Table 1 lists average ranges of fuel consumption and service hours for a load factor of approximately 60 percent. Use the range of fuel consumption only as a guideline.
| Major Overhaul
Service Hours and Fuel Consumption for 3516B HD Generator Set Engines (1) |
|
| Engine | Rated 1800 RPM |
| 22500 Service Hours | |
| 3516B | |
| (1) | Fuel consumption is based on a load factor of approximately 60 percent. |
The need for a major overhaul is determined by several factors:
- An increase in oil consumption
- An increase in 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: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals.
Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul.
Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.
A major overhaul includes all of the work that is done for the top end overhaul. A major overhaul includes additional parts and labor. Additional parts and labor are required in order to completely rebuild the engine.
For the major overhaul, all of the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned. The parts are 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 Caterpillar replacement part.
Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.
The following definitions explain the terminology for the services that are performed during an overhaul:
Exchange - Your Caterpillar dealer will exchange your worn parts for parts that conform to original functional specifications.
Inspect - Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts". The guidelines were developed in order to help Caterpillar dealers and customers avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service Manual, "Specifications" module.
Install New - The service life of the part is exhausted. The part cannot be reconditioned. Used parts are not appropriate. A new part must be installed.
Rebuild - The component can be reconditioned in order to comply with reusability guidelines.
Replace - The service life of the part is exhausted. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a rebuilt part, or a used part.
If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the recommendations in Table 2. Your Caterpillar dealer can provide these services and components.
| Major Overhaul Instructions (1) | |
|---|---|
| Clean | Oil suction screen |
| Clean
Inspect Test |
Aftercooler core (2) |
| Exchange
Install new |
Fuel injectors |
| Inspect
Rebuild |
Rocker arms |
| Inspect
Rebuild Install new |
Piston pins |
| Inspect
Rebuild Exchange |
Connecting rods |
| Cylinder head assemblies | |
| Fuel priming pump | |
| Fuel transfer pump | |
| Inspect | Camshafts |
| Cylinder block | |
| Crankshaft vibration damper | |
| Driven equipment (alignment) | |
| Electronic control module (ECM) (3) | |
| Flywheel | |
| Front gear train (gears) | |
| Rear gear train (gears) | |
| Inspect
Exchange |
Crankshaft |
| Cylinder liners | |
| Pistons (Crowns and Skirts) | |
| Inspect
Install new |
Camshaft thrust washers |
| Camshaft lifters | |
| Engine mounts | |
| Engine wiring harness | |
| Pushrods | |
| Spacer plates | |
| Inspect
Replace |
Fuel pressure regulating valve |
| Pushrods | |
| Inspect
Rebuild Replace |
Oil cooler core |
| Install new | Camshaft bearings |
| Connecting rod bearings | |
| Crankshaft seals | |
| Crankshaft thrust plates | |
| Exhaust manifold (seals and bellows) | |
| Gear train bushings | |
| Inlet manifold (gaskets and seals) | |
| Main bearings | |
| Piston rings | |
| Software (4) | |
| (1) | For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module. |
| (2) | For instructions on cleaning the core, see this Operation and Maintenance Manual, "Aftercooler Core - Clean/Test" topic. |
| (3) | Inspect the ECM for damage. |
| (4) | Install new software when a new ECM is installed. |