(029)engine3512.pdf

FRV40-226-029-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Engine, Diesel Model: 3512B

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-029-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Engine Diesel Model: 3512B

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

09 MAR 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-029-010

TITLE OF MANUAL: Engine, Diesel

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-029-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND, LLC

Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Engine, Diesel

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

50-SPNA-1-00031

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

c•TERPILLAR

@�®[J@�D@[fi) @[n)@ U0u@D [fi) � ® [fi)@[fi) © ®

U0tJ@[ru (ill@ �

SEBU6916-04

December 1999

3500B Engines and 3500 Engines With EUI Option

3DM1-Up (Engine) 4GM1-Up (Engine) 5XM1-Up (Engine) 6PM1-Up (Engine) 7KM1-Up (Engine) 8EM1-Up (Engine) 8RM1-Up (Engine) 6HN1-Up (Engine) 6PN1-Up (Engine) 6WN1 -Up (Engine) 7RN1-Up (Engine) 9AN1-Up (Engine) 3LS1-Up (Engine) 3MS1-Up (Engine) 3NS1-Up (Engine) 3TS1-Up (Engine) 3WS1-Up (Engine) 3XS1-Up (Engine) 1 NW1-Up (Engine) 1 PW1 -Up (Engine) 2FW1-Up (Engine)

2HW1-Up (Engine) 3DW1-Up (Engine) 4AW1-Up (Engine) i01097883

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

A WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

A WARNING

When replacement parts are required for this product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent specifications including, but not limited to, phys ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema ture failures, product damage, personal injury or death.

Table of Content; •

Table of Contents Maintenance Interval Schedule

Maintenance Interval Schedule (Standby Generator Foreword ................................................................. 4 Set Engines)

Safety Section Reference Information Section

Safety Signs and Labels ......................................... 6 Engine Ratings

General Hazard Information ................................. 12 Customer Service

Burn Prevention .................................................... 14 Reference Materials

Fire Prevention and Explosion Prevention ............ 14 Index Section

Crushing Prevention and Cutting Prevention ........ 15 Index

Mounting and Dismounting

Before Starting Engine

Engine Starting

Engine Stopping

Electrical System

Product Information Section

Model Views

Product Identification Information

Operation Section

Engine Lifting and Storage

Gauges and Indicators

Engine Features and Controls

Engine Starting

Engine Operation

Engine Stopping

Cold Weather Operation

Maintenance Section

Torque Specifications

Lubricant Specifications

Fuel Specifications

Cooling System Specifications

Refill Capacities

Foreword

Foreword

Literature Information

This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information.

English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information.

Safety

This safety section lists basic safety precautions.

In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation is a reference for vvv, uc cv,u.

Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required.

The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application .

We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record.

See the section in the Operation and Maintenance Manual, "Maintenance Records" for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval.

Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Caterpillar dealer.

Consult with your dealer for information regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Foreword

Safety Section Safety Signs and Labels

Safety Section

01231232

Safety Signs and Labels

SMCS Code: 1000; 7 405

There may be several specific safety signs on your engine. The exact location and a description of the signs are reviewed in this section. Please become familiar with all of the signs.

Ensure that all of the signs are legible. Clean the signs or replace the signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap for cleaning the signs. Do not use solvents, gasoline, or other harsh chemicals.

Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the signs. The signs that are loosened could drop off of the engine.

Replace any sign that is damaged or missing. If a sign is attached to a part of the engine that is replaced, install a new sign on the replacement part. Your Caterpillar dealer can provide new signs.

A, WARNING

Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Man ual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals.

Proper care is your responsibility.

The safety signs that may be attached on the engine are illustrated and described below.

Crankcase Covers

Illustration 1 g00386802

The warning labels for the crankcase covers are located on the crankcase covers.

·£WARNING

FLASH FIRE MAY RESULT IN PERSONAL

INJURY, IF CRANKCASE COVERS ARE

REMOVED WITHIN F IFTEEN MINUTES

AFTER EMERGENCY SHUT DOWN.

DO NOT REST ART ENGINE UNTIL CAUSE

FOR SHUT DOWN HAS BEEN CORRECTED.

1H4950 7

A,WARNING

g00123185

Flash fire may result in personal injury, if crankcase covers are removed within fifteen minutes after emergency shut down. Do not restart engine until cause for shutdown has been corrected.

Duplex Fuel Filter and Oil Filter

Illustration 2 g00580638

The warning label for the duplex fuel filter and the duplex oil filter is located on the cover of the fuel filter (1) and the oil filter (2).

FILTER CONTAINS HOT

PRESSURIZED FLUID WHEN

ENGINE IS RUNNING. FOLLOW

INSTRUCTIONS ON CONTROL.

VALVE TO AVOID INJURY.

IF RAPID AIR MOVEMENT

EXISTS TO BLOW FLUID. STOP

AWARNING'

g00306243

Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid injury if rapid air movement exists to blow fluid. Stop engine to avoid fire.

Safety Section

Safety Signs and Labels

Electrical Distribution (Generator)

Illustration 3 g00305862

The warning label for electrical distribution (generator) is located on the covers of the generator.

� WARNING

DO N(;f C(lNIIECl (;£NERA1(1R TO A UlllllY ElECTRICAJ.

D!SIR!Wl!ON SYSTEII UNLESS IT IS !SOU.TEO FROII THE S CTRICAl FE[OOACK INTO THE DIS!RllWTIOH

OCCUR ANO COULD CAUSE PERSONAL INJURY

CURE IIAlN DISTRI8U SYSTEM SWITCH.

CONNECTION IS PERIi A

E THROW TRANSFER SWlltH t[CTR]CAl ACK. SOIi[ GENERATORS ARE SPEC APPROVED

BY A UTll!TY TO RUN ]II PARAll[l WITH • IJOII SY$1[11 AND ISOlATlOII MAY NOT 8E Al.WAYS CHECK W]IH YOUR UT!lllY AS 10

CIRCUMSTANCES.

A WARNING

7W444S l g00296980

Do not connect generator to a utility electrical dis tribution system unless it is isolated from the sys tem. Electrical feedback into the distribution sys tem can occur and could cause personal injury or death.

Open and secure main distribution system switch, or if the connection is permanent, install a dou ble throw transfer switch to prevent electrical feed back. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circum stances.

Safety Section Safety Signs and Labels

Electrical Shock

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Illustration 4

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0 ?:��

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@ 8 g00580740

The warning label for electrical shock is located on the control panel.

g00580695

Electrical shock can cause personal injury or death. Before electrical equipment is serviced, disconnect the power. Electrical equipment includes the following components: engine control system, wiring harnesses, and sensors.

Emergency Stop

Illustration 5 g00305895

The warning label for emergency stop is located on the outside of the door of the control panel.

A WARNING

ALWAYS OPERATE THIS UNIT WITH

THE VANDAL DOOR OPEN.

OPERATING THE UNIT WITH THE

VANDAL DOOR CLOSED RESTRICTS

ACCESS TO THE EMERGENCY STOP

BUTTON AND COULD RESULT IN

INJURY OR DEATH.

109-4389

A WARNING

g00305896

Always operate this unit with the vandal door open. Operating the unit with the vandal door closed restricts access to the emergency stop button and could result in injury or death.

Radiator Coolant

Illustration 6 900658509

The radiator coolant warning label is located near the front of the radiator filler cap.

PRESSURIZED SYSTEM: HOT COOLANT

CAN CAUSE SERIOUS BURN. TO OPEN

CAP, STOP ENGINE. WAIT UNTIL

RADIATOR IS COOL. LOOSEN CAP

SLOWLY TO RELIEVE THE PRESSURE.

132-6200 g00658535

A, WARNING

Pressurized system: hot coolant can cause seri ous burn. To open cap, stop engine. Wait until radi ator is cool. Loosen cap slowly to relieve the pres sure.

Base Lifting

Illustration 7

Safety Section

Safety Signs and Labels g00658557

The base lifting warning label is located on the base.

1, WEIGHT, CENTER SYMBOL LOCATION ANO

INSTRUCTIONS GIVEN HEREIN APPLY TD UNIT

AS SHIPPED BY CATERPILLAR.

WEIGHT-kg (-POUNDS)

2. USE PROPER SPREAOER BAR AS DESCRIBED.

BECAVSE CENTER or GRAVITY 1$ ABOVE BASE LlrT POINTS.

3. AlTACH TWO PROPER RAlED CABLES FROM BASE Lin POINTS TO SPREADER BAR.

4, POSITION SPREADER BAR OVER CENTER

$'1'MB0Liif' FOR LEVfL LIFT.

,,A WARNING

900658561

Improper lift rigging can allow unit to tumble caus ing injury and damage.

Before lifting the generator set, read this Operation and Maintenance Manual, "Engine Lifting" topic (Operation Section).

If improper equipment is used to lift the generator set, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information on the warning label.

Safety Signs and Labels

High Voltage

Illustration 8 g00664982

The warning label for high voltage is located on the jacket water heater.

>� >.i,:

$, HIGH VOLT AGE$,

Power Source must be disconnected before working on equipment.

Failure to disconnect power source could result in injury or death.

111-7462 1

_A WARNING

g00481390

Power source must be disconnected before work ing on equipment.

Failure to disconnect power source could result in injury or death.

Engine Lifting

Illustration 9 g00580494

The warning label for lifting the engine is located on the valve covers.

IMPROPER L lrl

RIGGING CAN

ALLOW UNIT TO

TUMBLE CAUSING

INJURY AND

DAMAGE.

1. USE PROPER SPREADER

BAR AS SHOWN.

2. ATTACH TWO PROPER

RATED CABLES TO

SPREADER BAR FROM

ENGINE LIFTING EYE .••

3. REMOVE AF1ERC0DLER

WATER LINES Ir UFTING

APPARA1US INTERFERES.

�( .. :�n�:

3508 ENG -1112mm �43.8 IH) 3512 rnG-1652mmt55 IN) �""-ms

J508ENG-1112RH

3512ENG-1652RH

3516ENG-2192REF

_A WARNING

g00306083

Improper lift rigging can allow unit to tumble caus ing injury and damage.

Before lifting the engine, read this Operation and Maintenance Manual, "Engine Lifting" topic (Operation Section).

If improper equipment is used to lift the engine, injury and damage can occur. Use cables that are properly rated for the weight . Use a spreader bar and attach the cables according to the information on the warning label.

Operation

Illustration 10 g00306263

The warning label for operation is located on the outside of the door of the control panel.

Jl WARNING

00 NOT OPERATE OR WORK ON TH1S ENGINE OR

GENERATOR SET UNLESS YOll HAVE REAi> ANO

!INDERST AND THE INSTRUCTIONS ANO WARNINGS IN

TH[ OPERATlON AND IIA]NT[NANC[ IIANUALS.

FAILURE TO FOLLOW THE WARNlNGS AIII) INSTRUCTIONS COllLD RESIJL T IN INJURY OR DEATH. CONTACT

ANY CATERPILLAR DEALER FOR REPLACEMENT

MANllALS. PROPER CARE IS YOUR RESPONSIBllITY.

127-7071

A WARNII\IG ..

g00306265

Do not operate or work on this engine or genera tor set unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals.

Failure to follow the warnings and instructions could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Prop er care is your responsibility.

Safety Section

Safety Signs and Labels

Prelube Pump

Illustration 11 g00306383

The warning label for the prelube pump is located on the prelube pump.

BE

CODE AND LOCAL CODES, BY

PREVENT SERIOUS ELECTRICAL SHOCKS.

LlFTJNG PROVISIONS ARE INTENDED FOR LIFTING THE MOTOR HAS AN AUTOMATIC THERMAL PROTECTOR. Jr

OVERHEATS, THERMAL PROTECTOR WILL OPEN CIRCUIT.

AFTER MOTOR COOLS SUFFICIENTLY. THERMAL PROTECTOR Wll'c

RESET WITHOUT WARNING AND RESTART

TO SERVICE MOTOR. DISCONNECT POWER FROM MOTOR ANO ANY

ACCESSORY DEVICES AND ALLOW MOTOR TO COME TO A COMPLETE

STANDSTILL. 4W-67?2 1

g00306385

A,WARNING

Motor must be grounded in accordance with na tional electrical code and local codes, by trained personnel to prevent serious electrical shocks.

Lifting provisions are intended for lifting the motor only.

Motor has an automatic reset thermal protector. If motor overheats, thermal protector will open mo tor circuit.

After motor cools sufficiently, thermal protector will reset without warning and restart motor.

To service motor, disconnect power source from motor and any accessory devices and allow motor to come to a complete standstill.

General Hazard Information

Fuel Injectors

Illustration 12 g00580495

The unit injector warning label is located on the electronic control module (ECM) ( 1) and the valve covers (2).

ELECTRICAL SHOCK HAZARD

\&f UNIT INJECTOR SYSTEM� '{' 90-120 VOL TS rp

9Y-4294 2 g00103125

A, WARNING

Electrical shock hazard. The electronic unit injec tor system uses 90-120 volts.

The ECM sends a high voltage signal to the fuel injectors. To help prevent personal injury, disconnect the fuel injector connector. Do not come in contact with the harness connector for the fuel injector while the engine is operating.

i01159865

General Hazard Information

SMCS Code: 1000; 7405

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Tag, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls.

Illustration 13 g00104545

Do not allow unauthorized personnel on the engine or around the engine when the engine is serviced.

Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.

Cautiously remove the following parts:

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

Use caution when cover plates are removed.

Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.

• Wear a hard hat, protective glasses, and other protective equipment, as required.

• When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are secured in place on the engine.

• Never put maintenance fluids into glass containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine cannot be started.

• Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Always wear eye protection for cleaning the cooling system.

Fluid Penetration

Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. This includes leaks that are the size of a pin hole.

Safety Section

General Hazard Information

If fluid is injected into the skin, seek treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Fluid Spillage

Care must be used in order to ensure that the fluids are contained during the inspection, the maintenance, the testing, the adjusting, and the repair of the engine. Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled. Refer to the Special Publication, NENG2500. This publication explains the items that are needed for collecting and for containing fluids that are used in Caterpillar engines. Dispose of fluids according to local regulations.

Asbestos Information

Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free.

Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when any replacement parts that contain asbestos or debris that contains asbestos are handled.

The asbestos in these components is usually sealed or bonded in a resin. Handling these materials normally is not hazardous unless airborne dust that contains asbestos is generated.

Do not inhale dust that might be generated when components that contain asbestos fibers are handled. Inhaling this dust can be hazardous to your health.

If dust which may contain asbestos is present, follow these guidelines:

• Never use compressed air for cleaning.

• Avoid abrasion of materials that contain asbestos.

• Use a wet method to clean up asbestos debris.

A vacuum cleaner that is equipped with a high efficiency particulate air filter can also be used.

• Use exhaust ventilation when parts that contain asbestos are machined.

• Wear an approved respirator if there is no other way to control the dust.

• Comply with applicable rules and regulations for the work place. In the USA, use the Occupational Safety and Health Administration requirements.

These OSHA requirements can be found in "29

CFR 1910.1001".

Burn Prevention

• Obey environmental regulations for disposal of asbestos.

• Stay away from areas that might have asbestos particles in the air.

Lines, Tubes, and Hoses

Do not bend or strike high pressure lines. Do not install lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires.

Inspect all lines, tubes and hoses carefully. Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components for leaks. Tighten all connections to the recommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, and the heat shields are installed correctly. This will help to prevent these effects: vibration, rubbing against other parts, and excessive heat during operation.

Burn Prevention

SMCS Code: 1000; 7405 i00910250

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. When pressure is relieved rapidly, the hot coolant can turn into steam.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level only after the engine has been stopped.

Do not step on the engine in order to remove the filler cap. Use a ladder, if necessary. Ensure that the filler cap is cool before removing the filler cap.

Remove the filler cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Keep all of the exhaust manifold and turbocharger shields in place in order to protect components from oil spray if there is a failure of a line, a tube, or a seal.

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

Batteries give off combustible gases which can explode. Ensure proper ventilation for batteries that are in an enclosure. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases to ignite. Do not smoke when batteries are serviced.

Always thaw a frozen battery before jump starting the battery. Frozen batteries can explode.

i01027886

Fire Prevention and Explosion Prevention

SMCS Code: 1000; 7 405

A flash fire may result in personal injury if the crankcase covers are removed within fifteen minutes after an emergency shutdown.

Fire may result from lubricating oil or from fuel that is sprayed on hot surfaces. Fire may cause personal injury and property damage. Inspect all lines and tubes for wear or for deterioration. The lines must be properly routed. The lines must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires.

Determine whether the engine will be operated in an environment that allows combustible gases to be drawn in through the air inlet system. These gases could cause the engine to overspeed. This could result in bodily injury, property damage, or damage to the engine.

If the application involves the presence of combustible gases, consult your Caterpillar dealer in order to obtain additional information concerning suitable protection devices.

Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire.

All fuels, most lubricants, and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel fumes and gasoline fumes is extremely explosive.

Do not smoke while the engine is refueled. Do not smoke in the refueling area.

Store all fuels and all lubricants in properly marked containers. Store the protective containers in a safe place.

Do not smoke in battery charging areas. Batteries give off flammable fumes which can explode.

Do not smoke in areas that contain flammable material.

Store oily rags and other flammable material in protective containers.

Do not weld on pipes or tubes that contain flammable fluids. Do not flame cut pipes or tubes that contain flammable fluids. Before pipes or tubes are welded or flame cut, clean the inside and clean the outside of the pipes or tubes thoroughly with nonflammable solvent.

Do not allow flammable materials to accumulate on the engine.

Do not expose the engine to flames.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.

Safety Section

Crushing Prevention and Cutting Prevention

Dispose of oil according to local regulations. Oil filters and fuel filters must be properly installed. The housing covers must be tightened to the proper torque when the housing covers are reinstalled.

Batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Check the electrical wires daily for wires that are loose or frayed. Before the engine is operated, tighten all loose electrical wires. Repair all frayed electrical wires.

Wiring must be kept in good condition. Wires must be properly routed and securely attached. Routinely inspect the wiring for wear or for deterioration. Loose wiring, unattached wiring, or unnecessary wiring must be eliminated. All wires and all cables must be of the recommended gauge. Do not use a wire or a cable that is smaller than the recommended gauge. The wires and cables must be connected to a fuse or to a circuit breaker, as required. Do not bypass fuses and/or circuit breakers. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help prevent arcing or sparking.

Fire Extinguisher

Ensure that fire extinguishers are available. Be familiar with the operation of the fire extinguishers.

Inspect the fire extinguishers and service the fire extinguishers regularly. Service the fire extinguisher according to the recommendations on the instruction plate.

Crushing Prevention and Cutting Prevention

SMCS Code: '1000; 7 405 i00061952

Support the component properly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades (if equipped). The fan blades will throw objects and the fan blades can cut objects.

Mounting and Dismounting

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.

i00776840

Mounting and Dismounting

SMCS Code: 1000; 7405

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you are climbing. Use a hand line or other means for carrying equipment up to the work area.

i01072501

Before Starting Engine

SMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

Ensure that the engine is equipped with a lighting system that is suitable for the conditions. Ensure that all lights work properly.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.

For the initial start-up of a new engine and for start-up of an engine that has been serviced, prepare to stop the engine if an overspeed occurs.

This may be accomplished by shutting off the fuel and the air supply to the engine.

See the Service Manual for repairs and for adjustments.

Engine Starting

SMCS Code: 1000 i01103904

If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Start the engine from the operator's compartment or from the engine start switch.

Always start the engine according to the procedure that is described in this Operation and Maintenance Manual, "Engine Starting" topic (Operation Section).

Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working properly, check the water temperature gauge and the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion that can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

Ether

Ether is poisonous and flammable.

Do not inhale ether, and do not allow ether to contact the skin. Personal injury could result.

Do not smoke while ether cylinders are changed.

Use ether in well ventilated areas.

Use ether with care in order to avoid fires.

Keep ether cylinders out of the reach of unauthorized persons.

Store ether cylinders in authorized storage areas only.

Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).

Discard the ether cylinders in a sate place. Do not puncture the ether cylinders. Do not burn the ether cylinders.

i01032808

Engine Stopping

SMCS Code: 1000

To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to this Operation and Maintenance Manual, "Engine Stopping" topic (Operation Section).

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO NOT use the Emergency Stop Button for normal engine stopping.

After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed condition occurs. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine.

Electrical System

SMCS Code: 1000; 1400 i01105717

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

Safety Section

Engine Stopping

When the engine is started from an external source, follow this procedure: first, connect the positive "+" jump start cable from the external power source to the positive "+" battery terminal of the engine that is being started. Then connect the negative "-" jump start cable from the external power source to the negative "-" terminal of the starting motor. This will help to prevent sparks from igniting combustible gases that are produced by some batteries.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is operated. Repair all frayed electrical wires before the engine is started.

Grounding Practices

The electrical system for the engine must be properly grounded. Proper grounding is necessary for optimum engine performance and reliability.

Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in damage to main bearings, to the surface of crankshaft journals, and to aluminum components.

Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the performance of the engine electronics.

The alternator and the starting motor must be grounded to the negative "-" battery terminal.

A ground plate with a direct path to the negative "-" battery terminal may be used as a common ground for the components of one engine system.

For engines with an alternator that is grounded to an engine component, a ground strap must connect that component to the negative "-" battery terminal.

Also, that component must be electrically isolated from the engine.

The ground strap for the alternator must be of a size that is adequate for carrying the full charging current of the alternator.

Product Information Section Model Views

Product Information

Section

Model Views i01232663

Model View Illustrations

SMCS Code: 1000

The illustrations show various typical features of 35008 Engine. The illustrations do not show all of the options that are available.

Illustration 14

(1) Control panel

(2) Generator

(3) Oil filler cap

(4) OH level gauge {dipstick)

(5) Oil filters

(6) Secondary fuel filters

(7) Water drain

(8) Oil screen

(9) Oil drain plug g00659165

Illustration 15

(10) Cooling system filler cap

(11) Crankcase Breathers

Illustration 16

(1) Lifting eye

(2) Oil level gauge (dipstick)

(3) Oil filler cap

(4) Electronic instrument panel

(12) Exhaust

(13) Starting motors

(5) Oil filter

(6) Secondary fuel filter

(7) Air cleaner

(8) Cooling system filler cap

Product Information Section

Model Views g00659270

(14) Air cleaner

900659146

(9) Primary electronic control module (ECM)

(10) Water drain

(11) Oil screen

(12) Oil drain plug

Product Information Section

Model Views

Illustration 17

Marine auxiliary

( 1) Lifting eye

(12) Oil drain plug

Engine Description

SMCS Code: 1000

(13) Crankcase breathers

(14) Exhaust i01233137

The 3500 series engine and the 35008 series engine with EUI option are electronically controlled engines. The engines have electronic fuel injectors.

The engines are equipped with either jacket water aftercooling (JWAC) or separate circuit aftercooling (SCAC). The following engine models are available:

8 cylinder, 12 cylinder, and 16 cylinder.

Engine efficiency and engine performance depend on adherence to proper operation and malntenance recommendations. Follow the recommended Maintenance Schedule and use the recommended lubrication oils, fuels, and coolants.

Engine Specifications g00659132

Table 1

Item

Rated speed (rpm)

Cylinders and arrangement

Bore

Stroke

Type

Compression ratio

Aspiration

Method of cooling the turbocharged air

Displacement per cylinder

Total displacement

Rotation (flywheel end)

Fuel

Method of fuel injection

Method of starting

Exhaust back pressure (design)

Maximum allowable back pressure

Maximum inlet air Restriction

Inlet valve lash

Exhaust valve lash

8 --6- -4--2 i6ev6e\(o� (6e\

C

(.a\��� � _O)�_qJ�qJ �q)

7 --5--3--1

@--o ®--e

Illustration 18

3508 Engine

(A) Inlet valves

(B) Exhaust valves

(C) Flywheel

Product Information Section

Model Views

3500 Engine Specifications

3508 Engine I 3512 Engine l 3516 Engine

1000 to 1800

60 degree Vee 8 I 60 degree Vee 12 I 60 degree Vee 16

170 mm (6.7 inch)

190 mm (7.5 inch)

4 stroke cycle

13.5:1 (3500 Engines With EUI Option) 14:1 (3500B Engines)

Turbocharged

Separate circuit aftercooling (option)

Jacket water aftercooling

4.3 L (263 cu in)

34.5 L (2105 cu in) I 51.8 L (3158 cu in) l 69.1 L (4210 cu in)

Counterclockwise rotation is standard.

Clockwise rotation is optional.

See this Operation and Maintenance Manual, "Fuel Recommendations" g00308097

(Maintenance Section).

Electronic fuel injectors

Air starting motor

Electric starting motor

2.5 kPa (1 O inches of H20)

5 kPa (20 inch of H20)

6.2 kPa (25 inches of H20)

0.50 mm (0.020 inch)

01.00 mm (0.039 inch)

� (90\(90\ (90\ (90\ (90\ �q) \(t�O)�_q) �-q) �-q) �.O)

11-9-7-5-3--1

Illustration 19

3512 Engine

(A) Inlet valves

(B) Exhaust valves

(C) Flywheel g00308167

Model Views

16-14-12-10-8-6 -4- 2 (09\ (be'Voe'\ (Oe\(09\ r6e'\ r6e\ (Oe'\

I.a\ /9()\/.a\ /.a\/90\ I.a\ /90\ /90\ \•gJ\�9'�9)��¢J�_¢J�¢J�s)J�,q;15-13-11-9-7-5-3-1

Illustration 20 3516 Engine

(A) Inlet valves

(B) Exhaust valves

(C) Flywheel g00308357

Product Identification

Information

Engine Identification

SMCS Code: 1000 i01028428

Caterpillar engines are identified with serial numbers, with performance specification numbers, and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the Serial Number Plate and the Information Plate that are mounted on the engine.

Caterpillar dealers need these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers.

i00796457

Serial Number Plate

SMCS Code: 1000

Illustration 21 g00374172

(1) Location of the Serial Number Plate

The Serial Number Plate is on the left side of the cylinder block near the rear of the engine.

Product Information Section

Product Identification Information

ENGINE

MODEL

SERIAL

NUMBER

oC�TERPILLAR

C�T o

ARRANGEMENT

NUMBER

(ALWAYS GIVE ALL NUMBERS)

MADE IN U.S.A. 3N-3790 12

Illustration 22 g00123229

Serial Number Plate

The following information is stamped on the Serial Number Plate: engine serial number, model, and arrangement number.

Information Plate

SMCS Code: 1000

Illustration 23

(1) Location of the Information Plate i00796583 g00374353

The Information Plate is on the left side top surface of the cylinder block in front of the front cylinder head.

Product Identification Information

C..lT

SER. NO.

MOOIFICUION N(I.

,OS.

0£111

NO.

,1\\1�

:Sn

POWER

BARE E�.

ffl ll)l[ RPll

Illustration 24

Information Plate

HP

eORt Mt

8tlhtR£D

FIIU TORO.

suue run k• A/T RATIO

OYNAIIIIC

f P�t"c

ALT

900102789

The following information is stamped on the Information Plate: engine's maximum altitude, horsepower, high idle, full load rpm, fuel settings, and other information.

i01225382

Emissions Certification Film

SMCS Code: 1000

The emissions certification film (if equipped) is used to verify that the engine meets the EPA emissions requirements.

r··-- - - --- ----�

CIT

CATERPILLAR INC.

IMPORTANT ENGINE INFORMATION

SER NO. SRM00001

ENGINE MODEL 3516 DISPLACEMENT 69.0 L

VALVE LASH 0.50 mm INTAKE

ENGIHE FAMILY

MAX. ADVERTISED

POWER

MAX. RATED SPEED

1.00 mm EXHAUST

YCPXL69.DERK

1611 kW

(2160) IIP

1750 RPM

: MAX. LOW IDLE SPEED

MAX. FUEL RATE@

MAX.kW

EXHAUST EMISSION

700 RPM

463 mm3/STROKE

CONTROL SYSTEM EM,01, TC,ECM,CAC

. THIS ENlllNE CONFORMS TO 2000 U.S. EPA AND CALIFORNIA REGULATIONS IARGE NON-ROAll

COMPRESSION-IGNITION ENGINES. THIS ENGINE IS

CERTIFIED TO OPERATE OH COMMERCIALLY AVAILABLE

DIESEL FUEL.

OF MANUFACTURE (MONTH) 08 159•245S

Illustration 25 900633377

This is a typical example of the emissions certification film that is located on the engine.

ClT' CATERPILLAR INC.

I NFORMATION IMPORTA!m SUR LE MOTEUR

NO SERIE SRMOOOD1

MODELE MOTEUR 3516

JEU SOUl'APES

FAMILLE DE MOTE URS

MAXI PUB LIES

PIIISSANCE

DEBIT 69.0 I

ADM. 0,5-0mm �CHAP. 1,00 mm

YCPXL69.0ERK

161!

(215D) kW

HP

lr/nlll Ir/nm

MAXI REGIME NOMINAL

MAXI REGIMERALENTI

MAXI 9 EBIT D'INJ.

A PUIS. MAXI

DISPOSITIF

463 mm3,'STROKE (PISTON)

' AtlTl·POllUANT EM,01,TC,ECM,CAC

Illustration 26

CE MOTEUR EST CONFORME AUX REGLEMENTATIONS

OE L'AGENCE AMERICA!NE DE PROTECTION DE

L'ENVIRONNEMENT \EPA) ET DE LA CALIFORNIE POUR LES

GROS MOTEURS NON ROUTIERS A COMPRESSION•CONTACT.

CE MOTEUR EST HOMOLOGUE POUR FONCTIONNER AVEC LE

CARBUAANT DIESEL OU COMMERCE.

DATE DE FABRICATION (MOIS) 08

g00638527

This is the French version of the English emissions certification film that is located on the engine.

i01070185

Reference Numbers

SMCS Code: '1000

Identification of the items in Table 2 may be needed in order to obtain parts and service. Some of the numbers are on the engine Serial Number Plate and/or Information Plate. Locate the information for your engine. Record the information on the appropriate space in Table 2. Make a copy of this list for a record . Retain the information for future reference.

The top level part numbers in the Parts Manual for the engine are listed with the engine arrangement number. Occasionally, an arrangement may be slightly modified before the product is shipped from the factory. In these cases, a modification number indicates that the arrangement has been modified.

The packaging arrangement may also be called a pricing arrangement or a customer arrangement.

This is the total package with attachments and options that are not included in the engine arrangement.

The performance specification can be used by your Caterpillar dealer with the Technical Marketing Information system. Before the engine leaves the factory, the engine performance is tested. Detailed performance data is recorded. The performance specification number can be used for obtaining the data.

Table 2

Reference Numbers

Engine Model

Serial Number

Arrangement Number

Modification Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the Lubrication System

Capacity of the Cooling System

Performance Specification Number

Personality Module

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

Product Identification Information

Operation Section Engine Lifting and Storage

Operation Section

Engine Lifting and Storage i01028350

Engine Lifting

SMCS Code: 1000; "1 "122

Illustration 27 g00103219

NOTICE

Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remem ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be comes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. T he chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting fixtures in order to obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that are on the engine.

Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided.

Consult your Caterpillar dealer for information regarding fixtures for proper engine lifting.

Engine Lifting with a Generator

NOTICE

Do not use the engine lifting eyes to remove the engine and generator…