that do not remove bolts (4). Before removing bolts
will be disconnected. Fit a suitable cover over discon- (4), pry cover (5) loose in order to relieve any
nected fuel system component. spring pressure. Remove cover (5). Remove the
a-ring seal on the inside of the cover. Remove
the fuel filter elements.
NOTICE
Use a suitable container to catch any fuel that might 6. Clean cover (5) and clean the a-ring seal. Clean
spill. Clean up any spilled fuel immediately. the inside of the fuel filter housing.

7. Install new fuel filter elements.

8. Inspect the a-ring seal. Ensure that the surfaces

for the a-ring seal are clean. Install a new
a-ring seal if the old a-ring seal is damaged or
deteriorated.

9. Install cover (5). Ensure that the springs are ~

seated properly between the cover and the fuel

filter elements.

10. Open the fuel supply valve. Reconnect the

battery.

Illustration 75 gO0329184 11. Prime the fuel system. Refer to this Operation
and Maintenance Manual, "Fuel System - Prime"
(1) Drain
(2) Drain valve topic (Maintenance Section).
(3) Plug
(4) Bolts Spin-On Filter
(5) Cover

3. Connect a hose to drain (1). Place the other end NOTICE

of the hose into a suitable container in order to Do not allow dirt to enter the fuel system. Thoroughly
collect the fuel. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
4. Open drain valve (2). Remove plug (3). Allow nected fuel system component.
the fuel to drain. Clean the plug and install the
plug. Close the drain valve. Remove the hose
from the drain.

Note: Some fuel will remain in the housing after the

fuel has been drained. This fuel will pour out of
the housing when cover (5) is removed. Prepare to
catch the fuel in a suitable container. Clean up any
spilled fuel with absorbent towels or pillows. DO
NOT use absorbent particles to clean up the fuel.

--
 111
Maintenance Section
Fuel System Secondary Filter - Replace

Replacing the Fuel Filter Elements

~ During Engine Operation
DuplexFuel Filters

Illustration 76 gO0425598

Secondary fuel filters

1. Remove the used fuel filter with a 1U- 8760

Chain Wrench. Discard the used fuel filter. gO0657535
Illustration 77

2. Clean the gasket sealing surface of the fuel filter (1) Fill valve
base. (2) Control valve

Ensure that all of the old gasket is removed. 1. Open fill valve (1) for a minimum of five minutes.
Close the valve.
3. Apply clean diesel fuel to the new fuel filter
2. If the main filter will be serviced, rotate control
gasket.
valve (2) to the "AUX RUN" position.
~ NOTICE If the auxiliary filters will be serviced, rotate
Do not fill the fuel filters with fuel before installing the control valve (2) to the "MAIN RUN" position.
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
NOTICE
ated wear to fuel system parts.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
4. Install the new fuel filter. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Spin the new fuel filter onto the fuel filter base
until the gasket contacts the base. Tighten
the fuel filter by hand by one full turn. Do not NOTICE
overtighten the fuel filter. Use the rotation index Use a suitable container to catch any fuel that might
marks that are on the fuel filter as a guide for spill. Clean up any spilled fuel immediately.
proper tightening.
3. See "Replacing the Fuel Filter Elements with the
5. Prime the fuel system.
Engine Stopped". Perform Step 75 through Step
9 from the "Canister" instructions.
See this Operation and Maintenance Manual,
"Fuel System - Prime" topic (Maintenance
4. Open fill valve (1) for a minimum of five minutes
Section). in order to fill the new elements. Close the fill
valve.

After the new filter elements are full of fuel, either

the main filter or the auxiliary filter may be used.

~
 114
Maintenance Section

~ Jacket Water Heater - Check

Record the data in a log. Compare the new data to

the data that was previously recorded. Comparing
the new data to the recorded data will help to Overhaul (Major) i01253023 (
establish the trends of engine performance. A
gauge reading that is abnormal may indicate a SMCS Code: 7595-020-MJ
problem with operation or a problem with the gauge.
The maintenance intervals that are listed in this
Operation and Maintenance Manual, "Maintenance
i01042517 Interval Schedule" are expressed in service hours.
Jacket Water Heater - Check A more accurate figure to use is fuel consumption.
Fuel consumption corresponds more accurately to
SMCS Code: 1383-535 the engine load.

Table 44 lists average ranges of fuel consumption

Jacket water heaters help to improve startability in and service hours for a load factor of approximately
ambient temperatures that are below 21°C (70 OF). 60 percent. Use the range of fuel consumption only
All installations that require automatic starting as a guideline.
should have jacket water heaters.
Table 44
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 OF),the heater Major Overhaul
Service Hours and Fuel Consumption for
should maintain the jacket water temperature at 3500 Engines (1)
approximately 32 °C (90 OF).
Engine Rated Up To Rated 1301 Rated 1601
1300 RPM To 1600 RPM To 1800
iO0738324 RPM
Magnetic Pickups - 33000
Service
27000
Service
22500
Service
Clean/Inspect Hours Hours Hours
SMCS Code: 1907-040 3508 2 928 000 L (772,500 US gal)
3512 4 380 000 L (1,555,000US gal)
3516 5826000 L (1,537,500US gal)
(1) Fuel consumption is based on a load factor of approximately
60 percent.

----- The need for a major overhaul is determined by

several factors.

. An increase of oil consumption

. An increase of crankcase blowby
. The total amount of fuel consumption
Illustration 78 gO0293337
. The service hours of the engine
Typical magnetic pickup
. The wear metal analysis of the lube oil
1. Remove the magnetic pickup from the flywheel
housing. Check the condition of the end of the . An increase in the levels of noise and vibration
magnetic pickup. Check for signs of wear and
contaminants. An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
2. Clean the metal shavings and other debris from need to be serviced. An increase in the levels of
the face of the magnet. noise and vibration indicates that rotating parts
require service.
3. Install the magnetic pickup according to
the information in the Service Manual,
"Specifications" .
 r
115
Maintenance Section
Overhaul (Major)

Note: It is possible for oil analysis to indicate a Replace - The service life of the part is exhausted.
decrease of wear metals in the lube oil. The cylinder The part may fail before the next maintenance
liners may be worn so that polishing of the bore interval. The part must be replaced with a part that
occurs. Also, the increased use of lube oil will dilute meets functional specifications. The replacement
the wear metals. part may be a new part, a CAT remanufactured
part, a rebuilt part, or a used part. Some worn
Monitor the engine as the engine accumulates components may be exchanged with your
service hours. Consult your Caterpillar dealer about Caterpillar dealer for credit on replacement parts.
scheduling a major overhaul. Consult your Caterpillar dealer about repair options
for your engine.
Note: The driven equipment may also require
service when the engine is overhauled. Refer to the If you elect to perform an overhaul without the
literature that is provided by the OEM of the driven services of a Caterpillar dealer, be aware of the
equipment. recommendations in Table 45. Your Caterpillar
dealer can provide these services and components.
A major overhaul includes all of the work that is
Table 45
done for the top end overhaul. A major overhaul
includes additional parts and labor. Additional parts Major Overhaul Instructions (1)
and labor are required in order to completely rebuild
Clean Oil suction screen
the engine.
Clean Aftercooler core (2)
For the major overhaul, all of the bearings, Inspect
seals, gaskets, and components that wear Test
are disassembled. The parts are cleaned and Camshafts
Inspect
inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft Cylinder block
may require regrinding. Alternatively, the crankshaft Crankshaft vibration
may be replaced with a Caterpillar replacement
damper
part.
Driven equipment
Your Caterpillar dealer can provide these services (alignment)
and components. Your Caterpillar dealer can ensure
Flywheel
that the components are operating within the
appropriate specifications. Front gear train (gears)

Fuel system linkage

The following definitions explain the terminology for
the services that are performed during an overhaul: Rear gear train (gears)

Inspect Rocker arms

Inspect - Inspect the components according to Rebuild
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Inspect Connecting rods
Parts and Salvage Operations, SEBF8029, "Index Rebuild
Replace Cylinder head assemblies
of Publications on Reusability or Salvage of Used
Parts". The guidelines were developed in order to Fuel priming pump
help Caterpillar dealers and customers to avoid Fuel transfer pump
unnecessary expenditures. New parts are not
required if the existing parts can still be used, Oil cooler core
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service Piston pins
Manual, "Specifications" module. (continued)

Rebuild - The component can be reconditioned in

order to comply with reusability guidelines.

~,
~
III
116
Maintenance Section
Overhaul (Top End)

(Table 45, contd)

Major Overhaul Instructions (1)

Table 46

Top End Overhaul

- \
Inspect Camshaft lifters Service Hours and Fuel Consumption for
Replace 3500 Engines (1)
Camshaft thrust washers
Top End Overhaul (First Interval)
Crankshaft
Engine Rated Up To Rated 1301 Rated 1601
Cylinder liners 1300 RPM To 1600 RPM To 1800
RPM
Engine mounts
11000 9000 Service 7500 Service
Engine wiring harness Service Hours Hours
Hours
Fuel pressure regulating
valve 3508 976000 L (257,500 US gal)
Pistons (Crowns and 3512 1 460 000 L (385,000 US gal)
Skirts)
3516 1 942000 L (512,500 US gal)
Push rods

Spacer plates Top End Overhaul (Second Interval)

Replace Engine 22000 18000 15000

Camshaft bearings
Service Service Service
Connecting rod bearings Hours Hours Hours
Crankshaft seals 3508 1 952000 L (515,000 US gal)
Crankshaft thrust plates 3512 2 920 000 L (770,000 US gal)
Fuel injectors 3516 3 884 000 L (1,025,000 US gal)
Gear train bushings
(1) Fuel consumption is based on a load factor of approximately
Main bearings 60 percent.

Piston rings A top end overhaul involves the removal, the

Seals and bellows for the inspection, and the rework of the cylinder head
exhaust manifold components. A few additional components are
replaced and serviced.
Seals and gaskets for the
air Inlet manifold
The top end overhaul (second interval) involves
(1) For instructions on removal and installation of components, see the same service that is performed for the first
the Service Manual, "Disassembly and Assembly" module. interval. Because of the number of service hours,
(2) For instructions on cleaning the core, see this Operation and
Maintenance Manual, "Aftercooler Core - CleanlTest" topic.
some additional components are inspected and/or
serviced.

i01252793 Your Caterpillar dealer can provide these services

and components. Your Caterpillar dealer can ensure
Overhaul (Top End) that the components are operating within the
appropriate specifications.
SMCS Code: 7595-020-TE
Note: The driven equipment may also require
The maintenance intervals that are listed in this service when the engine is overhauled. Refer to the
Operation and Maintenance Manual, "Maintenance literature that is provided by the OEM of the driven
Interval Schedule" are expressed in service hours. equipment.
A more accurate figure to use is fuel consumption.
Fuel consumption corresponds more accurately to The following definitions explain the terminology for
the engine load. the services that are performed during an overhaul:

Table 46 lists average ranges of fuel consumption

and service hours for a load factor of approximately
60 percent. Use the range of fuel consumption only
as a guideline.
 117
Maintenance Section
Overhaul (Top End)
1

Inspect - Inspect the components according to

the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used
Parts". The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, "Specifications" module.

Rebuild - The component is reconditioned in order

to comply with reusability guidelines.

Replace - The service life of the part is exhausted.

The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured
part, a rebuilt part, or a used part. Some worn
components may be exchanged with your
Caterpillar dealer for credit on replacement parts.
Consult your Caterpillar dealer about repair options
for your engine.

If you elect to perform an overhaul without the

services of a Caterpillar dealer, be aware of the
recommendations in Table 47.
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118
Maintenance Section
Overhaul Considerations
ill
II.I
I

Table 47

Recommendations for Top End Overhauls (1)

~

Service Top End Overhaul (First Interval) Top End Overhaul (Second Interval)
Clean Oil suction screen

Clean Aftercooler core (2)

Inspect
Pressure test

Inspect Fuel system linkage

-
Connecting rod bearings (3)
-
Cylinder liners (3)
- Piston crowns and skirts (3)

-
Piston pins (3)
Inspect Rocker arms
Rebuild

Inspect Cylinder head assemblies

Rebuild
Replace Fuel priming pump
-
Engine oil pump
-
Fuel transfer pump
-
Prelube pump
-
Scavenge oil pump
- Camshaft lifters
Inspect
~
Replace
Engine wiring harness
Fuel pressure regulating valve
Push rods

Spacer plates
Rebuild -
Turbochargers
Replace
Replace Fuel injectors
Gaskets and seals for the air inlet manifold
Seals and bellows for the exhaust manifold
(1) For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.
(2) For instructions on cleaning the core, see this Operation and Maintenance Manual, "Aftercooler Core - Cleanrresf' topic.
(3) For 3508 and 3512 Engines, inspect ONLY ONE of the components from each cylinder bank. For 3516 Engines, inspect ONLY TWO of
the components from each cylinder bank. This inspection will provide adequate examples of the condition of the other corresponding
components. If the results are questionable, inspect more of the components.

iO1045650 An overhaul also includes the following maintenance:

Overhaul Considerations . Inspection of all the parts that are visible during
the disassembly
SMCS Code: 7595-043
. Replacement of the seals and gaskets that are
Overhaul Information removed

An overhaul is replacing the major worn components . Cleaning of the internal passages of the engine ~
of the engine. An overhaul interval is a maintenance and the engine block
interval that is planned. The engine is rebuilt with
certain rebuilt parts or new parts that replace the
worn parts.

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119
Maintenance Section
Overhaul Considerations

Most owners will save money by overhauling the . The service life of the engine can be extended
f) engine at the intervals that are recommended in this
Operation and Maintenance Manual. Consider the
without the risk of a major catastrophe due to
engine failure.
graph in Illustration 79.
. Achieve the best cost/value relationship per hour
of extended service life.

Overhaul Intervals
Some factors that are important for determining
the overhaul intervals include the following
considerations:

. Performance of preventive maintenance

. Use of recommended lubricants

CD ..
. Use of recommended coolants
Illustration 79 gO0541431
. Use of recommended fuels
Costs of overhauls over time
(V) Cost . Proper installation
(X) Time
(1)
(2)
Cost of maintenance
Cost of maintenance
and repair that is planned
and repair that is not planned
. Operating conditions
In Illustration 79, line (1) represents the maintenance
. Operation within acceptable limits
and repair costs for an owner that followed the
. Engine load
rJ recommendations for inspection, maintenance, and
repair. The peaks represent overhauls.

Line (2) represents the maintenance and repair

. Engine speed
Generally, engines that are operated at a reduced
costs for an owner that chose to operate beyond load and/or speed achieve more service life before
the recommended intervals. The initial cost of the
an overhaul. However, this is for engines that are
"repair-after-failure" philosophy is lower. Also, the properly operated and maintained.
first overhaul was delayed. However, the peaks are
significantly higher than the peaks for the customer Other factors must also be considered for
that used the "repair-before-failure" philosophy.
determining a major overhaul:
The higher peaks result from two key factors: . The total amount of fuel consumption
. Delaying an overhaul until a breakdown increases . The service hours of the engine
the chance of a catastrophic failure. This type of
failure requires more parts, labor, and cleanup. . An increase of oil consumption
. Excessive wear means that fewer components
. An increase of crankcase blowby
will be reusable. More labor may be required for
salvage or repair of the components. . The wear metal analysis of the lube oil
When all of the costs are considered,
"REPAIR-BEFORE-FAILURE"is the least expensive
. An increase in the levels of noise and vibration
alternative for most components and engines. An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
It is not practical to wait until the engine exhibits need to be serviced. An increase in the levels of
symptoms of excessive wear or failure. It is not less noise and vibration indicates that rotating parts
costly to wait. A planned overhaul before failure
require service.
may be the best value for the following reasons:
~I~
. Costly unplanned downtime can be avoided.

. Many original parts can be reused according to

the guidelines for reusable parts.
~- 120
Maintenance Section
Overhaul Considerations
~III

Note: It is possible for oil analysis to indicate a Oil Consumption as an Overhaul Indicator
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore Oil consumption, fuel consumption, and
occurs. Also, the increased use of lube oil will dilute maintenance information can be used to estimate
the wear metals. the total operating cost for your Caterpillar engine.
Oil consumption can also be used to estimate
Monitor the engine as the engine accumulates the required capacity of a makeup oil tank that is
service hours. Consult your Caterpillar dealer about suitable for the maintenance intervals.
scheduling a major overhaul.
Oil consumption is in proportion to the percentage
Note: The driven equipment may also require of the rated engine load. As the percentage of the
service when the engine is overhauled. Refer to the engine load is increased, the amount of oil that is
literature that is provided by the OEM of the driven consumed per hour also increases.
equipment.
The oil consumption rate (brake specific oil
Using Fuel Consumption For Calculating the consumption) is measured in grams per kW/h
Overhaul Intervals (Ib per bhp). The brake specific oil consumption
(BSOC) depends on the engine load. Consult your
The total fuel consumption is the most important Caterpillar dealer for assistance in determining the
factor for estimating the overhaul interval. Fuel typical oil consumption rate for your engine.
consumption compensates for the application and
for the engine load. When an engine's oil consumption has risen to
three times the original oil consumption rate due
If the total fuel consumption has not been recorded, to normal wear, an engine overhaul should be
use the equation in Table 48 in order to estimate the scheduled. There may be a corresponding increase
hours until the overhaul. The equation may also be in blowby and a slight increase in fuel consumption. I

used to estimate overhaul intervals for new engines.

Table48 Overhaul Inspection
Equation For Calculating Overhaul Intervals Refer to the Service Manual for the disassembly
H = FIR and assembly procedures that are necessary in
order to perform the required maintenance on the
"H" is the number of estimated hours until the overhaul items that are listed. Consult your Caterpillar dealer
interval. for assistance.
"P' is the estimated total amount of fuel consumption of
the engine. To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
"R" is the rate of fuel consumption in liters per hour or Reusable Parts and Salvage Operations, SEBF8029,
gallons per hour. "Index of Publications on Reusability or Salvage of
Used Parts".
Use the actual records of fuel consumption, when
possible. If the actual records are not available, use The Guidelines For Reusable Parts and Salvage
the following procedure in order to estimate the fuel Operations is part of an established Caterpillar
consumption. parts reusability program. These guidelines
were developed in order to assist Caterpillar
1. Estimate the average percent of the load for the dealers and customers reduce costs by avoiding
operation of the engine. unnecessary expenditures for new parts. If the
engine parts comply with the established inspection
2. Refer to the engine's Caterpillar, "Engine specifications, the parts can be reused.
Specifications" ("spec" sheet). This will
determine the fuel consumption for the percent The use of out-of-spec parts could result in
of the load that was estimated in Step 1. Use this unscheduled downtime and/or costly repairs. The
figure for the equation in Table 48. use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency. New parts are not necessary if the
old parts can be reused, repaired, or salvaged.
Otherwise, the old parts can be replaced or
exchanged.
1I 121
I
Maintenance Section
Radiator - Clean

. 11\
, II'
Your Caterpillar dealer can provide the parts that
are needed to rebuild the engine at the least
A WARNING
possible cost. Personal injury can result from air pressure.

Overhaul Programs Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
An economical way to obtain most of the parts tective face shield and protective clothing.
that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured Maximum air pressure at the nozzle must be less
parts are available at a fraction of the cost of new than 205 kPa (30 psi) for cleaning purposes.
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts: Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
. Cylinder heads of the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
. Oil Pumps the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
. Turbochargers
. Water pumps Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
Consult your Caterpillar dealer for details and for a must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
list of the remanufactured parts that are available.
both sides.
Your Caterpillar dealer may be offering a variety of
overhaul options. Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
A Flat Rate Overhaul guarantees the maximum price with detergent and hot water. Thoroughly rinse the
core with clean water.
~~ that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers After cleaning, start the engine and accelerate the
for all Caterpillar Engines. Consult your Caterpillar engine to high idle rpm. This will help in the removal
dealer in order to schedule a before failure overhaul. of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
Overhaul Recommendation the core for cleanliness. Repeat the cleaning, if
necessary.
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul Inspect the fins for damage. Bent fins may be
will provide the lowest cost and the greatest value. opened with a "comb". Inspect these items for
Schedule an overhaul with your Caterpillar dealer. good condition: welds, mounting brackets, air lines,
connections, clamps, and seals. Make repairs, if
Overhaul programs vary between dealers. To obtain necessary.
specific information about the types of overhaul
programs and services, consult your Caterpillar For more detailed information on cleaning and
dealer. inspection, see Special Publication, SEBD0518,
"Know Your Cooling System".
101206548

Radiator - Clean
SMCS Code: 1353-070

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

I~ Inspect the radiator for these items: damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary.