Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-06PublicationDate-01/10/2014DateUpdated-23/01/2018
Foreword
LiteratureInformation
Thismanualcontainssafety,operationinstructions,lubricationandmaintenanceinformation.This manualshouldbestoredinorneartheengineareainaliteratureholderorliteraturestoragearea. Read,studyandkeepitwiththeliteratureandengineinformation.
EnglishistheprimarylanguageforallCatpublications.TheEnglishusedfacilitatestranslation andconsistencyinelectronicmediadelivery.
Somephotographsorillustrationsinthismanualshowdetailsorattachmentsthatmaybedifferent fromyourengine.Guardsandcoversmayhavebeenremovedforillustrativepurposes. Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyour enginewhicharenotincludedinthismanual.Wheneveraquestionarisesregardingyourengine, orthismanual,pleaseconsultwithyourCatdealerforthelatestavailableinformation.
Safety
Thissafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifieshazardous, warningsituations.Readandunderstandthebasicprecautionslistedinthesafetysectionbefore operatingorperforminglubrication,maintenanceandrepaironthisproduct.
Operation
Operatingtechniquesoutlinedinthismanualarebasic.Theyassistwithdevelopingtheskillsand techniquesrequiredtooperatetheenginemoreefficientlyandeconomically.Skillandtechniques developastheoperatorgainsknowledgeoftheengineanditscapabilities.
Theoperationsectionisareferenceforoperators.Photographsandillustrationsguidetheoperator throughproceduresofinspecting,starting,operatingandstoppingtheengine.Thissectionalso includesadiscussionofelectronicdiagnosticinformation.
Maintenance
Themaintenancesectionisaguidetoenginecare.Theillustrated,step-by-stepinstructionsare groupedbyfuelconsumption,servicehoursand/orcalendartimemaintenanceintervals.Itemsin themaintenanceschedulearereferencedtodetailedinstructionsthatfollow.
Usefuelconsumptionorservicehourstodetermineintervals.Calendarintervalsshown(daily, annually,etc.)maybeusedinsteadofservicemeterintervalsiftheyprovidemoreconvenient schedulesandapproximatetheindicatedservicemeterreading.
Recommendedserviceshouldbeperformedattheappropriateintervalsasindicatedinthe MaintenanceIntervalSchedule.Theactualoperatingenvironmentoftheenginealsogovernsthe MaintenanceIntervalSchedule.Therefore,underextremelysevere,dusty,wetorfreezingcold operatingconditions,morefrequentlubricationandmaintenancethanisspecifiedinthe MaintenanceIntervalSchedulemaybenecessary.
Themaintenancescheduleitemsareorganizedforapreventivemaintenancemanagement program.Ifthepreventivemaintenanceprogramisfollowed,aperiodictune-upisnotrequired. Theimplementationofapreventivemaintenancemanagementprogramshouldminimize operatingcoststhroughcostavoidancesresultingfromreductionsinunscheduleddowntimeand failures.
MaintenanceIntervals
Performmaintenanceonitemsatmultiplesoftheoriginalrequirement.Eachleveland/or individualitemsineachlevelshouldbeshiftedaheadorbackdependinguponyourspecific maintenancepractices,operationandapplication.Werecommendthatthemaintenanceschedules bereproducedanddisplayedneartheengineasaconvenientreminder.Wealsorecommendthata maintenancerecordbemaintainedaspartoftheengine'spermanentrecord.
SeethesectionintheOperationandMaintenanceManual,"MaintenanceRecords"forinformation regardingdocumentsthataregenerallyacceptedasproofofmaintenanceorrepair.Your authorizedCatdealercanassistyouinadjustingyourmaintenancescheduletomeettheneedsof youroperatingenvironment.
Overhaul
MajorengineoverhauldetailsarenotcoveredintheOperationandMaintenanceManualexcept fortheintervalandthemaintenanceitemsinthatinterval.Majorrepairsarebestlefttotrained personneloranauthorizedCatdealer.YourCatdealeroffersavarietyofoptionsregarding overhaulprograms.Ifyouexperienceamajorenginefailure,therearealsonumerousafterfailure overhauloptionsavailablefromyourCatdealer.Consultwithyourdealerforinformation regardingtheseoptions.
CaliforniaProposition65Warning
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhands afterhandling.
SatJun2109:13:42UTC+05302025
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Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-13PublicationDate-01/10/2014DateUpdated-14/11/2019
ZincRods-Inspect/Replace
SMCS-1388-040;1388-510
i04802852
Corrosioninseawatercircuitscanresultinthefollowingissues:prematuredeteriorationof coolingsystemcomponents,leaksandpossiblecoolingsystemcontamination.Thecorrosionmay becausedbythelackofzincrodsintheseawatersystem.
Zincrodsareinstalledintheseawatercoolingsystemtohelppreventthecorrosiveoxidationthat iscausedbyseawater.Electricalcurrentisconductedthroughthecontactofthezincrodswiththe coolingsystemcomponents.Thezincrodsoxidizeratherthanthecoolingsystemcomponents. Rapiddeteriorationofzincrodsmayindicatethepresenceofuncontrolledelectricalcurrentsfrom improperlyinstalledelectricalattachmentsorimproperlygroundedelectricalattachments.
Theengineerfortheoperationmustdeterminetheintervalforinspectingthezincrods.The intervalforinspectingthezincrodswilldependonthesizeofthezincrodsandthenumberof zincrodsthatareinstalled.
InspecttheZincRods
1.Removethezincrod.
2.Inspectthezincrod.
Ensurethatthezincrodwillremaineffectiveuntilthenextscheduledinspection.
a.Ifthezincrodhasdeterioratedexcessively,installanewzincrod.
Illustration1g00481100 b.Tapthezincrodlightlywithahammer.Ifthezincrodbreaks,installanewzincrod.
3.Ifthezincrodwillbereused,scrapethelayerofoxidationfromthezincrodbefore installation.Thelayerofoxidationreducestheeffectivenessofthezincrod.
ReplacetheZincRods
1.Useplierstounscrewtheoldzincrodfromtheplug.
Ifnotenoughmaterialremainsorthezincrodhasbrokenoff,drillthezincfromtheplug.
2.Cleantheplug.
(1)Shoulder (2)Threads (3)Externalthreadsoftheplug
Note:Donotapplyadhesiveorsealanttothethreadsofthezincrod(2).
3.Apply9S-3263ThreadLockCompoundtotheshoulder(1)ofanewzincrod.Applythe compoundonlytotheshoulderofthezincrod.Installthezincrodontotheplug.
4.Coattheexternalthreadsoftheplug(3)with5P-3413PipeSealant.Installthezincrod.See Specifications,SENR3130,"TorqueSpecifications"forthetorquefortheplug.
Copyright1993-2025CaterpillarInc.
AllRightsReserved.
PrivateNetworkForSISLicensees.
SatJun2110:02:42UTC+05302025
Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-13PublicationDate-01/10/2014DateUpdated-14/11/2019
WaterPump-Inspect
SMCS-1361-040
Failureofawaterpumpmightcausesevereoverheating.Overheatingcouldresultinthe following:
•Cracksinthecylinderhead
•Damagetotheoilcoolers
•Pistonseizure
•Otherpotentialenginedamage
Visuallyinspectthewaterpumpforleaks.Theenginemaybeequippedwithmorethanonewater pump.
Ifacontinuousdripisfoundcomingfromthewaterpumpweepholewhentheengineisoff, replacethesealsorreplacethepump.Also,ifaconstantstreamisobservedwhentheengineis running,replacethesealsorreplacethepump.
Evidenceofdriedcoolantaroundtheweepholecanbeanindicationofintermittentdrippingthat ispartofthenormaloperationofthepump.Frequentobservationisrecommendedtodetermine thetypeofwaterpumpleak.
Formoreinformationoncoolingsystemtroubleshooting,refertotheapplicableTroubleshooting manual.
Forthereplacementofthewaterpumporthewaterpumpseals,refertotheapplicable DisassemblyandAssemblymanual.
ConsultwithyourCatdealerformoreinformationonwaterpumpleaksorcoolingsystemissues.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
SatJun2110:02:28UTC+05302025
Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-13PublicationDate-01/10/2014DateUpdated-14/11/2019
Walk-AroundInspection
SMCS-1000-040
InspecttheEngineforLeaksandforLooseConnections
Awalk-aroundinspectionshouldonlytakeafewminutes.Whenthetimeistakentoperform thesechecks,costlyrepairsandaccidentscanbeavoided.
Formaximumengineservicelife,thoroughlyinspecttheenginecompartmentbeforestartingthe engine.Lookforitemssuchasleaks,loosebolts,looseconnections,andtrashbuildup.Make repairs,asneeded.
•Theguardsmustbeintheproperplace.Repairdamagedguardsorreplacemissingguards.
•Wipeallcapsandplugsbeforetheengineisservicedtoreducethechanceofsystem contamination.
NOTICE
Foranytypeofleak(coolant,lube,orfuel)cleanupthefluid.If leakingisobserved,findthesourceandcorrecttheleak.Ifleakingis suspected,checkthefluidlevelsmoreoftenthanrecommendeduntil theleakisfoundorfixed,oruntilthesuspicionofaleakisprovedtobe unwarranted.
NOTICE
Accumulatedgreaseand/oroilonanengineordeckisafirehazard. Removethisdebriswithsteamcleaningorhighpressurewater.
Note:Usecarewhenyouusesteamcleaning.Usecarewhenyouusehigh-pressurewater.Direct spraytorotatingelectricsorelectroniccomponentscancausenonfixabledamage.
NOTICE
Waterand/orcondensationcancausedamagetoelectricalcomponents. Protectallelectricalcomponentsfromexposuretowater.
•Ensurethatthecoolinglinesareclampedproperlyandensurethatthecoolinglinesare tight.Checkforleaks.Checktheconditionofallpipes.
•Inspectthewaterpumpsforcoolantleaks.
Note:Thewaterpumpsealislubricatedbycoolantinthecoolingsystem.Whentheenginecools andthepartscontract,asmallamountofleakageisnormal.
Excessivecoolantleakagemayindicatetheneedtoreplacethewaterpumpseal.Fortheremoval ofwaterpumpsandtheinstallationofwaterpumpsand/orseals,refertotheDisassemblyand AssemblyManual,"WaterPump-RemoveandWaterPump-Install"orconsultyourCatdealer.
•Inspectthelubricationsystemforleaksatthefollowinglocations:frontcrankshaftseal,rear crankshaftseal,oilpan,oilfilters,valvecover,turbocharger,externaloillines,and connections.
•Inspectthefuelsystemforleaks.Lookforloosefuellineclampsorconnections.
•Inspectthepipingfortheairinletsystemandtheelbowsforcracksandforlooseclamps.
•Drainthewaterandthesedimentfromfueltanksdailytoensurethatonlycleanfuelenters thefuelsystem.
•Inspectthewiringandthewiringharnessesforlooseconnectionsandforwornwiresor frayedwires.
•Inspectthegroundstrapforagoodconnectionandforgoodcondition.
•Inspecttheclosedcrankcaseventilation(CCV)filter,ifequipped.Iftherestrictionindicator isvisible,servicetheCCV.
•Checktheconditionofthegauges.Replaceanygaugethatisdamaged.Replaceanygauge thatcannotbecalibrated.
•Inspecttheexhaustsystemforleaks.Inspectthegasketsandtheexhaustbellowsjoint.Ifa leakisfound,makerepairs.
•Ensurethatsensorsarenotcoveredwithinsulation.Theinsulationwouldtrapheatinthe sensorbodyandcable.Thisheatmaycausesensorfailure.
SatJun2110:02:12UTC+05302025
Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-13PublicationDate-01/10/2014DateUpdated-14/11/2019
Turbocharger-Inspect
SMCS-1052-040
Avoidcontactwithhotsurfaces.Exhaustpipingandenginecomponents becomehotduringengineoperationandcoolslowlyafterengine shutdown.Anycontactwithhotsurfacescancausesevereburns.
Periodicinspectionandcleaningisrecommendedfortheturbochargercompressorhousing(inlet side).
Foulingofthecompressorcancontributetolossofenginepower,increasedblacksmokeand overalllossofengineefficiency.
Iftheturbochargerfailsduringengineoperation,damagetotheturbochargercompressorwheel and/ortotheenginemayoccur.Damagetotheturbochargercompressorwheelcouldallowparts fromthecompressorwheeltoenteranenginecylinder.Thiscancauseadditionaldamagetothe pistons,thevalves,andthecylinderhead.
NOTICE
Turbochargerbearingfailurescancauselargequantitiesofoiltoenter theairinletandexhaustsystems.Lossofenginelubricantcanresultin seriousenginedamage.
Minorleakageofaturbochargerhousingunderextendedlowidle operationshouldnotcauseproblemsaslongasaturbochargerbearing failurehasnotoccurred.
Whenaturbochargerbearingfailureisaccompaniedbyasignificant engineperformanceloss(exhaustsmokeorenginerpmupatnoload), donotcontinueengineoperationuntiltheturbochargerisrepairedor replaced.
Aninspectionoftheturbochargercanminimizeunscheduleddowntime.Aninspectionofthe turbochargercanalsoreducethechanceforpotentialdamagetootherengineparts.
Note:Turbochargercomponentsrequireclearancesthatareprecise.Theturbochargercartridge mustbebalancedduetohighrpm.Severeserviceapplicationscanacceleratethewearofthe components.Severeserviceapplicationsmayrequiremorefrequentinspectionsofthe turbocharger.
RemovalandInstallation
Foroptionsregardingtheremoval,installation,repairandreplacement,consultyourCaterpillar dealer.RefertotheServiceManualforthisengineorconsultyourCaterpillardealerforthe procedureandspecifications.
CleaningandInspecting
1.Removetheexhaustoutletpipingandremovetheairinletpipingfromtheturbocharger. Visuallyinspectthepipingforthepresenceofoil.
2.Turnthecompressorwheelandtheturbinewheelbyhand.Theassemblyshouldturnfreely. Inspectthecompressorwheelandtheturbinewheelforcontactwiththeturbocharger housing.Thereshouldnotbeanyvisiblesignsofcontactbetweentheturbinewheelor compressorwheelandtheturbochargerhousing.Ifthereisanyindicationofcontact betweentherotatingturbinewheelortheturbochargerwheelandtheturbochargerhousing, theturbochargershouldbereconditionedorreplaced.
3.Checkthecompressorwheelforcleanliness.Ifonlythebladesideofthewheelisdirty,dirt and/ormoistureispassingthroughtheairfilteringsystem.Ifoilisfoundonlyontheback sideofthewheel,thereisapossibilityofafailedturbochargeroilseal.
Thepresenceofoilmaybetheresultofextendedengineoperationatlowidle.Thepresence ofoilmayalsobetheresultofarestrictionofthelinefortheinletair(pluggedairfilters), whichcausestheturbochargertoslobber.
4.Inspecttheboreoftheturbinehousingforcorrosion.
5.Cleantheturbochargerhousingwithstandardshopsolventsandasoftbristlebrush.
6.Fastentheairinletpipingandtheexhaustoutletpipingtotheturbochargerhousing.
InspecttheExhaustBypass
Theexhaustbypassisawearcomponentthatissensitivetotheloadcyclesoftheengine. Replacementoftheexhaustbypassispredictedatthetopendoverhaulforageneral"C"or"D" loadprofile.Applicationsthathavefrequentcyclingoftheenginewillincreasethewearrateof
thevalveintheexhaustbypass.Applicationsthathaveextendedperiodsofoperationatthe openingpositionofthevalvewillincreasethewearrateofthevalve.Thevalvestemshouldbe inspectedperiodicallyforwearofthevalvestem.Areducedserviceintervalmayberequiredif theinspectionrevealsheavywearofthevalve.Thiswillensureproperoperationoftheexhaust bypass.Usethefollowingstepsinordertoinspecttheexhaustbypass.
PressurizedSystem:Hotcoolantcancauseseriousburns.Toopenthe coolingsystemfillercap,stoptheengineandwaituntilthecooling systemcomponentsarecool.Loosenthecoolingsystempressurecap slowlyinordertorelievethepressure.
1.Drainthecoolingsystemtoasufficientlevelbelowtheexhaustbypassinordertoremove thecoolinglinesthatattachtotheexhaustbypass.Refertothemaintenancesectionofthis OperationandMaintenanceManual,"CoolingSystemCoolant-Change"forinstructionson drainingthecoolingsystem.
Illustration1g01174063
(1)Exhaustbypass (2)Boostline (3)Coolantline
2.Disconnecttheboostline(2)andthetwocoolantlines(3)fromtheexhaustbypass(1).The coolantlines(3)attachtobothsidesoftheexhaustbypass(1).
Illustration2g01173813
(1)ExhaustBypass (4)Nut (5)Housing
3.Removethenuts(4)thatfastentheexhaustbypass(1)tothehousing(5).
4.Removetheexhaustbypass(1)fromthehousing(5).
Illustration3g01173915
5.Inspectthevalvestem(6)forheavywear.
6.Replacetheexhaustbypass(1)ifthevalvestemisexcessivelyworn.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
SatJun2110:01:54UTC+05302025
Product:MARINEENGINE
Model:3516CMARINEENGINETKR
Configuration:3516CMarineEngineTKR00001-UP
OperationandMaintenanceManual
3500CMarineEngines
MediaNumber-SEBU8711-13PublicationDate-01/10/2014DateUpdated-14/11/2019
