Pon Power AS

Brobekkveien 54
Postboks 133 Vollebekk
N-0520 Oslo
Norway
Tel. +47 23 17 05 00
Fax +47 23 17 05 01
www.pon-cat.com

Maintenance schedule 3500 A og B

Up to 1300 rpm 1300-1600 rpm 1600-1800 rpm

Pon Power Caterpillar Pon Power Caterpillar Pon Power Caterpillar

Top end 16-18 000h 11 000 15 000h 9 000 h 12-15 000h 7 500 h

Major 32-34 000h 22 000 30 000h 18 000 h 24-30 000h 15 000 h

Maintenance schedule 3500 C

Up to 1300 rpm 1300-1600 rpm 1600-1800 rpm

Pon Power Caterpillar Pon Power Caterpillar Pon Power Caterpillar

Top end 12-15 000h 11 000h 12 000h 9 000 h 9-11 000h 7 500 h

Major 24-30 000h 22 000h 24 000h 18 000 h 18-22 000h 15 000 h

Oslo October 2010

 Comments/ condition to extend the intervall given from Pon Power (PPN)
We recommend the customer to follow these three important evaluations before extending of interval:
1) Evaluation of the load profile on the given engine. The hours of time before overhaul at
Caterpillar guideline is made from fuel consumption of approximately 60 percent. Use fuel
consumption, service hours, whichever occurs first.
2) Evaluation of quality of fuel, lubrication oil, and evaluation of the cooling system condition.
Control that customer has perform the maintenance up to given top end overhaul or major
3) Perform on regularly bases following analyses:
A) Scope of cylinder liner.
B) Oil trending.
C) Perform checklist or PAR test.

Oslo October 2010

 Specified with the fuel consumption on all 3500 engine

Engine type Up to 1300 rpm 1300-1600 rpm 1600-1800 rpm

3508 Caterpillar Caterpillar Caterpillar

Top end 976 000L 976 000L 976 000L

Major 1 952 000 L 1 952 000 L 1 952 000 L

Engine type Up to 1300 rpm 1300-1600 rpm 1600-1800 rpm

3512 Caterpillar Caterpillar Caterpillar

Top end 1 460 000L 1 460 000L 1 460 000L

Major 2 920 000 L 2 920 000 L 2 920 000 L

Engine type Up to 1300 rpm 1300-1600 rpm 1600-1800 rpm

3516 Caterpillar Caterpillar Caterpillar

Top end 1 942 000L 1 942 000L 1 942 000L

Major 3 884 000 L 3 884 000 L 3 884 000 L

Oslo October 2010

 Pon Power AS
Brobekkveien 54
Postboks 133 Vollebekk
N-0520 Oslo
Top End Overhaul of 3500/3500B/3500C Norway
Tel. +47 23 17 05 00
Fax +47 23 17 05 01
 Change of cylinder heads,Reman* and ** and **** www.pon-cat.com
 Change of fuel injectors,Reman* and ****
 Change of valve bridges**
 Change of wastegate valve******
 Change of crankshaft vibration damper*****, Reman*
 Inspect of rocker arms, valve and fuel injector
 Inspect of push rods and Camshaft followers.***
 Change of thermostats H.T.water.
 Change of all filters.
 Inspect of water pumps.
 Inspect of oil pump, and change of oil valvespring.
 Inspect of oil cooler
 Inspect and cleaning of aftercooler.
 Change to Reman* Turbocharger or inspect and change bearing/seal to overhaul of
turbocharger.***

• Adjustments and startup of engine.

• Parameter log and reporting

* Reman are factory overhauled components.

** Caterpillar has done a product improvement on cylinder heads and valve bridges, this
will be changed to new type.
*** Control and inspected according the Guideline for reusable parts given by Caterpillar
**** Alternativt for Reman is to overhaul/control/inspect the part at site.
***** Genset 1800 rpm, B & C engines only.
****** Engine with prefix PAG only.

Oslo October 2010

 Pon Power AS
Brobekkveien 54
Postboks 133 Vollebekk
N-0520 Oslo
Norway
Tel. +47 23 17 05 00
Fax +47 23 17 05 01
Major Overhaul of 3500/3500B/3500C www.pon-cat.com

 Change of cylinder heads,Reman** and ****

 Change of fuel injectors,Reman* and ****
 Change of cylinder packs,Reman* and ****
 Change of oil cooler,Reman.*
 Change of wastegate valve******
 Change of crankshaft vibration damper*****, Reman*
 Change of fuel transfer pump,Reman* and ****
 Change of water pumps HT and LT,Reman* and ****
 Change of valve bridges**
 Change of con rod bearing
 Change of main bearing and trust
 Recommend to change of crank shaft seal front and rear.
 Change of thermostats H.T.water.
 Change of all filters.
 Inspect and control of rocker arms, valve and fuel injector.***
 Inspect and control of camshaft and camshaft bearing.***
 Inspect and control of the rear and front gear train and bearing.***
 Inspect and control of push rods and Camshaft followers.***
 Inspect and control of oil pump, change of oil valvespring and bearing.***
 Inspect and cleaning of aftercooler.***
 Change to Reman* Turbocharger or inspect and change bearing/seal to
overhaul of turbocharger.***Inspect and inspection of crankshaft vibration
damper.***

Oslo October 2010

 Pon Power AS
Brobekkveien 54
Postboks 133 Vollebekk
N-0520 Oslo
Norway
Tel. +47 23 17 05 00
Fax +47 23 17 05 01
www.pon-cat.com

• Adjustments and startup of engine.

• Parameter log and reporting

* Reman Are factory overhauled components.

** Caterpillar has done a product improvement on cylinder heads and valve
bridges, so this will be changed to new type.
*** Control and inspected according the Guideline for reusable parts given by
Caterpillar
**** Alternativt for Reman is to overhaul/control/inspect the part at site.

Some dampers do not have a port for a fluid sample. These dampers must be rebuilt or the
dampers must be replaced when one of the following criteria has been met:

• The damper has reached 20,000 hours of operation.

• The engine is undergoing a major overhaul

***** Genset 1800 rpm, B & C engines only

****** Engine with prefix PAG only.

Oslo October 2010

Oslo October 2010