Engine Division November 1999

Product News Cat® 3500 Marine Engine

Extended Service Interval

Market Marine

Application Marine propulsion

Description The recommended overhaul schedules for most 3500 family

marine engines have been extended by 50 percent.
Recommendations for hours-to-overhaul are based on average
operational load factors and adherence to other recommended
service intervals. Lower load factors or better-than-recommended
maintenance practices will contribute to extended overhaul
intervals. Total fuel consumed, rather than the number of
operating hours, provides the best indicator for determining
service intervals for load-sensitive components.
Service hour and fuel consumption charts included in this
document provide average fuel consumption rates based on a load
factor of approximately 60 percent. Also included are maintenance
service schedules for basic engine, fuel system, air induction and
exhaust system, lubrication system, cooling system, start/stop
system, electrical system, and driven equipment.

Features & Benefits Extended overhaul intervals provide a significant reduction in

lifetime operating costs for existing field engines and new
engines.

General Comments
The extended overhaul interval does not apply to the new 3500B
High Displacement engines and the 3500 High Performance
engines.
Maintenance schedules are published in Operation and
Maintenance manuals for each engine and in other publications
such as Marine Engine Maintenance Schedules LEXM6231 for
commercial applications and LEXM8621 for high performance
applications.

LEXM9563 Information contained in this publication may be considered © 1999 Caterpillar Inc.
confidential. Discretion is recommended when distributing. All rights reserved.
Materials and specifications are subject to change without notice. Printed in U.S.A.
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series)

Maintenance Service Schedules
NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at
service interval.
Service Interval
Basic Engine Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Walk-Around Inspection Check X
Daily Engine Log Record Activity X
Valves/Bridge Adjust — 1st 250/500 hrs X
Engine — Clean Clean X
Valves/Bridge Adjust X
Engine Mounts Inspect X
Damper Inspect X
Push Rods Inspect/Replace 25% 25%
Spacer Plate Inspect/Replace 33% 33% 66%
Cylinder Head As
(Hd/Valve/etc.) Insp/Rebld/Exch 50% 50%
Cylinder Head As
(Hd/Valve/etc.) Install New 100%
Rocker Arms Insp/Rebld/Exch 25% 75%
Cam Shaft Lifters Inspect/Exchange 25% 75%
Cam Shaft Inspect 50%
Rear Gear Train — Gears Inspect 50%
Cylinder Block Inspect 1%
Front Gear Train — Gears Inspect 50%
Cam Thrust Washer Inspect/Exchange 50%
Crankshaft Inspect/Exchange 50%
Flywheel Inspect/Exchange 10%
Piston Pin Insp 2 pcs per cyl. bank 5%
Piston Pin Insp/Rebld/Exch 50%
Piston (Crown & Skirt) Insp 2 pcs per cyl. bank 5%
Piston (Crown & Skirt) Insp/Rebld/Exch 75%
Cam Bearings Install New 100%
Connecting Rod Install New 100%
Crankshaft Seals Install New 100%
Crankshaft Thrust Plates Install New 100%
Cylinder Liner Install New 100%
Damper Install New 100%
Engine Mounts Install New 100%
Gear Train Bushings Install New 100%
Main Bearings Install New 100%
Rings Install New 100%
Rod Bearings Insp 2 pcs per cyl. bank 5%
Rod Bearings Install New 100%

2
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series)

Maintenance Service Schedules
NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at
service interval.
Service Interval
Fuel System Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Fuel Filter Diff. Pressure Check X
Fuel Filter — Primary (H2O Separator) Drain X
Fuel Tank Drain H2O & Sediment X
Fuel Filter — Primary (H2O Separator) Replace 100%
Fuel System Prime (@ filter chg.) As Reqd
Fuel Filter — Spin on Replace 100%
Fuel Filter — Canister Replace 100%
Fuel Filter — Duplex Replace 100%
Fuel Filter — Primary Clean/Inspect/Replace 100%
Unit Injector Exch/Replace 100% 100% 100%
Fuel Transfer Pump Insp/Rebld/Exch 50% 100%
Fuel Priming Pump Insp/Rebld/Exch 50% 50% 100%
Fuel Press. Regulating Valve Inspect/Replace 50% 50%
Fuel Press. Regulating Valve Install New 100%
Electronic Control Module
(ECM) Inspect for Damage 25%
Software Install New (if new ECM) 25%

Service Interval
Air Induction and
Service to be Performed 1st 2nd
Exhaust System
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Air Leaks Inspect X
Air Cleaner/Filters Check Service Indicator X
Air Precleaner Clean As Reqd
Air Cleaner/Filters Clean/Replace As Reqd
Air Filter Primary Element Clean/Replace As Reqd
Air Filter Sec. Element Replace As Reqd
Air Filter Serv. Ind. Screen Replace As Reqd
Turbocharger Rebuild/Exchange 100%
Aftercooler Core Inspect/Clean/Test 25% 25% 50%
Intake Man. Gaskets/Seals Inspect/Replace 50% 50% 100%
Exh. Man. Seals/Bellows Insp/Rebld/Exch 50% 50% 100%

3
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series)

Maintenance Service Schedules
NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at
service interval.
Service Interval
Lubrication System Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Oil — Level Check X
Oil Filter Diff. Pressure Check X
Oil Leaks Check X
Oil (S•O•S Analysis) Check/Obtain Sample @oilchg
Oil Filter Inspect As Reqd
Oil Level Log Additions As Reqd
Oil Filter — Spin On Change 100%
Oil Change Shallow Sump Change 100%
Oil Filter — Canister Change 100%
Oil Change — Std. Sump Change 100%
Oil Filter — Duplex Change 100%
Oil Change — Deep Sump Change 100%
Crankcase Breather Clean 100%
Oil Pump — Main Insp/Rebld/Exch 100%
Prelube Oil Pump if Eqpd. Insp/Rebld/Exch 100%
Scavenge Oil Pump Insp/Rebld/Exch 100%

Service Interval
Cooling System Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Coolant Check Level X
Coolant Leaks Check X
Zinc Rods (if equipped) Inspect/Replace 50 Hrs
Coolant Additive — STD Add X
S•O•S Level I Analysis Check X
Cooling Sys. Relief Valve Clean X
Radiator Core Clean Fins X
Radiator Cap Clean/Replace X
Fan Belts Inspect/Adjust/Replace X
Hoses/Clamps Inspect/Check X
Fan Drive Brg. Lubricate X
S•O•S Level II Analysis Check X
Long Life Coolant Additive Add X
Coolant (STD) Drain/Flush/Replace X
Coolant — Long Life Drain/Flush/Replace X
Fan Drive Inspect X
Aux. Water Pump Insp/Rebld/Repl 100%
Jacket Water Pump Insp/Rebld/Repl 100%
Sea Water Pump Insp/Rebld/Repl 100%
Regulator (Thermostats) Replace 100%
Oil Cooler Core Insp/Rebld/Repl 100%

4
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3500 Commercial Engine (A & B Series)

Maintenance Service Schedules
NOTE: Expected percent that will require Rebuild/Exchange, Replace, or Install New is shown at
service interval.
Service Interval
Start/Stop System Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Air Supply Tank Drain H2O and Sediment X
Air Motor Lubricator Check Level X
Ether Aid Service Ether Cylinder
Air Shutoff — Actuate Inspect X
Air Shutoff Solenoid Inspect X
Jacket Water Heaters Inspect X
Engine Protection Devices Inspect X
Starter Motor — Electric Insp/Rebld/Repl 100%
Starter Motor — Air Insp/Rebld/Repl 100%

Service Interval
Electrical System Service to be Performed 1st 2nd
Daily 250 500 1000 2000 3000 6000 Top End Top End Overhaul
Electrical Gauges/Sensors Replace As Reqd
Alternator Belt Inspect/Check Tension X
Batteries Clean/Ck Electrolyte Level X
Alternator Insp/Rebld/Repl 100%
Engine Wire Harness Inspect/Install New 100%

Driven Equipment Service to be Performed

Inspect/Check/Lube Inspect/Check/Lube X
Air Compressor Rebuild/Exchange 100%
Driven Equip. Alignment Inspect X X X

5
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3508 Commercial Engine (A & B Series)

Maintenance Schedule Interval — Service Hours and Fuel Consumption
NOTE: Fuel consumption is based on a load factor of approximately 60 percent.
For engines that operate at less then 50 percent load, use the 50 percent load fuel
consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.
Maintenance intervals must be reduced for engines that operate in a severe service
application and for engines that operate in excess of the engine rating definition.

Interval Rated rpm up to 1300 Rated rpm up to 1600 Rated rpm up to 1800
Every 250 Service 22 700 L 27 200 L 32 000 L
Hours or (6000 U.S. gal) (7200 U.S. gal) (8500 U.S. gal)
Every 500 Service 45 400 L 54 400 L 64 000 L
Hours or (12 000 U.S. gal) (14 400 U.S. gal) (17 000 U.S. gal)
Every 1000 Service 89 000 L 109 000 L 128 000 L
Hours or (23 500 U.S. gal) (28 800 U.S. gal) (34 000 U.S. gal)
Every 2000 Service 178 000 L 218 000 L 257 000 L
Hours or (47 000 U.S. gal) (57 600 U.S. gal) (68 000 U.S. gal)
Every 3000 Service 267 500 L 327 500 L 386 500 L
Hours or (70 500 U.S. gal) (84 000 U.S. gal) (102 000 U.S. gal)
Every 6000 Service 535 000 L 636 000 L 774 000 L
Hours or (141 000 U.S. gal) (168 000 U.S. gal) (204 000 U.S. gal)
1st Top End 976 000 L 976 000 L 976 000 L
(257 500 U.S. gal) (257 500 U.S. gal) (257 500 U.S. gal)
or Every 11,000 or Every 9000 or Every 7500
Service Hours Service Hours Service Hours
2nd Top End 1 952 000 L 1 952 000 L 1 952 000 L
(515 000 U.S. gal) (515 000 U.S. gal) (515 000 U.S. gal)
or Every 22,000 or Every 18,000 or Every 15,000
Service Hours Service Hours Service Hours
Overhaul 2 928 000 L 2 928 000 L 2 928 000 L
(772 500 U.S. gal) (772 500 U.S. gal) (772 500 U.S. gal)
or Every 33,000 or Every 27,000 or Every 22,500
Service Hours Service Hours Service Hours

6
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3512 Commercial Engine (A & B Series)

Maintenance Schedule Interval — Service Hours and Fuel Consumption
NOTE: Fuel consumption is based on a load factor of approximately 60 percent.
For engines that operate at less then 50 percent load, use the 50 percent load fuel
consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.
Maintenance intervals must be reduced for engines that operate in a severe service
application and for engines that operate in excess of the engine rating definition.

Interval Rated rpm up to 1300 Rated rpm up to 1600 Rated rpm up to 1800
Every 250 Service 33 400 L 41 000 L 48 500 L
Hours or (8800 U.S. gal) (10 800 U.S. gal) (12 800 U.S. gal)
Every 500 Service 66 800 L 82 000 L 97 000 L
Hours or (17 600 U.S. gal) (21 600 U.S. gal) (25 600 U.S. gal)
Every 1000 Service 133 500 L 164 000 L 194 000 L
Hours or (35 000 U.S. gal) (43 200 U.S. gal) (51 200 U.S. gal)
Every 2000 Service 267 000 L 328 000 L 388 000 L
Hours or (70 000 U.S. gal) (86 400 U.S. gal) (102 400 U.S. gal)
Every 3000 Service 398 000 L 491 000 L 582 000 L
Hours or (105 000 U.S. gal) (129 600 U.S. gal) (153 600 U.S. gal)
Every 6000 Service 796 000 L 982 000 L 1 164 000 L
Hours or (210 000 U.S. gal) (259 200 U.S. gal) (307 200 U.S. gal)
1st Top End 1 460 000 L 1 460 000 L 1 460 000 L
(385 000 U.S. gal) (385 000 U.S. gal) (385 000 U.S. gal)
or Every 11,000 or Every 9000 or Every 7500
Service Hours Service Hours Service Hours
2nd Top End 2 920 000 L 2 920 000 L 2 920 000 L
(770 000 U.S. gal) (770 000 U.S. gal) (770 000 U.S. gal)
or Every 22,000 or Every 18,000 or Every 15,000
Service Hours Service Hours Service Hours
Overhaul 4 380 000 L 4 380 000 L 4 380 000 L
(1 155 000 U.S. gal) (1 155 000 U.S. gal) (1 155 000 U.S. gal)
or Every 33,000 or Every 27,000 or Every 22,500
Service Hours Service Hours Service Hours

7
 3500 MARINE ENGINE EXTENDED SERVICE INTERVAL

3516 Commercial Engine (A & B Series)

Maintenance Schedule Interval — Service Hours and Fuel Consumption
NOTE: Fuel consumption is based on a load factor of approximately 60 percent.
For engines that operate at less then 50 percent load, use the 50 percent load fuel
consumption rate to determine the 1st and 2nd Top End and Overhaul hour intervals.
Maintenance intervals must be reduced for engines that operate in a severe service
application and for engines that operate in excess of the engine rating definition.

Interval Rated rpm up to 1300 Rated rpm up to 1600 Rated rpm up to 1800
Every 250 Service 44 000 L 53 000 L 64 500 L
Hours or (11 600 U.S. gal) (14 000 U.S. gal) (17 000 U.S. gal)
Every 500 Service 88 000 L 106 000 L 129 000 L
Hours or (23 200 U.S. gal) (28 000 U.S. gal) (34 000 U.S. gal)
Every 1000 Service 176 000 L 212 000 L 258 000 L
Hours or (46 500 U.S. gal) (56 000 U.S. gal) (68 000 U.S. gal)
Every 2000 Service 352 000 L 424 000 L 516 000 L
Hours or (93 000 U.S. gal) (112 000 U.S. gal) (136 000 U.S. gal)
Every 3000 Service 528 700 L 636 700 L 773 000 L
Hours or (139 500 U.S. gal) (168 000 U.S. gal) (204 000 U.S. gal)
Every 6000 Service 1 056 000 L 1 272 000 L 1 548 000 L
Hours or (279 000 U.S. gal) (336 000 U.S. gal) (408 000 U.S. gal)
1st Top End 1 942 000 L 1 942 000 L 1 942 000 L
(512 500 U.S. gal) (512 500 U.S. gal) (512 500 U.S. gal)
or Every 11,000 or Every 9000 or Every 7500
Service Hours Service Hours Service Hours
2nd Top End 3 884 000 L 3 884 000 L 3 884 000 L
(1 025 000 U.S. gal) (1 025 000 U.S. gal) (1 025 000 U.S. gal)
or Every 22,000 or Every 18,000 or Every 15,000
Service Hours Service Hours Service Hours
Overhaul 5 826 000 L 5 826 000 L 5 826 000 L
(1 537 000 U.S. gal) (1 537 000 U.S. gal) (1 537 500 U.S. gal)
or Every 33,000 or Every 27,000 or Every 22,500
Service Hours Service Hours Service Hours