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Operation and Maintenance Manual 3500E Marine Engines MR2 1-UP (Engine) MR3 1-UP (Engine) MR4 1-UP (Engine) MR7 1-UP (Engine) MR8 1-UP (Engine) MR9 1-UP (Engine) MRC 1-UP (Engine) MRN 1-UP (Engine) MRY 1-UP (Engine) MD3 1-UP (Engine) MD5 1-UP (Engine)

M0065584-05 (en-us) October 2017 i06558969

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, including human factors that can affect safety. 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 verify that you are authorized to perform this work, and 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.

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.

A non-exhaustive list of 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. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

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. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat re-placement parts.

Failure to follow this warning may lead to pre-mature failures, product damage, personal in-jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

Table of Contents

Foreword

Safety Section

Safety Messages

General Hazard Information

Burn Prevention

Fire Prevention and Explosion Prevention

Crushing Prevention and Cutting Prevention.. 17

Mounting and Dismounting

Before Starting Engine

Engine Starting

Engine Stopping

Electrical System

Engine Electronics

Product Information Section

General Information

Product Identification Information

Operation Section

Lifting and Storage

Features and Controls

Engine Starting

Engine Operation

Cold Weather Operation

Engine Stopping

Maintenance Section

Refill Capacities

Maintenance Recommendations

Maintenance Interval Schedule

Warranty Section

Warranty Information

Reference Information Section

Engine Ratings

Engine Performance and Performance Analysis Report (PAR)

Customer Service

Reference Materials

Index Section

Index

M0065584-05 3 Table of Contents

Foreword

Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine 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 Cat 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 Cat 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 section is a reference for operators.

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 Cat 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 Cat dealer. Your Cat 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 Cat 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.

4 M0065584-05 Foreword

Safety Section i06672655

Safety Messages SMCS Code: 1000; 7405

There may be several specific safety messages on your engine. The exact location and a description of the safety messages are reviewed in this section.

Become familiar with all the safety messages.

Ensure that all the safety messages are legible.

Clean the safety messages or replace the safety messages if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap for cleaning the safety messages. Do not use solvents, gasoline, or other harsh chemicals.

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

Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Cat dealer can provide new safety messages.

M0065584-05 5

Safety Messages

Illustration 1 g06067848

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Illustration 2 g06067995

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Illustration 3 g06110613

(1) Universal Warning

Illustration 4 g01370904

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

One safety message is on the first rocker arm cover and on the last rocker arm cover on each side of the engine. A safety message is also on the front of the dosing cabinet.

(2) Hot Surface

Illustration 5 g01372256

Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or compo-nents to contact your skin. Use protective cloth-ing or protective equipment to protect your skin.

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These safety messages are on the valve cover on each side of the engine.

(3) Hot Surface

Illustration 6 g01384734

Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or compo-nents to contact your skin. Use protective cloth-ing or protective equipment to protect your skin.

One safety message is on the oil cooler on the right side of the engine. One safety message is on a crankcase cover on the left side of the engine.

(4) Fire Hazard

Illustration 7 g01948611

Fire Hazard! Stop the Engine. Do not open the service doors if a fire exists. Opening the service doors if a fire exists could result in personal in-jury or death. Read and understand the instruc-tions in the Operation and Maintenance Manual.

One safety message is on a crankcase cover on each side of the engine.

(5) Vapor Explosion

Illustration 8 g01407639

Warning: Vapor Explosion. Could cause serious injury or death. Read the Operation and Mainte-nance Manual before conducting any mainte-nance on the duplex fuel filter.

M0065584-05 9

This safety message is on the oil filter housing and fuel filter housing.

(6) Hot Fluid Under Pressure

Illustration 9 g01371640

Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before per-forming any cooling system maintenance.

One safety message is on the top of the expansion tank.

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General Hazard Information SMCS Code: 1000; 4450; 7405

Illustration 10 g03838041

Attach a “Do Not Operate” warning tag to the start switch or controls before the engine is serviced or repaired. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Attach the warning tags to the engine and to each operator control station. When appropriate, disconnect the starting controls.

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

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

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.

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

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General Hazard Information

Illustration 11 g00702020

• 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 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.

• The protective locks or the controls are in the applied position.

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

Tape the leads to help prevent sparks.

• When starting a new engine, make provisions to stop the engine if an overspeed occurs. If an engine has not been started since service has been performed, make provisions to stop the engine if an overspeed occurs. Shutting down the engine may be accomplished by shutting off the fuel supply and/or the air supply to the engine.

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

• Start the engine with the operator controls. Never short across the starting motor terminals or the batteries. This method of starting the engine could bypass the engine neutral start system and/or the electrical system could be damaged.

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

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Always wear eye protection for cleaning the cooling system.

M0065584-05 11

Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited on hot surfaces.

Fluid Penetration

Illustration 12 g00687600

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICE

Care must be taken to ensure that fluids are con-tained during performance of inspection, mainte-nance, testing, adjusting, and repair of the product.

Be prepared to collect the fluid with suitable contain-ers before opening any compartment or disassem-bling any component containing fluids.

Refer to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultra-low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive.

Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.

Avoid static electricity risk when fueling. Ultra-low sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formula-tions with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

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

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Ensure that all the clamps, the guards, and the heat shields are installed correctly. Correct installation of these components will help to prevent these effects:

vibration, rubbing against other parts and excessive heat during operation.

Inhalation

Illustration 13 g02159053

Exhaust Use caution. Exhaust fumes can be hazardous to your health. If you operate the equipment in an enclosed area, adequate ventilation is necessary.

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

Caterpillar recommends the use of only genuine Cat replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, there are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method to clean up asbestos materials.

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

• Use exhaust ventilation on permanent machining jobs.

• 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 United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of asbestos.

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

Softwrap Keep the engine room ventilation operating at full capacity. Wear a particulate respirator that has been approved by the National Institute of Occupational Safety and Health (NIOSH). Wear appropriate protective clothing to minimize direct contact. Use good hygiene practices and wash hands thoroughly after handling Softwrap material. Do not smoke until washing hands thoroughly after handling Softwrap material. Clean up debris with a vacuum or by wet sweeping. Do not use pressurized air to clean up debris.

M0065584-05 13

Reference: The applicable material safety data sheets can be found at the following web site by searching using part number or the name:

https://emsds.ecorp.cat.com/catmsdssearch.cfm msdsSearch.controller.

UserIdentificationDisplayServlet

Dispose of Waste Properly

Illustration 14 g00706404

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Aftertreatment A used catalyst should be disposed of in a method conforming to all applicable local, state, and federal/ national regulations and that does not constitute a hazard to the surrounding population or environment. Such method(s) of disposal potentially may include recycling or disposal into a landfill, if allowed by local, state, and federal/national regulations.

i01480768

Burn Prevention SMCS Code: 1000; 4450; 7405

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 air system, in the hydraulic system, 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.

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 after the engine has stopped and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure.

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Burn Prevention

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 lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

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.

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Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405

Illustration 15 g00704000

Use of personal protection equipment (PPE) may be needed.

All fuels, most lubricants, and some coolant mixtures are flammable.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your Cat dealer for service.

Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.

A flash fire may result if the covers for the engine crankcase are removed within 15 minutes after an emergency shutdown.

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

If the application involves the presence of combustible gases, consult your Cat dealer for additional information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any flammable materials to accumulate on the engine.

All fluids that are captured in the fluid spill containment basin should be cleaned up immediately. Failure to clean up spilled fluids can cause a fire. Fire may cause personal injury and property damage.

Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

Do not expose the engine to any flame.

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

Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.

Wiring must be kept in good condition. Properly route and attach all electrical wires. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.

Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires.

Properly install all oil filters and fuel filters. The filter housings must be tightened to the proper torque.

M0065584-05 15

Fire Prevention and Explosion Prevention

Illustration 16 g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.

Avoid static electricity risk when fueling. Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations with a higher Sulfur content. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Illustration 17 g02298225

Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

Do not charge a frozen battery. Charging a frozen battery may result in an explosion.

The 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.

Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Ether Ether is flammable and poisonous.

Use ether in ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.

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Fire Prevention and Explosion Prevention

Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks.

Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel.

Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting.

Lines, Tubes, and Hoses Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install any lines that are bent or damaged.

Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Cat dealer for repair or for replacement parts.

Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Replace the parts if any of the following conditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly in order to prevent vibration, rubbing against other parts, and excessive heat.

i01359666

Crushing Prevention and Cutting Prevention SMCS Code: 1000; 4450; 7405

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. The fan blades will throw objects or cut objects.

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.

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Mounting and Dismounting SMCS Code: 1000; 4450; 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 mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

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Before Starting Engine SMCS Code: 1000

NOTICE

For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.

M0065584-05 17

Crushing Prevention and Cutting Prevention

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

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.

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

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.

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.

See the Service Manual for repairs and for adjustments.

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Engine Starting SMCS Code: 1000

NOTICE

DO NOT USE ETHER STARTING FLUID IN DIESEL

ENGINES EQUIPPED WITH SCR CATALYSTS

If a warning tag is attached to the engine start switch or to the controls, DO NOTstart 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 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.

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 ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

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Engine Stopping SMCS Code: 1000

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

To avoid overheating the engine and accelerated wear of 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 NOTstart the engine until the problem that caused the emergency stop has been corrected.

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

Ensure that the Dosing System air supply is maintained during cool down and shutdown to ensure that the system can purge unused urea properly.

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Engine Starting i05581769

Electrical System SMCS Code: 1000; 1400

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.

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 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 crankshaft bearing journal surfaces, and to aluminum components.

Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications.

Ensure that all grounds are secure and free of corrosion.

The engine alternator must be grounded to the negative “-” battery terminal. The ground wire must be adequate to carry the full charging current of the alternator.

For the starting motor, do not attach the battery negative terminal to the engine block.

Ground the engine block with a ground strap that is furnished by the customer. Connect this ground strap to the ground plane.

Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane.

A grounding stud is located inside the dosing cabinet of the aftertreatment system.

If rubber couplings connect the steel piping of the cooling system and the radiator, the piping and the radiator can be electrically isolated. Ensure that the piping and the radiator are continuously grounded to the engine. Use ground straps that bypass the rubber couplings.

i04561495

Engine Electronics SMCS Code: 1000; 1900

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

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

Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/ or engine damage.

Note: The monitoring system can only be programmed with electronic service tools and passwords. For information on programming, see the Service Manual, “Troubleshooting” module.

The engine has a monitoring system that can respond to abnormal engine operation with these modes:WARNING, DERATE and SHUTDOWN.

These modes are available in order to help prevent damage to the engine. The customer can program these modes “ON” or “OFF” .

A warning indicates a serious condition that requires immediate attention. If a derating occurs, the engine power and/or the engine rpm is limited.

The following conditions will cause an engine shutdown:

• Engine overspeed

• High aftercooler coolant temperature

• Low aftercooler coolant level

• High coolant temperature (jacket water)

• Low coolant level (jacket water)

• High crankcase pressure

M0065584-05 19

Electrical System

• High oil temperature

• Low engine oil pressure

Except for an overspeed shutdown, the monitoring system can be overridden. An override switch is located in the Electronic Instrument Panel. Use of the switch will allow the engine to provide full power during an abnormal engine operating condition. The override switch is provided only for use in emergency situations.

For more information on the conditions that can initiate warnings, deratings, and shutdowns, see this Operation and Maintenance Manual, “Monitoring System” topic (Operation Section).

20 M0065584-05

Engine Electronics

Product Information Section

General Information i06580320

Model View Illustrations SMCS Code: 1000

The illustrations show typical features of the Cat 3500E Marine Engine. The illustrations also show typical aftertreatment components. The illustrations do not show all the options and configurations that may be available.

Illustration 18 g06068323

Right side view of the 3516E Marine Engine

(1) Exhaust outlet

(2) Heat shield for the turbochargers and for the exhaust outlet elbow

(3) Exhaust bypass valve

(4) Aftercooler cover

(5) Engine crankcase breathers

(6) Wiring harness heat shield

(7) Engine oil filler

(8) Engine oil filter

(9) Fuel filter

(10) Fuel priming pump

(11) Expansion tank

(12) Engine oil sampling port

(13) Engine oil pump

(14) Pyrometer gauge

(15) Engine oil cooler

(16) Fuel transfer pump

(17) Engine oil level gauge

M0065584-05 21 Product Information Section

General Information

Illustration 19 g06068332

Left side view of the 3516E Marine Engine

(1) Water level gauge/switch

(2) Cooling system temperature regulator

(3) Air cleaner

(4) Starting motors

(5) Explosion relief valves

(6) Electronic Control Module (ECM)

(7) Thermostatic valve

(8) Water pump

(9) Electronic Control Module (ECM)

22 M0065584-05

Model View Illustrations

Illustration 20 g06070088

Right Side View of the 3512E Marine Engine

M0065584-05 23

Illustration 21 g06070092

Left Side View of the 3512E Marine Engine

24 M0065584-05

Illustration 22 g06070374

Dosing Cabinet

(1) Assist air out to CEM

(2) Assist air in and air strainer

(3) DEF inlet and strainer

(4) DEF out to CEM

(5) Service tool connector

(6) Electrical harness connection to engine

ECM

(7) Electrical harness connection to DEF transfer pump and DEF tank

(8) Electrical harness connection to CEM

(9) DEF vent port

(10) Circuit breaker cover

(11) Electrical wiring access grommet

(12) Circuit breakers

M0065584-05 25

Illustration 23 g06031600

U-Flow Reactor Housing

(1) Outlet spool

(2) DEF nozzle

(3) Inlet spool

(4) Inlet sensor box

(5) Serial number/information plate

(6) Lifting eyes

(7) Catalyst access cover

(8) Outlet sensor box

(9) Mounting brackets

26 M0065584-05

Illustration 24 g06031612

Z-Flow Reactor Housing

(1) Outlet spool

(2) DEF nozzle

(3) Inlet spool

(4) Inlet sensor box

(5) Serial number/information plate

(6) Lifting eyes

(7) Catalyst access cover

(8) Outlet sensor box

(9) Mounting brackets i06580381

Product Description SMCS Code: 1000; 4450; 4491

The 3500E Marine Engine is an electronically controlled diesel engine. The engine has an electronic unit injector. The engine can be equipped with either separate circuit aftercooling or jacket water aftercooling.

Engine efficiency and engine performance depend on adherence to proper operation and maintenance recommendations. Use the recommended fuels, lubrication oils, and coolant. Pay special attention to the air cleaner, to the fuel system, to the lubrication system, and to the cooling system maintenance.

Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information on maintenance items.

M0065584-05 27

Product Description

Table 1

3500E Engine Specifications

Item 3516E 3516E

Rated speed (rpm) 1800 RPM 1800 RPM

Cylinders and arrangement 60 degree Vee 16 60 degree Vee 12

Bore 170 mm (6.7 inch) 170 mm (6.7 inch)

Stroke 215 mm (8.5 inch) 215 mm (8.5 inch)

Type 4-stroke cycle 4-stroke cycle

Compression ratio 14.3:1 14.3:1

Aspiration Turbocharged Turbocharged

Method of cooling the turbocharged air Separate circuit aftercooling Separate circuit aftercooling

Displacement per cylinder 4.9 L (299 cubic inch) 4.9 L (299 cubic inch)

Total displacement 78 L (4760 cubic inch) 58.8 L (3588 cubic inch)

Rotation (flywheel end) Counterclockwise rotation Counterclockwise rotation

Method of fuel injection Electronic fuel injectors Electronic fuel injectors

Method of starting Electric starting motor or air starting motor Electric starting motor or air starting motor

Exhaust back pressure (customer piping) 6.7 kPa (26.92 inch of H2O) 6.7 kPa (26.92 inch of H2O)

Total back pressure 18.65 kPa (75 inch of H2O) 18.65 kPa (75 inch of H2O)

Maximum inlet air restriction 2.5 kPa (10 inch of H2O) 2.5 kPa (10 inch of H2O)

Illustration 25 g00308167

3512E Marine Engine

(A) Inlet valve

(B) Exhaust valve

(C) Flywheel

Illustration 26 g00308357

3516E Marine Engine

(A) Inlet valves

(B) Exhaust valves

(C) Flywheel

28 M0065584-05

Aftertreatment system description

Illustration 27 g06031628

Caterpillar supplied aftertreatment components are illustrated with dashed line rectangles.

Selective Catalyst Reduction (SCR) catalyst technology is used to reduce NOx emissions and particulate matter.

The aftertreatment system is composed of the following components:

• Air compressor

• Bulk Urea Transfer Pump

• DEF Dosing cabinet

• DEF Filter

• DEF Mixing tube

• DEF Nozzle

• DEF Supply tank

• SCR catalysts

• SCR reactor housing

Engine exhaust flows into the SCR System reactor housing through the exhaust inlet. Once sufficient temperature is achieved, the DEF is injected into the exhaust. Exhaust flows through a mixer assembly in the mixing tube to ensure that exhaust is not stratified for uniformity. This mixing will ensure complete disbursement across SCR catalyst section. Precise DEF injection is monitored and controlled by an electronic controller in the dosing cabinet. The following components provide signals to the controller to control DEF injection for emission reduction:

• Thermocouple located in the reactor housing.

• Inlet NOx sensor located in the exhaust before the inlet to the SCR catalyst reactor housing.

M0065584-05 29

• Outlet NOx sensor located in the exhaust at the outlet of the SCR catalyst reactor housing.

When engine operating conditions dictate, DEF fluid is injected into the exhaust stream before entering the SCR. When injected into the exhaust stream, the DEF is atomized into droplets. The atomized droplets are then sent through the mixer. The mixer disrupts the exhaust flow and allows DEF to be distributed throughout the exhaust gas. Water evaporates due to the high temperature of the exhaust. This process will cause the DEF to decompose and release ammonia (NH3) that was bound to the DEF. NH3 is free to react with the NOX and the oxygen present in the exhaust system stream. This reaction occurs on the SCR catalyst. NH3 and NOX are converted into gas particles of nitrogen and water. The inlet and outlet NOX sensors read the levels of NOX and determine how much DEF needs to be injected into the exhaust.

Dosing Cabinet

The dosing control cabinet controls the following:

• Rate of DEF flow to the injector

• Compressed air pressure

• Urea purge shutdown cycle

The aftertreatment ECM located in the dosing cabinet and the Cat ECM are designed to communicate with each other. This communication controls the complete engine/emission system to meet emission levels.

DEF Tank There are two separate DEF tanks in the dosing system.

• DEF tank 1 is the customer installed DEF tank.

DEF tank 1 is the bulk DEF tank. A DEF high and low-level switch in tank 1 will notify the operator when the tank requires refilling.

• DEF tank 2 is the buffer tank located in the dosing cabinet. Tank 2 is a small DEF tank that is filled from DEF tank 1. Tank 2 provides DEF to the DEF pump to be injected into the exhaust.

Reactor Housing

The reactor housing contains the following:

• SCR catalyst substrates

• DEF nozzle

• DEF mixing tube

• SCR catalyst temperature and pressure sensors

• NOx sensors

The aftertreatment ECM uses the sensors on the module to determine how much DEF needs to be injected into the exhaust system.

Selective Catalytic Reduction Substrate

The Selective Catalyst Reduction (SCR) substrates are located in the reactor housing. These catalysts allow exhaust to flow through the substrate converting the NOx into N2 and H20.

The exact chemical formulation of the catalyst has been engineered for this engine to provide optimal system performance and durability.

30 M0065584-05

Product Identification Information i06580424

Plate Locations and Film Locations SMCS Code: 1000; 4450

Engine Identification Cat 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.

Cat dealers need these numbers to determine the components that were included with the engine.

Information on the Serial Number Plate and the Information Plate allows dealers to identify replacement part numbers.

Serial Number Plate

Illustration 28 g02871718

View of the Serial Number Plate on the left side of a typical 3500E Marine Engine. Components have been removed for visibility.

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

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

Illustration 29 g00123229

Typical Serial Number Plate

Information Plate

Illustration 30 g02871719

View of the Information Plate on the left side of a typical 3500E Marine Engine. Components have been removed for visibility.

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

M0065584-05 31

Product Identification Information

Illustration 31 g00102789

Typical Information Plate

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

Dosing Cabinet Identification The dosing cabinet identification plate is on the front of the dosing cabinet.

CEM Identification

Illustration 32 g06067128

Typical location of the CEM identification plate. The identification plate is on top of the CEM housing. The specific location may be different depending on CEM configuration.

i04019095

Emissions Certification Film SMCS Code: 1000; 7405

Note: This information…