3516B HD Generator Set Caterpillar

The maintenance intervals that are listed in this Operation and Maintenance Manual, "Maintenance Interval Schedule" are expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load.

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.

Table 1

Top End Overhaul Service Hours and Fuel Consumption for 3516B HD Engines (1)
Engine	Rated 1800 RPM
	7500 Service Hours
3516B	1942000 L (512,500 US gal)
Second Top End Overhaul
Engine	15000 Service Hours
3516B	3884000 L (1,025,000 US gal)

(1)	Fuel consumption is based on a load factor of approximately 60 percent.

A top end overhaul involves the removal, the inspection, and the rework of the cylinder head components. Some additional components are replaced and serviced.

Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.

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.

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 to 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. The replacement part must be a new part.

Rebuild - The component is 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 Tables 2 and 3.

Table 2

Top End Overhaul (1)
Clean	Oil suction screen
Clean Inspect Pressure test	Aftercooler core (2)
Exchange Install new	Fuel injectors
Inspect Install new	Engine wiring harness
Inspect Rebuild	Rocker arms
Inspect Rebuild Exchange	Cylinder head assemblies
	Fuel priming pump
Inspect Replace	Fuel pressure regulating valve
	Pushrods
	Spacer plates
Install new	Air inlet manifold (gaskets and seals)
	Exhaust manifold (seals and bellows)

(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.

Table 3

Second Top End Overhaul (1)
Clean	Oil suction screen
Clean Inspect Pressure test	Aftercooler core (2)
Exchange Install new	Fuel injectors
Inspect Exchange	Camshaft lifters
Inspect	Connecting rod bearings (3)
	Cylinder liners (3)
	Piston crowns and skirts (3)
	Piston pins (3)
Inspect Install new	Camshaft lifters
	Engine wiring harness
Inspect Rebuild Exchange	Cylinder head assemblies
	Engine oil pump
	Fuel priming pump
	Fuel transfer pump
	Prelube pump
	Scavenge oil pump
Inspect Replace	Fuel pressure regulating valve
	Pushrods
	Spacer plates
Inspect Rebuild	Rocker arms
Install new	Air inlet manifold (gaskets and seals)
	Exhaust manifold (seals and bellows)
Rebuild Exchange	Turbochargers

(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 ONLY TWO of the components from each cylinder bank. This inspection will provide adequate examples of the condition of the other corresponding components.