- Electric Power Generation:
- 3516B GEN SET (S/N: ZAP1-UP)
- Engine:
- 3516B (S/N: BPJ1-UP; FDN1-UP; ZAR1-UP; GZS1-UP; YAT1-UP; YAW1-UP)
- Power Module:
- PM3516 (S/N: BPD1-UP; NBR1-UP)
Introduction
This Special Instruction is intended to provide information on the Engine Overhaul Kit Consist and detailed information on specific parts that should be used based on engine arrangements.
This Engine Overhaul Kit may contain extra parts and extra quantities due to the variety of engine arrangements assigned to a given kit. Refer to the corresponding Parts Manual or Disassembly and Assembly manual in Table 1.
Note: This Kit may contain upgraded parts. These upgraded part numbers may be different than what you have in the parts manual or engine, but these parts have been technically reviewed for compatibility with your application.
Note: This kit contains gasket kits and includes additional parts needed to perform an engine overhaul.
Note: This kit does not contain rod bearings, main bearings, and thrust plates.
Note: For more information, visit us at: electricpowersupport.cat.com.
Note: For assistance with technical questions, contact your local Cat dealer.
Reference Material
| Engine Model | Engine Serial Number Prefix | Package Serial Number Prefix | Engine Arrangements | Parts Book Media | Disassembly and Assembly Media |
| 3516 EPG |
S/N:1HZ |
S/N:FDN | 195-5874 | SEBP3303 | UENR0181 |
| 197-9039 | |||||
| S/N:BPD | 188-9442 | SEBP3197 | UENR5578 | ||
| 237-0915 | |||||
| 269-2013 | |||||
| S/N:BPD S/N:NBR |
289-0524 | SEBP5738 | |||
| S/N:NBR | 367-8100 | ||||
| S/N:ZAR | 256-0760 | SEBP4058 | RENR5060 | ||
| S/N:YAW | 325-9345 | SEBP5406 | |||
| S/N:CTG | S/N:BPJ | 195-5886 | SEBP3318 | UENR0181 | |
| S/N:ZAP | 256-0757 | SEBP4057 | RENR5060 | ||
| 256-0758 | |||||
| 281-9204 | |||||
| S/N:YAT | 325-9342 | SEBP5405 | RENR5060 | ||
| 325-9343 | |||||
| 328-2059 | |||||
| S/N:GZS | S/N:GZS | 260-3688 | SEBP3935 | UENR0181 |
|
| 260-3689 | |||||
| S/N:GZS | 282-5210 | ||||
| S/N:DD8 | S/N:NBR | 399-3452 | SEBP5738 | UENR5578 | |
Note: For ordering reference material, contact your local Cat dealer.
3516 Generator Set 464-6602 Major Overhaul Kit Consist
| 464-6602 Major Overhaul Kit Consist | ||
| Gasket Kits | ||
| Part Number | Part Name | Qty |
| 463-9257 | Single Cylinder Head Gasket Kit | 16 |
| 463-9569 | Rear Structure Gasket Kit | 1 |
| 463-9811 | Turbocharger Installation Gasket Kit | 4 |
| 464-0329 | Oil Cooler and Lines Gasket Kit | 1 |
| 464-0331 | Aftercooler and Lines Gasket Kit | 1 |
| 464-0483 | Front Structure Gasket Kit | 1 |
| Additional Parts Included in This Kit | ||
| Part Number | Part Name | Qty |
| 1R-0726 | Engine Oil Filter Element As | 3 |
| 1R-0756 | Fuel Filter Element | 5 |
| 2W-0752 | Gasket | 6 |
| 3K-0360 | O-Ring Seal | 2 |
| 3P-0654 | O-Ring Seal | 2 |
| 3S-9643 | Lip Type Seal | 6 |
| 4W-0530 | Retaining Ring | 1 |
| 4W-3027 | Breather As | 4 |
| 4W-3100 | Gasket | 1 |
| 5D-5957 | O-Ring Seal | 3 |
| 5F-9657 | O-Ring Seal | 4 |
| 5P-4892 | O-Ring Seal | 4 |
| 5P-7818 | O-Ring Seal | 1 |
| 5P-8210 | O-Ring Seal | 2 |
| 5P-8872 | O-Ring Seal | 1 |
| 6B-9202 | Spring | 2 |
| 6F-4868 | Gasket | 2 |
| 6V-1454 | O-Ring Seal | 4 |
| 6V-3348 | O-Ring Seal | 8 |
| 6V-3907 | O-Ring Seal | 4 |
| 6V-4368 | O-Ring Seal | 4 |
| 6V-4589 | O-Ring Seal | 4 |
| 6V-5048 | O-Ring Seal | 24 |
| 6V-5101 | O-Ring Seal | 1 |
| 6V-8001 | O-Ring Seal | 1 |
| 6V-9027 | O-Ring Seal | 3 |
| 7E-2632 | Oil Pan Gasket | 1 |
| 7E-6016 | Gasket | 4 |
| 7N-4782 | Lifter Guide Spring | 32 |
| 7N-4927 | Housing Cover Gasket | 1 |
| 7N-4945 | Gasket | 3 |
| 7N-6806 | Rectangular Seal | 4 |
| 7N-7697 | Plunger | 2 |
| 7X-1547 | O-Ring Seal | 2 |
| 7X-4805 | O-Ring Seal | 3 |
| 8C-3445 | Dust Cap | 1 |
| 8L-2786 | O-Ring Seal | 1 |
| 8T-2928 | O-Ring Seal | 4 |
| 8T-2929 | O-Ring Seal | 4 |
| 8T-5452 | O-Ring Seal | 1 |
| 9L-1480 | Gasket | 3 |
| 9Y-8389 | Gasket | 1 |
| 033-6031 | O-Ring Seal | 4 |
| 101-1198 | Camshaft Bearing | 18 |
| 122-8856 | Gasket | 2 |
| 125-9794 | O-Ring Seal | 1 |
| 140-9597 | Bushing | 2 |
| 154-6389 | Button | 48 |
| 214-7566 | O-Ring Seal | 1 |
| 214-7568 | O-Ring Seal | 8 |
| 219-3240 | Temperature Regulator | 2 |
| 230-1072 | Gasket | 1 |
| 238-5080 | O-Ring Seal | 1 |
| 238-5081 | O-Ring Seal | 5 |
| 243-2288 | Gasket | 6 |
| 248-5513 | Temperature Regulator | 4 |
| 272-0759 | Seal | 16 |
3516 Generator Set Engine Gasket Kit Locations
 | |
| Illustration 1 | g03779940 |
(1) Turbocharger Installation (463-9811 Gasket Kit) (2) Aftercooler and Lines (464-0331 Gasket Kit) (3) Single Cylinder Head (463-9257 Gasket Kit) (4) Front Structure (464-0483 Gasket Kit) (5) Oil Cooler and Lines (464-0329 Gasket Kit) (6) Rear Structure (463-9569 Gasket Kit) | |
Gasket Kit Consists
Single Cylinder Head (463-9257 Gasket Kit)
| 463-9257 Gasket Kit (Single Cylinder Head) | ||
| Part Number | Part Name | Qty |
| 4S-5898 | O-Ring Seal | 1 |
| 5P-0840 | O-Ring Seal | 2 |
| 6J-2245 | O-Ring Seal | 1 |
| 6V-5101 | O-Ring Seal | 1 |
| 6V-6228 | O-Ring Seal | 3 |
| 6V-9769 | O-Ring Seal | 1 |
| 7N-5080 | Manifold Gasket | 1 |
| 7W-8145 | Exhaust Manifold Gasket | 1 |
| 110-6991 | Cylinder Head Gasket | 1 |
| 127-2176 | Integral Seal | 1 |
| 144-5692 | Plate Gasket | 1 |
| 214-7568 | O-Ring Seal | 2 |
| 240-7032 | Seal | 1 |
| 241-5928 | Gasket | 1 |
| 272-0758 | Seal | 1 |
| 272-0760 | Valve Cover Seal | 1 |
| 420-0652 | Water Seal Assembly | 4 |
| 420-0653 | Water Seal Assembly | 4 |
Refer to Illustration 1.
Rear Structure (463-9569 Gasket Kit)
| 463-9569 Gasket Kit (Rear Structure) | ||
| Part Number | Part Name | Qty |
| 4B-8407 | Copper Gasket | 4 |
| 4H-7869 | Gasket | 3 |
| 5F-9657 | O-Ring Seal | 2 |
| 7N-3368 | Gasket | 1 |
| 7N-4320 | Gasket | 2 |
| 113-8433 | Crankshaft Seal Gp | 1 |
| 234-8937 | Integral Seal | 2 |
| 252-8374 | Gasket | 2 |
Refer to Illustration 1.
Turbocharger Installation (463-9811 Gasket Kit)
| 463-9811 Gasket Kit (Turbocharger Installation) | ||
| Part Number | Part Name | Qty |
| 1S-4810 | Oil Drain Gasket | 1 |
| 1S-6595 | Oil Supply Gasket | 1 |
| 2N-2765 | High Temperature Bolt | 4 |
| 2N-2766 | Locknut | 4 |
| 5D-5957 | O-Ring Seal | 1 |
| 6V-3917 | O-Ring Seal | 4 |
| 109-7411 | O-Ring Seal | 1 |
| 112-3540 | O-Ring Seal | 2 |
| 121-5736 | Gasket | 1 |
Refer to Illustration 1.
Oil Cooler and Lines (464-0329 Gasket Kit)
| 464-0329 Gasket Kit (Oil Cooler and Lines) | ||
| Part Number | Part Name | Qty |
| 3P-0655 | O-Ring Seal | 3 |
| 4B-8407 | Copper Gasket | 1 |
| 4N-1320 | Gasket | 2 |
| 5P-4892 | O-Ring Seal | 3 |
| 5P-5846 | O-Ring Seal | 1 |
| 6V-3908 | O-Ring Seal | 1 |
| 6V-4589 | O-Ring Seal | 2 |
| 6V-5048 | O-Ring Seal | 2 |
| 6V-5066 | O-Ring Seal | 4 |
| 6V-6609 | O-Ring Seal | 2 |
| 7N-4945 | Gasket | 1 |
| 8L-2786 | O-Ring Seal | 1 |
| 109-2332 | O-Ring Seal | 8 |
| 111-3820 | Retaining Ring | 1 |
| 228-7097 | O-Ring Seal | 1 |
| 238-5080 | O-Ring Seal | 1 |
| 247-3796 | Gasket | 2 |
Refer to Illustration1.
Aftercooler and Lines (464-0331 Gasket Kit)
| 464-0331 Gasket Kit (Aftercooler and Lines) | ||
| Part Number | Part Name | Qty |
| 3J-7354 | O-Ring Seal | 2 |
| 4W-0530 | Retaining Ring | 3 |
| 5B-4399 | O-Ring Seal | 1 |
| 5P-8940 | O-Ring Seal | 3 |
| 6J-2680 | O-Ring Seal | 3 |
| 6V-9027 | O-Ring Seal | 1 |
| 8T-1919 | O-Ring Seal | 6 |
| 107-3758 | Seal | 4 |
| 230-1072 | Gasket | 1 |
Refer to Illustration 1.
Front Structure (464-0483 Gasket Kit)
| 464-0483 Gasket Kit (Front Structure) | ||
| Part Number | Part Name | Qty |
| 1H-9696 | O-Ring Seal | 1 |
| 1S-5772 | Gasket | 1 |
| 3P-0654 | O-Ring Seal | 1 |
| 3P-6061 | Gasket | 1 |
| 4N-1320 | Gasket | 2 |
| 4W-0530 | Retaining Ring | 2 |
| 5H-6734 | O-Ring Seal | 1 |
| 5P-0840 | O-Ring Seal | 3 |
| 5P-6302 | O-Ring Seal | 1 |
| 5R-7136 | Seal Washer | 2 |
| 5R-7137 | Seal Washer | 4 |
| 6J-2680 | O-Ring Seal | 1 |
| 6V-3348 | O-Ring Seal | 2 |
| 6V-5066 | O-Ring Seal | 3 |
| 6V-5101 | O-Ring Seal | 1 |
| 6V-6809 | O-Ring Seal | 1 |
| 7N-3049 | Gasket | 1 |
| 7N-3368 | Gasket | 1 |
| 7N-4932 | Gasket | 1 |
| 8N-9885 | Cover Gasket | 1 |
| 8T-1919 | O-Ring Seal | 1 |
| 9X-7371 | O-Ring Seal | 2 |
| 113-8432 | Crankshaft Seal Gp | 1 |
| 235-3546 | O-Ring Seal | 4 |
| 238-5080 | O-Ring Seal | 1 |
| 238-5081 | O-Ring Seal | 1 |
| 259-4598 | O-Ring Seal | 6 |
| 298-6387 | O-Ring Seal | 1 |
Refer to Illustration 1.