22/09/2019 3512C Marine Auxiliary SLM00001-UP(SEBP4539 - 43) - Documentation

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Product: MARINE AUXILIARY
Model: 3512C MARINE AUXILIARY SLM00266
Configuration: 3512C Marine Auxiliary SLM00001-UP

Operation and Maintenance Manual

3512C and 3516C Marine Auxiliary and Generator Set Engines
Media Number -SEBU8224-17 Publication Date -01/05/2019 Date Updated -31/05/2019

i07452117

Overhaul (Major)
SMCS - 7595-020-MJ

Refer to this Operation and Maintenance Manual, "Maintenance Recommendations" to determine the
maintenance interval for a major overhaul.

The need for a major overhaul is determined by several factors.

An increase of oil consumption

An increase of crankcase blowby

The total amount of fuel consumption

The service hours of the engine

The wear metal analysis of the lube oil

An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to
be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service.

Note: Oil analysis can indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so
that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals.

Monitor the engine as the engine accumulates service hours. Consult your Cat dealer about scheduling a
major overhaul.

Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.

A major overhaul includes all the work that is done for the top end overhaul. A major overhaul includes
more parts and labor. More parts and labor are required to rebuild the engine.

For the major overhaul, all the bearings, seals, gaskets, and components that wear are disassembled. The
parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The
crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Cat replacement
part.

Your Cat dealer can provide these services and components. Your Cat dealer can ensure that the components
are operating within the appropriate specifications.
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Inspection of Components
Inspect the following components according to the instructions that are in Cat reusability publications. Refer
to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability
or Salvage of Used Parts".

Aftertreatment - CEM housing and mounting structure

Aftertreatment - DEF nozzle

Aftertreatment - dosing cabinet

Aftercooler core

Camshaft

CEM

Crankshaft

Dosing cabinet

Driven equipment (alignment)

Engine cylinder block

Engine control module

Exhaust bellows shields

Flywheel

Front gear train (gears)

Oil suction screen

Rear gear train

Inspect the camshaft for damage to the journals and the lobes.

Inspect the crankshaft for any of the following conditions:

Deflection

Damage to the journals

Bearing material that has seized to the journals

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting
the wear patterns on the following components:

Rod bearing

Main bearings

Note: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection
process to check for cracks.

Replace the crankshaft vibration damper if any of the following conditions occur:

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Engine failure due to a broken crankshaft

Excessive wear of the front bearing for the crankshaft

Excessive wear of the gear train that is not caused by a lack of lubrication

Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:

Worn gear teeth

Unusual fit

Unusual wear

In addition to the inspection of components, inspect the alignment of the driven equipment. See the
Application and Installation Guide for the engine or see the literature that is provided by the OEM of the
driven equipment.

Inspection, Reconditioning, or Exchanging of Components

Inspect the following components according to the instructions that are in Cat reusability publications. Refer
to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability
or Salvage of Used Parts".

Recondition the worn components or exchange the components, if necessary. Your Cat dealer can provide
these services and components.

Camshaft followers

Camshaft thrust washers

Compressor outlet tubes and seals

Connecting rods

Crankshaft vibration damper

Cylinder head assembly

Cylinder liners

Dosing pump

Engine mounts

Scavenge oil pump

Engine wiring harness

Exhaust manifold seals

Exhaust manifold bellows

Fuel pressure regulating valve

Fuel priming pump

Fuel transfer pump

Inlet manifold gaskets

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Inlet manifold seals

Oil cooler core

Oil pump

Pistons

Piston pins

Prelube pump

Pushrods

Rocker arms

Spacer plate

Software update

Turbocharger

Inspect and Lubricate

Inspect and lubricate the following (If Equipped):

Duplex oil control valve linkage

Replacement of Components
Replace the following components during the major overhaul:

Aftertreatment - air regulator

Aftertreatment - air strainer

Aftertreatment - CEM sensors and harness

Aftertreatment - dosing cabinet sensors, harness, and solenoid valves

Aftertreatment - DEF nozzle

Aftertreatment - DEF strainer

Aftertreatment - SCR catalysts

Camshaft bearings

Check valve assembly (duplex filter group)

Connecting rod bearings

Crankshaft seals

Crankshaft thrust washers

Electronic unit injectors

Gear train bushings

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Gear train bearings

Main bearings

Piston rings

Cleaning of Components
Clean the oil cooler core and the aftercooler core. Then, pressure test both of these cores. For instructions on
cleaning the cores, see this Operation and Maintenance Manual, "Aftercooler Core - Inspect/Clean" topic.

Clean the oil suction screen. Also, remove side covers to clean the oil sump. For instructions on removal and
installation of components, see the Service Manual, "Disassembly and Assembly" module.

Obtain a Coolant Analysis

For conventional heavy-duty coolant/antifreeze, check the concentration of supplemental coolant additive
(SCA) regularly. The concentration of SCA can be checked with an S·O·S coolant analysis (Level 1). A
more detailed coolant analysis is recommended periodically.

For example, considerable deposits are found in the water jacket areas on the external cooling system, but the
concentrations of coolant additives were carefully maintained. The coolant water probably contained
minerals which were deposited on the engine over time.

A coolant analysis can be conducted to verify the condition of the water that is being used in the cooling
system. A full water analysis may be obtained from the following sources:

Cat dealer

Local water utility company

Agricultural agent

Independent laboratory

Caterpillar recommends an S·O·S coolant analysis (Level II). This analysis is a comprehensive chemical
evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system. The
following services are provided:

Full Level 1 analysis

Identification of the source of metal corrosion and of contaminants

Identification of buildup of the impurities that cause corrosion

Identification of buildup of the impurities that cause scaling

Determination of possible electrolysis within the engines cooling system

A report of the results of the analysis is provided. Maintenance recommendations are based on the results.

For more information about S·O·S coolant analysis, consult your Cat dealer.

Copyright 1993 - 2019 Caterpillar Inc. Sun Sep 22 2019 10:29:06 GMT-0300 (Horário Padrão de Brasília)
All Rights Reserved.
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