D3500MM M01 Overview en TXT-Participant

Global Manpower Development
d3500 master mechanic

3500 Engine Overview
Module 1 - Text Reference
SERV1971
CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2017 Caterpillar Inc. All Rights Reserved.
Caterpillar: Confidential Yellow
SERV1971 - 01/17 -2- Module 1 - 3500 Engine Overview
LEARNING OUTCOMES
You will meet the following learning outcomes during
this 3500 Engine Overview module of the D3500
Master Mechanic course:
• Identify applications in which D3500 engines are used.
• Define specifications of a D3500 engine.
• Identify the major components of a D3500 engine.
• Describe the major differences between the A, B, and C
series D3500 engines.
• Review the maintenance intervals for a D3500 engine.
LEARNING OUTCOMES
You will meet the following learning outcomes during this 3500 Engine
Overview module of the D3500 Master Mechanic course:
• Identify applications in which D3500 engines are used.
• Define specifications of a D3500 engine.
• Identify the major components of a D3500 engine.
• escribe the major differences between the A, B, and C series

D
D3500 engines.
• Review the maintenance intervals for a D3500 engine.

Number RPM
Displacement Bore Stroke
Cylinders Ratings
4.3 liters/ 170 mm 190 mm

Standard 8, 12, 16 1,800
cylinder (6.7”) (7.5”)
High 1,500
4.9 liters/ 170 mm 215 mm
Displacement 12, 16, 24 and
cylinder (6.7”) (8.5”)
(HD) 1,600
3_1
D3500 Engine History
In 1980, the D3500 engine went into production with eight, twelve, and sixteen
cylinder configurations available.A twenty four cylinder configuration was offered
later. D3500 engines evolved through the first three phases of production from a
maximum rating of 135 horsepower per cylinder to 188 horsepower per cylinder.
In 1992, D3500 B series engines with Electronic Unit Injectors (EUI) and Electronic
Control Modules (ECM) were produced for Cat machine engine applications. Some
machine engine applications featured Programmable Electronic Engine Control
(PEEC) ECMs, while most used the Advanced Diesel Engine Management (ADEM)
2 ECMs.
In 1995, D3500 B series engines were first produced and offered to the market for
power generation, machine, industrial, marine, and petroleum applications.
In 1999, a High Displacement (HD) D3500 series B engine was offered as an option
for the D3512 B, D3516 B, and D3524 B.
In 2006, the D3500 C series engines were first produced and offered to the market
for power generation, machine, industrial, marine, and petroleum applications. The
D3500 C series features the ADEM 3 or A4 ECM and meets more strict emission
standards versus the D3500 B series model.

4_1 4_2
4_3 4_4
D3500 Applications - Machine Engine
The D3500 engines are commonly used in the larger Cat machines such as:
• 777, 785, 787, 789, and 797 Off Highway Trucks (top left image)
• 5130 and 5230 Mining Excavators (top right image)
• D11R Track-Type Tractors (bottom left image)
• 992, 993, and 994 Wheel Loaders (bottom right image)

5_1
D3500 Applications - Electric Power Generation (EPG)
D3500 engines are used in a variety of electric power generation applications,

including prime power, standby units, and power modules. The above image shows
a power generation plant in Brazil featuring several D3516 engines.

6_1 6_2
6_3 6_4
D3500 Applications - Industrial and Petroleum
D3500 engines are used in a variety of industrial and petroleum applications. Some
examples are:
• Locomotives (top left image)

• Oil and natural gas well fracture rigs (top right image)
• Oil and natural gas well servicing rigs (bottom left image)
• Fire pumps (bottom right image)
• Land and offshore drilling and production (not shown)
• Natural gas compression (not shown)

7_1 7_2
7_3 7_4
D3500 Applications - Marine
D3500 marine engines (top left image) are used in a variety of marine applications.
Some examples are:
• Tug boats (top right image)

• Pleasure craft/yachts (bottom left image)
• Fire and rescue boats (bottom right image)
• Ferry boats (not shown)
• Commercial fishing boats (not shown)
• Research vessels (not shown)

8_1
Engine Specifications - D3508
The following are engine specification for the D3508:
• Used in generator, machine, marine, industrial, and petroleum applications

• Arrangement of cylinders: 60 degree Vee
• Four valves per cylinder (two intake and two exhaust)
• Displacement: 34.5 L (2105 cubic inches)
• Standard Bore: 170 mm (6.7 inches)
• Standard Stroke: 190 mm (7.5 inches)
• Standard Compression Ratio: 14:1
• Direct injection combustion
• Standard rotation: Counterclockwise
• Valve lash:
- Inlet: 0.50 mm (0.020 inch)
- Exhaust: 1.00 mm (0.040 inch)

9_1
• Used in generator, industrial, machine, marine, and petroleum applications

• Standard Compression Ratio: 14:1
• Valve lash:
- Inlet: 0.50 mm (0.020 inch)

10_1
• Used in generator, industrial, machine, marine, and petroleum applications

• Standard Compression Ratio: 14.7:1
• Valve lash:
- Inlet: 0.50 mm (0.020 inch)

11_1
The D3524 is two D3512 engines connected and working in tandem. The following
are engine specification for the D3524:
• Used in 797 Off-Highway Truck applications

• Available as a D3524 B series only
• Displacement: 117 L (7140 cubic inches) total
• Standard Compression Ratio: 15.5:1
• Valve lash:
- Inlet: 0.50 mm (0.020 inch)

2 3
1
12_1
Engine Orientation
The front of the engine is opposite of the flywheel end (1) of the engine. The left side
(2) and the right side (3) of the engine are determined from the flywheel end.
Standard rotation is counterclockwise, determined from the flywheel end. Reverse

rotation is clockwise, determined from the flywheel end.

1 1
2 2
3
4
5
6
7
8
13_1
Engine Orientation (cont.)
The number 1 cylinder is the front cylinder on the right side (1) of the engine. The
number 2 cylinder is the front cylinder on the left side (2) of the engine. The odd
numbered cylinder heads are positioned forward of the even numbered cylinder
heads by the length of a connecting rod.

2
1
14_1
Serial Number and Information Plates
The serial number plate (1) is located at the left rear side of the engine, between the
camshaft cover and flywheel housing.
The information plate (2) is located on the left front side of the engine, between
cylinder head two and the front gear train housing.

15_1
Serial Number Plate
The serial number plate provides the model number, serial number, and arrangement
number of the engine.

16_1
Information Plate
The information plate provides information such as serial number, arrangement

number, high idle rpm, full load rpm, full load fuel setting, full torque fuel setting,
fuel timing, horsepower (hp) rating, kW output, and the performance specification
numbers.

3
2
6
7 8
17_1
Component Identification - Right Side
The following are components located on the right side of the engine:
• Oil filter housing (1)

• Fuel filter housing (2)
• Air shutoff (3)
• Air filter housing (4)
• Engine oil cooler (5)
• Fuel transfer pump (6)
• Engine oil pump (7)
• Water pump (8)

5 2
1
7
6 8 9
18_1
Component Identification - Left Side
The following are components located on the left side of the engine:
• Turbocharger (1)
• Crankcase breather (2)
• Aftercooler cover (3)
• Fuel filter housing (4)
• Oil filter housing (5)
• Separate circuit water pump (6)
• Crankcase explosion relief (7)
• Starter (8)
• Jacket water heater (9)

5 3
2
6
7 1 19_1
Component Identification - Front
The following are components located on the front side of the engine:
• Balancer (1)
• Electronic Control Module (2)
• Fuel lines (3)
• Regulator housing (4)
• Return tube from regulator housing to water pump (5)
• Alternator (6)
• Water pump inlet (7)

1 2 1
5 3 5
4 4
20_1
Component Identification - Top
The following are components located on the top of the engine:
• Inlet air tubes (1)

• Aftercooler housing (2)
• Exhaust manifolds (3)
• Coolant manifolds (4)
• Fuel manifolds (5)

1
2
4
5 5
3
21_1
Component Identification - Cutaway
The following are components located on the cutaway image of the engine:
• Inlet air tubes (1)

• Aftercooler core (2)
• Inlet air manifold (3)
• Exhaust air manifold (4)
• Coolant manifolds (5)
• Engine oil pump (6)

22
3500 Block
The above image shows a display of a D3500 engine block. The grey half is the
casting alone, and the yellow half is after the machining work has been performed.

23
3500 Block
This image is of the same display block as the previous slide, shown from a top
view.

24_1
D3500 A Series
In 1980, the D3500 A series engine went into production with eight, twelve, and
sixteen cylinder configurations available. Original ratings offered 135 hp per cylinder.
Design changes to the D3500 A resulted in later offerings up to 180 hp per cylinder.
Some of the features of a D3500 A series engine are:
• Mechanical Unit Injector (MUI) is used for fuel delivery.

• Fuel is controlled by a mechanical governor and mechanical fuel rack.
• No electronic sensors or Electronic Control Module (ECM).
• Low mount aftercooler.
NOTE: These features will be covered in detail in subsequent modules.

25_1
D3500 B Series
In 1992, D3500 B series engines with Electronic Unit Injection (EUI) were produced
for Cat machine applications. In 1995, D3500 B series engines were first produced
and offered for generator, marine, industrial, and petroleum applications.
D3500 B series engines are electronically controlled by an ECM. Most D3500 B

applications feature the Advanced Diesel Engine Management (ADEM) 2 ECM,
while some machine engine applications use Programmable Electronic Engine
Controler (PEEC) ECMs.
Eight, twelve, and sixteen cylinder configurations were offered for the standard
D3500 B engine. In 1999, a High Displacement (HD) D3500 B series engine was
offered as an option for the D3512 B, D3516 B, and D3524 B engines.
Standard D3500 B series engines offer many different horsepower ratings. In

general, a D3500 B series engine will offer 188 hp per cylinder. The HD model offers
up to 215 hp per cylinder.
Some of the features of the D3500 B series engine are:
• Larger camshaft
• Cylinder block camshaft bore areas reinforced
• Injector lobe and lifter follower increased width

• Two piece piston: A forged steel crown and a cast aluminum skirt
provide added strength in the high load area and the aluminum skirt
reduces weight and dissipates heat. The one piece piston featured in
D3500 A series engines cannot tolerate the higher cylinder pressures in
a D3500 B series engine.
• Taller piston with elevated piston rings: The D3500 B series piston
is taller with all the rings higher on the piston in order to help control the
unburned fuel which reduces emissions up to 70% and to lower fuel
consumption.
• Timing wheel on left camshaft: Installed on the rear of the left
camshaft to provide an engine speed and timing signal to the Engine
Control Module.
• Electronic Unit Injector (EUI) or (MEUI): The D3500 B engines use
Electronic Unit Injectors. These are mechanically actuated by the
camshaft and electronically controlled by the Engine Control Module.
The injectors produce a 20% higher injection pressure than D3500 A
series injectors for improved fuel vaporization.
• ADEM 2 ECM: Provides a signal to the injectors in order to control the
amount of fuel for engine speed control and to vary timing, as needed.
The EUI system is the major reason for increased engine performance,
reduced fuel consumption, reduced emissions and startup smoke, and
provides easy monitoring and diagnostic troubleshooting.
• Fuel injector helper spring: The rocker arm base features an injector
helper spring. This spring exerts a pressure on the cam lifter follower
in order to maintain constant contact between the lifter follower and the
camshaft lobe. This significantly reduces the risk of camshaft or lifter
follower failure during non-injection periods.
• Strengthened rear gear train: Compared to the D3500 A series
engine, the rear gear train of the D3500 B series engine has been
strengthened in order to drive the larger camshafts and heavier valve
train components. The gears have been widened and the gear pitch has
been engineered to add strength to the gear train.
• High mount aftercooler: Compared to the D3500 A series engine,
higher capacity aftercoolers are used in D3500 B series engines and
are located in a higher position on the engine. Air is transferred from
the aftercooler to the cylinder heads through a shorter, straighter path.
This configuration provides one 90º turn instead of two 90º turns, which
helps to decrease the inlet air temperature entering the cylinders. The
location of the aftercooler is the most common identifier between the
D3500 A and D3500 B. The aftercooler on the D3500 B is located in a
higher position in reference to the “Vee” on the engine. The further down
in the Vee, the hotter the temperatures are.
• Larger turbocharger: Compared to the D3500 A series engine, larger
turbochargers are utilized on the D3500 B series engines. The larger
turbochargers provide more air for the combustion process.

1
2
5
6
27_1 27_2
D3500 A and D3500 B Comparisons
The above images compare the EUI (left image) and MUI (right image) components.
The EUI injector features a stronger rocker arm (1), rocker arm shaft (2), lifter
follower (3), and push rod (4). The push rod also contains an injector helper spring
(5). The MUI features similar components, with the mechanical rack linkage (6) used
to control the fuel supply..
NOTE: These features will be covered in detail in the Fuel System module.

2 2
3
3
4
4
1
1
28_1 28_2
D3500 A and D3500 B Comparisons (cont.)
The above images illustrate a comparison of the EUI (left image) and MUI (right
image) fuel injectors and their actuating mechanisms. The differences between the
mechanical and electronic unit injectors (1), the rocker arms (2), push rods (3), and
lifter followers (4) can be seen. The EUI push rod contains a return spring (5) which
reacts against a boss cast into the rocker base. The return spring ensures constant
contact between the lifter follower and the camshaft lobe at all times in order to
reduce wear and camshaft and lifter follower failure. This feature is necessary with
the very aggressive cam lift profile that also has a shorter injection duration.

29_1
D3500 C Series
In 2006, the D3500 C engine went into production with eight, twelve, and sixteen
cylinder configurations available. D3500 C series engines offer many different
horsepower ratings. In general, a D3500 C series engine will offer 195 hp per cylinder.
D3500 C engines are able to meet stricter EPA emission standards than D3500 B
series engines. Some of the features of a D3500 C series engine, as compared to a
D3500 B series engine, are:
• ADEM 3 ECM: Offers more memory and a faster processor than

the ADEM 2. The ADEM 3 provides improved engine monitoring,
communication, and display capabilities, which results in easier
integration with customer installed systems.
• Separate Circuit Cooling System: Most D3500 C engines feature
separate circuit aftercoolers, which optimizes cooling capability and
helps lower combustion air temperatures.
• ACERT® Technology: Advanced computer modeling is used in order
to optimize the fuel spray, timing, and injection pressure during the
combustion process.
• Monotherm Piston: One-piece design, forged steel, with an improved
crown design that helps to optimize fuel economy and emissions.

30_1
D3500 Maintenance Intervals
Regular and proper maintenance is essential to the life of the engine. Always refer
to SIS Web for the engine being serviced for the most current maintenance intervals
and procedures. The following is a reference for maintenance intervals on D3500
engines:
Daily:
• Air Starting Motor Lubricator Oil Level – Check

• Air Tank Moisture and Sediment – Drain
• Cooling System Coolant Level – Check
• Driven Equipment - Inspect/Replace/Lubricate
• Engine Air Cleaner Service Indicator – Inspect
• Engine Air Precleaner – Clean
• Engine Oil Filter Differential Pressure – Check
• Engine Oil Level – Check
• Fuel System Fuel Filter Differential Pressure – Check
• Fuel Tank Water and Sediment – Drain
• Instrument Panel – Inspect

Initial 250 Service Hours:
• Engine Valve Lash – Inspect/Adjust

• Fuel Injector – Inspect/Adjust
Every 250 Service Hours:
• Alternator and Fan Belts – Inspect/Adjust/Replace

• Battery Electrolyte Level – Check
• Cooling System Supplemental Coolant Additive (SCA) – Test/Add
• Engine Oil Sample – Obtain
• Fan Drive Bearing – Lubricate
• Hoses and Clamps – Inspect/Replace
• Radiator – Clean
• Engine Oil and Filter – Change
• Cooling System Coolant Analysis (Level II) – Obtain

• Engine – Clean
• Engine Crankcase Breather – Clean
• Engine Oil and Filter – Change
• Engine Protective Devices – Check
• Fuel System Primary Filter – Clean/Inspect/Replace
• Fuel System Secondary Filter – Replace
• Air Starting Motor Lubricator Bowl – Clean

• Crankshaft Vibration Damper – Inspect
• Engine Mounts – Check
• Turbocharger - Inspect
Every 3000 Service Hours or Three Years:
• Cooling System Coolant (DEAC) – Change

• Cooling System Coolant Extender (ELC) – Add

• Engine Valve Lash – Inspect/Adjust

• Fuel Injector – Inspect/Adjust
Every 6000 Service Hours or Six Years:
• Alternator – Inspect
• Cooling System Water Temperature Regulator – Replace
• Prelube Pump – Inspect
• Starting Motor – Inspect
• Water Pump – Inspect
Every 12,000 Service Hours or Six Years:
• Cooling System Coolant (ELC) – Change
When Required:
• Batteries – Replace
• Engine Air Cleaner Element (Dual Element) – Clean/Replace
• Fuel System – Prime
• Zinc Rods – Inspect/Replace

LEARNING OUTCOMES
You have met the following learning outcomes during
this 3500 Engine Overview module of the D3500
Master Mechanic course:
• Identified applications in which D3500 engines are used.
• Defined specifications of a D3500 engine.
• Identified the major components of a D3500 engine.
• Described the major differences between the A, B, and
C series D3500 engines.
• Reviewed the maintenance intervals for a D3500
engine.
LEARNING OUTCOMES
You have met the following learning outcomes during this 3500 Engine
Overview module of the D3500 Master Mechanic course:
• Identified applications in which D3500 engines are used.
• Defined specifications of a D3500 engine.
• Identified the major components of a D3500 engine.
• escribed the major differences between the A, B, and C series

D
D3500 engines.
• Reviewed the maintenance intervals for a D3500 engine.

D3500MM M01 Overview en TXT-Participant

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D3500MM M01 Overview en TXT-Participant

Uploaded by

Copyright:

Available Formats

Global Manpower Development

d3500 master mechanic

• Identify applications in which D3500 engines are used.

• Define specifications of a D3500 engine.

• Identify the major components of a D3500 engine.

•  escribe the major differences between the A, B, and C series

• Review the maintenance intervals for a D3500 engine.

Caterpillar: Confidential Yellow

4.3 liters/ 170 mm 190 mm

D3500 Engine History

Caterpillar: Confidential Yellow

D3500 Applications - Machine Engine

Caterpillar: Confidential Yellow

D3500 Applications - Electric Power Generation (EPG)

D3500 engines are used in a variety of electric power generation applications,

Caterpillar: Confidential Yellow

D3500 Applications - Industrial and Petroleum

• Locomotives (top left image)

Caterpillar: Confidential Yellow

D3500 Applications - Marine

• Tug boats (top right image)

Caterpillar: Confidential Yellow

Engine Specifications - D3508

The following are engine specification for the D3508:

• Used in generator, machine, marine, industrial, and petroleum applications

Caterpillar: Confidential Yellow

Engine Specifications - D3512

The following are engine specification for the D3512:

• Used in generator, industrial, machine, marine, and petroleum applications

Caterpillar: Confidential Yellow

Engine Specifications - D3516

The following are engine specification for the D3516:

• Used in generator, industrial, machine, marine, and petroleum applications

Caterpillar: Confidential Yellow

Engine Specifications - D3524

• Used in 797 Off-Highway Truck applications

Caterpillar: Confidential Yellow

Standard rotation is counterclockwise, determined from the flywheel end. Reverse

Caterpillar: Confidential Yellow

Engine Orientation (cont.)

Caterpillar: Confidential Yellow

Serial Number and Information Plates

Caterpillar: Confidential Yellow

Serial Number Plate

Caterpillar: Confidential Yellow

The information plate provides information such as serial number, arrangement

Caterpillar: Confidential Yellow

Component Identification - Right Side

• Oil filter housing (1)

Caterpillar: Confidential Yellow

Component Identification - Left Side

Caterpillar: Confidential Yellow

Component Identification - Front

Caterpillar: Confidential Yellow

Component Identification - Top

The following are components located on the top of the engine:

• Inlet air tubes (1)

Caterpillar: Confidential Yellow

Component Identification - Cutaway

• Inlet air tubes (1)

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

• Mechanical Unit Injector (MUI) is used for fuel delivery.

• escribe the major differences between the A, B, and C series

• escribed the major differences between the A, B, and C series