A New Cylinder Pack Components are Now Used on Certain D3512B and D3516B Electric Power Generation (EPG) Engines {1239, 7555} Caterpillar

A New Cylinder Pack Components are Now Used on Certain D3512B and D3516B Electric Power Generation (EPG) Engines {1239, 7555}

Usage:

3516B JCH

Engine: 3512B (S/N: JM31-106; YBB1-498; YAM1-997; YAY1-1440); 3516B (S/N: JCH1-107; YAP1-812; ZBP1-306; YAT1-962; YBT1-606)
Power Module: PM3512 (S/N: TC81-278); PM3516 (S/N: NBR1-947)

Description Of Change: The new cylinder pack components improve engine reliability and durability by reducing deposits attributed to wear and liner polishing.

Cylinder Liner with Anti-Polishing Sleeve (Cuffed Cylinder System)
Upper Liner Seal with improved thermal properties

Adaptable To: The new cylinder pack components are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.

The new cylinder pack components are direct replacements for previous cylinder pack components used in certain D3512B and D3516B Electric Power Generation (EPG) Engines.

Piston Cooling Jets and Cuff Liner

Install the cuff liner and piston with the high spray piston cooling jet. Also, install the oil pump cover to assure oil pump pressure increase. Follow the parts group listed below for your serial number.

Tooling

Reference Disassembly and Assembly, UENR5578 document in SIS web for your engine to perform the repair.

Steel piston rings are sensitive to bending. Failure to use proper ring expansion or compression tooling will result in damage to piston rings and possible early hour engine failure.

471-6593 is the installation tool which is required with standard ring compressor tooling when installing cuffed cylinder system components.

Install the 458-7071 Sleeve in each cylinder prior to installing the cylinder heads.

Note: Connecting Rods and Piston Pins are highly reusable. For this reason, the Parts Needed tables do not include these parts.

Note: Do not mix single piece forged steel pistons designed for the single piece cylinder system with single piece forged steel pistons designed for the cuff cylinder system. Rotating masses and system dynamics are different between the designs and are not compatible within the same engine.

Show/hide table

Table 1
3512B Engines & PM3512 Engines
Qty	New Part Number	Part
12	1H-9696	O-Ring Seals
4	1S-4810	Oil Drain Gaskets
4	2W-0752	Gaskets
3	3P-0655	O-Ring Seals
1	3P-6061	Gasket
2	4N-1320	Gaskets
12	4S-5898	O-Ring Seals
24	5P-0840	O-Ring Seals
1	5P-7818	O-Ring Seal
8	5P-9890	O-Ring Seals
2	6V-1454	O-Ring Seals
5	6V-5066	O-Ring Seals
12	6V-5101	O-Ring Seals
12	6V-9769	O-Ring Seals
36	7N-2046	O-Ring Seals
1	7N-4932	Gasket
1	7N-4945	Gasket
12	7N-5080	Manifold Gaskets
12	7W-8145	Exhaust Manifold Gaskets
4	033-6031	O-Ring Seals
12	107-7330	Connecting Rod Bearings
6	109-2332	O-Ring Seals
12	110-6991	Cylinder Head Gaskets
1	111-1349	Gasket
2	122-8856	Gaskets
12	127-2176	Integral Seals
12	144-5692	Plate Gaskets
12	198-9926	Oil Jet Tube As
12	223-6361	Piston Rings
12	240-7032	Seals
1	245-6770	Cover
12	268-8154	Gasket Kits
12	272-0759	Seals
12	272-0760	Valve Cover Seals
1	298-6387	O-Ring Seal
48	420-0652	Water Seal Assemblies
48	420-0653	Water Seal Assemblies
12	448-3650	Piston Rings
12	448-3651	Piston Rings
12	454-9920	Cylinder Liners
12	458-7071	Sleeves
12	480-7093	Liner Seals
12	481-5615	Pistons

Show/hide table

Table 2
3516B Engines & PM3516 Engines
Qty	New Part Number	Part
16	1H-9696	O-Ring Seals
4	1S-4810	Oil Drain Gaskets
4	2W-0752	Gaskets
3	3P-0655	O-Ring Seals
1	3P-6061	Gasket
2	4N-1320	Gaskets
16	4S-5898	O-Ring Seals
32	5P-0840	O-Ring Seals
1	5P-7818	O-Ring Seal
8	5P-9890	O-Ring Seals
2	6V-1454	O-Ring Seals
5	6V-5066	O-Ring Seals
16	6V-5101	O-Ring Seals
16	6V-9769	O-Ring Seals
48	7N-2046	O-Ring Seals
1	7N-4932	Gasket
1	7N-4945	Gasket
16	7N-5080	Manifold Gaskets
16	7W-8145	Exhaust Manifold Gaskets
4	033-6031	O-Ring Seals
16	107-7330	Connecting Rod Bearings
6	109-2332	O-Ring Seals
16	110-6991	Cylinder Head Gaskets
1	111-1349	Gasket
2	122-8856	Gaskets
16	127-2176	Integral Seals
16	144-5692	Plate Gaskets
16	198-9926	Oil Jet Tube As
16	223-6361	Piston Rings
1	231-5128	Cover
16	240-7032	Seals
16	268-8154	Gasket Kits
16	272-0759	Seals
16	272-0760	Valve Cover Seals
1	298-6387	O-Ring Seal
64	420-0652	Water Seal Assemblies
64	420-0653	Water Seal Assemblies
16	448-3650	Piston Rings
16	448-3651	Piston Rings
16	454-9920	Cylinder Liners
16	458-7071	Sleeves
16	480-7093	Liner Seals
16	481-5615	Pistons

Note: You will be installing the high flow piston spray jets and an oil pump pressure regulator cover to increase the engine oil pressure. Because of this update, you will also need to increase the oil filter pressure differential warning set point. For D3516 "Only" reset the oil filter pressure differential warning set point from 105 kPa (15 psi) to 138 kPa (20 psi). The D3512 set points remain 105 kPa (15 psi).

Show/hide table