16154 3 Mercury IMPELLER

Introduction
This Special Instruction applies to both categories of engine upgrade kits described below.Emissions Upgrade Kits - These designs are focused on regulatory compliance and/or sustainability efforts. Options in this category often carry compliance recognition through certification or verification. While compliance is the focus, these kits also provide many operational benefits like improved diagnostic capability, lower vibration and noise, and often lower fuel consumption.Performance Upgrade Kits - These designs are focused on fuel savings. Options in this category often result in a short return on investment and on-going savings. While performance is the focus, these kits also provide significant emissions benefits. Typically, the kits do not carry a compliance designation like certification or verification.This Special Instruction does not include all of the procedures that can be found in your existing manuals.Do not perform any procedure in this Special Instruction until the information has been read completely and understood.Reference Refer to the Service Manuals, Parts Manuals, and Operation and Maintenance Manuals for the original and upgraded engine arrangements for more information.When you have completed this procedure, prepare the engine for service. Refer to the Operation and Maintenance Manual.The kit for the needed upgrade will vary between engines. However, the affected subsystem components are similar. Examples of the subsystem components that are affected are listed below:
Control group
Camshaft group
Cylinder head group
Flywheel housing group
Air lines group
Engine oil lines group
Fuel injection lines group
Turbocharger oil lines group
Water lines group
Exhaust manifold group
Aftercooler group
Valve mechanism group
Piston and rod group
Fuel injection pump group
Exhaust heat shield
Turbocharger shield group
Turbocharger group
Wiring group
Marine Power Display (MPD) panelNote: Perform the following steps after reviewing the Special Instruction:
Complete the Request Form
Complete the CAT Engine Upgrade Kit Request Form for 3500 Series Marine available on the Emissions Solution website. To complete, navigate to the Marine Emissions Solutions link under Retrofit Solutions on the page:
NACD site: //dealer.cat.com/EmissionsSolutions
LACD site: https://lacd.cat.com/EmissionsSolutions
APD site: https://apdnet.cat.com/EmissionsSolutions
EAME site: https://eame.cat.com/EmissionsSolutionsNote: Include any iron or ratings changes performed on the engine since the engine left the factory in order to receive the correct kit match. Also, use this form to communicate any desired ratings changes or class certification considerations.
Submit inquiry through the Application Support Center
Fill out the Application Support Center (ASC) inquiry as a new inquiry and select "3500 Marine Emissions Upgrade" from the pull down tab entitled Task.
Attach the completed request form to the ASC inquiry and submit the inquiry. Caterpillar engineering will receive the form and request any additional information required for the upgrade kit match.
A kit part number, reference test specification, reference engine arrangement, and reference serial number will be sent from Caterpillar engineering back through the ASC.Note: The reference serial number and reference test spec is to be used for application and installation information only. The reference engine arrangement number should be used for consist information.
Complete A&I Review and Place OrderNote: The application and installation requirements may change for the upgraded engine. Examples include, but are not limited to, the cooling system, control, system, and air inlet/outlet modifications.
Perform the required application and installation analysis with input from the customer and/or shipyard referencing Marine application and installation guides. Contact the ASC for assistance as needed.
Perform a Torsional Vibration Analysis (TVA) during the upgrade process as some modifications may be required. Submitting a copy of the TVA will not be required; however, the decision of whether or not one was completed will be documented as part of the label request process.
The upgrade kit does not contain all parts needed to complete an overhaul. Each order will need to be supplemented with additional parts of the following varieties:
Application and Installation Components: -This group includes additional parts needed to modify the vessel required by the application and installation review.
Overhaul Components: The upgrade kit is composed of all the components which are different from the original engine configuration to the new engine configuration. This kit contains many overhaul parts but the kit is not all inclusive. The kit will need to be reviewed to determine which additional overhaul parts such as gaskets and bearings are needed.
Configuration Specific and Customer Preferred Components: This set of parts includes components that need to be ordered based on the engine configuration and the preference of the customer. These include electronic options, heat shields, tubes, and additional components required for reverse rotation engines. The options are located in the conversion arrangement. The notes associated with each part should be reviewed in order to make the appropriate selections. Several of these groups are marked as a "misc-ref" category. The identification helps visibility to the options and provides the dealer the most flexibility in selecting the appropriate parts to order.
Communicate the timeline for kit availability, cost, and other relevant information to the customer.
Schedule the upgrade with the customer. Be certain to allow sufficient time for delivery of the upgrade kit and related parts. The Committed Planned Repair Order (CPRO) process is recommended. The CPRO option requires orders to be placed a minimum of 90 calender days in advance of the scheduled repair. This type of order provides the highest probability of receiving a complete order for a planned repair.
Place a CPRO for the upgrade kit, overhaul parts, and any additional parts through the Antares Ordering System.
Service Fulfillment
Complete the overhaul and upgrade installation as directed in the following section of this Special Instruction.
Return the eligible component cores according to Reman Policies and Core Management, SELD0122. Refer to the following website for more information.https://reman.cat.com
Sea Trial and Registrations
Complete a full sea trial utilizing the reference test specification and reference serial number provided through ASC. Additional details on the validation process are included in the following sections of the Special Instruction.
Verify the results of the Computer Aided Marine Performance Analysis Report (CAMPAR) and submit to the Sea Trial Database.
Register the upgrade in the Service Information Management System (SIMS) as specified in the following sections of this Special Instruction.
Complete the CAT Engine Upgrade Kit Label Request Form for 3500 Series Marine available on the Emissions Solution website. To complete, navigate to the Marine Emissions Solutions link under Retrofit Solutions on the page:
NACD site: //dealer.cat.com/EmissionsSolutions
LACD site: https://lacd.cat.com/EmissionsSolutions
APD site: