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Engine Division

Product News

November 1999

Cat ® 3500 Marine Engine Extended Service Interval

Market

Marine

Application

Marine propulsion

Description

The recommended overhaul schedules for most 3500 family marine engines have been extended by 50 percent. Recommendations for hours-to-overhaul are based on average operational load factors and adherence to other recommended service intervals. Lower load factors or better-than-recommended maintenance practices will contribute to extended overhaul intervals. Total fuel consumed, rather than the number of operating hours, provides the best indicator for determining service intervals for load-sensitive components.

Service hour and fuel consumption charts included in this document provide average fuel consumption rates based on a load factor of approximately 60 percent. Also included are maintenance service schedules for basic engine, fuel system, air induction and exhaust system, lubrication system, cooling system, start/stop system, electrical system, and driven equipment.

Features & Benefits

Extended overhaul intervals provide a significant reduction in lifetime operating costs for existing field engines and new engines.

General Comments

The extended overhaul interval does not apply to the new 3500B High Displacement engines and the 3500 High Performance engines.

Maintenance schedules are published in Operation and Maintenance manuals for each engine and in other publications such as Marine Engine Maintenance Schedules LEXM6231 for commercial applications and LEXM8621 for high performance applications.

LEXM9563

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice.

© 1999 Caterpillar Inc. All rights reserved. Printed in U.S.A.

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3500 Commercial Engine (A & B Series) Maintenance Service

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series) Maintenance Service Schedules

NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at service interval.

     

Service Interval

 

Basic Engine

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Walk-Around Inspection

Check

X

                 

Daily Engine Log

Record Activity

X

                 

Valves/Bridge

Adjust — 1st 250/500 hrs

 

X

               

Engine — Clean

Clean

     

X

           

Valves/Bridge

Adjust

       

X

         

Engine Mounts

Inspect

       

X

         

Damper

Inspect

       

X

         

Push Rods

Inspect/Replace

             

25%

25%

 

Spacer Plate

Inspect/Replace

             

33%

33%

66%

Cylinder Head As (Hd/Valve/etc.)

Insp/Rebld/Exch

             

50%

50%

 

Cylinder Head As (Hd/Valve/etc.)

Install New

                 

100%

Rocker Arms

Insp/Rebld/Exch

               

25%

75%

Cam Shaft Lifters

Inspect/Exchange

               

25%

75%

Cam Shaft

Inspect

                 

50%

Rear Gear Train — Gears

Inspect

                 

50%

Cylinder Block

Inspect

                 

1%

Front Gear Train — Gears

Inspect

                 

50%

Cam Thrust Washer

Inspect/Exchange

                 

50%

Crankshaft

Inspect/Exchange

                 

50%

Flywheel

Inspect/Exchange

                 

10%

Piston Pin

Insp 2 pcs per cyl. bank

               

5%

 

Piston Pin

Insp/Rebld/Exch

                 

50%

Piston (Crown & Skirt)

Insp 2 pcs per cyl. bank

               

5%

 

Piston (Crown & Skirt)

Insp/Rebld/Exch

                 

75%

Cam Bearings

Install New

                 

100%

Connecting Rod

Install New

                 

100%

Crankshaft Seals

Install New

                 

100%

Crankshaft Thrust Plates

Install New

                 

100%

Cylinder Liner

Install New

                 

100%

Damper

Install New

                 

100%

Engine Mounts

Install New

                 

100%

Gear Train Bushings

Install New

                 

100%

Main Bearings

Install New

                 

100%

Rings

Install New

                 

100%

Rod Bearings

Insp 2 pcs per cyl. bank

               

5%

 

Rod Bearings

Install New

                 

100%

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3500 Commercial Engine (A & B Series) Maintenance Service Schedules

3500 Commercial Engine (A & B Series) Maintenance Service Schedules

NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at service interval.

     

Service Interval

 

Fuel System

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Fuel Filter Diff. Pressure

Check

X

                 

Fuel Filter — Primary

(H 2 O Separator) Drain

X

                 

Fuel Tank

Drain H 2 O & Sediment

 

X

               

Fuel Filter — Primary

(H 2 O Separator) Replace

   

100%

             

Fuel System

Prime (@ filter chg.)

     

As Reqd

           

Fuel Filter — Spin on

Replace

     

100%

           

Fuel Filter — Canister

Replace

     

100%

           

Fuel Filter — Duplex

Replace

     

100%

           

Fuel Filter — Primary

Clean/Inspect/Replace

     

100%

           

Unit Injector

Exch/Replace

             

100%

100%

100%

Fuel Transfer Pump

Insp/Rebld/Exch

               

50%

100%

Fuel Priming Pump

Insp/Rebld/Exch

             

50%

50%

100%

Fuel Press. Regulating Valve

Inspect/Replace

             

50%

50%

 

Fuel Press. Regulating Valve

Install New

                 

100%

Electronic Control Module (ECM)

Inspect for Damage

                 

25%

Software

Install New (if new ECM)

                 

25%

     

Service Interval

 

Air Induction and Exhaust System

   

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Air Leaks

Inspect

X

                 

Air Cleaner/Filters

Check Service Indicator

X

                 

Air Precleaner

Clean

As Reqd

                 

Air Cleaner/Filters

Clean/Replace

As Reqd

                 

Air Filter Primary Element

Clean/Replace

As Reqd

                 

Air Filter Sec. Element

Replace

As Reqd

                 

Air Filter Serv. Ind. Screen

Replace

As Reqd

                 

Turbocharger

Rebuild/Exchange

           

100%

     

Aftercooler Core

Inspect/Clean/Test

             

25%

25%

50%

Intake Man. Gaskets/Seals

Inspect/Replace

             

50%

50%

100%

Exh. Man. Seals/Bellows

Insp/Rebld/Exch

             

50%

50%

100%

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3500 Commercial Engine (A & B Series) Maintenance Service

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series) Maintenance Service Schedules

NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at service interval.

     

Service Interval

 

Lubrication System

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Oil — Level

Check

X

                 

Oil Filter Diff. Pressure

Check

X

                 

Oil Leaks

Check

X

                 

Oil (S•O•S Analysis)

Check/Obtain Sample

@oilchg

                 

Oil Filter

Inspect

As Reqd

                 

Oil Level

Log Additions

As Reqd

                 

Oil Filter — Spin On

Change

 

100%

               

Oil Change Shallow Sump

Change

 

100%

               

Oil Filter — Canister

Change

   

100%

             

Oil Change — Std. Sump

Change

   

100%

             

Oil Filter — Duplex

Change

     

100%

           

Oil Change — Deep Sump

Change

     

100%

           

Crankcase Breather

Clean

     

100%

           

Oil Pump — Main

Insp/Rebld/Exch

               

100%

 

Prelube Oil Pump if Eqpd.

Insp/Rebld/Exch

               

100%

 

Scavenge Oil Pump

Insp/Rebld/Exch

               

100%

 
     

Service Interval

 

Cooling System

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Coolant

Check Level

X

                 

Coolant Leaks

Check

X

                 

Zinc Rods (if equipped)

Inspect/Replace

50 Hrs

                 

Coolant Additive — STD

Add

 

X

               

S•O•S Level I Analysis

Check

 

X

               

Cooling Sys. Relief Valve

Clean

 

X

               

Radiator Core

Clean Fins

 

X

               

Radiator Cap

Clean/Replace

 

X

               

Fan Belts

Inspect/Adjust/Replace

 

X

               

Hoses/Clamps

Inspect/Check

 

X

               

Fan Drive Brg.

Lubricate

 

X

               

S•O•S Level II Analysis

Check

     

X

           

Long Life Coolant Additive

Add

         

X

       

Coolant (STD)

Drain/Flush/Replace

         

X

       

Coolant — Long Life

Drain/Flush/Replace

           

X

     

Fan Drive

Inspect

           

X

     

Aux. Water Pump

Insp/Rebld/Repl

           

100%

     

Jacket Water Pump

Insp/Rebld/Repl

           

100%

     

Sea Water Pump

Insp/Rebld/Repl

           

100%

     

Regulator (Thermostats)

Replace

           

100%

     

Oil Cooler Core

Insp/Rebld/Repl

                 

100%

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3500 Commercial Engine (A & B Series) Maintenance Service Schedules

3500 Commercial Engine (A & B Series) Maintenance Service Schedules

NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at service interval.

     

Service Interval

 

Start/Stop System

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Air Supply Tank

Drain H 2 O and Sediment

X

                 

Air Motor Lubricator

Check Level

X

                 

Ether Aid

Service Ether Cylinder

                   

Air Shutoff — Actuate

Inspect

 

X

               

Air Shutoff Solenoid

Inspect

 

X

               

Jacket Water Heaters

Inspect

 

X

               

Engine Protection Devices

Inspect

     

X

           

Starter Motor — Electric

Insp/Rebld/Repl

           

100%

     

Starter Motor — Air

Insp/Rebld/Repl

           

100%

     
     

Service Interval

 

Electrical System

Service to be Performed

             

1st

2nd

 

Daily

250

500

1000

2000

3000

6000

Top End

Top End

Overhaul

Electrical Gauges/Sensors

Replace

As Reqd

                 

Alternator Belt

Inspect/Check Tension

 

X

               

Batteries

Clean/Ck Electrolyte Level

 

X

               

Alternator

Insp/Rebld/Repl

           

100%

     

Engine Wire Harness

Inspect/Install New

                 

100%

Driven Equipment

Service to be Performed

                   

Inspect/Check/Lube

Inspect/Check/Lube

X

                 

Air Compressor

Rebuild/Exchange

           

100%

     

Driven Equip. Alignment

Inspect

             

X

X

X

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3508 Commercial Engine (A & B Series) Maintenance Schedule

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3508 Commercial Engine (A & B Series) Maintenance Schedule Interval — Service Hours and Fuel Consumption

NOTE: Fuel consumption is based on a load factor of approximately 60 percent.

For engines that operate at less then 50 percent load, use the 50 percent load fuel consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.

Maintenance intervals must be reduced for engines that operate in a severe service application and for engines that operate in excess of the engine rating definition.

Interval

Rated rpm up to 1300

Rated rpm up to 1600

Rated rpm up to 1800

       

Every 250 Service Hours or

 

22

700 L

 

27

200 L

 

32

000 L

(6000 U.S. gal)

(7200 U.S. gal)

(8500 U.S. gal)

Every 500 Service Hours or

 

45

400 L

 

54

400 L

 

64

000 L

(12 000 U.S. gal)

(14 400 U.S. gal)

(17 000 U.S. gal)

Every 1000 Service Hours or

 

89

000 L

 

109

000 L

 

128

000 L

(23 500 U.S. gal)

(28 800 U.S. gal)

(34 000 U.S. gal)

Every 2000 Service Hours or

 

178

000 L

 

218

000 L

 

257

000 L

(47 000 U.S. gal)

(57 600 U.S. gal)

(68 000 U.S. gal)

Every 3000 Service Hours or

 

267

500 L

 

327

500 L

 

386

500 L

(70 500 U.S. gal)

(84 000 U.S. gal)

(102 000 U.S. gal)

Every 6000 Service Hours or

 

535

000 L

 

636

000 L

 

774

000 L

(141 000 U.S. gal)

(168 000 U.S. gal)

(204 000 U.S. gal)

1st Top End

 

976

000 L

 

976

000 L

 

976

000 L

(257 500 U.S. gal) or Every 11,000 Service Hours

(257 500 U.S. gal) or Every 9000 Service Hours

(257 500 U.S. gal) or Every 7500 Service Hours

2nd Top End

1

952 000 L

1

952 000 L

1

952 000 L

(515 000 U.S. gal) or Every 22,000 Service Hours

(515 000 U.S. gal) or Every 18,000 Service Hours

(515 000 U.S. gal) or Every 15,000 Service Hours

Overhaul

2

928 000 L

2

928 000 L

2

928 000 L

(772 500 U.S. gal) or Every 33,000 Service Hours

(772 500 U.S. gal) or Every 27,000 Service Hours

(772 500 U.S. gal) or Every 22,500 Service Hours

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3512 Commercial Engine (A & B Series) Maintenance Schedule Interval

3512 Commercial Engine (A & B Series) Maintenance Schedule Interval — Service Hours and Fuel Consumption

NOTE: Fuel consumption is based on a load factor of approximately 60 percent.

For engines that operate at less then 50 percent load, use the 50 percent load fuel consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.

Maintenance intervals must be reduced for engines that operate in a severe service application and for engines that operate in excess of the engine rating definition.

Interval

Rated rpm up to 1300

Rated rpm up to 1600

Rated rpm up to 1800

       

Every 250 Service Hours or

 

33

400 L

 

41

000 L

 

48

500 L

(8800 U.S. gal)

(10 800 U.S. gal)

(12 800 U.S. gal)

Every 500 Service Hours or

 

66

800 L

 

82

000 L

 

97

000 L

(17 600 U.S. gal)

(21 600 U.S. gal)

(25 600 U.S. gal)

Every 1000 Service Hours or

 

133

500 L

 

164

000 L

 

194

000 L

(35 000 U.S. gal)

(43 200 U.S. gal)

(51 200 U.S. gal)

Every 2000 Service Hours or

 

267

000 L

 

328

000 L

 

388

000 L

(70 000 U.S. gal)

(86 400 U.S. gal)

(102 400 U.S. gal)

Every 3000 Service Hours or

 

398

000 L

 

491

000 L

 

582

000 L

(105 000 U.S. gal)

(129 600 U.S. gal)

(153 600 U.S. gal)

Every 6000 Service Hours or

 

796

000 L

 

982

000 L

1

164 000 L

(210 000 U.S. gal)

(259 200 U.S. gal)

(307 200 U.S. gal)

1st Top End

1

460 000 L

1

460 000 L

1

460 000 L

(385 000 U.S. gal) or Every 11,000 Service Hours

(385 000 U.S. gal) or Every 9000 Service Hours

(385 000 U.S. gal) or Every 7500 Service Hours

2nd Top End

2

920 000 L

2

920 000 L

2

920 000 L

(770 000 U.S. gal)

(770 000 U.S. gal)

(770 000 U.S. gal)

or Every 22,000 Service Hours

or Every 18,000 Service Hours

or Every 15,000 Service Hours

Overhaul

4

380 000 L

4

380 000 L

4

380 000 L

(1 155 000 U.S. gal) or Every 33,000 Service Hours

(1 155 000 U.S. gal) or Every 27,000 Service Hours

(1 155 000 U.S. gal) or Every 22,500 Service Hours

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL 3516 Commercial Engine (A & B Series) Maintenance Schedule

3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3516 Commercial Engine (A & B Series) Maintenance Schedule Interval — Service Hours and Fuel Consumption

NOTE: Fuel consumption is based on a load factor of approximately 60 percent.

For engines that operate at less then 50 percent load, use the 50 percent load fuel consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.

Maintenance intervals must be reduced for engines that operate in a severe service application and for engines that operate in excess of the engine rating definition.

Interval

Rated rpm up to 1300

Rated rpm up to 1600

Rated rpm up to 1800

       

Every 250 Service Hours or

 

44

000 L

53 000 L (14 000 U.S. gal)

64 500 L (17 000 U.S. gal)

(11 600 U.S. gal)

Every 500 Service Hours or

 

88

000 L

 

106

000 L

 

129

000 L

(23 200 U.S. gal)

(28 000 U.S. gal)

(34 000 U.S. gal)

Every 1000 Service Hours or

 

176

000 L

 

212

000 L

 

258

000 L

(46 500 U.S. gal)

(56 000 U.S. gal)

(68 000 U.S. gal)

Every 2000 Service Hours or

 

352

000 L

 

424

000 L

 

516

000 L

(93 000 U.S. gal)

(112 000 U.S. gal)

(136 000 U.S. gal)

Every 3000 Service Hours or

 

528

700 L

 

636

700 L

 

773

000 L

(139 500 U.S. gal)

(168 000 U.S. gal)

(204 000 U.S. gal)

Every 6000 Service Hours or

1

056 000 L

1

272 000 L

1

548 000 L

(279 000 U.S. gal)

(336 000 U.S. gal)

(408 000 U.S. gal)

1st Top End

1

942 000 L

1

942 000 L

1

942 000 L

(512 500 U.S. gal) or Every 11,000 Service Hours

(512 500 U.S. gal) or Every 9000 Service Hours

(512 500 U.S. gal) or Every 7500 Service Hours

2nd Top End

3

884 000 L

3

884 000 L

3

884 000 L

(1 025 000 U.S. gal)

(1 025 000 U.S. gal)

(1 025 000 U.S. gal)

or Every 22,000 Service Hours

or Every 18,000 Service Hours

or Every 15,000 Service Hours

Overhaul

5

826 000 L

5

826 000 L

5

826 000 L

(1 537 000 U.S. gal) or Every 33,000 Service Hours

(1 537 000 U.S. gal) or Every 27,000 Service Hours

(1 537 500 U.S. gal) or Every 22,500 Service Hours