T E C H N I C A L S U P P L E M E N T

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 folllowing 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.
Finding parts to service a Reman engine
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.

SELD0179-11 (05/09) CAT, CATERPILLAR, their respective logos, and "Caterpillar Yellow," as well as corporate and Page 1 of 5
product identity used herein, are trademarks of Caterpillar and may not be used without permission.
 New Reman Gross Cubic Inch Serial Number Prefixes
Machine Engine Arrangement Part Weight Dimensions Perform Engine Engine
Model Model Number Number (c) Net HP RPM (lbs) (HxWxL) Specs Machine New Reman

5130 3508 EUI 6I2758 0R3985 700 1750 11270 86x67x92 2T6721 5ZL 7YG 5TL
DITA

5230 3516 EUI 100-6339 0R3986 1468 1750 18440 86x67x136 2T6722 7LL 2PK 7CL
DITA

5130B 3508B 135-0135 0R8552 800 1750 11270 86x67x92 2T9685 4CS 2GR 5XS

5130B 3508B 163-2630 0R9843 800 1750 11270 86x67x92 0K3637 4CS 2GR BWA

5230B 3516B HD 157-2835 0R8558 1554 1750 18440 86x67x136 OK3644 4HZ 7TR 7DS

776B 3508 MUI 2W0174 0R3951b 870 1750 11270 86x67x92 2T5443 6JC 99W 4ZL
DITA

776C 3508 EUI 7E9078 0R3981 870 1750 11270 86x67x92 2T5357 2TK 7YG 5TL
DITA 121-5777

776D 3508B 104-4777 0R8551 939 1750 11270 86x67x92 2T9101/2 5ER 2GR 5XS

776D 3508B 155-0537 0R9841 939 1750 11270 86x67x92 0K3634/5 AFS 2GR BTR

776D 3508B 195-3816 10R-5596 11270 86X67X92 0K8108 AFS 2GR BTR
0K8109

777B 3508 MUI 2W0174 0R3951b 870 1750 11270 86x67x92 2T5443 4YC 99W 4ZL
DITA

777C 3508 EUI 7E9078 0R3981 870 1750 11270 86x67x92 2T5357 4XJ 7YG 5TL
DITA 121-5777

777D 3508B 104-4777 0R8551 939 1750 11270 86x67x92 2T9101/2 3PR 2GR 5XS

777D 3508B 155-0537 0R9841 939 1750 11270 86x67x92 0K3634/5 AGC 2GR BTR

784B 3512 EUI 7E9079 0R3982 1290 1750 13740 86x67x114 2T5358 5RK 4WJ 6FL
DITA 121-5785

784C 3512B 175-5285 0R9844 d 1348 1750 13740 86x67x114 0K3638/9 2PZ1-105 8BR605 SDW
-940

785 3512 MUI 1W5220 0R3952b 1290 1750 13740 86x67x114 2T4444 8GB 96Z 5EL
DITA

785B 3512 EUI 7E9079 0R3982 1290 1750 13740 86x67x114 2T5358 6HK 4WJ 6FL
DITA 121-5785

785C 3512B 100-8085 0R8554 1348 1750 13740 86x67x114 0K0584 1HW 8BR 6SS
0K6372

785C 3512B 175-5285 0R9844 d 1348 1750 13740 86x67x114 0K3638/9 APX1-450 8BR605 7SS
-940

785C 3512B 175-5285 10R6700 1348 1750 13740 86x67x114 0K3838/9 APX 8BR SDW
g

SELD0179-11 (05/09) CAT, CATERPILLAR, their respective logos, and "Caterpillar Yellow," as well as corporate and Page 2 of 5
product identity used herein, are trademarks of Caterpillar and may not be used without permission.
 New Reman Gross Cubic Inch Serial Number Prefixes
Machine Engine Arrangement Part Weight Dimensions Perform Engine Engine
Model Model Number Number (c) Net HP RPM (lbs) (HxWxL) Specs Machine New Reman

789 3516 MUI 2W3691 0R3953b 1705 1750 18440 86x67x136 2T5445 9ZC 54Z 6CL
DITA

789B 3516 EUI 7E9080 0R3983 1705 1750 18440 86x67x136 2T5359 7EK 2PK 7CL
DITA 121-
5789

789B 3516 EUI 156-6250 0R9583 d 1705 1750 18440 86x67x136 2T5359 7EK 2PK 7CL
DITA

789C 3516B 100-8089 0R8556d 1790 1750 18440 86x67x136 0K0584 2BW1- 7TR1- 7DS
0K6371 658 1435

789C 3516B 175-5289 0R9845d 1790 1750 18440 86x67x136 0K3640/1 2BW1- 7TR1- 7DS
658 1435

789C 3516B 246-5600 10R2854 1690 1750 18440 86x67x136 0K5847 2BW1- 8WM MSX
High 658
Altitude

789C 3516B 175-5289 10R6702 1790 1750 18440 86x67x136 0K2122/3 2BW1- 7TR 7DS
g 658

793 3516 MUI 9Y8881 0R3954 2057 1750 19640 86x67x136 2T5446 3SJ 54Z 6CL
DITA

793B 3516 EUI 7E6499 0R3959 2057 1750 19640 86x67x136 2T5360 1HL 2PK 7CL
DITA 121-5793
155-0530

793B 3516 EUI 155-0538 0R9659 2057 1750 19640 86x67x136 0K1302 1HL 2PK 7CL
High
Altitude

793B 3516B HD N.A. 10R0946 2057 1750 19640 86x67x136 0K3677 1HL N.A KNS
Without e
fan drive

793C 3516B 167-9570 0R9551d 2166 1750 19640 86x67x136 0K1303 4AR 4GZ 7TR 7DS
Freeport 0K1304

793C 3516B HD 147-0797 0R7568d 2166 1750 19640 86x67x136 0K3572/3 4AR 8WM CPW
Without f
fan drive d

793C 3516B 187-4593 10R2851 2166 1750 19640 86x67x136 0K1303/4 4GZ ATY 7TR 7DS
HIGH d
ALT.
Without
fan drive d

793C 3516B 100-8093 0R8842 2166 1750 19640 86x67x136 2T9416/7 4AR 7TR 7DS
HIGH
ALT.
Without
fan drived

SELD0179-11 (05/09) CAT, CATERPILLAR, their respective logos, and "Caterpillar Yellow," as well as corporate and Page 3 of 5
product identity used herein, are trademarks of Caterpillar and may not be used without permission.
 New Reman Gross Cubic Inch Serial Number Prefixes
Machine Engine Arrangement Part Weight Dimensions Perform Engine Engine
Model Model Number Number (c) Net HP RPM (lbs) (HxWxL) Specs Machine New Reman

793C 3516B 147-0793 0R8842 2166 1750 19640 86x67x136 2T9416/7 4GZ 7TR 7DS
HIGH
ALT.
Without
fan drived

793C 3516B 156-6240 0R9558d 2166 1750 19640 86x67x136 0K1303/4 7TR 7DS
HIGH
ALT.
Without
fan drived

793C 3516B 100-8093 0R8557 2166 1750 19640 86x67x136 2T9416/7 4AR 7TR 7DS
LOW
ALT.
Without
fan drived

793C 3516B 147-0840 0R8557 2166 1750 19640 86x67x136 2T9416/7 4GZ 7TR 7DS
LOW
ALT.
Without
fan drived

793C 3516B 156-6230 0R9557d 2166 1750 19640 86x67x136 2T9416/7 7TR 7DS
LOW
ALT.
Without
fan drived

793D 3516B HD 235-0300 10R-2852 19640 86X67X136 0K5842 FDB 8WM MSK
Emissions
0K5843
0K5844

797A 3524B HD 136-3200 0R8668 3400 1750 35670 94x92x198 0K6347 5YW 3TN CND
Low Alt. 186-4797

797B 3524B HD 209-5260 10R1433 3550 1750 35670 94x92x198 0K6349 JSM 3TN NPM
High Alt. 213-6610

797B 3524B HD 209-5259 10R1676 3550 1750 35670 94x88x198 0K6348 JSM 3TN NPM
Low Alt. 213-6600

854G 3508B 161-1592 0R9842 801 1750 11270 86x67x92 0K3636 AMP 2GR KAM

992G 3508B 107-8762 0R8553 801 1750 11270 86x67x92 2T9684 7HR 2GR 5XS

992G 3508B 161-1592 0R9842 801 1750 11270 86x67x92 0K3636 ADZ 2GR KAM

994 3516 MUI 9Y9200 0R3955 1250 1600 18440 86x67x136 2T5447 9YF 54Z 6CL
DITA

994D 3516B 100-8094 0R8555 1307 1600 18440 86x67x136 0K0775 3TZ 7TR 7DS

994F 3516B HD 240-7750 10R-2853 1577 1600 18440 86X67X136 0K5845 442 8WM KDK

SELD0179-11 (05/09) CAT, CATERPILLAR, their respective logos, and "Caterpillar Yellow," as well as corporate and Page 4 of 5
product identity used herein, are trademarks of Caterpillar and may not be used without permission.
 New Reman Gross Cubic Inch Serial Number Prefixes
Machine Engine Arrangement Part Weight Dimensions Perform Engine Engine
Model Model Number Number (c) Net HP RPM (lbs) (HxWxL) Specs Machine New Reman

D11N 3508 EUI 7E9077 0R3980 770 1800 11270 86x67x92 2T5356 4HK 7YG 5TL
DITA 127-4511

D11N 3508 MUI 8N9602 0R3950 770 1800 11270 86x67x92 2T5402 74Z 99W 4ZL
DITA 147-0811

D11R 3508 EUI 127-4511 0R3980 770 1800 11270 86x67x92 2T5356 8ZR 7YG 5TL
DITA

D11R 3508 B 100-8111 0R8550 850 1800 11270 86x67x92 2T9969 9TR 2GR 5XS

D11R 3508B 155-5556 0R9840 850 1800 11270 86x67x92 OK4747 7PZ 2GR BTB

D11R 3508 B 100-8111 0R8550 850 1800 11270 86x67x92 2T9969 9XR 2GR 5XS
CAR

D11R 3508B 155-5556 0R9840 850 1800 11270 86x67x92 OK4747 AAF 2GR BTB
CAR

Short Engine Usage Piston,

Block P/N Model Rod
Configura
tion

0R7635 3512B Prime 101-0829

Product 281-6139
Commercial

0R7634 3508B Prime 101-0829

Product 281-6139
Commercial

0R7636 3516B Prime 101-0829

Product 281-6139
Commercial

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product identity used herein, are trademarks of Caterpillar and may not be used without permission.
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 PELE0954 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

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product identity used herein, are trademarks of Caterpillar and may not be used without permission.
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)

SELD0179-11 (05/09) CAT, CATERPILLAR, their respective logos, and "Caterpillar Yellow," as well as corporate and Page 2 of 2
product identity used herein, are trademarks of Caterpillar and may not be used without permission.