3512B MARINE ENGINE

S/N 7HM00001-UP

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 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-09 Publication Date -01/07/2013 Date Updated -06/09/2018

s03548137

Foreword
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

WARNING - This product can expose

you to chemicals including ethylene
glycol, which is known to the State of
California to cause birth defects or other
reproductive harm. For more information
go to:

www.P65Warnings.ca.gov

Do not ingest this chemical. Wash hands after handling to avoid incidental ingestion.

WARNING - This product can expose

you to chemicals including lead and lead
compounds, which are known to the
State of California to cause cancer, birth
defects, or other reproductive harm. For
more information go to:

www.P65Warnings.ca.gov

Wash hands after handling components that may contain lead.

Literature Information
This manual contains safety, operation instructions, lubrication, and maintenance information.
This manual should be stored in or near the engine area in a literature holder or literature storage
area. Read, study, and keep it with the literature and engine information.

English is the primary language for all Cat publications. The English used facilitates translation
and consistency in electronic media delivery.

Some photographs or illustrations in this manual show details or attachments that may be different
from your engine. Guards and covers may have been removed for illustrative purposes.
Continuing improvement and advancement of product design may have caused changes to your
engine which are not included in this manual Whenever a question arises regarding your engine,
or this manual, please consult with your Cat dealer for the latest available information.

Safety
This safety section lists basic safety precautions. In addition, this section identifies hazardous,
warning situations. Read and understand the basic precautions listed in the safety section before
operating or performing lubrication, maintenance, and repair on this product.

Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and
techniques required to operate the engine more efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating, and stopping the engine. This section also
includes a discussion of electronic diagnostic information.

Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are
grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in
the maintenance schedule are referenced to detailed instructions that follow.

Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily,
annually, etc.) may be used instead of service meter intervals if they provide more convenient
schedules and approximate the indicated service meter reading.

Recommended service should be performed at the appropriate intervals as indicated in the

Maintenance Interval Schedule. The actual operating environment of the engine also governs the
Maintenance Interval Schedule. Therefore, under severe, dusty, wet, or freezing cold operating
conditions, more frequent lubrication, and maintenance than is specified in the Maintenance
Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management
program. If the preventive maintenance program is followed, a periodic tune-up is not required.
The implementation of a preventive maintenance management program should minimize
operating costs through cost avoidances resulting from reductions in unscheduled downtime and
failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or
individual items in each level should be shifted ahead or back depending upon your specific
maintenance practices, operation, and application. We recommend that the maintenance schedules
be reproduced and displayed near the engine as a convenient reminder. We also recommend that a
maintenance record be maintained as part of the engine's permanent record.

See the section in the Operation and Maintenance Manual, "Maintenance Records" for information
regarding documents that are accepted as proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating
environment.

Overhaul
Major engine overhaul details are not covered in the Operation and Maintenance Manual except
for the interval and the maintenance items in that interval. Major repairs are best left to trained
personnel or an authorized Cat dealer. Your Cat dealer offers various options regarding overhaul
programs. If you experience a major engine failure, there are also numerous after failure overhaul
options available from your Cat dealer. Consult with your dealer for information regarding these
options.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:17:36 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
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 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i02828620

Aftercooler Core - Inspect/Clean

SMCS - 1063-040; 1064-571

1. Remove the core. Refer to the Disassembly and Assembly Manual, "Aftercooler - Remove and
Install" for the procedure.

2. Turn the aftercooler core on one side in order to remove debris. Remove the debris that is
accessible.

NOTICE

Do not use a high concentration of caustic cleaner to clean the core. A

high concentration of caustic cleaner can attack the internal metals of
the core and cause leakage. Only use the recommended concentration
of cleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 1 lists Hydrosolv liquid
cleaners that are available from your Caterpillar dealer.

Table 1
Hydrosolv Liquid Cleaners (1)
Part Number Description Size
1U-5490 Hydrosolv 4165
 19 L (5 US gallon)

174-6854 Hydrosolv 100

19 L (5 US gallon)
(1)
Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Consult your
Caterpillar dealer for more information.

4. Remove the drain plug.

5. Steam clean the core in order to remove any residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside and from the outside of the core.

Note: Do not use high pressure when the fins are cleaned. High pressure can damage the fins.

6. Wash the core with hot, soapy water.

7. Flush the core thoroughly in order to remove residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the core is clear and free of debris.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.

8. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.

9. Prior to installation, inspect any O-rings or seals for damage. If necessary, replace the O-rings
or seals.

10. Inspect the core for trapped debris and cleanliness. If it is necessary, remove the debris and
repeat the cleaning procedure.

11. Inspect the core for damage and perform a pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform pressure tests.

12. Install the core. Refer to Disassembly and Assembly Manual, "Aftercooler - Remove and
Install" for the procedure.

For more information on cleaning the core, consult your Caterpillar dealer.
Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:25:59 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i02566367

Air Shutoff - Test - Engines That Are Equipped with ADEM II

or ADEM III Engine Control Modules
SMCS - 1078-081
Illustration 1 g01285348
Typical air shutoffs on a 3500B engine
(1) Air shutoffs
This is the sample of the sample click on
the download link for complete manual
DOWNLOAD LINK
For some reason if link demos not work
download this pdf and then click
Illustration 2 g01285609
Left hand side air shutoff in the OPEN position

Illustration 3 g01285610
Right hand side air shutoff in the OPEN position

Refer to the Troubleshooting Guide, "Air Shutoff System" information in your Service Manual for
further information about the electrical system for the air shutoff system.

Engines That Are Equipped with ADEM II Engine Control

Modules
Note: Do not start the engine. Ensure that the engine control is in the "OFF" position.

1. Ensure that both air shutoff gates are latched in the OPEN position and ensure that both air
shutoff switches are connected. Turn on the power to the engine control panel. Both air shutoff
gates should remain open. If both air shutoff gates do not remain open, check the wiring for the
air shutoff switches.

2. With the power for the engine control panel in the ON position, activate the "EMERGENCY
STOP" switch. Both of the air shutoff gates should close. If both air shutoff gates close, proceed
to step 3. If both air shutoff gates do not close, check the wiring for the air shutoff switches and
check the wiring for the solenoids. Activate the "EMERGENCY STOP" switch again. When
both air shutoff gates close, proceed to step 3.

3. Turn the power to the engine control panel to the OFF position. Ensure that the
"EMERGENCY STOP" switch is in the RUN position. Latch only the right side air shutoff gate
to the OPEN position. Turn the power for the engine control panel to the ON position. The right
side air shutoff gate should close. If the right side air shutoff closes, proceed to step 4. If the
right side air shutoff gate does not close, check the air shutoff switch for the right side air
shutoff and check the wiring for the right side air shutoff . When the right side air shutoff
closes, proceed to step 4.

4. Turn the power for the engine control panel to the OFF position. Latch only the left side air
shutoff gate to the OPEN position. Turn the power for the engine control panel to the ON
position. The left side air shutoff gate should close. If the left side air shutoff gate closes the test
is complete. If the left side air shutoff gate does not close, check the switch and the wiring for
the left side air shutoff .

Note: Testing is only complete when the engine successfully passes step 1 through step 4.

5. Operate the engine normally. Ensure that the air shutoff gates continue to be latched.

Engines That Are Equipped with ADEM III Engine Control

Modules
Note: Do not start the engine. Ensure that the engine control is in the "OFF" position.

1. Ensure that both air shutoff gates are latched in the OPEN position. Ensure that both air shutoff
switches are connected. Turn the power for the engine control panel to the ON position. The air
shutoff gates should remain in the OPEN positions. If the air shutoff gates do not remain in the
OPEN positions, check the wiring for the air shutoffs. When step 1 has been successfully
completed, proceed to step 2.

2. While the power for the engine control panel is in the ON position, activate the
"EMERGENCY STOP" switch . Both air shutoff gates should close. If the air shutoff gates do
not close, check the wiring for the air shutoffs and the wiring for the solenoids. Both air shutoff
gates must close before proceeding to step 3.

3. Turn the power for the engine control panel to the OFF position. Reset the "EMERGENCY
STOP" switch to the RUN position. Reset the right side air shutoff to the OPEN position. Turn
 the power for the engine control panel to the ON position. Select "Run/Start" on the engine
control panel. The engine should fail to start. If the engine does not start, proceed to 4. If the
engine starts, turn off the engine. Check the right side air shutoff. Check the wiring for the right
side air shutoff. Retest the air shutoff. When the procedure in 3 is followed and the engine fails
to start, proceed to 4.

4. Reset the "EMERGENCY STOP" switch to the RUN position. Set the power for the engine
control panel to the ON position. Activate the"EMERGENCY STOP" switch . Both air shutoff
gates should close. Set power for the engine control panel to the OFF position. Reset the
"EMERGENCY STOP" switch to the RUN position. Reset the left side air shutoff to the OPEN
position. Turn the power for the engine control panel to the ON position. Select "START/RUN"
on the engine control panel. The engine should fail to start. If the engine does not start,
proceed to 5. If the engine starts, turn off the engine. Check the left side air shutoff. Check the
wiring for the left side air shutoff. Retest the left side air shutoff. When the procedure in step 4
is followed and the engine fails to start, proceed to 5.

5. Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start
the engine. Disconnect only the right side air shutoff. Both air shutoff gates should close. The
engine should shut down. If the engine does not shut down, use the "EMERGENCY STOP"
switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in
order to retest the right side air shutoff. When the procedure in step 5 is followed and results of
the test are successful, reconnect the right side air shutoff. Reset both air shutoffs.

6. Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start
the engine. Disconnect only the left side air shutoff. Both air shutoff gates should close. The
engine should shut down. If the engine does not shut down, use the "EMERGENCY STOP"
switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in
order to retest the left side air shutoff. When the procedure in 6 is followed and the results of
the test are successful, reconnect the right side air shutoff. Reset both air shutoffs.

7. Testing is complete only when the engine successfully passes steps 1 through 6.

8. Reset both air shutoffs. Ensure that the "EMERGENCY STOP" switch has been reset. Operate
the engine normally.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:26:10 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i02567801

Air Shutoff Damper - Remove/Check

SMCS - 1078-011; 1078-535

Illustration 1 g01286554
Typical air shutoff (back view)
(1) Air shutoff gate
(2) Damper assembly

The vibration damper on the air shutoff minimizes the vibration of the air shutoff gate when the
engine is operating and the air shutoff gate is in the latched position. The components of the damper
assembly must be removed in order to ensure correct performance of the damper.
Illustration 2 g01286567
Damper assembly
(3) Plug
(4) Seal ring
(5) Housing
(6) Spring
(7) Plunger

1. The body of the damper should not be loosened or removed from the air shutoff when the
plunger is removed. In order to remove the plunger without loosening or removing the damper,
unscrew the plug with the following tools: a 6.35 mm (0.25 inch) Allen wrench and an open
end wrench .

2. Check the seal ring for damage or wear. If necessary, replace the seal ring.

3. Inspect the internal parts of the vibration damper for wear or damage. Clean the components
with 138-8440 component cleaner.

Illustration 3 g01286606
Damper plunger
 4. Remove the plunger from the spring. Visually inspect the exposed end of the plunger for dirt,
fouling, damage, and wear. If distance "A" is less than 18.3 mm (0.72 inch) or if a visual
inspection reveals dirt, fouling, damage, or wear on the active end of the plunger, replace the
plunger. Insert the tapered end of a clean, undamaged plunger into the spring. Install the open
end of the spring into the plug. Apply 9S-3263 thread lock or apply 9S-4030 thread lock onto
the threads of the plug. Screw the assembly into the damper body. The thread lock should cure
for a minimum of 1 hour before the air shutoff is used.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:26:56 UTC+0530 2024
All Rights Reserved.
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3512B Marine Engine 7HM00001-UP(SEBP2445 - 80) - Documentation Page 1 of 3





Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i06049302

Air Starting Motor Lubricator Bowl - Clean

SMCS - 1451-070

If the engine is equipped with an air starting motor, use the following procedure:

Personal injury can result from removing hoses or fittings in a pressure

system.

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the

system has been relieved.

1. Ensure that the air supply to the lubricator is OFF.

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3512B Marine Engine 7HM00001-UP(SEBP2445 - 80) - Documentation Page 2 of 3

Illustration 1 g03789898

(1) Filler plug

(2) Bowl

(3) Drain valve

2. Slowly loosen filler plug (1) in order to release the pressure from the lubricator.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.

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3512B Marine Engine 7HM00001-UP(SEBP2445 - 80) - Documentation Page 3 of 3

Dispose of all fluids according to local regulations and mandates.

3. Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from
the bowl.

4. Remove bowl (2) . Clean the bowl with warm water.

5. Dry the bowl. Inspect the bowl for cracks. If the bowl is cracked, replace the damaged bowl
with a new bowl. Inspect the gasket. If the gasket is damaged, replace the gasket.

6. Install the bowl.

7. Make sure that drain valve (3) is closed.

8. For instructions on filling the lubricator, see this Operation and Maintenance Manual, "Air
Starting Motor Lubricator Oil Level - Check" topic.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:27:12 UTC+0530 2024
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 6/29/2024
 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i06049122

Air Starting Motor Lubricator Oil Level - Check

SMCS - 1451-535

NOTICE

Never allow the lubricator bowl to become empty. The air starting
motor will be damaged by a lack of lubrication. Ensure that sufficient
oil is in the lubricator bowl.
 Illustration 1 g03789862

1. Observe the oil level in sight gauge (3) . If the oil level is less than 1/2, add oil to the lubricator
bowl.

Personal injury can result from removing hoses or fittings in a pressure

system.

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the

system has been relieved.

2. Ensure that the air supply to the lubricator is OFF. Slowly loosen filler plug (4) in order to
release pressure from the lubricator bowl.
 3. Remove filler plug (4) . Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below
0 °C (32 °F).

4. Install filler plug (4) .

Adjust the Lubricator

Note: Adjust the lubricator with a constant rate of air flow. After the adjustment, the lubricator will
release oil in proportion to variations of the air flow.

1. Ensure that the fuel supply to the engine is OFF.

NOTICE

Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.

2. Operate the air starting motor. Observe the drops of oil that are released in dome (1) .

Note: Some lubricators have an adjustment screw rather than a knob.

3. If necessary, adjust the lubricator in order to release from one to three drops of oil per second.
To increase the rate, turn knob (2) counterclockwise. To decrease the rate, turn the knob
clockwise.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:27:25 UTC+0530 2024
All Rights Reserved.
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

Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i04534752

Air Tank Moisture and Sediment - Drain

SMCS - 1466-543-M&S

Moisture and sediment in the air starting system can cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protective gloves, a protective face
shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal injury.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Cat Dealer Service Tool

Catalog" or refer to Special Publication, PECJ0003, "Cat Shop
 Supplies and Tools Catalog" for tools and supplies suitable to collect
and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.

1. Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment to
drain.

2. Close the drain valve.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:27:38 UTC+0530 2024
All Rights Reserved.
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 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i04342909

Alternator - Inspect
SMCS - 1405-040

Inspect the alternator for the following conditions:

• Proper connections

• Clean ports for cooling airflow

• Proper charging of the battery

Observe the ammeter during engine operation in order to ensure proper battery performance and/or
proper performance of the electrical system.

Make repairs, if necessary. See the Service Manual for service procedures. Consult your Cat dealer
for assistance.

Copyright 1993 - 2024 Caterpillar Inc. Sat Jun 29 10:27:51 UTC+0530 2024
All Rights Reserved.
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 



Product: MARINE ENGINE

Model: 3512B MARINE ENGINE 7HM
Configuration: 3512B Marine Engine 7HM00001-UP

Operation and Maintenance Manual

3500B and 3500 Marine Propulsion Engines with EUI Option
Media Number -SEBU6917-08 Publication Date -01/07/2013 Date Updated -15/07/2013

i01041029

Batteries - Replace
SMCS - 1401-510

Batteries give off combustible gases which can explode. A spark can
cause the combustible gases to ignite. This can result in severe personal
injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow

the proper procedures in order to help prevent electrical arcs and/or
sparks near batteries. Do not smoke when batteries are serviced.

1. Turn the key start switch to the OFF position. Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect the charger.

3. The NEGATIVE "-" cable connects the NEGATIVE "-" battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE "-" battery terminal.

4. The POSITIVE "+" cable connects the POSITIVE "+" battery terminal to the starting motor.
Disconnect the cable from the POSITIVE "+" battery terminal.

Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate
recycling facility.

5. Remove the used battery.

6. Install the new battery.

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