3500 Engines and Short Blocks Caterpillar

3500 Engines and Short Blocks

Engine Configurations and "Updates"

Cat Remanufactured 3500 Engines may require modifications and additional parts for installation. To determine the correct Reman engine for each application, refer to the machine model and new engine arrangement number in the engine application chart on the following page. Caution: Some Reman engines are serviced at a slightly different level than their new engine counterparts. The new engine may not include a fan drive, for example, when the Reman engine does. If in doubt about the exact consist of a Reman engine, consult your dealership technical coordinator. Another source of information is the Reman "Hot Line" (in North America) on 1-888-88-REMAN.

Cat Remanufactured engines are remanufactured to the latest critical engineering changes. Customers will receive the most technically advanced engine available at time of engine remanufacture. Critical engineering changes incorporated into the Reman engine may require machine modifications at the time of engine installation. Search the latest service literature for the engine model being purchased (especially Service Magazine articles) and read any Installation Special Instructions shipped with the engine. Together, the service literature and Special Instructions will tell what engineering updates are included in the Reman engine and what modifications may need to be made to the machine before engine installation.

To look up replacement parts for a Remanufactured engine, refer to the new engine serial prefix and arrangement numbers. New parts are directly interchangeable unless the block has been bored or the crankshaft remachined undersized. The corresponding new engine arrangement number can be found on the Reman engine block identification plate. The engine block identification plate also includes the crankshaft rod and main journal sizes for each engine.

"Future Dated Orders" (FDO) vs. :Distribution" (Dist.) engines

Reman "Future Dated Orders" (FDO) 3500 engines will ship from the Caterpillar engine plant (Lafayette, Indiana) 90 days after the order is received by Caterpillar. Reman "Distribution" (Dist.) engines ship immediately from stock, using normal Cat parts distribution procedures.

Retrofitting newer engines to older machines

Reman is often used to update older machines in the field. When a Reman 3500 engine is used to update an older machine, the pricing logic is as follows: Dealers are charged the purchase price and core charge for the engine purchased. Dealers receive the core refund for the core returned. For example: MIU (Mechanical Unit Injection) engine cores are eligible for full MUI core deposit refund when purchasing a Reman EUI (Electronic Unit Injection) engine, subject to normal core acceptance criteria. The MUI core refund may be slightly less than the EUI core deposit. See the Core Acceptance Criteria for 3500 Engines (SELD0164) and EUI retrofit Special Instructions (777B-SEHS9690, 785-SEHS9688, 789- SEHS9674, and 793-SEHS9686) for detailed conversion information.

Former MAO Options

Effective January 1, 2004, the "Made As Ordered" (MAO) prgram was cancelled. It has been replaced with the "Future Dated Order" (FDO) program. The "MAO" program offered the ability to order engine arrangements in different paint stock colors, please note this option is no longer available in the new program. In addition, factory installed MAO attachments are no longer available. Service parts will need to be ordered through the normal distribution channels.

Notes

a- Non-North American Dealers must provide complete shipping instructions, including port of entry, when they place the FDO order with their assigned Caterpillar Distribution Center.
b- Reman engines have limited thermal heat shielding. Earlier serial numbered engines and vehicles have full thermal heat shielding. Refer to Special Instructions SEHS9256 to modify full heat shield vehicles to limited heat shield applications. In addition to several modifications, a fire suppression system is recommended if not already equipped. FAILURE TO COMPLY COULD LEAD TO PHYSICAL INJURY OR A FIRE HAZARD.
c- Includes engine stand part numbers 3508- 0R3874, 3512- 0R3904, 3516- 0R3914, or 3524- 188-4440 Engine cores must be returned on the stand the reman engine shipped on.
d- These engines are shipped with a TF-1000 air compressor.
e- Engine is 793B upgrade to 3516B HD engine. Reference IRM PELJ0954 for information regarding 793B upgrade to 3516B HD engine.
f- Engine maybe used to upgrade an older 793C to 3516B HD engine. Reference IRM PELE0872 for information regarding 793C upgrade to 3516B HD engine.
g- These engines are shipped with 2-cylinder air compressor

Reman 3500 Engine Special Instructions and Other Media

Correct installation is essential for proper performance and longevity. Please review REHS0082, "Mining Truck Major Component Removal and Installation Enhancement".

Media Common to all 3500 Reman Engines

These publications are shipped with every Reman 3500 engine.

Envelope                                         01-755-82719
Core Acceptance Criteria                  SELD0164
Core Credit Request/Packing List      01-84927
Engine Delivery Service Record         01-83995
Lubrication Recommendations          SEBU6250
Torque Specifications                       SENR3130

Some of the following application-specific service literature may be shipped with each Cat Remanufactured 3500 Engine.

Document                                                                      Title
REHS0130                    Procedure to Retrofit 3516B EUI Engine In 793B Off-Highway Trucks equipped with Vital Information Management System (VIMS)
REHS0203                    Converting the Engine from the IMRM Radiator Configuration to the Folded Core Radiator Configuration for Use in the D11 Track Type Tractors
SEBU5596                    Identification Number Location Guide
SEBU6019                    D11N Track Type Tractor
SEBU6024                    776B and 777B Off-Highway Tractor and Truck
SEBU6039                    789 Off-Highway Truck
SEBU6092                    785 Off-Highway Truck
SEBU6329                    994 Wheel Loader
SEBU6333                    793 Off-Highway Truck
SEBU6407                    776C and 777C Off-Highway Tractor and Truck
SEBU6517                    784B and 785B Off-Highway Truck/Tractors
SEBU6518                    789B Off-Highway Truck
SEBU6519                    793B Off-Highway Truck
SEBU6551                    5130 Excavator
SEBU6670                    D11N Track Type Tractor
SEBU6737                    5230 Excavator
SEBU6757                    776D Off-Highway Tractor & 777D Off-Highway Truck
SEBU6995                    793C Off-Highway Truck
SEBU7103                    D11R Track-Type Tractor
SEHS8830                    Governor and Decelerator Control Linkage Modification
SEHS8863                    Installation of 8W7507 Off-Highway Truck Engine Overspeed Warning Indicator Group
SEHS9227                    Installation of Switches/Sensors with Sure-Seal Connectors
SEHS9241                    Operator Instruction Card for the Automatic Ether Injection System (AEIS)
SEHS9256                    Thermal Heat Shield Removal
SEHS9257                    Installation of Overspeed Monitoring System
SEHS9293                    Installation of Automatic Ether Injection System
SEHS9329                    Installation of Automatic Ether Injection System
SEHS9340                    Jacket Water Heater Installation Procedures
SEHS9375                    Installation of Elevated Low Idle Control on 785 and 789 Trucks
SEHS9397                    Installation of Multipoint Pressure Sensing System (MPPS) Version of Automatic Ether Injector System (AEIS)
SEHS9398                    Installation of Multipoint Pressure Sensing System (MPPS) Version of Automatic Ether Injector System (AEIS)
SEHS9399                    Installation of Multipoint Pressure Sensing System (MPPS) Version of Automatic Ether Injector System (AEIS)
SEHS9628                    Installation of 0R3950 and 0R3960 3508 (MUI) Remanufactured Engines in D11N Off-Highway Tractors
SEHS9629                    Installation of 0R3951 and 0R3961 3508 (MUI) Remanufactured Engines in 776B Off-Highway Tractors and 777B Off-Highway Trucks
SEHS9630                    Installation of 0R3952 and 0R3962 3512 (MUI) Remanufactured Engines in 785 Off-Highway Trucks
SEHS9631                    Installation of 0R3953 and 0R3963 3516 (MUI) Remanufactured Engines in 789 Off-Highway Trucks
SEHS9632                    Installation of 0R3954 and 0R3964 3516 (MUI) Remanufactured Engines in 793 Off-Highway Trucks
SEHS9633                    Installation of 0R3955 and 0R3965 3516 (MUI) Remanufactured Engines in 994 Off-Highway Wheel Loaders
SEHS9634                    Installation of 0R3980 and 0R3990 3508 (EUI) Remanufactured Engines in D11N Off-Highway Tractors   
SEHS9635                    Installation of 0R3981 and 0R3991 3508 (EUI) Remanufactured Engines in 776C/777C Off-Highway Tractors/Trucks
SEHS9636                    Installation of 0R3982 and 0R3992 3512 (EUI) Remanufactured Engines in 785B Off-Highway Trucks
SEHS9637                    Installation of 0R3983 and 0R3993 3516 (EUI) Remanufactured Engines in 789B Off-Highway Trucks
SEHS8895                    Installation of Fumes Disposal Tube
SEHS8951                    Installation of 6Y2396 Engine Enclosure Group
SEHS9173                    Installation of Automatic Ether Injection System (AEIS)