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Using Fuel Consumption For Calculating the Overhaul Intervals
Experience has shown that maintenance intervals are most accurately based on fuel consumption. Fuel consumption corresponds more accurately to the engine load. Table1 list average ranges of fuel consumption and service hours for a load factor of approximately 60 percent. Use the range of fuel consumption only as a guideline.
Table 1
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3516C Engines (1)
Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM
250 Service Hours 44000 L (11600 US gal) 53000 L (14000 US gal) 64500 L (17000 US gal)
500 Service Hours 88000 L (23200 US gal) 106000 L (28000 US gal) 129000 L (34000 US gal)
1000 Service Hours 176000 L (46500 US gal) 212000 L (56000 US gal) 258000 L (68000 US gal)
2000 Service Hours 352000 L (93000 US gal) 424000 L (112000 US gal) 516000 L (136000 US gal)
3000 Service Hours 528700 L (139500 US gal) 636700 L (168100 US gal) 773000 L (204000 US gal)
6000 Service Hours 1056000 L (279000 US gal) 1272000 L (336000 US gal) 1548000 L (408000 US gal)
Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours
2000000 L (528000 US gal)
Second Top End Overhaul 22000 Service Hours 18000 Service Hours 15000 Service Hours
4000000 L (1056000 US gal)
Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours
6000000 L (1584000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.Use the actual records of fuel consumption, when possible. If the actual records are not available, use the following procedure to estimate the fuel consumption.
Estimate the average percent of the load for the operation of the engine.
Refer to the fuel consumption data in the Technical Marketing Information (TMI) for your engine. This data will determine the fuel consumption for the percent of the load that was estimated in Step 1. Use this figure as variable "F" for the equation in Table 2. For more information about the Technical Marketing Information (TMI) for your engine, consult your Cat dealer.
Table 2
Equation For Calculating Overhaul Intervals
F/R = H
“F” is the estimated total amount of fuel consumption of the engine.
“R” is the rate of fuel consumption in liters per hour or gallons per hour.
“H” is the number of estimated hours until the overhaul interval. Oil Consumption as an Overhaul Indicator
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Cat engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.The oil consumption rate (brake-specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake-specific oil consumption (BSOC) depends on the engine load. Consult your Cat dealer for assistance in determining the typical oil consumption rate for your engine.When an engine oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase in blowby and a slight increase in fuel consumption.Severe Operation
Severe operation is the use of an engine that exceeds current published standards for that engine. Caterpillar maintains standards for the following engine parameters:
Horsepower
Range of rpm
Fuel consumption
Fuel quality
Altitude
Maintenance intervals
Selection of oil
Selection of coolant
Environmental qualities
InstallationRefer to the standards for your engine or consult your Cat dealer to determine if your engine is operating within the defined parameters.Severe operation can accelerate component wear. Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons:
Maximum reliability
Retention of full service lifeBecause of individual applications, identifying all factors which can contribute to severe operation is impossible. Consult your Cat dealer about the maintenance that is needed for your specific engine.The following factors can contribute to severe operation: environment, improper operating procedures, and improper maintenance practices.Environmental Factors