Overhaul Intervals

3512B Generator Set YBB00001-UP(SEBP6577 - 11) - Systems & Components Page 1 of 6
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Product: GENERATOR SET

Model: 3512B GENERATOR SET YBB00430
Configuration: 3512B Generator Set YBB00001-UP
Operation and Maintenance Manual

3500B Generator Sets
Media Number -SEBU8468-17 Publication Date -01/01/2015 Date Updated -06/09/2017
i03195329
Maintenance Recommendations
SMCS - 1000
Overhaul Intervals
Some factors that are important for determining the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants
• Use of recommended coolants
• Use of recommended fuels
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
Generally, engines that are operated at a reduced load and/or speed achieve more service life before
an overhaul. However, this is for engines that are properly operated and maintained.
Other factors must also be considered for determining a major overhaul:
• The total amount of fuel consumption
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/30/2019
• The service hours of the engine
• An increase of oil consumption
• An increase of crankcase blowby
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts
require service.
Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute
the wear metals.
Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service when the engine is overhauled. Refer to the
literature that is provided by the OEM of the driven equipment.
Using Fuel Consumption For Calculating the Overhaul Intervals

Experience has shown that maintenance intervals are most accurately based on fuel consumption. Fuel
consumption corresponds more accurately to the engine load. Tables 1, and 2 list average ranges of
fuel consumption and service hours for standard displacement engines. Tables 3 and 4 list average
ranges of fuel consumption and service hours for high displacement engines. These tables are based
on a load factor of approximately 60 percent.
Standard Displacement Engines

Table 1
Service Hours and Fuel Consumption for 3512B Engines(1)
Interval Rated Up To 1300 Rated 1301 to 1600 Rated 1601 to 1800
RPM RPM RPM
250 Service 33400 L 41000 L (10800 US gal) 48500 L (12800 US gal)
Hours (8800 US gal) of fuel of fuel
2000 Service 267000 L 328000 L (86400 US gal) 388000 L
Hours (70000 US gal) of fuel (102400 US gal) of fuel
3000 Service 398000 L 491000 L 582000 L

Hours (105000 US gal) (129600 US gal) of fuel (153600 US gal) of fuel
6000 Service 796000 L 982000 L 1164000 L
Top End 11000 Service Hours 9000 Service Hours 7500 Service Hours
Overhaul
1500000 L (395000 US gal) of fuel
Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours
Overhaul 3000000 L (790000 US gal) of fuel
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
4500000 L (1185000 US gal) of fuel
(1)
Fuel consumption is based on a load factor of approximately 60 percent.
Table 2
Service Hours and Fuel Consumption for 3516B Engines(1)
Interval Rated Up To 1300 Rated 1301 to 1600 Rated 1601 to 1800
RPM RPM RPM
2000 Service 352000 L 424000 L 516000 L
3000 Service 528700 L 636700 L 773000 L
6000 Service 1056000 L 1272000 L 1548000 L
Overhaul
2000000 L (528000 US gal) of fuel
Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
6000000 L (1584000 US gal) of fuel

(1)
High Displacement Engines

Table 3
Service Hours and Fuel Consumption for 3512B High Displacement Engines(1)
Interval Rated 1301 to 1600 Rated 1601 to 1800
Rated Up to 1300 RPM
RPM RPM
250 Service 33400 L (8800 US gal) of 41000 L (10800 US gal) 48500 L (12800 US gal)
Hours fuel of fuel of fuel
500 Service 66800 L (17600 US gal) 82000 L (21600 US gal) 97000 L (25600 US gal)
Hours of fuel of fuel of fuel
2000 Service 267000 L (70000 US gal) 328000 L (86400 US gal) 388000 L
Hours of fuel of fuel (102400 US gal) of fuel
3000 Service 398000 L 491000 L 582000 L
Hours (105000 US gal) of fuel (129600 US gal) of fuel (153600 US gal) of fuel
6000 Service 796000 L 982000 L 1164000 L
Overhaul
1500000 L (395000 US gal) of fuel
Major 22000 Service Hours 18000 Service Hours 15000 Service Hours
(1)
Table 4
Service Hours and Fuel Consumption for 3516B High Displacement Engines(1)
Interval Rated 1301 to 1600 Rated 1601 to 1800
Rated Up to 1300 RPM
RPM RPM
2000 Service 352000 L (93000 US gal) 424000 L 516000 L
Hours of fuel (112000 US gal) of fuel (136000 US gal) of fuel
3000 Service 528700 L 636700 L 773000 L
6000 Service 1056000 L 1272000 L 1548000 L
Overhaul
2000000 L (528000 US gal) of fuel
Major 22000 Service Hours 18000 Service Hours 15000 Service Hours
(1)
Use the actual records of fuel consumption, when possible. If the actual records are not available, use
the following procedure in order to estimate the fuel consumption.
1. Estimate the average percent of the load for the operation of the engine.
2. Refer to the fuel consumption data in the Technical Marketing Information (TMI) for your
engine. This will determine the fuel consumption for the percent of the load that was estimated
in Step 1. Use this figure as variable "F" for the equation in Table 5. For more information
about the Technical Marketing Information (TMI) for your engine, consult your Caterpillar
dealer.
Table 5
Equation For Calculating Overhaul Intervals
F/R = H
“F” is the estimated total amount of fuel consumption of the engine.
“R” is the rate of fuel consumption in liters per hour or gallons per hour.
“H” is the number of estimated hours until the overhaul interval.
Oil Consumption as an Overhaul Indicator

Oil consumption, fuel consumption, and maintenance information can be used to estimate the total
operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required
capacity of a makeup oil tank that is suitable for the maintenance intervals.
Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is consumed per hour also increases.
The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your
Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.
When an engine's oil consumption has risen to three times the original oil consumption rate due
to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.
Copyright 1993 - 2019 Caterpillar Inc. Tue Jul 30 21:28:09 UTC+0200 2019
All Rights Reserved.
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3512B Generator Set YBB00001-UP(SEBP6577 - 11) - Systems & Components Page 1 of 6

Product: GENERATOR SET

Operation and Maintenance Manual

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Operation within acceptable limits

Other factors must also be considered for determining a major overhaul:

• The total amount of fuel consumption

• The service hours of the engine

• An increase of oil consumption

• An increase of crankcase blowby

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

Using Fuel Consumption For Calculating the Overhaul Intervals

Standard Displacement Engines

3000 Service 398000 L 491000 L 582000 L

6000000 L (1584000 US gal) of fuel

High Displacement Engines

Oil Consumption as an Overhaul Indicator

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