SIS News 3500 Series

Engine News January 2004
Media Number -SEBD9329-00 Publication Date -2004/01/01 Date Updated -2004/01/01
A New Shield is used for the Seal on the Aftercooler {1063}

Engine:
3508B (S/N: 2BM1-UP; 4GM1-UP; 6PN1-UP; 1TW1-UP)
3512B (S/N: 7HM1-UP; 8RM1-UP; 4TN1-UP; 6WN1-UP; 2GW1-UP; 4AW1-UP; 6GW1-UP)
3516 (S/N: 5SJ1-UP)
3516B (S/N: BCK1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 2FW1-UP; 4BW1-UP;
8NW1-UP)
Generator Set:
3508B (S/N: 5KW1-UP)
3512B (S/N: CMC1-UP)
3516B (S/N: FDN1-UP; FDX1-UP)
Engine News SEBD9328, 1 December 2003, "A New Shield is used for the Seal on the
Aftercooler". This supplement provides additional information.
Description of Change: The new shield helps protect the seal from high temperatures that can
degrade the seal. This improves the service life of the seal.
The aftercooler has an upper seal and a lower seal. The shield is intended for use on the upper seal
only. Refer to Illustration 1 for the proper orientation of the shield.
Adaptable To: The 237-0598 Shield As is used for 8 and 16 cylinder engines. The 237-0599
Shield As is used for 12 cylinder engines. The shield assemblies are adaptable to the above engines
and generator sets. The effectivity for the shield assemblies is listed in Table 1.
Table 1
Effective Serial Numbers
S/N:6WN00803-UP
S/N:8RM00754-UP
S/N:6HN01720-UP
S/N:7RN001951-UP
S/N:BCK00278-UP
Illustration 1
(1) Shield for the aftercooler seal
(2) Lower seal
Engine News December 03

Procedure for Cylinder Head Bolt Tightening {1100}

SMCS - 1100
Caterpillar Products: All
 3500B Engines
There is a new torque procedure for the cylinder head bolts on 3500B Engines. The new procedure
provides a more consistent torque on all of the cylinder head bolts. The procedure will improve the
sealing capability of the joint.
Reference: Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8301, "Inspection
and Reuse of Critical Fasteners Used in All Engines" for reuse information for the cylinder head
bolts.
Use the following procedure to tighten the cylinder head bolts.
1. Coat the threads of all ten cylinder head bolts with clean engine oil.
2. Tighten all ten bolts in the numbered sequence that is pictured in Illustration 1.
Torque ... 30 ± 5 N·m (22 ± 4 lb ft)
3. Tighten bolts 1 through 8 in the numbered sequence.
Torque ... 200 ± 15 N·m (148 ± 11 lb ft)
4. Tighten bolts 1 through 8 again in the numbered

sequence.
Torque ... 200 ± 15 N·m (148 ± 11 lb ft)
5. Tighten bolts 1 through 8 again to the following rotation.
Rotation for bolts ... 180 degrees
6. Tighten bolt 9 and bolt 10.
Torque ... 55 ± 10 N·m (40 ± 7 lb ft)
The Two-Piece Pistons are Cancelled {1214}

Caterpillar Products:
 3500 Family Pumpers
 3500 and 3500B Family Generator Sets and Power Modules with Standard Displacement
Engine: Commercial
 3500 and 3500B Engines with Standard Displacement
Description of Change:
Reference: Refer to Engine News, SEBD9327-00, November 2003, "Introduction of New Pistons
and Remanufactured Cylinder Packs".The former two-piece pistons have been cancelled and
replaced by the one-piece pistons. The former remanufactured cylinder packs which included the
two-piece pistons are also cancelled and replaced by the cylinder packs with the one-piece pistons.
Adaptable To: The new pistons are suitable for use in the above Engines. The 233-2431 Pistons
are a direct replacement for the cancelled 144-0720 Piston Crown As. The 233-2430 Pistons are a
direct replacement for the cancelled 133-8383 Piston Crown As. The remanufactured cylinder
packs are direct replacements for the former cylinder packs, which are cancelled. Table 1 lists the
usage, the former parts, and the new parts. For more details, refer to the above reference.
Note: Some of the parts that were used with the former two-piece pistons are still serviceable for
repair. The following parts are still serviceable: 125-2782 Piston Skirt, 138-8507 Piston Pin, 8N-
7296 Pin Retainer, 229-1631 Piston Ring (Top), 144-5695 Piston Ring (Intermediate ring) and
123-4268 Piston Ring (Oil).
NOTICE
Failure to install the correct piston cooling jet and retainer will result in inadequate
lubrication. This will cause piston seizure and catastrophic engine damage. Install the correct
piston cooling jet and the correct retainer.
Table 1
3500 MUI
Status 3500B
3500 with EUI
New Part 223-6362 Piston and Rod Gp 223-6363 Piston and Rod Gp
Former Part 6I-2861 Piston and Rod Gp 101-0829 Piston and Rod Gp
New Remanufactured Part 10R-1816 Cylinder Pack Gp 10R-1817 Cylinder Pack Gp
Former Remanufactured Part 0R-4445 Cylinder Pack Gp (1) 0R-9007 Cylinder Pack (1)
( 1 )
This part number is no longer available.
New Gaskets in the Water Lines Groups {1380}

SMCS - 1380
Engine: Commercial
 3500 Family All
 G3500 Family All
 3500 Family Generator Sets and Power Modules
 G3500 Family Generator Sets and Power Modules
Illustration 1
Typical water lines group
(1) 241-5928 Gasket
(2) 243-2288 Gasket
New gaskets have been designed in
order to improve the sealing capability
of the water lines groups that are used in
the 3500 Engines. The new gaskets are designed with a different material and with new geometry.
The new design helps to prevent the gasket from creeping. One gasket (1) is located between the
elbows and the water manifold of the water lines group and the other gasket (2) is located between
the sections of the water manifold in the water lines groups.
Adaptable To: The part numbers of the new gaskets and of the former gaskets that are being
replaced are listed below.
Table 1
Gaskets for the 3500 Water Lines Groups
New Gasket Former Gasket
241-5928 8N-4524
243-2288 1W-8545
The new gaskets are adaptable to first production of the above engines. The former gaskets have
not been cancelled.
A New Dowel Improves Lubrication to the Rocker Assembly

{1123, 1123}
Engine: Commercial
 3500 Family All
Description of Change: A new dowel that meters the oil is available for the above engines. This
new metering dowel has a larger orifice that will provide an increased supply of engine oil to the
rocker shaft and to the rocker arm bearings. The increased supply of engine oil will provide a
better film of oil that will decrease the wear of the rocker shaft and of the rocker arm bearings.
Adaptable To: The new 197-7008 Dowel is a direct replacement for the previous 7N-2049
Dowel. The 197-7008 Dowel is adaptable to all 3500 Engines. The new dowel can be used in order
to service a single cylinder or the new dowel can be used in order to service all of the cylinders.
The new 197-7008 Dowel is effective with the engines that are listed in Table 1, Table 2, Table 3,
and Table 4.
Illustration 1
(1) Dowel
Parts List for Prelube Pump Group Kits {1319}

Engine:
3516 (S/N: 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5SJ1-UP; 25Z1-UP; 27Z1-UP; 28Z1-UP; 29Z1-
UP; 71Z1-UP; 72Z1-UP; 73Z1-UP)
3516B (S/N: BCK1-UP)
3606 (S/N: 8RB1-UP)
3608 (S/N: 6MC1-UP; 8LL1-UP; 7WR1-UP)
3612 (S/N: 9RC1-UP)
3616 (S/N: 1PD1-UP)
3618 (S/N: 2MW1-UP)
G3516 (S/N: 3RC1-UP; 8LD1-UP; 4EK1-UP; 5PN1-UP)
G3606 (S/N: 3XF1-UP)
G3608 (S/N: 4WF1-UP)
G3612 (S/N: 1YG1-UP)
G3616 (S/N: BLB1-UP; 4CG1-UP)
Engine News SEBD9231, January 1996, "Parts List for Prelube Pump Group Kits". Disregard this
article. Corrections have been made to the original document. The correct information follows.
Description of Change: The parts list has changed due to new part numbers.
Adaptable To: The following prelube pumps are used with 3500 and 3600 Commercial Engines:
9Y-6016 Prelubrication Pump Gp, 9Y-9992 Prelubrication Pump Gp, 9Y-9993 Prelubrication
Pump Gp and 9Y-9995 Prelubrication Pump Gp .
Table 1 lists the parts for the 9Y-6016 Prelubrication Pump Gp.
Table 1
9Y-6016 Prelubrication Pump Gp
Qty Serviceable Part Serviceable Part in Kit Qty
106-5029 Needle Bearing As 4
129-6306 Lip Seal 1
129-6307 Gasket 3

1 128-2808 Prelubrication Pump Kit
129-6308 Needle Roller 1
129-6311 Retaining Ring 4
129-6312 Ball 1
129-6313 Oil Pump Drive Shaft 1

129-6314 Shaft (1) 1
1 128-3543 Motor As
1 128-3548 Gear Pump Assembly

( 1 )
The driven shaft can only be obtained with the kit.
Table 2 lists the parts for the following pump groups: 9Y-9992 Prelubrication Pump Gp, 9Y-9993
Prelubrication Pump Gp and 9Y-9995 Prelubrication Pump Gp.
Table 2

Qty Serviceable Part Serviceable Part in Kit Qty
106-5029 Needle Bearing As 4
127-6930 Dowel Pin 1
129-6306 Lip Seal 1

1 128-2759 Pump Repair Kit
129-6307 Gasket 3
129-6311 Retaining Ring 4
129-6312 Ball 1
129-6315 Driver Shaft 1

1 128-2760 Pump Shaft Kit
129-6316 Driven Shaft 1
1 128-2761 Pump Gear Kit
1 128-3543 Motor As (1)
1 128-3544 Motor As (1)
1 128-3545 Motor As (1)
1 128-3547 Gear Pump Assembly

( 1 )
9Y-9992 Prelubrication Pump Gp uses 128-3543 Motor As. 9Y-9993 Prelubrication Pump Gp uses 128-3544
Motor As. 9Y-9995 Prelubrication Pump Gp uses 128-3545 Motor As .
Table 3 lists the usage of the prelube pumps.
Table 3
Usage
9Y-6016 9Y-9992 9Y-9993 9Y-9995

Sales Serial
Prelubrication Prelubrication Prelubrication Prelubrication
Model Number
Pump Gp Pump Gp Pump Gp Pump Gp
(S/N:
3606 8RB1- X X X X
UP)
(S/N:
3608 6MC1- X X X X
UP)
(S/N:
3612 9RC1- X X X X
UP)
(S/N:
3616 X X X X
1PD1-UP)
(S/N:
G3606 X X X X
3XF1-UP)
(S/N:
G3608 4WF1- X X X X
UP)
(S/N:
G3612 1YG1- X X X X
UP)
(S/N:
G3516 4CG1- X X X X
UP)
(S/N:
3516 X
9KF1-UP)
(S/N:
G3516 4EK1- X
UP)
(S/N:
G3516 X
5PN1-UP)
(S/N:
3516B BCK1- X
UP)
(S/N:
G3616 BLB1- X
UP)
(S/N:
3618 2MW1- X
UP)
(S/N:
3608 X
8LL1-UP)
(S/N:
3608 7WR1- X
UP)
New Cylinder Head Groups and Valve Mechanisms

Engine: Commercial
 3500 Family All
Engine News SEBD9326, October 2003, "New Cylinder Head Groups and Valve Mechanisms".
Disregard this article. Corrections have been made to the original document. The correct
information follows.
Description of Change: New cylinder head groups and assemblies are available for all 3500 and
3500B Engines. The new head groups and assemblies include a new exhaust valve with a larger
stem diameter and an exhaust valve guide with a larger inside diameter. The larger stem diameter
reduces stress in the valve stem during severe engine operation. The new groups also include
floating valve bridges that eliminate the need for bridge adjustments. The new groups also include
the following new components: valve springs, rotators, spring washers and valve stem seals.
Adaptable To: Use the new basic cylinder head groups for Top End overhauls and for Major
overhauls on all 3500 and 3500B Engines. The new basic cylinder head groups may be used
individually in replacement of the former basic cylinder head groups.
The former cylinder head groups and the new cylinder head groups are listed in Table 1.
Table 1
New Basic Cylinder Head

Cylinder Head Group Former Basic Cylinder Head Group
Group
3500 Engine with EUI
7E-8758 Cylinder Head

172-0837 Cylinder Head Gp 239-0691 Cylinder Head Gp
Gp
3500 MUI Engine (Locomotive)
203-2170 Cylinder Head

Gp
3500 MUI Engine
4W-0095 Cylinder Head

Gp
3500B Engine

Gp
3500B Engine (Locomotive)

Gp
Use the new individual parts for replacement of any former individual parts. If any of the new
parts are installed, all of the former parts on that side of the cylinder head must be replaced with
the new parts. For example, if one inlet valve spring is replaced with the corresponding new
spring, then all of the springs on both inlet valves, both of the seals, and both of the valve rotators
must be replaced with the new part numbers. The former parts and the new parts of the basic
cylinder head groups are listed in Table 2.
Table 2
Former Part Number New Part Number
133-9306 Valve Guide (Inlet 133-9306 Valve Guide (Inlet)

and Exhaust) 197-6995 Valve Guide (Exhaust)
210-2542 Inlet Valve 210-2542 Inlet Valve
210-2529 Exhaust Valve 194-4897 Exhaust Valve

137-6856 Seal 197-7006 Seal
2W-2662 Spring Seat 209-0962 Washer
101-1180 Outer Spring

194-4901 Outer Spring
7N-1904 Outer Spring
101-1177 Inner Spring

194-4902 Inner Spring
7N-1903 Inner Spring
197-6999 Rotocoil Assembly 197-7062 Rotocoil Assembly (Inlet)

(Inlet and Exhaust) 197-7063 Rotocoil Assembly (Exhaust)
2A-4429 Retainer Lock (Inlet 2A-4429 Retainer Lock (Inlet)

and Exhaust) 197-7055 Retainer Lock (Exhaust)
8T-6759 Pipe Plug 8T-6759 Pipe Plug
7N-1902 Dowel 239-0689 Dowel (1)
234-8777 Rotocoil Assembly is serviced by the 197-7063

133-9307 Rotocoil Assembly
Rotocoil Assembly and the 234-8776 Shield . (2)
230-3152 Bridge (Exhaust)

129-4181 Bridge Assembly
230-3153 Bridge (Inlet)
( 1 )
Only required on 3500 MUI
( 2 )
Only required on 3500 Locomotive
The bridge dowels must be removed and/or a bridge dowel must be modified when a cylinder head
that originally had adjustable bridges is rebuilt.
Because of the design of the floating bridge, the cylinder head for a 3500 Engine with EUI and for
a 3500B Engine does not require any dowels.
Because force is placed on the fuel injector by the rack, the cylinder head for a 3500 MUI Engine
requires one 239-0689 Dowel in order to maintain correct orientation of the fuel injector.
Illustration 1
(1) 239-0689 Dowel in a cylinder head for a 3500 MUI Engine
When the cylinder head for a 3500 MUI Engine is
rebuilt, only the right hand dowel is installed. The
dimension from the surface of the cylinder head to the
top of the dowel must not exceed 30 mm (1.2 inch).
Use a 239-0689 Dowel for the correct orientation of
the 3500 MUI fuel injector.
Illustration 2
Typical example of the slot in the floating valve bridge
When viewing the bottom of the new valve bridges the
new valve bridges have a pocket on either end for each
tip of the valve stem. One of the pockets is round and the other
pocket is slotted. The bridge must be placed on the cylinder head so
that the pocket that is slotted is placed on the inboard valve stem.
This orientation of the valve bridge is more stable. This orientation keeps the bridge in position
during the initial valve lash adjustment after an engine rebuild.
Table 3 lists the effectivity for the new cylinder head groups and assemblies.
Table 3
Effectivity of the New Cylinder Head Groups in 3500 Engines
3500 Engine with EUI
Serial Number Serial Number
S/N:3LS00228-UP S/N:3ZW00473-UP
S/N:3MS00233-UP S/N:5PS00315-UP
S/N:3NS00246-UP S/N:7KM00077-UP
3500 MUI Engine (Locomotive)
S/N:2WK00087-UP
3500 MUI Engine
S/N:1JZ00603-UP S/N:67Z02050-UP
S/N:1KZ01244-UP S/N:68Z01252-UP
S/N:1LZ00524-UP S/N:69Z00889-UP
S/N:23Z07938-UP S/N:70Z01077-UP
S/N:24Z10152-UP S/N:71Z00403-UP
S/N:25Z07100-UP S/N:72Z00567-UP
S/N:27Z00851-UP S/N:73Z00968-UP
S/N:29Z01389-UP S/N:95Y01216-UP
S/N:49Y01032-UP S/N:96Y02060-UP
S/N:50Y01802-UP S/N:CTD00183-UP
S/N:65Z01130-UP S/N:CTE00333-UP
S/N:66Z00939-UP S/N:CTF00263-UP
S/N:2TS00008-UP S/N:3HM00015-UP
S/N:3JS00009-UP S/N:51Y00861-UP
S/N:8TL00011-UP S/N:97Y00742-UP
S/N:9WN00358-UP S/N:LPD00005-UP
3500B Engine
S/N:1FZ01864-UP S/N:7SM00910-UP
S/N:1GZ01498-UP S/N:8CN00212-UP
S/N:1NW00145-UP S/N:8EM00508-UP
S/N:1PW00427-UP S/N:8KN00567-UP
S/N:1TW00347-UP S/N:8RM00754-UP
S/N:2AF00364-UP S/N:9AN00358-UP
S/N:2BM00186-UP S/N:AAG00006-UP
S/N:2EZ00331-UP S/N:BAG00025-UP
S/N:2FW00334-UP S/N:BPX00098-UP
S/N:2GW00401-UP S/N:BRC00154-UP
S/N:2HW00248-UP S/N:BRN00192-UP
S/N:2JW00409-UP S/N:CAN00111-UP
S/N:3CW00254-UP S/N:CBB00189-UP
S/N:3DM00451-UP S/N:CBN00312-UP
S/N:3DW00175-UP S/N:CDE00313-UP
S/N:3KD00266-UP S/N:CTA00153-UP
S/N:4AW00816-UP S/N:CTB00186-UP
S/N:4BW00544-UP S/N:CTC00254-UP
S/N:4DR00007-UP S/N:CTD00183-UP
S/N:4GM00743-UP S/N:CTE00333-UP
S/N:4TN00786-UP S/N:CTF00263-UP
S/N:5AW00135-UP S/N:CTG00267-UP
S/N:6WN00803-UP S/N:CTH00235-UP
S/N:7HM00264-UP S/N:CTJ00200-UP
S/N:7RN01949-UP S/N:FFG00018-UP
S/N:S2X00102-UP S/N:S2E00102-UP
S/N:1HZ02430 and 02443-UP
3500B Engine (Locomotive)
S/N:8DF00187-UP S/N:BCK00274-UP
S/N:9WF00118-UP S/N:PWG00110-UP
Service Magazine December 2003
Media Number -SEPD0715-00 Publication Date -2003/12/22 Date Updated -2003/12/22
Technical Information Bulletin

Proper Installation of the 214-6073 Retainer for the Piston Pin
Media Number -TIBU4013-00 Publication Date -2003/11/26 Date Updated -2003/11/20
Proper Installation of the 214-6073 Retainer for the Piston Pin

CONFIDENTIAL TIBU4013
TECHNICAL
November 26, 2003
INFORMATION BULLETIN
Caterpillar Products Machine Engines with Electronic Unit

Injectors 3500 Series

Machine Engines with Mechanical Unit
Injectors 3500 Series
3500B Machine Engines with Standard

Displacement

3500B Family Pumpers

3500 and 3500B Family Generator Sets and
Power Modules with Standard Displacement
3500 and 3500B Engines with Standard

Displacement
Engines
SUBJECT:
Proper Installation of the 214-6073 Retainer for the Piston
Pin used with the Monotherm Piston
PROBLEM:
The retainer does not currently have any identification for the
proper orientation during installation. If the retainer is
improperly installed the retainer can stop the piston pin from
rotating and cause a seizure of the piston. During the
manufacturing process one face of the retainer is rolled over. The
opposite face has a burr formed. *Refer to Illustration 1.
Illustration 1
* The edges of the tangs have a slight angle. The side of the tang
on the rolled face is wider than the side of the tang on the burr
face.
SOLUTION:
The clip must be installed with the rolled edge facing in towards
the piston pin. After the assembly of the piston and rod, check
the rotation of the pin. If the clips are not installed correctly,
the pin will not rotate smoothly. Failure to check the rotation
could cause a seizure of the piston. Illustration 2 is an exploded
view of the piston and rod group.
Illustration 2
Engine News November 2003

Improved Gasket for the Exhaust Elbow {1059}

Engine: Commercial
 3500 Family All
Description of Change: A new exhaust gasket will improve the sealing capability of the exhaust
manifold elbow on 3500 and G3500 Engines. The new gasket's material will provide an improved
service life because the material is better able to withstand high exhaust temperatures.
Adaptable To: The 245-3512 Gasket is a direct replacement for the 5L-3773 Exhaust Elbow
Gasket. The 245-3512 Gasket is adaptable to the engines that are listed above.
Illustration 1
Typical example
(1) Location of the new gasket
(2) 245-3512 Gasket
New Seal for the Front Housing

{1151}
SMCS - 1151
Engine: Commercial
 3500 Family All
Description of Change: A new O-ring seal is available for the following components that are
located on the front housing of 3500 and 3500B Gas and Diesel Engines: auxiliary drive groups,
front housing cover groups, auxiliary drive pulley groups and accessory drive groups. The new O-
ring seal has improved sealing capability. The new seal is made of Viton.
Adaptable To: The 235-3546 O-Ring Seal is adaptable to the 3500 Engines that are listed above.
Table 1 lists the new part that is a direct replacement for the former part.
Table 1
Former Part New Part
1T-0132 O-Ring Seal 235-3546 O-Ring Seal
Introduction of New Pistons and Remanufactured Cylinder

Packs {1214, 1239}
 3500 and 3500B Family Generator Sets and Power Modules with Standard Displacement
Engine: Commercial
 3500 and 3500B Engines with Standard Displacement
Illustration 1
A new piston has been introduced for 3500 Engines. The
forged steel piston is a one piece piston. A large
circumferential slot separates the crown and the skirt. The
crown and the skirt remain attached by the strut for the pin
bore.
The new top ring is steel and very sensitive to bending. The
ring expander tool must be used in order to install the top
ring. Failure to use the ring expander tool will result in early
hour failure of the piston ring. This will result in engine
failure. Refer to table 1 for the part numbers of the tools that
are used in servicing the piston.
Table 1
Service Tools
Pt. No. Description
6V-4020 Piston Ring Expander Gp
6V-4023 Handle As
6V-4024 Guide Ring
1P-1861 Retaining Ring Pliers
1U-7616 Piston Ring Compressor Gp

Adaptable To: The new pistons are a direct replacement for previous pistons that are used in 3500
Engines. The new pistons have the same balance weight as the previous pistons. The new pistons
can be used in the same engine with the previous pistons. Table 2 lists the usage of the new piston
and rod groups and the former piston and rod groups. The new remanufactured cylinder packs that
include the new piston and the former remanufactured cylinder packs are also listed.
Note: The new piston cannot be used in 3500B High Displacement Engines.
Table 2
Usage 3500 MUI 3500 with EUI 3500B
New Part 223-6362 Piston and Rod Gp 223-6363 Piston and Rod Gp
Former Part 6I-2861 Piston and Rod Gp 101-0829 Piston and Rod Gp
New Remanufactured Part 10R-1816 Cylinder Pack Gp 10R-1817 Cylinder Pack Gp
Former Remanufactured Part 0R-4445 Cylinder Pack Gp (1) 0R-9007 Cylinder Pack (1)
( 1 )
This part number is no longer available.
Note: The 223-6362 Piston and Rod Gp, and the 223-6363 Piston and Rod Gp cannot be ordered
as groups. Each part must be ordered individually. .If a former piston is replaced with the new one
piece piston, it is important to note that all of the top end parts in the piston and rod group must be
replaced. Replace the following components, if a new piston is installed: 197-0560 Piston Pin,
214-6073 Retainer (Piston Pin), 214-6066 Piston Ring, 144-5695 Piston Ring (Intermediate) and
223-6361 Piston Ring (Oil Control).
The new pistons require a new 204-5447 Piston Cooling Jet As and a new 193-3282 Retainer As
(Piston Cooling Jet) that are part of the piston and rod group.
The 10R-1816 Cylinder Pack Gp and the 10R-1817 Cylinder Pack Gp are ordered as a group.
However, the packs will require the 204-5447 Piston Cooling Jet As and the 193-3282 Retainer As
(Piston Cooling Jet). If you order a remanufactured cylinder pack make sure that you order the
204-5447 Piston Cooling Jet As and the 193-3282 Retainer As (Piston Cooling Jet).
Failure to use the correct cooling jet tubes with the correct piston will cause engine failure.
Table 3 lists all of the parts in the 223-6362 Piston and Rod Gp. Table 4 lists all of the parts in the
223-6363 Piston and Rod Gp.
Table 3
223-6362 Piston and Rod Gp
Pt. No. Description
233-2430 Piston
197-0560 Piston Pin
214-6073 Retainer (Piston Pin)
214-6066 Piston Ring
144-5695 Piston Ring (Intermediate)
223-6361 Piston Ring (Oil Control)
204-5447 Piston Cooling Jet As
193-3282 Retainer As (Piston Cooling Jet)
0T-0102 Bolt
1B-2790 Bolt
5M-2894 Hard Washer
9M-1974 Hard Washer
144-0725 Rod
107-7330 Connecting Rod Bearing
Table 4
223-6363 Piston and Rod Gp
Pt. No. Description
233-2431 Piston
197-0560 Piston Pin
204-5447 Piston Cooling Jet As
193-3282 Retainer As (Piston Cooling Jet)
0T-0102 Bolt
1B-2790 Bolt
5M-2894 Hard Washer
9M-1974 Hard Washer
144-0725 Rod
107-7330 Connecting Rod Bearing
Table 5 lists the effectivity of the new pistons in 3500 MUI and in 3500 with EUI Engines. Table 6
lists the effectivity of the new pistons in 3500B Engines.
Table 5
3500 MUI
(S/N: 1JZ00557-UP)
(S/N: 1KZ01241-UP)
(S/N: 1LZ00523-UP)
(S/N: CTD00183 and Up)
(S/N: CTE00333 and Up)
(S/N: CTF00263 and Up)
(S/N: 23Z07936-UP)
(S/N: 24Z10152-UP)
(S/N: 25Z07100-UP)
(S/N: 27Z00851-UP)
(S/N: 29Z01389-UP)
(S/N: 49Y01031 and Up)
(S/N: 50Y01802 and Up)
(S/N: 51Y00861 and Up)
(S/N: 65Z01130 and Up)
(S/N: 66Z00939 and Up)
(S/N: 67Z02050 and Up)
(S/N: 68Z01250 and Up)
(S/N: 69Z00887 and Up)
(S/N: 70Z01076 and Up)
(S/N: 71Z00403 and Up)
(S/N: 72Z00567 and Up)
(S/N: 73Z00968 and Up)
(S/N: 95Y01216 and Up)
(S/N: 96Y02051 and Up)

(S/N: 97Y00742 and Up)
3500 with EUI
(S/N: 3NS00246-UP)
(S/N: 3MS00233-UP)
(S/N: 3LS00228-UP)
(S/N: 7KM00077 and Up)
Table 6
3500B Engines
(S/N: 1FZ01735-UP)
(S/N: 1GZ01494-UP)
(S/N: 1HZ02440-UP)
(S/N: 1NW00145-UP)
(S/N: 1PW00427-UP)
(S/N: 1TW00329-UP)
(S/N: 2AF00364-UP)
(S/N: 2BM00186-UP)
(S/N: 2FW00334-UP)
(S/N: 2GW00401-UP)
(S/N: 2HW00245-UP)
(S/N: 2WK00087-UP)
(S/N: 3CW00254-UP)
(S/N: 3DM00423-UP)
(S/N: 3DW00172-UP)
(S/N: 3KD00266-UP)
(S/N: 3ZW00466-UP)
(S/N: 4AW00814-UP)
(S/N: 4GM00743-UP)
(S/N: 4TN00786-UP)
(S/N: 5PS00309-UP)
(S/N: 6HN01720-UP)
(S/N: 6PN00839-UP)
(S/N: 6WN00803-UP)
(S/N: 7HM00264-UP)
(S/N: 7RN01951-UP)
(S/N: 7SM00875-UP)
(S/N: 8CN00212-UP)
(S/N: 8DF00187-UP)
(S/N: 8EM00508-UP)
(S/N: 8KN00566-UP)
(S/N: 8RM00754-UP)
(S/N: 9AN00358-UP)
(S/N: 9WF00118-UP)
(S/N: BPX00098-UP)
(S/N: BRC00154-UP)
(S/N: CAN00111-UP)
(S/N: CBB00177-UP)
(S/N: CTA00153-UP)
(S/N: CTB00186-UP)
Table 7 lists all of the parts in the 10R-1816 Cylinder Pack Gp. Table 8 lists all of the parts in the
10R-1817 Cylinder Pack Gp.
Table 7
10R-1816 Cylinder Pack Gp For 3500 MUI and 3500 with EUI Engines
Pt. No. Description
233-2430 Piston
197-0560 Piston Pin

0R-9200 Connecting Rod
211-7826 Cylinder Liner
6V-3774 Gasket Kit
Table 8
10R-1817 Cylinder Pack Gp For 3500B Engines
Pt. No. Description
233-2431 Piston
197-0560 Piston Pin
0R-9200 Connecting Rod
211-7826 Cylinder Liner
6V-3774 Gasket Kit
Antifreeze is Added to the Corrosion Inhibitor {1395}

Engine: Commercial
 3500 Family All
Ethylene glycol has been added to the Vapor Corrosion Inhibitor (VCI) mixture. The VCI mixture
is used to keep 3500 Engines free from corrosion during shipping and storage. Ethylene glycol is
now a permanent addition to the VCI mixture.
To ensure that the cooling system is free of corrosion, water passages are flushed with a VCI
mixture. The VCI mixture provides corrosion protection for at least one year. There are pockets of
the VCI mixture that cannot be drained. Previously, the pockets of VCI mixture could freeze if the
temperatures were below freezing. Ethylene glycol has been added to the VCI mixture in order to
provide freeze protection for temperatures above -40 °C (-40 °F).
The storage preservation with VCI is an option in the price list that is available for 3500 diesel
engines. The storage preservation with VCI is a part of the storage preservation package. The anti-
corrosion package keeps the engine free from corrosion for at least one year. The storage
preservation with VCI is recommended for engines that will be put into service at least 90 days
after production. The storage preservation with VCI is also recommended for any 3500 Engine that
will be exposed to a damp, corrosive environment during shipment.
The storage preservation with VCI may be purchased by ordering the feature codes that are listed
in Table 1. If a new engine is ordered, consult the price list for the most current information.
Table 1
Storage preservation with VCI
Number of Cylinders Feature Code
8 Cylinders SRP0016
12 Cylinders SRP0015
16 Cylinders SRP0014
New Expansion Tank Assembly {1354}

Engine:
3508 (S/N: 3HM1-UP; 9WN1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 23Z1-UP; 68Z1-
UP; 69Z1-UP; 70Z1-UP)
3508B (S/N: LPD1-UP; S2E1-UP; BAG1-UP; 3DM1-UP; 4GM1-UP; 7SM1-UP; 6PN1-UP;
1TW1-UP; 2HW1-UP; 3DW1-UP)
3512 (S/N: 3MS1-UP; 3RS1-UP; 49Y1-UP; 50Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-
UP)
3512B (S/N: 8EM1-UP; 8RM1-UP; BRN1-UP; 4TN1-UP; 6WN1-UP; 1PW1-UP; 2GW1-UP;
4AW1-UP; 2EZ1-UP)
3516 (S/N: 4MJ1-UP; 3NS1-UP; 3SS1-UP; 3XS1-UP; 25Z1-UP; 27Z1-UP; 29Z1-UP; 71Z1-
UP; 72Z1-UP; 73Z1-UP)
3516B (S/N: CDE1-UP; CBN1-UP; 6HN1-UP; 7RN1-UP; 8KN1-UP; 9AN1-UP; 1NW1-UP;
2FW1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP)
Generator Set:
3508 (S/N: CTF1-UP; 1JZ1-UP)
3508B (S/N: CTC1-UP; 1FZ1-UP)
3512 (S/N: CTE1-UP; 1KZ1-UP)
3512B (S/N: CTB1-UP; CTH1-UP; 1GZ1-UP)
3516 (S/N: CTD1-UP; 1LZ1-UP)
G3516 (S/N: CTL1-UP)
3516B (S/N: CTA1-UP; CTG1-UP; CTJ1-UP; 1HZ1-UP)
Pumper:
SPF343 (S/N: 6RZ1-UP; 8ZZ1-UP; 5XZ1-UP)
Description of Change: There is a new expansion tank assembly for 3500 and 3500B Engines
that are equipped with an expansion tank. The new expansion tank has an improved internal
structure that reduces stress of the material in the walls of the tank.
The new tank can be visually distinguished from the former tank by looking at the side of the
tanks. On the former tank, the coolant level gauge is mounted with a flat bar with two drilled and
tapped holes. On the new tank, the coolant level gauge is mounted with two separate bosses. Refer
to Illustration 1.
Illustration 1
(1) New 245-2876 Expansion Tank As
(2) Former 7E-7597 Tank
Adaptable To: The new 245-2876 Expansion Tank is a direct
replacement for the former 7E-7597 Tank. The 245-2876
Expansion Tank is now a serviced part. The 245-2876 Expansion
Tank is adaptable to all of the 3500 and 3500B Engines that are
listed above. Table 1 lists the effectivity of the new tank in 3500
and 3500B Engines.
Table 1
Effectivity of the New Tank in 3500 and 3500B Engines
Sales Model Serial Number
3508 (S/N: 3HM00015-UP)
3508 (S/N: 9WN00016-UP)
3508 (S/N: 3LS00228-UP)
3508 (S/N: 95Y01218-UP)
3508 (S/N: 96y02065-UP)
3508 (S/N: 23Z07944-UP)
3508 (S/N: 68Z01253-UP)
3508 (S/N: 69Z00892-UP)
3508 (S/N: 70Z01078-UP)
3508 (S/N: CTF00263-UP)
3508 (S/N: 1JZ00262-UP)
3508B (S/N: LPD00009-UP)
3508B (S/N: S2E00102-UP)
3508B (S/N: BAG00025-UP)
3508B (S/N: 3DM00458-UP)
3508B (S/N: 4GM00742-UP)
3508B (S/N: 7SM00938-UP)
3508B (S/N: 6PN00868-UP)
3508B (S/N: 1TW00353-UP)
3508B (S/N: 2HW00258-UP)
3508B (S/N: 3DW00176-UP)
3508B (S/N: CTC00254-UP)
3508B (S/N: 1FZ01936-UP)
3512 (S/N: 3MS00233-UP)
3512 (S/N: 49Y01033-UP)
3512 (S/N: 50Y01805-UP)

3512 (S/N: 24Z10152-UP)
3512 (S/N: 65Z01132-UP)
3512 (S/N: 66Z00944-UP)
3512 (S/N: 67Z02059-UP)
3512 (S/N: CTE00343-UP)
3512 (S/N: 1KZ01301-UP)
3512B (S/N: 8EM00516-UP)
3512B (S/N: 8RM00754-UP)
3512B (S/N: BRN00191-UP)
3512B (S/N: 4TN00799-UP)
3512B (S/N: 6WN00803-UP)
3512B (S/N: 1PW00435-UP)
3512B (S/N: 2GW00406-UP)
3512B (S/N: 4AW00823-UP)
3512B (S/N: 2EZ00345-UP)
3512B (S/N: CTB00187-UP)
3512B (S/N: CTH00246-UP)
3512B (S/N: 1GZ01578-UP)
3512B (S/N: 3KD00268-UP)
3516 (S/N: 3NS00246-UP)
3516 (S/N: 25Z07100-UP)
3516 (S/N: 27Z00852-UP)
3516 (S/N: 29Z01390-UP)
3516 (S/N: 71Z00404-UP)
3516 (S/N: 72Z00567-UP)
3516 (S/N: 73Z00968-UP)
3516 (S/N: CTD00183-UP)
3516 (S/N: 1LZ00535-UP)
3516B (S/N: CDE00313-UP)

3516B (S/N: CBN00316-UP)
3516B (S/N: 6HN01720-UP)
3516B (S/N: 7RN01951-UP)
3516B (S/N: 8KN00571-UP)
3516B (S/N: 9AN00367-UP)
3516B (S/N: 1NW00145-UP)
3516B (S/N: 2FW00334-UP)
3516B (S/N: 3CW00257-UP)
3516B (S/N: 4BW00559-UP)
3516B (S/N: CTA00153-UP)
3516B (S/N: CTG00272-UP)
3516B (S/N: CTJ00200-UP)
3516B (S/N: 1HZ02501-UP)
3516B (S/N: S2X00106-UP)
G3516 (S/N: CTL00651-UP)
New Gasket for the Turbocharger's Water Lines

Engine:
3508 (S/N: 1ZF1-UP; 6TJ1-UP; 5XM1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 97Y1-
UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP)
3508B (S/N: CBB1-UP; CNB1-UP; 2BM1-UP; 3DM1-UP; 4GM1-UP; 7SM1-UP; PTN1-UP;
5PS1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; 5KW1-UP; BGX1-UP; BPX1-UP; 1FZ1-UP)
3512 (S/N: 3YF1-UP; PTG1-UP; PTH1-UP; CMJ1-UP; 2WK1-UP; 1LM1-UP; 6PM1-UP;
FDR1-UP; 3MS1-UP; 3RS1-UP; 6WW1-UP; 49Y1-UP; 50Y1-UP; 51Y1-UP; 24Z1-UP; 65Z1-
UP; 66Z1-UP; 67Z1-UP; 1KZ1-UP)
3512B (S/N: BRC1-UP; CMC1-UP; FDE1-UP; BLF1-UP; PTF1-UP; 2AF1-UP; 8DF1-UP;
PWG1-UP; BRK1-UP; PTM1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP; BRN1-UP; 4TN1-UP;
6WN1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 2EZ1-UP;
1GZ1-UP)
3516 (S/N: CMD1-UP; PTD1-UP; 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5MJ1-UP; 5SJ1-UP;
CAL1-UP; 6CL1-UP; 7KM1-UP; 2TS1-UP; 3JS1-UP; 3NS1-UP; 3SS1-UP; 3XS1-UP; 8TW1-
UP; 25Z1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP; 1LZ1-UP)
3516B (S/N: CPA1-UP; BMB1-UP; 9WF1-UP; BPJ1-UP; BCK1-UP; CAN1-UP; FDN1-UP;
6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; PPS1-UP; 1NW1-UP; 2FW1-UP;
2JW1-UP; 3CW1-UP; 4BW1-UP; 8NW1-UP; FDX1-UP; 1HZ1-UP)
Pumper:
SPF343 (S/N: 6RZ1-UP)
SPS343 (S/N: 8ZZ1-UP)
SPT343 (S/N: 5XZ1-UP)
Power Module:
PM3508 (S/N: BLM1-UP)
PM3512 (S/N: BRF1-UP; BNR1-UP)
PM3516 (S/N: CAC1-UP; BPD1-UP)
PMG3516 (S/N: CFD1-UP)
Generator Set:
3508 (S/N: CNF1-UP; PTK1-UP; CAW1-UP; 5PW1-UP; 1JZ1-UP)
3508B (S/N: CNB1-UP; PTN1-UP; 5KW1-UP; BGX1-UP; 1FZ1-UP)
3512 (S/N: PTG1-UP; PTH1-UP; CMJ1-UP; FDR1-UP; 6WW1-UP; 1KZ1-UP)
3512B (S/N: CMC1-UP; FDE1-UP; BLF1-UP; PTF1-UP; BRK1-UP; PTM1-UP; 6GW1-UP;
1GZ1-UP)
3516 (S/N: CMD1-UP; PTD1-UP; CAL1-UP; 8TW1-UP; 1LZ1-UP)
3516B (S/N: CPA1-UP; BMB1-UP; BPJ1-UP; FDN1-UP; 8NW1-UP; FDX1-UP; 1HZ1-UP)
G3508 (S/N: CPJ1-UP; CPS1-UP; CPY1-UP)
G3512 (S/N: CRN1-UP; CSP1-UP)
G3516 (S/N: CSZ1-UP)
G3516B (S/N: CSC1-UP; CME1-UP; CEY1-UP)
G3520B (S/N: CWD1-UP)
G3520C (S/N: CWW1-UP; CWY1-UP)
Description of Change: A new gasket improves the sealing capability of the joint between the
turbocharger and the turbocharger water lines. The new gaskets are designed with a different
material and with new geometry. The new design helps to prevent the gasket from creeping. The
gasket material is better able to withstand higher temperatures.
Adaptable To: The 241-3283 Gasket is a direct replacement for the 7N-7628 Gasket. The 241-
3283 Gasket is adaptable to the above engines. Refer to Illustration 1 for the location of the gasket.
Illustration 1
Typical example
(1) Location of the gasket
(2) 241-3283 Gasket
Improved Exhaust Seal for the

Exhaust Manifold {1059}
Engine:
3508 (S/N: 95Y1-UP; 23Z1-UP; 68Z1-UP; 70Z1-UP)
3508B (S/N: S2E1-UP; BAG1-UP; 2BM1-UP; 3DM1-UP; 5PS1-UP; 1TW1-UP; 3DW1-UP;
BPX1-UP)
3512 (S/N: 2WK1-UP; 1LM1-UP; 49Y1-UP; 24Z1-UP; 65Z1-UP; 67Z1-UP)
3512B (S/N: BRC1-UP; 2AF1-UP; 8DF1-UP; FFG1-UP; PWG1-UP; S2L1-UP; S2M1-UP;
7HM1-UP; 8EM1-UP; BRN1-UP; 4TN1-UP; 4DR1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP;
2EZ1-UP)
3516 (S/N: 5MJ1-UP; 6CL1-UP; 7CL1-UP)
3516B (S/N: CDE1-UP; 9WF1-UP; BCK1-UP; CBN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP;
2FW1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP)
G3508 (S/N: 2TJ1-UP)
G3516 (S/N: 4EK1-UP)
G3516B (S/N: CEY1-UP; 7EZ1-UP)
G3520B (S/N: BGW1-UP; GET1-UP)
G3524 (S/N: 7SZ1-UP)
G3532 (S/N: 8BZ1-UP)
Pumper:
SPF343 (S/N: 6RZ1-UP)
Power Module:
Generator Set:
G3508 (S/N: CPS1-UP)
G3512 (S/N: CRN1-UP)
G3516 (S/N: CSZ1-UP)
3512B (S/N: BLF1-UP)
G3516B (S/N: CSC1-UP; CME1-UP)
G3520B (S/N: CWD1-UP)
Description of Change: There is an improved seal for sealing between the exhaust manifold and
the cylinder head on 3500 and 3500B Diesel and Gas Engines. The new seal has a spiral winding
that is made of stainless steel. The winding is wrapped around a filler material that is made of
graphite.
Adaptable To: The new 229-5332 Seal is a direct replacement for the 167-9526 Seal. The new
seal is adaptable to first production of the engines that are listed above.
Fuel Inlet Screens are Removed from Remanufactured Fuel

Injectors {1250, 1252}
Engine: Commercial
 3500 Family All
Engine News SEBD9322, June 2003, "Fuel Inlet Screens Are Removed From Remanufactured
Fuel Injectors". Disregard this article. This article has been replaced by the following article.
Reports have been received about problems with the fuel inlet screens for the fuel inlet ports on the
fuel injectors. To improve reliability, Cat Reman has removed the fuel inlet screens from all
remanufactured fuel injectors for 3500 Engines.
Extensive field tests were performed on the fuel injectors without the screens. No significant
difference in the wear of the fuel injectors was found in comparison to fuel injectors with screens.
Illustration 1
Typical example of a fuel inlet port on the case of a fuel injector
A washer is installed in place of the fuel inlet screen.
Installation of the washer depends on the geometry of the
case and on the previous method of screen installation.
The washers are roll formed onto new cases and onto cases
that had staked screens.
The washers are welded onto the cases that had welded
screens. The geometry of these cases do not have sufficient
material for roll forming.
For Electronic Unit Injectors (EUI), serial number 195245 has welded washers. Serial number
198960 has washers that are roll formed.
For Mechanical Unit Injectors (MUI), serial number 124341 has washers that are roll formed.
The part numbers of the modified fuel injectors are listed in Table 1.
Table 1
Remanufactured Fuel Injector Groups for 3500 Engines
3500 with MUI 3500 with EUI 3500B
0R-0906 0R-7780 (1)
0R-0995 0R-7977
0R-1756 0R-8215
0R-1758 0R-8619
0R-1759 0R-8688
0R-1760 0R-8690
0R-2921 0R-8691
0R-2922 0R-9735
0R-2923 0R-9796
0R-2924 0R-9944
0R-2925 0R-3539 -
0R-3051 0R-4149 -
0R-3052 - -
0R-3743 - -
0R-8338 - -
0R-8680 - -
0R-8681 - -

( 1 )
The fuel inlet ports for this fuel injector are modified by two different methods. Some of the cases have fuel inlet
ports with a diameter of 2.8 mm (0.11 inch). The remainder of the cases have washers that are roll formed. None of
these fuel injectors have welded washers.
Engine News September 2003

Improved Pump Drive Gear for an Auxiliary Sea Water

Pump {1242}
Engine:
3508B (S/N: 2BM1-UP)
3512 (S/N: 3YF1-UP; 3RS1-UP; 50Y1-UP)
3512B (S/N: S2G1-UP; S2H1-UP; S2J1-UP; S2K1-UP; S2L1-UP; 7HM1-UP; 8EM1-UP;
8RM1-UP; BRN1-UP; S2N1-UP; 4TN1-UP; 6WN1-UP; BMS1-UP; 2GW1-UP; 2EZ1-UP;
1GZ1-UP)
3516 (S/N: 4XF1-UP; 4MJ1-UP; 5MJ1-UP; 3SS1-UP; 29Z1-UP)
3516B (S/N: CDE1-UP; BLH1-UP; FDN1-UP; 6HN1-UP; 7RN1-UP; 8KN1-UP; 9AN1-UP;
S2P1-UP; S2R1-UP; S2S1-UP; S2T1-UP; S2W1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP;
1HZ1-UP)
Description of Change: A new pump drive gear is used in the 9Y-5710 Auxiliary Sea Water
Pump Group. The new pump drive gear has a larger shaft diameter for increased strength.
Adaptable To: The new 239-5790 Pump Drive Gear is a direct replacement for the 122-3205
Pump Drive Gear. Eight new 0S-1588 Bolts and eight new 8M-3175 Hard Washers are required
when you install the new pump drive gear.
Illustration 1
(1) Bolts and hard washers
(2) Pump drive gear
Illustration 2. (2) Pump drive gear
New Rocker Arm Improves Lubrication {1123}

Engine: Commercial
 3500 Family All
Description of Change: A new fuel injector rocker arm assembly, a new valve rocker arm
assembly, and a new rocker shaft assembly are used for all 3500B Engines. The new rocker arms
have a new sleeve bearing with oil distribution grooves that will better distribute the engine oil
across the load bearing area of the bearing. The improved distribution of the engine oil provides a
better film of oil that will decrease the wear of the bearing.
Adaptable To: The new 230-2622 Rocker Arm Assembly (Injector) is a direct replacement for the
196-4793 Rocker Arm Assembly (Injector). The new 230-2621 Rocker Arm Assembly (Valve) is
a direct replacement for the 154-6388 Rocker Arm Assembly (Valve). The new 230-2633 Rocker
Shaft Assembly is a direct replacement for the 196-4791 Rocker Shaft Assembly. The 230-2622
Rocker Arm Assembly (Injector), the 230-2621 Rocker Arm Assembly (Valve), the 230-2633
Rocker Shaft Assembly, and the 230-2620 Sleeve Bearing are now serviced parts.
Illustration 1. Old rocker arm assembly
Illustration 2. New rocker arm assembly (1) Oil distribution grooves in the bearing
Oversized Bearings are Available for Reconditioning of

Remanufactured Engine Oil Pumps and Scavenge Oil Pumps
{1304, 1312} (machine engines are below)
Engine: Commercial
 3500 Family All
Cat Reman is sometimes using oversized bearings to help salvage the housings and the covers of
engine oil pumps and of scavenge oil pumps for 3500 Engines and for G3500 Engines.
Sometimes, the bores for the bearings in the pump housings and in the pump covers become
enlarged from wear. In these cases, a new bearing of the original part number will not fit tightly. If
an enlarged bore is found during remanufacturing, the bore is machined in order to accommodate
the outer diameter of an oversized bearing. The new oversized bearing has the same inner diameter
as the original bearing.
The new oversized bearing is the 227-4147 Sleeve Bearing. This bearing is now used in
remanufacturing when the original 1W-6005 Sleeve Bearing cannot fit properly. The 1W-6005
Sleeve Bearing is still installed in remanufactured pumps when the bores for the bearings meet the
appropriate specification.
The bores of a remanufactured pump could have a combination of the new 227-4147 Sleeve
Bearing and of the original 1W-6005 Sleeve Bearing .
The remanufactured engine oil pumps and scavenge oil pumps that may use the new oversized
227-4147 Sleeve Bearing are listed in Table 1.
Table 1
Remanufactured Engine Oil Pumps and Scavenge Oil Pumps that May Use the 227-4147
Sleeve Bearing
0R-2561 Engine Oil Pump Gp
0R-3233 Gear Pump (Scavenge)
Install the Spin-On Engine Oil Filter Properly {1308}

Engine:
3306C (S/N: 9TL1-UP)
3406 (S/N: 91U1-UP)
3508 (S/N: CNE1-UP; CMR1-UP; 3LS1-UP; CAW1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP;
23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP; CTF1-UP; 1JZ1-UP)
3508B (S/N: S2A1-UP; CBB1-UP; CNB1-UP; S2B1-UP; LPD1-UP; S2D1-UP; S2E1-UP;
S2F1-UP; BAG1-UP; BNG1-UP; PTJ1-UP; 2BM1-UP; 3DM1-UP; 4GM1-UP; 7SM1-UP;
PTN1-UP; 6PN1-UP; 5PS1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; BPX1-UP; BGZ1-UP;
CTC1-UP; 1FZ1-UP)
3512 (S/N: 3YF1-UP; CMJ1-UP; CPK1-UP; 1LM1-UP; CNP1-UP; FDR1-UP; 3MS1-UP;
49Y1-UP; 50Y1-UP; 51Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP; CTE1-UP; 1KZ1-
UP)
3512B (S/N: FDA1-UP; BRC1-UP; CMC1-UP; PTE1-UP; BLF1-UP; PTF1-UP; 2AF1-UP;
AAG1-UP; S2G1-UP; S2H1-UP; S2J1-UP; BRK1-UP; S2K1-UP; S2L1-UP; PTM1-UP;
S2M1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP; BRN1-UP; S2N1-UP; 4TN1-UP; 6WN1-UP;
4DR1-UP; BMS1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP; 4AW1-UP; 5AW1-UP; 2EZ1-UP;
CTB1-UP; CTH1-UP; 1GZ1-UP)
3516 (S/N: CMD1-UP; 5MJ1-UP; CAL1-UP; 7KM1-UP; 3NS1-UP; CNW1-UP; CMY1-UP;
25Z1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP; CTD1-UP; 1LZ1-
UP)
3516B (S/N: CAA1-UP; CPA1-UP; BMB1-UP; PTB1-UP; PTC1-UP; CDE1-UP; BLH1-UP;
BPJ1-UP; CAN1-UP; CBN1-UP; FDN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP;
9AN1-UP; S2P1-UP; S2R1-UP; S2S1-UP; S2T1-UP; S2W1-UP; 1NW1-UP; 2FW1-UP;
2JW1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP; S2Y1-UP; 6HZ1-UP; CTA1-UP; CTG1-UP;
CTJ1-UP; 1HZ1-UP)
G3304 (S/N: N4F1-UP)
G3306 (S/N: CNR1-UP)
G3306 (S/N: G6X1-UP)
G3306 (S/N: CTT1-UP)
G3516 (S/N: 4EK1-UP)
G3520C (S/N: GDB1-UP; GHC1-UP)
Generator Set:
G3520C (S/N: B9P1-UP; CWW1-UP; CWY1-UP)
Power Module:
PM3508 (S/N: BLM1-UP; BPY1-UP)
Pumper:
SPF343 (S/N: 6RZ1-UP; 3KD1-UP)
Proper installation of the 2P-4005 Engine Oil Filter Assembly is necessary to ensure proper
functioning of the filter.
If the filter is not tightened adequately, vibration that occurs during operation can loosen the filter.
A loosened filter will allow engine oil to leak. Downtime is required for the correction of any leak.
A leak that is not corrected in a timely manner or a major leak can result in significant damage
from inadequate lubrication.
Note: All types of spin-on filters depend on correct tightening in order to avoid subsequent
loosening. Always follow the proper installation procedures that are illustrated on the filters.
Use the following procedure to install the 2P-4005 Engine Oil Filter Assembly. The procedure is
applicable to the old design and to the new design.
Illustration 1. Typical mounting base and filter gasket
1. Clean the sealing surface of the mounting base.

Ensure that all of the old filter gasket is
removed.
2. Apply clean engine oil to the new filter gasket.
3. Install the filter. Tighten the filter until the

filter gasket contacts the mounting base.
Observe one of the index marks on the filter
and tighten the filter for an additional one full
turn (360 degrees).
Note: The additional one full turn (360

degrees) is the minimum requirement for
installation.
The filter can be tightened beyond the minimum one full turn for a 1/8 turn (45 degrees)
further. The filter will not be damaged by tightening for a total of 1 and 1/8 turns (405
degrees) after the filter gasket initially contacts the mounting base.
A 185-3630 Strap Wrench As can be used to perform the tightening. Use the strap wrench
near the filter's threaded end in order to reduce the possibility of damage to the threads on
the filter and on the stud.
Fuel Transfer System for Power Modules {1256}

SMCS - 1256
Power Module:
PM3412 (S/N: 5FL1-UP; CAJ1-UP)
Power Modules that are equipped with the "On-Board Import/Export Fuel Transfer System"
require the external fuel supply plumbing to be correct in order to achieve optimum performance.
A positive head is required in order to push the fuel through the suction pipe and into the fuel
transfer pump.
The fuel transfer pump requires a specific minimum Net Positive Suction Head Available
(NPSHA) to operate properly. The NPSHA can be estimated by adding the Static Suction Head
and the Dynamic Restriction in the piping for the fuel system that is external to the Power Module
fuel supply connection.
The Power Module will have one of two different types of "On-Board Import/Export Fuel
Transfer" systems. One system is configured with the 141-7898 Fuel Transfer Pump As and the
other system is configured with the 207-4512 Fuel Transfer Pump As .
The published maximum external restriction for each of the fuel transfer systems is listed below.
 141-7898 Fuel Transfer Pump As has a maximum restriction of 10 inches Hg.
 207-4512 Fuel Transfer Pump As has a maximum restriction of 16 inches Hg.
A fuel supply line that is set up improperly will cause the fuel transfer pump to lose prime. This
may cause the fuel transfer pump to run dry. When this happens, the fuel transfer pump will
eventually fail.
Refer to, LEBX5048 for a chart of the relative resistance of pipe valves and pipe fittings to the
flow of fluids. Also, refer to , TIBU3551 for more detailed information.
Service Magazine September 2003

Media Number -SEPD0698-00 Publication Date -2003/09/01 Date Updated -2003/09/01
Oversized Bearings are Available for Reconditioning of

Remanufactured Engine Oil Pumps and Scavenge Oil Pumps
{1304, 1312}
Caterpillar Products: Machine Engines
 All 3500 Series
Cat Reman is sometimes using oversized bearings to help salvage the housings and the covers of
engine oil pumps and of scavenge oil pumps for 3500 Engines.
Sometimes, the bores for the bearings in the pump housings and in the pump covers become
enlarged from wear. In these cases, a new bearing of the original part number will not fit tightly. If
an enlarged bore is found during remanufacturing, the bore is machined in order to accommodate
the outer diameter of an oversized bearing. The new oversized bearing has the same inner diameter
as the original bearing.
The new oversized bearing is the 227-4147 Sleeve Bearing. This bearing is now used in
remanufacturing when the original 1W-6005 Sleeve Bearing cannot fit properly. The 1W-6005
Sleeve Bearing is still installed in remanufactured pumps when the bores for the bearings meet the
appropriate specification.
The bores of a remanufactured pump could have a combination of the new 227-4147 Sleeve
Bearing and of the original 1W-6005 Sleeve Bearing.
The remanufactured engine oil pumps and scavenge oil pumps that may use the new oversized
227-4147 Sleeve Bearing are listed in Table 1.
Table 1
Remanufactured Engine Oil Pumps and Scavenge Oil Pumps that May Use the 227-4147
Sleeve Bearing
Engine News August 2003

A Pin for the Rocker Shaft Is Now Available for Parts Service
{1102}
Engine: Commercial
 3500 Diesel
(1) 196-4791 Shaft As
(2) 155-4094 Spring Pin

Note: The 196-4791 Shaft As includes the
155-4094 Spring Pin.
The 155-4094 Spring Pin that is used on the
3500 series rocker shaft is now available for parts service.
When the pin must be replaced, pay attention to the orientation of the new pin. The split in the pin
must be toward the end of the shaft. Refer to Illustration 1. If the pin is not properly installed, the
pin can cause a leak path for the oil supply to the rocker bushings.
An Improved Alternator Belt is Used {1357}

Engine: Commercial
 3500 Family All
Description of Change: An new alternator belt is being introduced for use in all 3500 and G3500
Engines. The new alternator belt is constructed of a material that has a proven resistance to fatigue.
The new alternator belt also has a higher temperature rating.
Adaptable To: The 141-7116 V-Belt is a direct replacement for the 7E-4841 Serpentine Belt,
which is being discontinued in August 2003. In August 2003, the new alternator belt will be used
on all of the above products. The new alternator belt has the same dimensions as the previous
alternator belt.
Belt Tension is Critical to the Service Life of Alternator Belts

To obtain the maximum service life of the alternator belt and of the pulleys, the correct belt
tension is critical. If the tension is inadequate, the V-belt may roll on the pulley or the V-belt may
slip. The slipping will reduce the service life of the V-belt. If the tension is excessive, the extra
tension on the V-belt and on the pulleys will reduce the service life of the parts.
Tension for the 141-7116 V-Belt
Tension for a new V-belt ... 245 N·m (180 lb ft)
Tension for a used V-belt ... 150 N·m (110 lb ft)
When you install a new V-belt, adjust the V-belt to the correct tension. Then, operate the engine
for a minimum of 30 minutes at the rated speed.
A V-belt is considered to be used after at least 30 minutes of use at the rated speed. Then, stop the
engine and adjust the tension to the specification for a used V-belt.
The new 240-8220 Belt Tension Gauge Gp is recommended for tensioning of the V-belt.
A New Belt Tension Gauge is Available

The new 240-8220 Belt Tension Gauge Gp is now available. The gauge is for use with V-belts that
have eight ribs. The gauge will work with V-belts that have a top width in the range of 9.65 to
31.75 mm (0.380 to 1.250 inch). The gauge has a working range of 135 to 270 N·m (100 to 200 lb
ft).
New Fabricated Tool for Piston Pin Installation {1225}

SMCS - 1225
Engine: Commercial
 3500 Family All
A new fabricated tool is available to improve the installation of the piston pin. The new fabricated
tool will help prevent nicking and galling while you are installing the piston pin.
The FT2984 Fabricated Tool is used for installing a 3500B HD piston pin.
The FT2985 Fabricated Tool is used for installing a 3500A, or a 3500B standard displacement
piston pin. The FT2985 Fabricated Tool is also used for installing a G3500 piston pin.
Illustration 1
Fabricated tool for installing the piston pin
Line drawings of a fabricated tool are ordered from the Caterpillar Service Technology Group by
calling the following numbers:
 USA 1-800-542-8665
 Canada 1-800-523-8665
 World 1-309-675-6277
After each tool is fabricated, mark the fabricated tool number on the tool.
Use the following procedure for installing the piston pin with the fabricated tool:
Note: Ensure that all of the parts and the fabricated tool are clean.
1. Install the fabricated tool into the bore of the piston pin.
2. Coat the bore of the piston crown, of the piston skirt and of the piston pin with clean engine
oil.
3. Align the bore of the piston skirt with the bore of the piston crown. Use the fabricated tool
to insert the piston pin into the bore of the piston skirt.
4. Slide the fabricated tool and the piston pin into the bore of the piston skirt and the bore of
the piston crown until the fabricated tool reaches the inside of the first bore of the piston
crown.
5. Coat the piston pin bore of the connecting rod with clean engine oil.
6. Insert the piston pin bore of the connecting rod between the bores of the piston crown.
7. Gently slide the fabricated tool and the piston pin through the piston pin bore of the
connecting rod and through the other side of the bore of the piston crown and the bore of
the piston skirt.
8. Gently remove the fabricated tool.
New Flywheels Are Used {1156}

Electric Power Generation:
G3520B (S/N: CWD1-UP; GET1-UP; BGW1-UP)
G3520C (S/N: HEA1-UP; HEB1-UP; CWW1-UP; CWY1-UP)
Engine:
3508 (S/N: CNF1-UP; 6TJ1-UP; PTK1-UP; 8TL1-UP; 3HM1-UP; 5XM1-UP; 9WN1-UP;
3LS1-UP; CAW1-UP; 5PW1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-
UP; 70Z1-UP)
3508B (S/N: CBB1-UP; CNB1-UP; 7AF1-UP; BAG1-UP; 2BM1-UP; 3DM1-UP; 4GM1-UP;
7SM1-UP; PTN1-UP; 6PN1-UP; 5PS1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; 5KW1-UP;
BGX1-UP; BPX1-UP)
3512 (S/N: PTG1-UP; PTH1-UP; CMJ1-UP; 2WK1-UP; 1LM1-UP; 6PM1-UP; FDR1-UP;
3MS1-UP; 6WW1-UP; 49Y1-UP; 50Y1-UP; 51Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-
UP)
3512B (S/N: BRC1-UP; CMC1-UP; 2RD1-UP; FDE1-UP; BLF1-UP; PTF1-UP; 2AF1-UP;
8DF1-UP; AAG1-UP; PWG1-UP; BRK1-UP; PTM1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP;
BRN1-UP; 4TN1-UP; 6WN1-UP; 4DR1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP; 4AW1-UP;
5AW1-UP; 6GW1-UP; 2EZ1-UP)
3516 (S/N: CMD1-UP; 9KF1-UP; 5SJ1-UP; CAL1-UP; 7KM1-UP; 2TS1-UP; 3JS1-UP;
3NS1-UP; 8TW1-UP; 25Z1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-
UP)
3516B (S/N: CAA1-UP; CPA1-UP; BMB1-UP; PTB1-UP; PTC1-UP; 2TD1-UP; 9WF1-UP;
BPJ1-UP; BCK1-UP; CAN1-UP; CBN1-UP; FDN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP;
9AN1-UP; PPS1-UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; 8NW1-UP;
FDX1-UP; 6HZ1-UP)
G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; CPS1-UP; 9AW1-UP; CPY1-UP)
G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP; 6JW1-UP)
G3516 (S/N: 3RC1-UP; 8LD1-UP; CPG1-UP; 4EK1-UP; 8PW1-UP; CSZ1-UP)
G3516B (S/N: CSC1-UP; CME1-UP; CEY1-UP; 7EZ1-UP)
G3520 (S/N: 5XW1-UP)
G3524 (S/N: 7SZ1-UP)
G3532 (S/N: 8BZ1-UP)
Power Module:
PM3508 (S/N: BLM1-UP)
Description of Change: The new design incorporates a cast steel blank. The steel blank is then
machined in order to meet specifications. The casting has surfaces that are not machined. This is
an improvement over the previous flywheel that was made from ductile iron and then machined
100 percent.
Adaptable To: The new flywheels that are listed below are a direct replacement for the former
flywheels. The former flywheels are cancelled.
Table 1
New Part Number Former Part Number
223-0858 Flywheel 2W-8773 Flywheel
223-0859 Flywheel 1N-3565 Flywheel
223-1621 Flywheel 174-4630 Flywheel
226-1759 Flywheel 7E-1719 Flywheel
226-1760 Flywheel 7C-1923 Flywheel

A Previous High Temperature Locknut is Used in Engine
Exhaust System Groups {7553}
Engine: Commercial
 3500 Family All
Engine News SEBD9277, October 1999, "New High Temperature Locknut Used In Engine
Exhaust System Groups". Disregard this article. Refer to the following article.
Description of Change: The current high temperature locknut is being replaced by the locknut
that was previously used. The previous locknut is more resistant to becoming deformed or loose
under extreme heat. The locknut is used in parts groups that are related to the exhaust system on
the 3500 and 3500B Engines. The locknut is used in the engines that are listed above.
Adaptable To: The 2N-2766 Locknut is a direct replacement for the 168-7800 Locknut in
following parts groups:
 Air lines groups
 Exhaust bypass groups
 Exhaust manifold groups
 Turbocharger groups
Engine News July 2003

Media Number - SEBD9323-00 Publication Date - 2003/07/01 Date Updated - 2003/07/01
New Connecting Rod {1218, 1225}

Engine:
3512B (S/N: PWG1-UP; BRN1-UP; 5AW1-UP; 2EZ1-UP; CTH1-UP)
3516B (S/N: BCK1-UP; CBN1-UP; 2JW1-UP; 4BW1-UP; CTG1-UP; CTJ1-UP)
Description of Change: A new connecting rod is available for 3500B High Displacement
Engines. The new connecting rod has the same performance as the former connecting rod. The
new connecting rod can be used with the former connecting rod.
Adaptable To: In the 160-5910 Piston and Rod Gp, the 160-5919 Rod is cancelled and replaced
by the 203-2157 Rod. The new connecting rod is adaptable to all of the above engines.
An Improved Spin-On Oil Filter Is Now Available {1306,

1308}
Engine: Commercial
 3500 Family All
Engine:
 G3500 Series
Description of Change: An improved 2P-4005 Engine Oil Filter is now available.
The new engine oil filter has an improved thread design that retains the engine oil filter firmly
against the engine oil filter base during engine operation.
Illustration 1
(1) New thread design

(2) Previous thread design
The threads protrude outward from the top plate of the new engine oil filter. The threads protrude
inward on the previous design. The design change will substantially increase the engine oil filter's
retention to the engine oil filter base over a wide range of engine speed.
Adaptable To: The newly designed engine oil filter is adaptable to all 3500 applications that are
equipped with spin-on oil filters. The 2P-4005 Engine Oil Filter should be used as a replacement
to all other part numbers for spin-on oil filters for the 3500 engine.
Failure to use the 2P-4005 Engine Oil Filter may result in a severe oil leak between the engine oil
filter base and the engine oil filter. Engine damage could result.
Quality of Remanufactured Camshafts {1210}

Engine: Commercial
 3500 Family All
The quality and the service life of Cat Remanufactured Camshafts are equivalent to the quality and
to the service life of new camshafts.
Remanufacturing Processes
Camshafts for 3500 Engines are remanufactured with the same grinding process that is used in the
manufacture of new camshafts.
For remanufacturing, each individual lobe is precisely measured. Only the minimum amount of
material is removed during the grinding. This process ensures that the maximum depth of the case
is maintained.
Dimensionally, remanufactured camshafts are equivalent to new camshafts. The remanufactured
camshafts have the same specifications and tolerances as new camshafts for these characteristics:
size of lobe, profile of lobe, hardness and depth of case.
The metallurgy of remanufactured camshafts is equivalent to new camshafts. The remanufactured
camshafts are inspected with the same methods as new camshafts for evidence of burns from
grinding, for cracks, and for imperfections on the surface. Detailed inspections are performed for
each camshaft.
Metal Fatigue
Metal fatigue is indicated by cracking and/or by spalling (chipping or flaking) of the surface.
Fatigue on the surface indicates that the camshaft has been operated at loads that exceeded the
limit of the metal's strength for resisting fatigue. A camshaft that has fatigue on the surface will
fail.
The presence of metal fatigue is identified during manufacture by the magnetic particle inspection.
Any camshaft that exhibits signs of metal fatigue is scrapped.
Some 3500 Engines have exhibited fatigue in the lobe for the fuel injector's lifter. The chance of
this occurrence is equal for remanufactured camshafts and for new camshafts. This problem has
been addressed by design changes to the profile of the lifter's crown. Because Caterpillar has
confidence in the reliability of remanufactured camshafts, the remanufactured camshafts have been
specified in the required parts for the Product Support project.
Reliability of Camshafts
A limited number of remanufactured camshafts for 3500 Engine parts have only been available
since June 2002. In October 2002, remanufactured camshafts were included in the parts for
remanufactured 3500 Engines. Because of the limited number, the remanufactured camshafts have
been seeded with new camshafts for distribution of parts and for remanufactured engines.
Because of the limited availability of remanufactured camshafts and of the limited data from the
field, a validated prediction on the reliability of the remanufactured camshafts is pending.
However, the initial data that has been gathered does not indicate any difference between the
reliability of remanufactured camshafts and new camshafts.
Caterpillar is confident in the quality and in the reliability of Cat Remanufactured Camshafts.
Engine News June 2003

SOLAS Requirement for Screening Fuel and Oil Line

Connections on Marine Engines {1274, 1307}
Engine:
3508 (S/N: 8TL1-UP; 9WN1-UP; 3PS1-UP; 96Y1-UP; 69Z1-UP; CTF1-UP; 1JZ1-UP;
3HM1-UP; 23Z1-UP; 70Z1-UP)
3508B (S/N: BAG1-UP; 2BM1-UP; 3DM1-UP; 7SM1-UP; 1TW1-UP; 3DW1-UP; CTC1-UP;
1FZ1-UP; S2A1-UP; S2B1-UP; S2D1-UP; S2E1-UP; S2F1-UP)
3512 (S/N: 50Y1-UP; CTE1-UP; 1KZ1-UP; 3RS1-UP; 3WS1-UP; 66Z1-UP; 24Z1-UP)
3512B (S/N: 2RD1-UP; AAG1-UP; 7HM1-UP; BRN1-UP; 4TN1-UP; 4DR1-UP; 1PW1-UP;
2GW1-UP; 8EM1-UP; CTB1-UP; FFG1-UP; S2G1-UP; S2H1-UP; S2J1-UP; S2K1-UP;
S2L1-UP; S2M1-UP; S2N1-UP; 2EZ1-UP; 1GZ1-UP)
3516 (S/N: 2TS1-UP; 3JS1-UP; 3XS1-UP; 29Z1-UP; CTD1-UP; 1LZ1-UP; 4MJ1-UP; 5MJ1-
UP; 3SS1-UP; 72Z1-UP; 25Z1-UP)
3516B (S/N: 2TD1-UP; CBN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; 2FW1-UP; 3CW1-UP;
4BW1-UP; CTA1-UP; 1HZ1-UP; CDE1-UP; TAK1-UP; S2P1-UP; S2R1-UP; S2S1-UP;
S2T1-UP; S2W1-UP; S2X1-UP; S2Y1-UP)
3606 (S/N: 8RB1-UP)
3608 (S/N: 6MC1-UP; 1ZD1-UP; 8LL1-UP; 7WR1-UP)
3612 (S/N: 9RC1-UP; 9FR1-UP; NZA1-UP; 2NZ1-UP)
3616 (S/N: 1PD1-UP; 1FN1-UP)
3618 (S/N: 2MW1-UP)
3616 (S/N: RMN1-UP)
The International Convention for the Safety of Life at Sea (SOLAS) creates regulations in order to
ensure the safety of shipping. For marine diesel engines, SOLAS has regulations that are
documented in the SOLAS consolidated edition 2001 that is published by the International
Maritime Organization (IMO). The specific regulations that are addressed by this article are in
"chapter II-2 Fire protection, Fire detection, and Fire extinction". "SOLAS Regulation 15.2.11"
"Oil fuel lines shall be screened or otherwise suitably protected to avoid, as far as practicable, oil
spray or oil leakages onto hot surfaces, into machinery intakes, or other sources of ignition. The
number of joints in such piping systems shall be kept to a minimum."
The above SOLAS regulation has been subject to interpretation. Some marine surveyors advise an
exact interpretation of this rule. In these cases, the shipyard has been required to apply screening to
all fuel and oil line connections in order to get a marine certification. The standards organization
DNV will make sure that all DNV certified engines comply with the regulation for fuel and oil
containment. The new requirements become effective 1July 2003 for all Caterpillar marine engines
regardless of the date of manufacture. If a marine engine must be recertified after 1July 2003, the
marine engine must conform to the new regulation.
In order to meet the SOLAS regulation, customers and shipyards have applied a marine
certification society approved tape to fuel and oil line connections. The tape will prevent spraying
if the joint should work loose. The marine certification society approved tape is now available as a
Caterpillar part number. The tape should be applied to all fuel line connectors and all oil line
connectors on marine certified diesel engines. The new part numbers are 237-3859 Tape for 35
mm (1.4 inch) wide tape and 237-3860 Tape for 50 mm (1.9 inch) wide tape. The tape is available
in rolls that are 10 m (33 ft) long.
A rough estimate of the amount of tape that is needed for 3500 and 3600 diesel engines is provided
in Table 1. These estimates are based on covering all fuel and oil line connections. Engine
attachments can drive the need for additional tape. The quantities that are listed in Table 1 should
be a sufficient amount of tape in order to cover fuel and oil line connections on most marine diesel
engines.
Table 1
All 3600 2 rolls 237-3859 Tape and 2 rolls 237-3860 Tape
All 3500 1 roll 237-3859 Tape and 1 roll 237-3860 Tape
The tape can be applied easily to a connection. A single wrap is sufficient to seal a joint from fuel
or oil spray. A clear film must be peeled off the adhesive side of the tape before the tape is applied
to a joint. The foil side of the tape will be visible after the application of the tape. Refer to
Illustration 1 for the correct application.
Illustration 1 g00999326
Although the tape will prevent fuel or oil spray, fuel or oil may still leak from the tape. The tape
should be applied so that any potential leaks will not fall on a hot surface or a heat source. Refer to
Illustration 2.
Note: The tape should not be reused. New tape should be applied if the old tape is removed in
order to service the engine.
The standards organization does not require the tape to be classified with a Society Type
Approval. However, the tape must withstand the temperatures of an operating engine and the
adhesive should be resistant to fuel and to oil. There are other tapes that can be used as screening
material. Use the following types of tape: 3M aluminum foil tape 425 and 427 and Venture Tape
Corporation VentureClad 1577CW. These tapes are not available through the Caterpillar parts
system. These tapes are another option for screening fuel and oil line connections.
The tape is meant only as a backup for safety. The proper torque must be applied to all fuel line
connections and all oil line connections. Ensure that all connections have the required torque
before applying the tape.
New Top Piston Ring {1215}

Engine:
3512B (S/N: PWG1-UP; BRN1-UP; 5AW1-UP; 2EZ1-UP; CTH1-UP)
3516B (S/N: BCK1-UP; CBN1-UP; 2JW1-UP; 4BW1-UP; CTG1-UP; CTJ1-UP)
Description of Change: A new top ring is available for the pistons that are used in 3500B High
Displacement Engines. The face of the ring has a new coating. The coating will make the top ring
less abrasive to the cylinder liner.
Adaptable To: In the 160-5910 Piston and Rod Gp, the 151-2778 Piston Ring is cancelled and
replaced by the new 229-1632 Piston Ring. The new piston ring is adaptable to all of the above
engines. Table 1 lists the serial number effectivity of the new top ring.
Table 1 Effectivity of the 3512B and 3516B HD Engines

(S/N: 2JW00406-UP)
(S/N: 5AW00133-UP)
(S/N: 2EZ00300-UP)
(S/N: 4BW00498-UP)
(S/N: BCK00262-UP)
(S/N: CBN00296-UP)
(S/N: BRN00185-UP)
(S/N: PWG00108-UP)
(S/N: CTG00255-UP)
(S/N: CTH00210-UP)
(S/N: CTJ00200-UP)
A New Jacket Water Heater is Available {1383}

Generator Set:
3508 (S/N: CNF1-UP; CAW1-UP; 5PW1-UP)
3508B (S/N: CNB1-UP; BGX1-UP)
3512 (S/N: CMJ1-UP; FDR1-UP; 6WW1-UP)
3512B (S/N: CMC1-UP; FDE1-UP; BLF1-UP; BRK1-UP; 6GW1-UP)
3516 (S/N: CMD1-UP; CAL1-UP; 8TW1-UP)
3516B (S/N: CPA1-UP; BMB1-UP; BPJ1-UP; FDN1-UP; PPS1-UP; 8NW1-UP; FDX1-UP)
Power Module:
New jacket water heaters are available for 3500 Generator Sets and for 3500B Generator Sets.
Unlike the heaters that transfer heat via the convection of jacket water, the new heater utilizes a
pump in order to circulate the jacket water.
The pump allows the heater to operate at a higher wattage and with greater efficiency. The
continuous circulation of the coolant results in a lower peak temperature for the coolant.
Degradation of heater hoses, of the engine's seals, and of the heating elements is reduced by the
lower peak temperatures.
The new heating system exceeds the requirements of ratings for low ambient temperatures. In
comparison to convection heaters, the new systems can save the customer in excess of 30 percent
of the electrical costs that are associated with heating the jacket water.
Note: The new heating systems enable the use of heavy-duty air cleaners for 3500 Generator Set
Engines. The heavy-duty air cleaners were not previously available for these packages with jacket
water heaters.
Illustration 1. Jacket water heater with pump
Two heating systems are available. One system is for 50 Hz generator sets and the other system is
for 60 Hz generator sets. There are no differences in the appearance of the two systems: refer to
Illustration 1. However, the electrical ratings for the heating elements are different.
Table 1 Jacket Water Heater Groups

50 Hz Generator Sets 60 Hz Generator Sets
237-2236 Jacket Water Heater Gp 235-1224 Jacket Water Heater Gp
Refer to Special Instruction, REHS1658, "Replacing the Convection Jacket Water Heaters with a
Recirculating Jacket Water Heater on 3500 Engines" for a complete parts list, for the electrical
requirements, and for installation instructions.
Engine News May 2003

New Cylinder Liner {1216}

SMCS - 1216
Engine: Commercial
 3500 Diesel
The 118-9494 Cylinder Liner for 3500 engines is being replaced by a new 211-7826 Cylinder
Liner. The new 211-7826 Cylinder Liner was released in order to accommodate an improved
manufacturing process. The new liner is a direct replacement for the old liner. The new liner can
be used in conjunction with the old liner.
Engine News April 2003
New Water Pumps for 3500 Engines {1361, 1389}

SMCS - 1361; 1389
Engine: Commercial
 3500 Diesel
Engine News SEBD9318, February 2003, "New Water Pumps for 3500 Engines". Disregard this
article. The correct information follows:
Water pumps on 3500 engines have changed. The mating surface between the impeller and the
shaft has changed from a tapered joint to a straight joint. The former parts are no longer serviced.
The table provides a cross reference between the part numbers for the former pumps and the part
numbers for the new pumps. In most cases, rebuild kits and remanufactured pumps are available.
The rebuild kits are intended for use with both the former pump and the new pump.
Table 1
Cross Reference for 3500 Engine Water Pumps
Former New New New Remanufactured Water

Rebuild Kit
Pump Pump Shaft Impeller Pump
156-9817 212-8167 212-8178 212-8181 N/A N/A
6I-3520 212-8168 212-8179 212-8183 221-9278 0R-4570
7E-9781 212-8169 212-8179 212-8183 221-9278 0R-3192
7E-9782 212-8166 212-8179 212-8183 221-9278 N/A
166-4381 212-8172 212-8180 212-8184 222-5152 0R-9673
166-4379 212-8173 212-8180 212-8185 N/A N/A
166-4382 212-8174 212-8180 212-8186 N/A N/A
166-4380 212-8175 212-8180 212-8187 222-5153 0R-9670
166-4377 212-8176 212-8180 212-8187 222-5153 0R-9672
166-4378 212-8177 212-8180 212-8184 222-5152 0R-9671
199-5590 221-5352 221-5349 206-4282 N/A N/A
199-5589 221-5353 221-5348 206-4283 N/A N/A

The procedure for disassembling the new water pumps and assembling the new water pumps is
similar to the procedures for the former pump. During disassembly, a puller should be used to
remove the impeller from the shaft. During assembly, the impeller should be pressed onto the shaft
after the shaft is assembled into the housing assembly. Prior to pressing the impeller onto the shaft,
the impeller and the shaft should be at room temperature. Apply a light coat of clean engine oil to
the shaft before pressing the impeller onto the shaft. The force that is required will be a minimum
of 3,855 kg (8,500 lb) with a nominal force of 14,060 kg (31,000 lb).
Note: While you are pressing the impeller onto the shaft, force should not be placed on the
housing assembly. The shaft should be placed in a fixture that is designed to absorb the load of the
press while the impeller is pressed onto the shaft.
When the face of the impeller and the face of the shaft are flush, the proper assembly dimensions
for the water seal and the other pump components has been reached.
Engine News February 2003
Some Of The Tees In Some Breather Groups May Be

Damaged By Normal Operation {1317}
Engine:
3512B (S/N: CMC1-UP; PTM1-UP; 8RM1-UP; 6WN1-UP; 5AW1-UP)
3516B (S/N: BPJ1-UP; FDN1-UP; 6HN1-UP; 7RN1-UP; 8NW1-UP; FDX1-UP)
Power Module:
PM3512 (S/N: BNR1-UP)
The tees for the crankcase breathers are manufactured from rubber. In some applications, some of
these tees are being damaged by the heat from the turbocharger exhaust housing. The damage may
result in a leak from the tee. Illustration 1 shows a typical rubber tee in a fumes disposal group.
(1) Tee
In some cases, the breathers can be moved to alternate
locations that will increase the distance between the
rubber tee and the turbocharger exhaust housing. This
will reduce the heating of the rubber tee and this will
prevent damage to the tee. If moving the crankcase
breathers is not an option, a 210-2593 Shield As can
be installed over the rubber tee. The shield assembly
will prevent damage to the rubber tee from heat. The
210-2593 Shield As is now available through the
Caterpillar parts system. This new shield assembly can
be used to protect the rubber tees on any existing 3500
engine.
(2) Shield assembly
(3) Lockwire
Use the following instructions in order to install the new
shield assembly:
1. Place the 210-2593 Shield As over the tee.

2. Use two pieces of 5P-6025 Lockwire that are 305
mm (12 inches) long to secure the shield assembly in
position.
Engine News January 2003

A New Adjusting Screw Is Used In

The Fuel Injector Rocker Arm {1123}
Engine: Commercial
 3500B Series
Description of Change: A new adjusting screw is used in
the fuel injector rocker arm in the valve mechanism groups
on these engines. The new adjusting screw includes an oil
passage that allows pressurized oil to lubricate the joint
between the adjusting screw and the pushrod. The former adjusting screw relied on splash
lubrication at this joint. The new adjusting screw will provide increased lubrication in order to
reduce the wear between the adjusting screw and the pushrod.
(1) 230-2619 Adjusting Screw

Adaptable To: The new 230-2619 Adjusting Screw has replaced the 200-2004 Adjusting Screw in
the valve mechanism groups on all of the above engines. The new adjusting screw can be used as a
replacement for an individual 200-2004 Adjusting Screw in any 3500B Commercial Engine. The
new adjusting screws can be used in groups in order to replace all of the 200-2004 Adjusting
Screws in any 3500B Commercial Engine. No change is required to the fuel injector rocker arm.
New Maintenance Intervals for Valve Bridge and Valve Lash

Adjustment {1102}
SMCS - 1102-025
Engine: Commercial
 3500 Diesel
 3500B Series
Engine tests have determined the optimum maintenance intervals for adjustment of the valve
bridge and valve lash in the above engines. The maintenance intervals are listed in Table 1.
Table 1
3500 and 3500B Engines

Maintenance Intervals for Valve Bridge and Valve Lash Adjustment
Initial Interval Initial 250 Service Hours
Subsequent Interval Every 4000 Service Hours

The engine tests have revealed that the initial adjustment of the valve bridge and valve lash
is critical for new engines and for engines that have been overhauled. The tests have indicated
that the valve bridge and valve lash settings change during the period from the initial start-up
through the first 100 hours of operation. The settings can continue to change during further
operation. For this reason, adjust the valve bridge and the valve lash after the break-in period of
the initial 250 operating hours.
NOTICE
Incorrect adjustment of the valve bridge and/or of the valve lash can
result in engine damage from these conditions: excessive exhaust
temperatures, incorrect seating of the valves and contact between the
valves and the piston.
Perform the initial adjustment for the following circumstances:
 The engine is new.
 The engine has been overhauled.
 At least one of the engine's cylinder heads has been serviced with a new valve train
component.
Note: Perform the initial adjustment even if an adjustment was performed after a dyno test or after
the engine's initial start-up.
The engine tests have also indicated that valve bridge and valve lash settings are significantly more
stable after the break-in period. For this reason, adjust the valve bridge and the valve lash after
every 4000 operating hours.
Note: The initial 250 service hour adjustment of the valve bridge and valve lash enables the
regular maintenance at every 4000 service hours until the engine is overhauled. If the initial 250
service hour adjustment is not performed, more frequent subsequent adjustment may be necessary.
For instructions on adjusting the valve bridge and the valve lash, refer to the engine's Systems
Operation/Testing and Adjusting manual.
Note: Make sure that you note the new maintenance intervals in the engine's Operation and
Maintenance Manual, "Maintenance Interval Schedule". The new maintenance intervals will be
included in the Operation and Maintenance Manual when the manual is revised.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
Perform the adjustment when the engine is cold. Before the adjustment is performed, the engine
must be shut down for a minimum of 20 minutes. After the stopped engine's valve covers have
been removed, the engine is considered cold because approximately 20 minutes are needed for
removal of the valve covers.
The valve bridge must be adjusted before the valve lash is checked and/or adjusted. Verify
that both valve bridges for each cylinder are correct. Then measure the valve lash.
If the valve lash is within ± 0.08 mm (± 0.003 inch) of the specification that is listed in Table 2,
adjustment of the valve lash is not necessary. If the measurement is not within the tolerance, adjust
the valve lash according to the specification that is listed in Table 2.
Table 2
3500 and 3500B Engine Valve Lash
Valve Specification
Inlet 0.50 mm (0.020 inch)
Exhaust 1.00 mm (0.040 inch)
Engine News
A New Top Piston Ring Promotes Reduced Cylinder Liner

Wear {1214, 1215}
Engines: Commercial
 3500 Diesel
Reference: Engine News, SEPD9263, August 1998, "The Causes Of Worn And Broken Pistion
Rings"
Description of Change: A new top piston ring is available for use in these commercial engines.
The coating on the face of the new top piston ring is less dense. This will help reduce the wear on
the cylinder liner.
Adaptable To: The new 229-1631 Piston Ring (Top) can be used as a replacement for the 144-
5694 Piston Ring (Top) in 3500 Diesel Commercial Engines.
New Water Seals Provide Increased Stability At Higher
Temperatures {1124}
Engines: Commercial
 3500 Family
Description of Change: New water seals are used in these engines. The new water seals are
manufactured from different materials that provide increased stability at higher temperatures. This
will help prevent the deformation of the water seals at higher temperatures. The material that is
inside of the new water seals is stainless steel. The material that is inside of the former water seals
is yellow plastic. The new water seals are located between the bottom of the cylinder head and the
top of the cylinder block. See the illustration.
Locations Of The New Water Seals
(1) 204-5426 Seal
(2) 204-5427 Seal
(A) Cylinder Head
(B) Head Gasket

Adaptable To: The new 204-5426 Seal is a
direct replacement for the 126-1112 Seal. The
new 204-5427 Seal is a direct replacement for the
126-1113 Seal. Each engine cylinder head
requires four 204-5426 Seals and four 204-5427
Seals. The table lists the effectivity of the water
seals. The new water seals can be used as a
replacement for the water seals in all earlier 3500
Commercial Engines.
Table 1
Effectivity of the New Water Seals
S/N S/N S/N
1DW413 1FZ1448 1GZ1230
1HZ2222 1JZ481 1KZ983
1LM249 1LZ416 1TW323
24A10139 25Z7093 27Z846
2EZ299 2FW314 2GW369
2HW234 2JW405 2TJ177
2TS008 3CW249 3DM367
3HM015 3JS009 3KD260
3LS228 2MS233 3NS246

3ZW360 49Y1009 4AW780
4BW483 4DR005 4EK37807
4FZ1448 4GM742 4TN662
4WD027 4WJ1298 50Y1782
51Y857 5AW132 5JD092
5PS299 5XM032 5ZZ268
65Z1100 66Z929 67Z2023
68Z1240 69Z884 6EF327
6HN1719 6JW129 6PM053
6PN824 6WN803 70Z1077
71Z397 72Z565 73Z963
7EZ304 7HM251 7KM076
7NJ902 7RN1943 7SM777
84Z1203 8CN206 8DF187
8EM448 8JZ302 8KN520
8LD122 8PW344 8RM750
8TL011 95Y1193 96Y2043
97Y736 9AN328 9FP228
9TG318 9WF118 9WN016
AAG006 BAG025 BCK262
BGW131 BPX095 BRC152
CAN111 CBB173 CBN292
CEY160 CTA152 CTB172
CTC247 CTD171 CTE315
CTF259 CTG255 CTH208
CTJ200 CTK211 CTL467
CTN177 CTW282 FFG002
GDB008 GET104 GSE155
HEA103 HEB104 IFZ1448

IJZ481 IKZ983 ILZ416
PWG104 RWA151 WWO145
ZAF316 ZBM176 ZCS1035

Media Number - TIBU3815-00
Top Piston Ring Identification for 3500 Diesel Engines with

Two Piece Pistons
SMCS - 1215
TECHNICAL INFORMATION BULLETIN March 12, 2003
Engine Commercial 3500 Diesel

PRODUCT FAMILY(S) Engines
Caterpillar Products Machine
Engines All 3500 Series
SUBJECT: Top Piston Ring Identification for

3500 Diesel Engines with Two Piece Pistons
PROBLEM:
If a standard displacement piston ring is put on a high
displacement piston it will break after approximately 200 hours of
operation in a machine engine. The piston ring may reach higher
hours in a marine engine or a genset engine. Symptoms of a broken
top ring include high engine oil consumption, and high crankcase
blow-by. From January 2000 to August 2002 both the high
displacement piston rings and the standard displacement rings had
two yellow stripes. From August 2002 to September 2002 the stripes
were completely removed from both rings. These two changes make
piston ring identification difficult.
SOLUTION:
Paint marks are being applied on the face of the ring in order to identify the rings. The standard
displacement ring has two yellow stripes, and the high displacement ring has three yellow stripes.
In order to positively identify the high displacement ring as compared to the standard displacement
ring the piston ring must be measured. The high displacement ring is 4.5 mm thick. The standard
displacement ring is 3.91 mm thick.
Top Piston Rings for 3500 Diesel Engines with
Two Piece Pistons
Standard Part number High Part number
displacement displacement
Old ring 144-5694 Old ring 151-2778
New ring 229-1631 New ring 229-1632
Engine news March 2003
Use the Correct Tooling for Installing Piston Rings {1214,

1215}
Engine: Commercial
 3500 Diesel
There have been some complaints of top ring breakage on 3500 Engines. This ring is very
sensitive to twisting, which can lead to early hour failure. Extreme care must be taken in order to
avoid twisting the ring during installation. Caterpillar only recommends the use of the Caterpillar
service tools in order to install the rings onto the pistons on 3500 Engines. Use the 6V-4024 Guide
Ring and 6V-4023 Handle Assembly to install the piston rings.

Unsatisfactory Cam & follower Life
Media Number - TIBU3539-02 Publication Date - 2002/06/05 Date Updated - 2002/05/29

CONFIDENTIAL
Unsatisfactory Cam & follower Life

SMCS - 1209; 1210
CONFIDENTIAL TIBU3539-02
TECHNICAL INFORMATION BULLETIN JUNE 05, 2002
TRACK-TYPE TRACTORS, THIS TECHNICAL INFORMATION

BULLETIN REPLACES THE MARCH 13,
OFF-HIGHWAY TRUCKS/TRACTORS, 2002 TRACK-TYPE TRACTORS, OFF-
HIGHWAY TRUCKS/TRACTORS, WHEEL
WHEEL LOADERS, LOADERS, EXCAVATORS TIB,
"UNNSATISFACTORY CAMSHAFT AND
EXCAVATORS CAMSHAFT FOLLOWER LIFE". DESTROY
THE MARCH 13, 2002 TIB.
D11R (AAF, 8ZR, 9TR, 9XR, 7PZ)

TRACTORS;
776D (5ER, AFS),
777D (AGC, 3PR, 2YW, AGY),
785C (1HW, APX),
789C (2BW),
793C (4AR, ATY, 4GZ),
797 (5YW) OFF-HIGHWAY

TRUCKS/TRACTORS;
992G (7HR, ADZ),
994D (3TZ) WHEEL LOADERS;
5130B (4CS),
5230 (7LL) EXCAVATORS

Component Code 1209, 1210
Engine News
A New Fuel Transfer Pump Group Is Used {1256}

Engines: Commercial
 3500 Diesel
Description of Change: A new fuel transfer pump group is used on these engines. The new fuel
transfer pump group includes a drive shaft assembly (1) that has a chrome finish. This will help
reduce wear between the drive shaft assembly and the lip type seals (A).
New 225-4260 Fuel Transfer Pump Gp
(1) 225-4259 Drive Shaft Assembly
(A) Lip Type Seals

Adaptable To: The new 225-4260 Fuel Transfer Pump Gp is a direct replacement for the former
169-8615 Fuel Transfer Pump Gp. The former fuel transfer pump group is cancelled. The new
225-4259 Drive Shaft Assembly is a direct replacement for the former 124-9437 Drive Shaft
Assembly. The former drive shaft assembly is cancelled. The new drive shaft assembly can be
installed in the former fuel transfer pump group.
New Cover Seals are Available {1107, 1201, 1210}

Engine: Commercial
 3500 Family
Engine:
 G3500 Series
The 3500 and G3500 engines have a new seal design that is used in the locations that are described
in Table 1.
Top view of new seal (typical example)

Section A-A (cross section of new seal)
Section B-B (cross section of retention ribs)
Table 1
Locations of Seals and Part Numbers
Engine Location Former Seal New Seal
Valve Cover (A Series) 169-4833 O-Ring Seal 206-7030 Seal
Valve Cover (B Series) 162-7473 O-Ring Seal 208-2364 Seal
Camshaft Cover 162-7473 O-Ring Seal 208-2362 Seal
Side Cover 169-4834 O-Ring Seal 208-2363 Seal

The new seal utilizes a unique sealing design and retention ribs. This design improves the sealing
area of the seal. This design is also less likely to be displaced during the assembly process. The
new seals are a direct replacement for the former seals. The seals will fit into existing covers
without any modification to the covers.
A New Water Tank Group Is Used To Contain The Overflow

Of Coolant {1354, 1377}
Engines:
G3516 (S/N: 3RC; 8LD; CPG; 4EK; CSZ)
The new 201-5872 Water Tank Gp is used on these engines. This water tank group is used to
contain the overflow of coolant. This new group is used instead of the former 113-9480 Water
Tank Gp. The former group is cancelled. The new group includes a stronger water tank with
improved mounting.
Note: The new 201-5872 Water Tank Gp is not available for parts service at the group level. The
individual components of the group must be ordered.
The individual components of the new 201-5872 Water Tank Gp are identified in the Service
Information System (SIS).
Service Magazine
Media Number - SEPD0631-00 Publication Date - 2002/05/27 Date Updated - 2002/05/27
Use The 2P-4005 Engine Oil Filter Assembly If The Machine

Engine Is Equipped With Spin-on Oil Filters {1308}
Machine Engines: with Mechanical Unit Injection
 3500 Series
Machine Engines: with Electronic Unit Injection
 3500 Series
Machine Engines:
 3500B Series
Caterpillar recommends the use of the 2P-4005 Engine Oil Filter Assembly on the above machine
engines that are equipped with spin-on oil filters. Do not use the 1R-0716 Engine Oil Filter
Assembly on any 3500 Engines. The use of the 2P-4005 Engine Oil Filter Assembly will help
prevent oil leaks from the joint between the filter seal and the filter base.
When you install a 2P-4005 Engine Oil Filter Assembly, tighten the filter for an additional full
turn after the seal that is on the filter contacts the oil filter base.
Engine News
Use The 2P-4005 Engine Oil Filter Assembly If The Engine Is

Equipped With Spin-on Oil Filters {1308}
Engines: Commercial
 3500 Family
Caterpillar recommends the use of the 2P-4005 Engine Oil Filter Assembly on the above engines
that are equipped with spin-on oil filters. Do not use the 1R-0716 Engine Oil Filter Assembly on
any 3500 Engines. The use of the 2P-4005 Engine Oil Filter Assembly will help prevent oil leaks
from the joint between the filter seal and the filter base.
When you install a 2P-4005 Engine Oil Filter Assembly, tighten the filter for an additional full
turn after the seal that is on the filter contacts the oil filter base.
PI70052 - PRODUCT IMPROVEMENT PROGRAM FOR REMOVING ALL 1R0716 OIL

FILTERS FROM DEALER STOCK

SIS News 3500 Series

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Engine News January 2004

Media Number -SEBD9329-00 Publication Date -2004/01/01 Date Updated -2004/01/01

A New Shield is used for the Seal on the Aftercooler {1063}

Effective Serial Numbers

Engine News December 03

Procedure for Cylinder Head Bolt Tightening {1100}

Torque ... 30 ± 5 N·m (22 ± 4 lb ft)

3. Tighten bolts 1 through 8 in the numbered sequence.

Torque ... 200 ± 15 N·m (148 ± 11 lb ft)

4. Tighten bolts 1 through 8 again in the numbered

Torque ... 200 ± 15 N·m (148 ± 11 lb ft)

5. Tighten bolts 1 through 8 again to the following rotation.

Rotation for bolts ... 180 degrees

6. Tighten bolt 9 and bolt 10.

Torque ... 55 ± 10 N·m (40 ± 7 lb ft)

The Two-Piece Pistons are Cancelled {1214}

New Remanufactured Part 10R-1816 Cylinder Pack Gp 10R-1817 Cylinder Pack Gp

New Gaskets in the Water Lines Groups {1380}

New Gasket Former Gasket

A New Dowel Improves Lubrication to the Rocker Assembly

Parts List for Prelube Pump Group Kits {1319}

9Y-6016 Prelubrication Pump Gp

Qty Serviceable Part Serviceable Part in Kit Qty

106-5029 Needle Bearing As 4

129-6306 Lip Seal 1

129-6307 Gasket 3

129-6311 Retaining Ring 4

129-6312 Ball 1

129-6313 Oil Pump Drive Shaft 1

1 128-2810 Prelubrication Pump Kit

1 128-3543 Motor As

1 128-3548 Gear Pump Assembly

9Y-9992 Prelubrication Pump Gp

106-5029 Needle Bearing As 4

127-6930 Dowel Pin 1

129-6306 Lip Seal 1

129-6311 Retaining Ring 4

129-6312 Ball 1

129-6315 Driver Shaft 1

1 128-2761 Pump Gear Kit

1 128-3543 Motor As (1)

1 128-3544 Motor As (1)

1 128-3545 Motor As (1)

1 128-3547 Gear Pump Assembly

9Y-6016 9Y-9992 9Y-9993 9Y-9995

New Cylinder Head Groups and Valve Mechanisms

New Basic Cylinder Head

3500 Engine with EUI

7E-8758 Cylinder Head

3500 MUI Engine (Locomotive)

203-2170 Cylinder Head

3500 MUI Engine

4W-0095 Cylinder Head

101-0830 Cylinder Head

3500B Engine (Locomotive)