3500 Engine Emissions Upgrade Groups{1000, 775E} Caterpillar

3500 Engine Emissions Upgrade Groups{1000, 775E}

Usage:

Engine:: 3508 (S/N: 96Y1-UP); 3508B (S/N: S2D1-UP; S2E1-UP; 7SM1-UP; 1TW1-UP); 3512 (S/N: 50Y1-UP; 66Z1-UP); 3512B (S/N: S2J1-UP; S2K1-UP; S2L1-UP; S2N1-UP; 4TN1-UP; 2GW1-UP; 2EZ1-UP); 3512C (S/N: MKH1-UP); 3516 (S/N: 29Z1-UP; 72Z1-UP); 3516B (S/N: 8KN1-UP; S2S1-UP; S2W1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP); 3516C (S/N: PAG1-UP)

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) panel

Note:

Perform the following steps after reviewing the Special Instruction:

Complete the Request Form
1. 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/EmissionsSolutions
  Note: 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
1. 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.
1. 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.
1. 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 Order
Note: 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.
1. 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.
1. 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.
1. 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.
1. Communicate the timeline for kit availability, cost, and other relevant information to the customer.
1. 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.
1. Place a CPRO for the upgrade kit, overhaul parts, and any additional parts through the Antares Ordering System.

Service Fulfillment
1. Complete the overhaul and upgrade installation as directed in the following section of this Special Instruction.
1. 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
1. 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.
1. Verify the results of the Computer Aided Marine Performance Analysis Report (CAMPAR) and submit to the Sea Trial Database.
1. Register the upgrade in the Service Information Management System (SIMS) as specified in the following sections of this Special Instruction.
1. 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: https://apdnet.cat.com/EmissionsSolutions
  - EAME site: https://eame.cat.com/EmissionsSolutions
1. Fill out the Application Support Center (ASC) inquiry as a new inquiry or reopen the initial inquiry submission and select "3500 Marine Emissions Upgrade" from the pull down tab entitled Task.
1. Attach the completed request form to the ASC inquiry and submit the inquiry. Caterpillar engineering will verify the results of the sea trial and SIMS update. After approval, a new engine information label and emissions label will be sent to the address specified in the ASC label request.
1. Install the new engine information label and the new emissions label.
1. Marine Classification Society (MCS) certificates and approved IMO/EIAPP technical files can be ordered through the standard ordering process. Refer to LEMX7151, "Orders Process for Marine Classification Society and IMO/EIAPP Certificates" in order to obtain the technical files required for propulsion and auxiliary engines that are on board classified vessels and offshore applications. The product news is available at Electronic Media Center (EMC). Go to the following:
  - https://emc.cat.com
  Note: Inform the representative of the society early and often of the upgrade process in order to ensure that there are no unforeseen issues.

The following criteria must be completed in order to obtain a new emissions label:
- All procedures in this Special Instruction must be completed by a Caterpillar dealer. The emissions upgrade requires a Caterpillar dealership to verify the process.
- The engine that has received the emissions upgrade must be performance tested after the upgrade kit has been installed. For Marine applications, this performance test requires a full Sea Trial and CAMPAR report to be conducted. The engine must pass the requirements as detailed in the following sections of this special instruction.
- Validation data (Performance Test Results) must be posted in Sea Trial Database and approved by Caterpillar engineering.
- The upgrade must be registered as specified in the following sections of the Special Instruction.

Safety

Show/hide table

Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Show/hide table

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. Dispose of all fluids according to local regulations and mandates.

Validation and Post Sea Trial Approval

Validation of the upgrade requires sea trial data collection and CAMPAR analysis to be performed by a Caterpillar Certified Marine Analyst and approved by Caterpillar engineering.

A Manual Performance Sea Trial must be performed upon the completion of the emissions upgrade. Upgrade labels and plates will not be provided until acceptable Sea Trial results are posted to the Sea Trial Data Logger website. The Caterpillar Emissions Solutions (CES) Engineering must be notified via ASC.

Reference Marine Analyst Service Handbook, LEBV4830

Reference Paper copy of Manual Sea Trial Guide, LEXM0581, "Manual Performance Sea Trial" from the EMC website.

Perform the following steps:

Complete a Bollard or Free-Running Sea Trial and record the engine operating conditions with Cat ET and/or with the Manual Sea Trial Guide.

Utilize a calibrated set of fuel flow meters. Sized the meters appropriately to measure the flow rates in the fuel supply line and fuel return line. The difference of these two values is the fuel rate that will be entered into CAMPAR. The fuel rates must be measured with calibrated flow meters. Do not use the flow rates provided by the ECM.

Enter the results of the Manual Sea Trial into the CAMPAR Software.
1. Do not use the test spec that the software automatically associates with the engine serial number. The original spec is for the engine arrangement prior to the upgrade. The original spec will not provide the correct results.
1. Enter the spec number and the reference serial number provided by Caterpillar Emissions Solutions (CES) Engineering for this upgrade. Verify that the preview spec record locates the expected result.
1. Complete all pre-test information fields including the following information required to provide new labels:
  - Static Full Load Fuel Setting / Rated Fuel Position
  - Static Full Torque Fuel Setting
  - Measured Low Idle RPM
  - Measured High Idle RPM
  - Turbo Part Number
  - Injector Part Number
  Reference CAMPAR Software CD-ROM, LEXM7082
1. Complete the "Fuel Rate Table". The "Full Throttle" point must be at maximum throttle position. Record the remaining points at engine speeds in even 100 RPM increments. The suggested RPMs listed in the table are suggestions only. The actual engine speed does not have to equal the suggested speed. The RPM and fuel rate information in this section will be the primary basis for determining if the engine is operating correctly.
  Note: A data point at full throttle and full load must be included in the file submitted for review.

Show/hide table




Illustration 3	g02475589
Fuel rate table Typical example...

Analyze the data in order to determine if the fuel demand and propeller torque curves are within the CAMPAR database established operating zone.
1. If the curves are in this zone, the upgraded engine performance is acceptable.
1. If the curves are outside of this zone, adjust the engine accordingly and complete another CAMPAR to verify acceptable performance of the upgraded engine.
  Note: Refer to the Marine Analyst Service Handbook for more information about understanding the Fuel Rate Graph.

Review the CAMPAR report and verify that all other parameters are within the specification.

Post the results of the successful sea trial to the Sea Trial Data Logger Database for review by Caterpillar engineering.
1. Go to:
  https://cds.cat.com/seatrial/
  
  Enter the database
1. On the top of the page, select the "New Sea Trial" Option
1. Complete all informational fields
1. The attached sea trial results that must be included are as follows:
  - The ".par" file from CAMPAR
  - A copy of the CAMPAR report

Complete and submit the CAT Engine Upgrade Kit Label Request Form for 3500 Series Marine through the ASC.

Obtain validation data approval by Caterpillar engineering and the register the emissions upgrade in SIMSi correctly. Then, new engine plates and emissions labels will be sent to the address specified in the ASC request.

Labels

New labels will be sent to the address specified in the ASC request. Labels are sent after the validation data has been approved by Caterpillar engineering and the emissions upgrade has been registered in SIMS correctly.

Emissions Label

Show/hide table




Illustration 4	g02391405
Typical example of emissions label on valve cover (1) Emissions labels

Install emissions labels on the right hand rear valve cover, visible from the side of the engine. If that valve cover is not available, place labels on the next valve cover forward.

Show/hide table

NOTICE

Do not remove or cover existing factory emissions labels. Install the labels on the next available valve cover.

Engine Identification

The following section gives a brief overview of the locations of serial number plate and engine information plate.

Replace original plates with new plates after the performance is validated, SIMS is updated and new plates are received.

Engine Serial Number Plate

Install the new serial plate in the exact location of the original plate.

Show/hide table




Illustration 5	g00798278
(1) Location of the serial number plate

The serial number plate is on the left side of the cylinder block near the rear of the engine.

The following information is stamped on the serial number plate:

Engine serial number
Model
Arrangement number

Show/hide table




Illustration 6	g00123229
Typical serial number plate

Engine Information Plate

The new information plate will be placed on engine in the exact location of the original plate.

Show/hide table




Illustration 7	g00798277
(1) Location of the information plate

The information plate is on the left side top surface of the cylinder block in front of the front cylinder head.

The following information is stamped on the information plate:

Maximum altitude of the engine
Horsepower
High idle rpm
Full load rpm
Fuel settings
Other information

Show/hide table




Illustration 8	g00102789
Typical information plate

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

When performing a retrofit installation, record the vital information in Table 1.

Show/hide table

Table 1
Repair Date
Product Serial Number
Service Hours or Service Meter Units
Removed Component Part Number ⁽¹⁾
Removed Component Serial Number ⁽¹⁾
Installed Component Part Number ⁽²⁾
Installed Component Serial Number ⁽³⁾

Show/hide table

^( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
^( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
^( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

Update the product configuration by entering the information from Table 1 into SIMSi and AIMS.

For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".

Upgrade from Mechanical Unit Injection to Electronic Unit Injection

The steps that are required to upgrade the engine to an electronic unit injection with an upgrade kit are listed in this section.

This Special Instruction does not include all of the procedures that can be found in your existing manuals. Refer to the Service Manuals, Parts Manuals, and Operation and Maintenance Manuals for the original and upgraded engine arrangements for more information.

The kit needed for the needed upgrade is serial number specific. Contact the ASC for more information.

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Start the emissions upgrade by disassembling the engine for a complete rebuild. Rebuild the engine by installing the core engine components. The rebuild is to be completed with the following Cat parts:

New and remanufactured Cat replacement parts
Cat parts that have been approved by the Reuse/Salvage guidelines

Reference Refer to Disassembly and Assembly, SENR6564, "3500B Engines".

Follow the steps that are listed below in order to complete the emissions upgrade.

Show/hide table




Illustration 9	g01897135
Typical example of cover

Remove the front housing cover from the front left side of the engine.
1. Install the mounting bracket for the Electronic Control Module (ECM) in the location of the removed cover assembly.
1. Install the ECM on the bracket. Reference Step 1.a.
  Reference Disassembly and Assembly, SENR6564, "Electronic Control Module (Engine) - Remove and Install", "Installation Procedure".

Show/hide table




Illustration 12	g01897115

Remove the mechanical governor.

Install the cover assembly from the left side of the engine to this location if a new cover is not in the kit.

Show/hide table




Illustration 13	g01893937
Typical example of rear gear group

Install the rear gear group.
Reference Disassembly and Assembly, SENR6564, "Gear Group (Rear) - Install"

Show/hide table




Illustration 14	g01894176
Typical example of an installed camshaft bearing

Install the camshaft bearings.
Reference Disassembly and Assembly, SENR6564, "Camshaft Bearings - Install"

Show/hide table




Illustration 15	g01894179
View of camshaft and installation tool

Install the camshaft.
Reference Disassembly and Assembly, SENR6564, "Camshaft - Install"

Show/hide table




Illustration 16	g01894182
Typical example of the flywheel housing

Install the flywheel housing.
Reference Disassembly and Assembly, SENR6564, "Flywheel Housing - Install"

Show/hide table




Illustration 17	g01894237
Typical example of the rear seal

Install the rear seal and the wear sleeve for the crankshaft.
Reference Disassembly and Assembly, SENR6564, "Crankshaft Rear Seal and Wear Sleeve - Install"

Install the flywheel.
Reference Disassembly and Assembly, SENR6564, "Flywheel - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 18	g01894267
Typical example of installed cylinder liners

Check the liner projection and install the cylinder liners.
Reference Disassembly and Assembly, SENR6564, "Cylinder Liner - Install"

Install the piston and connecting rods.
Reference Disassembly and Assembly, SENR6564, "Pistons and Connecting Rods - Install"

Install the piston cooling jets.
Reference Disassembly and Assembly, SENR6564, "Piston Cooling Jets - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 19	g01894595
View of plate that is mounted to the top of the cylinder block

Install the plate on top of cylinder block.

Show/hide table




Illustration 20	g01895193
Typical example of the water regulator housing

Install the new regulator housing.

Show/hide table




Illustration 21	g01895217
Typical example of the aftercooler housing

Install the aftercooler housing.

Assemble the cylinder heads.
Reference Disassembly and Assembly, SENR6564, "Cylinder Head - Assemble", "Assembly Procedure"

Show/hide table




Illustration 22	g01895239
Typical example of the cylinder head

Install the cylinder heads.
Reference Disassembly and Assembly, SENR6564, "Cylinder Head - Install", "Installation Procedure"
1. Attach the air intake manifold to the aftercooler housing.
  Reference Disassembly and Assembly, SENR6564, "Air Inlet Manifold - Remove and Install", "Installation Procedure"
1. Install the exhaust bellows to the exhaust elbows.
  Reference Disassembly and Assembly, SENR6564, "Exhaust Manifold - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 24	g01896085
Typical example of electronic unit injector

Record the trim codes and install the electronic unit injectors.
Reference Disassembly and Assembly, SENR6564, "Electronic Unit Injector - Install", "Installation Procedure"

Show/hide table




Illustration 25	g01895573
Typical example of valve cover base

Assemble the valve cover base.
1. Install the rocker arm supports as the supports are shown in Illustration 25.
1. Install the connector as the connector is shown in Illustration 25.
1. Connect the harness to the connector.
1. Route the harness in the trough as the harness is shown in Illustration 25.

Install the valve cover base.
Reference Disassembly and Assembly, SENR6564, "Valve Cover Base - Remove and Install", "Installation Procedure"

Assemble the rocker shaft assembly.
Reference Disassembly and Assembly, SENR6564, "Rocker Shaft - Assemble", "Assembly Procedure"

Install the rocker shaft assembly and the pushrods.
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft and Push Rods - Install", "Installation Procedure"
Reference Specifications, SENR6562, "Valve Mechanism"

Set the injector height.
1. For the correct injector settings refer to the reference test spec and the service manual for the reference serial number.

Set the valve lash.

Install the valve covers.
Reference Disassembly and Assembly, SENR6564, "Valve Cover - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 26	g01938054
Typical example of installed covers

Install original covers to the left side of the engine.

Show/hide table




Illustration 27	g01981846
Typical example of cover with sensor

Install the original covers and the new cover with the sensor port to the right side of the engine.

Show/hide table




Illustration 28	g01897576
Typical example of fuel lines

Install the fuel lines.

Install the aftercooler.
Reference Disassembly and Assembly, SENR6564, "Aftercooler - Remove and Install", "Installation Procedure"
Note: Be careful not to damage the fins on the aftercooler core.
Note: The 3508 and 3512 Engines have one aftercooler. The 3516 Engines have two aftercoolers.

Show/hide table




Illustration 29	g02255996

Install the water manifold tee fitting before installing the after cooler.

Show/hide table




Illustration 30	g01897033
Typical example of water manifolds

Install the water manifolds.

Install the oil pump.
Reference Disassembly and Assembly, SENR6564, "Engine Oil Pump - Install", "Installation Procedure"

Install the fuel transfer pump.
Reference Disassembly and Assembly, SENR6564, "Fuel Transfer Pump - Install", "Installation Procedure"

Install the oil cooler.
Reference Disassembly and Assembly, SENR6564, "Engine Oil Cooler - Install", "Installation Procedure"

Show/hide table




Illustration 31	g01897169
Typical example of the separate circuit aftercooler

Install the separate circuit aftercooler.
Reference Disassembly and Assembly, SENR6564, "Water Pump (Separate Circuit Aftercooler) - Install", "Installation Procedure"

Show/hide table




Illustration 32	g01897334
Typical example of the exhaust elbow (1) Exhaust elbow (2) Mounting bracket for the exhaust elbow (3) Coolant tube for the aftercooler

Install the exhaust elbow for the turbochargers.
Note: Exhaust elbow (1) must be installed before the coolant tube for the aftercooler (3) .
Reference Disassembly and Assembly, SENR6564, "Exhaust Elbow - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 33	g01897421
Typical example of the installed turbochargers

Install the turbochargers to the exhaust elbow.
Reference Disassembly and Assembly, SENR6564, "Turbocharger - Install - Rear Mounted Turbocharger", "Installation Procedure"
1. Install the turbocharger oil lines.
1. Install the coolant lines for the turbocharger.

Install the air cleaner assemblies.
Reference Disassembly and Assembly, SENR6564, "Air Cleaner - Remove and Install", "Installation Procedure"

Install the remaining lines groups for the fuel, oil, air, and the coolant.

Show/hide table




Illustration 34	g01898693
Typical example of ECM bracket

Install the bracket for the ECM on the right-hand side of the engine as the bracket is shown in Illustration 34.
1. Install the ECM on the bracket in Step 40.
  Reference Disassembly and Assembly, SENR6564, "3500B Engines", "Electronic Control Module (Engine) - Remove and Install"
  ReferenceTroubleshooting, SENR1008, "3500B Marine Engines", "Replacing the ECM"

Install the harness assembly to the engine.
Reference Schematic, RENR1297, "3500B Engine for Marine Propulsion Electrical System"

The following requirements are to be completed after the upgrade is complete:

Complete the required software flash. Refer to the reference test spec for file number.
Prepare the engine for service.
Complete the required performance checks.
Complete the Sea Trial.
Complete the CAMPAR report.
Register the retrofit
Complete and submit Label Request Form

Upgrade from Mechanical Unit Injection to Tier 1

The steps that are required to upgrade the engine from mechanical unit injection to Tier 1 emissions are listed in this section. Additional upgrades are covered in other sections.

The kit needed for the needed upgrade is serial number specific. Contact the ASC for more information.

New and/or remanufactured Cat replacement parts
Cat parts that have been approved by the Reuse/Salvage guidelines

Reference Refer to Disassembly and Assembly manual for the engine that is being overhauled.

Follow the steps that are listed below in order to complete the emissions upgrade.

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table




Illustration 36	g01897135
Typical example of cover

Remove the front housing cover from the front left side of the engine.
1. Install the mounting bracket for the Electronic Control Module (ECM) in the location of the removed cover assembly.
1. Install the ECM on the bracket. Reference Step 1.a.
  Reference Disassembly and Assembly, SENR6564, "Electronic Control Module (Engine) - Remove and Install", "Installation Procedure".

Show/hide table




Illustration 39	g01897115

Remove the mechanical governor.

Install the cover assembly from the left side of the engine to this location if a new cover is not in the kit.

Show/hide table




Illustration 40	g01893937
Typical example of rear gear group

Install the rear gear group.
Reference Disassembly and Assembly, SENR6564, "Gear Group (Rear) - Install"

Show/hide table




Illustration 41	g01894176
Typical example of an installed camshaft bearing

Install the camshaft bearings.
Reference Disassembly and Assembly, SENR6564, "Camshaft Bearings - Install"

Show/hide table




Illustration 42	g01894179
View of camshaft and installation tool

Install the camshaft.
Reference Disassembly and Assembly, SENR6564, "Camshaft - Install"

Show/hide table




Illustration 43	g01894182
Typical example of the flywheel housing

Install the flywheel housing.
Reference Disassembly and Assembly, SENR6564, "Flywheel Housing - Install"

Show/hide table




Illustration 44	g01894237
Typical example of the rear seal

Install the rear seal and the wear sleeve for the crankshaft.
Reference Disassembly and Assembly, SENR6564, "Crankshaft Rear Seal and Wear Sleeve - Install"

Install the flywheel.
Reference Disassembly and Assembly, SENR6564, "Flywheel - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 45	g01894267
Typical example of installed cylinder liners

Check the liner projection and install the cylinder liners.
Reference Disassembly and Assembly, SENR6564, "Cylinder Liner - Install"

Install the piston and connecting rods.
Reference Disassembly and Assembly, SENR6564, "Pistons and Connecting Rods - Install"

Install the piston cooling jets.
Reference Disassembly and Assembly, SENR6564, "Piston Cooling Jets - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 46	g01894595
View of plate that is mounted to the top of the cylinder block

Install the plate on top of cylinder block.

Show/hide table




Illustration 47	g01895193
Typical example of the water regulator housing

Install the new regulator housing.

Show/hide table




Illustration 48	g01895217
Typical example of the aftercooler housing

Install the aftercooler housing.

Assemble the cylinder heads.
Reference Disassembly and Assembly, SENR6564, "Cylinder Head - Assemble", "Assembly Procedure"

Show/hide table




Illustration 49	g01895239
Typical example of the cylinder head

Install the cylinder heads.
Reference Disassembly and Assembly, SENR6564, "Cylinder Head - Install", "Installation Procedure"
1. Attach the air intake manifold to the aftercooler housing.
  Reference Disassembly and Assembly, SENR6564, "Air Inlet Manifold - Remove and Install", "Installation Procedure"
1. Install the exhaust bellows to the exhaust elbows.
  Reference Disassembly and Assembly, SENR6564, "Exhaust Manifold - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 51	g01896085
Typical example of electronic unit injector

Record the trim codes and install the electronic unit injectors.
Reference Disassembly and Assembly, SENR6564, "Electronic Unit Injector - Install", "Installation Procedure"

Show/hide table




Illustration 52	g01895573
Typical example of valve cover base

Assemble the valve cover base.
1. Install the rocker arm supports as the supports are shown in Illustration 52.
1. Install the connector as the connector is shown in Illustration 52.
1. Connect the harness to the connector.
1. Route the harness in the trough as the harness is shown in Illustration 52.

Install the valve cover base.
Reference Disassembly and Assembly, SENR6564, "Valve Cover Base - Remove and Install", "Installation Procedure"

Assemble the rocker shaft assembly.
Reference Disassembly and Assembly, SENR6564, "Rocker Shaft - Assemble", "Assembly Procedure"

Install the rocker shaft assembly and the pushrods.
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft and Push Rods - Install", "Installation Procedure"
ReferenceSpecifications, SENR6562, "Valve Mechanism"

Set the injector height.
1. For the correct injector settings refer to the reference test spec and the service manual for the reference serial number.

Set the valve lash.

Install the valve covers.
Reference Disassembly and Assembly, SENR6564, "Valve Cover - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 53	g01938154
Typical example of cover with sensor

Install original covers and the new cover with the sensor port to the left side of the engine.

Show/hide table




Illustration 54	g01938115
Typical example of cover with sensor

Install the original covers and the new cover with the sensor port to the right side of the engine.

Show/hide table




Illustration 55	g01897576
Typical example of fuel lines

Install the fuel lines.

Install the aftercooler.
Reference Disassembly and Assembly, SENR6564, "Aftercooler - Remove and Install", "Installation Procedure"
Note: Be careful not to damage the fins on the aftercooler core.
Note: The 3508 and 3512 Engines have one aftercooler. The 3516 Engines have two aftercoolers.

Show/hide table




Illustration 56	g02255996

Install the water manifold tee fitting before installing the aftercooler.

Show/hide table




Illustration 57	g01897033
Typical example of water manifolds

Install the water manifolds.

Install the oil pump.
Reference Disassembly and Assembly, SENR6564, "Engine Oil Pump - Install", "Installation Procedure"

Install the fuel transfer pump.
Reference Disassembly and Assembly, SENR6564, "Fuel Transfer Pump - Install", "Installation Procedure"

Install the oil cooler.
Reference Disassembly and Assembly, SENR6564, "Engine Oil Cooler - Install", "Installation Procedure"

Show/hide table




Illustration 58	g01897169
Typical example of the separate circuit aftercooler

Install the separate circuit aftercooler.
Reference Disassembly and Assembly, SENR6564, "Water Pump (Separate Circuit Aftercooler) - Install", "Installation Procedure"

Show/hide table




Illustration 59	g01897334
Typical example of the exhaust elbow (1) Exhaust elbow (2) Mounting bracket for the exhaust elbow (3) Coolant tube for the aftercooler

Install the exhaust elbow for the turbochargers.
Note: Exhaust elbow (1) must be installed before the coolant tube for the aftercooler (3) .
Reference Disassembly and Assembly, SENR6564, "Exhaust Elbow - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 60	g01897421
Typical example of the installed turbochargers

Install the turbochargers to the exhaust elbow.
Reference Disassembly and Assembly, SENR6564, "Turbocharger - Install - Rear Mounted Turbocharger", "Installation Procedure"
1. Install the turbocharger oil lines.
1. Install the coolant lines for the turbocharger.

Install the air cleaner assemblies.
Reference Disassembly and Assembly, SENR6564, "Air Cleaner - Remove and Install", "Installation Procedure"

Install the remaining lines groups for the fuel, oil and coolant.

Show/hide table




Illustration 61	g01943265
Typical example of ECM bracket location

Install the bracket for the ECM on the left-hand side of the engine as the bracket is shown in Illustration 61.
1. Install the ECM on the bracket in Step 40.
  Reference Troubleshooting, SENR1008, "3500B Marine Engines", "Replacing the ECM"

Show/hide table




Illustration 63	g01937307
Typical example of control box

Install the control box to the right rear mounting blocks.
1. Install the new rigid wire harness assemblies on both the left and the right sides of the engine.
  Reference Schematic, RENR1297, "3500B Engine for Marine Propulsion Electrical System"

The following requirements are to be completed after the upgrade is complete:

Complete the required software flash. Refer to the reference test spec for file number.
Prepare the engine for service.
Complete the required performance checks.
Complete the sea trial.
Complete the CAMPAR report.
Register the retrofit
Complete and submit the Label Request Form

Upgrade from Mechanical Unit Injection to Tier 2

The steps that are required to upgrade the engine from mechanical unit injection to Tier 2 emissions are listed in this section. Additional upgrades are covered in other sections.

The kit needed for the needed upgrade is serial number specific. Contact the ASC for more information.

New and/or remanufactured Cat replacement parts
Cat parts that have been approved by the Reuse/Salvage guidelines

Reference Refer to Disassembly and Assembly manual for the engine that is being overhauled.

Follow the steps that are listed below in order to complete the emissions upgrade.

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table




Illustration 66	g01897135
Typical example of cover

Remove the front housing cover from the front left side of the engine.
1. Install the mounting bracket for the Electronic Control Module (ECM) in the location of the removed cover assembly.
1. Install the ECM on the bracket. Reference Step 1.a.
  Reference Disassembly and Assembly, KENR6055, "Electronic Control Module (Engine) - Remove and Install", "Installation Procedure".

Show/hide table




Illustration 69	g01897115

Remove the mechanical governor.

Install the cover assembly from the left side of the engine to this location if a new cover is not in the kit.

Show/hide table




Illustration 70	g01893937
Typical example of rear gear group

Install the rear gear group.
Reference Disassembly and Assembly, KENR6055, "Gear Group (Rear) - Install"

Show/hide table




Illustration 71	g01894176
Typical example of an installed camshaft bearing

Install the camshaft bearings.
Reference Disassembly and Assembly, KENR6055, "Camshaft Bearings - Install"

Show/hide table




Illustration 72	g01894179
View of camshaft and installation tool

Install the camshaft.
Reference Disassembly and Assembly, KENR6055, "Camshaft - Install"

Show/hide table




Illustration 73	g01894182
Typical example of the flywheel housing

Install the flywheel housing.
Reference Disassembly and Assembly, KENR6055, "Flywheel Housing - Install"

Show/hide table




Illustration 74	g01894237
Typical example of the rear seal

Install the rear seal and the wear sleeve for the crankshaft.
Reference Disassembly and Assembly, KENR6055, "Crankshaft Rear Seal and Wear Sleeve - Install"

Install the flywheel.
Reference Disassembly and Assembly, KENR6055, "Flywheel - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 75	g01894267
Typical example of installed cylinder liners

Check the liner projection and install the cylinder liners.
Reference Disassembly and Assembly, KENR6055, "Cylinder Liner - Install"

Install the piston and connecting rods.
Reference Disassembly and Assembly, KENR6055, "Pistons and Connecting Rods - Install"

Install the piston cooling jets.
Reference Disassembly and Assembly, KENR6055, "Piston Cooling Jets - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 76	g01894595
View of plate that is mounted to the top of the cylinder block

Install the plate on top of cylinder block.

Show/hide table




Illustration 77	g01895193
Typical example of the water regulator housing

Install the new regulator housing.

Show/hide table




Illustration 78	g01895217
Typical example of the aftercooler housing

Install the aftercooler housing.

Assemble the cylinder heads.
Reference Disassembly and Assembly, KENR6055, "Cylinder Head - Assemble", "Assembly Procedure"

Show/hide table




Illustration 79	g01895239
Typical example of the cylinder head

Install the cylinder heads.
Reference Disassembly and Assembly, KENR6055, "Cylinder Head - Install", "Installation Procedure"
1. Attach the air intake manifold to the aftercooler housing.
  Reference Disassembly and Assembly, KENR6055, "Air Inlet Manifold - Remove and Install", "Installation Procedure"
1. Install the exhaust bellows to the exhaust elbows.
  Reference Disassembly and Assembly, KENR6055, "Exhaust Manifold - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 81	g01896085
Typical example of electronic unit injector

Record the trim codes and install the electronic unit injectors.
Reference Disassembly and Assembly, KENR6055, "Electronic Unit Injector - Install", "Installation Procedure"

Show/hide table




Illustration 82	g01895573
Typical example of valve cover base

Assemble the valve cover base.
1. Install the rocker arm supports as the supports are shown in Illustration 82.
1. Install the connector as the connector is shown in Illustration 82.
1. Connect the harness to the connector.
1. Route the harness in the trough as the harness is shown in Illustration 82.

Install the valve cover base.
Reference Disassembly and Assembly, KENR6055, "Valve Cover Base - Remove and Install", "Installation Procedure"

Assemble the rocker shaft assembly.
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft - Assemble", "Assembly Procedure"

Install the rocker shaft assembly and the pushrods.
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft and Push Rods - Install", "Installation Procedure"
Reference Specifications, KENR5402, "Valve Mechanism"
Note: The firing order of the engine will change when the engine is upgraded to a Tier II kit.
Reference Testing and Adjusting, KENR5403, "3500C Marine Engines ", "Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting"

Set the injector height.
1. For the correct injector settings refer to the reference test spec and the service manual for the reference serial number.

Set the valve lash.

Install the valve covers.
Reference Disassembly and Assembly, KENR6055, "Valve Cover - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 83	g01938154
Typical example of cover with sensor

Install original covers and the new cover with the sensor port to the left side of the engine.

Show/hide table




Illustration 84	g01938115
Typical example of cover with sensor

Install the original covers and the new cover with the sensor port to the right side of the engine.

Show/hide table




Illustration 85	g01897576
Typical example of fuel lines

Install the fuel lines.

Install the aftercooler.
Reference Disassembly and Assembly, KENR6055, "Aftercooler - Remove and Install", "Installation Procedure"
Note: Be careful not to damage the fins on the aftercooler core.
Note: The 3508 and 3512 Engines have one aftercooler. The 3516 Engines have two aftercoolers.

Show/hide table




Illustration 86	g02255996

Install the water manifold tee fitting before installing the aftercooler.

Show/hide table




Illustration 87	g01897033
Typical example of water manifolds

Install the water manifolds.

Install the oil pump.
Reference Disassembly and Assembly, KENR6055, "Engine Oil Pump - Install", "Installation Procedure"

Install the fuel transfer pump.
Reference Disassembly and Assembly, KENR6055, "Fuel Transfer Pump - Install", "Installation Procedure"

Install the oil cooler.
Reference Disassembly and Assembly, KENR6055, "Engine Oil Cooler - Install", "Installation Procedure"

Show/hide table




Illustration 88	g01897169
Typical example of the separate circuit aftercooler

Install the separate circuit aftercooler.
Reference Disassembly and Assembly, KENR6055, "Water Pump (Separate Circuit Aftercooler) - Install", "Installation Procedure"

Show/hide table




Illustration 89	g01897334
Typical example of the installed exhaust elbow (1) Exhaust elbow (2) Mounting bracket for the exhaust elbow (3) Coolant tube for the aftercooler

Install the exhaust elbow for the turbochargers.
Note: Exhaust elbow (1) must be installed before the coolant tube for the aftercooler (3) .
Reference Disassembly and Assembly, KENR6055, "Exhaust Elbow - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 90	g01897421
Typical example of installed turbochargers

Install the turbochargers to the exhaust elbow.
Reference Disassembly and Assembly, KENR6055, "Turbocharger - Install - Rear Mounted Turbocharger", "Installation Procedure"
1. Install the turbocharger oil lines.
1. Install the coolant lines for the turbocharger.

Install the air cleaner assemblies.
Reference Disassembly and Assembly, KENR6055, "Air Cleaner - Remove and Install", "Installation Procedure"

Install the remaining lines groups for the fuel, oil, and the coolant., fuel lines and coolant lines.

Show/hide table




Illustration 91	g01943265
Typical example of ECM bracket location

Install the bracket for the ECM on the left-hand side of the engine as the bracket is shown in Illustration 91.
1. Install the ECM on the bracket in Step 40.
  Reference Troubleshooting, KENR5404, "3500C Marine Propulsion Engines", "ECM - Replace"

Show/hide table




Illustration 93	g01937307
Typical example of control box

Install the control box to the right rear mounting blocks.
1. Install the new rigid wire harness assemblies on both the left and the right sides of the engine.
  Reference Schematic, KENR5406, "3500C Series II Engine For Marine Propulsion Electrical System"

The following requirements are to be completed after the upgrade is complete:

Complete the required software flash. Refer to the reference test spec for file number.
Prepare the engine for service.
Complete the required performance checks.
Complete the sea trial.
Complete the CAMPAR report.
Register the retrofit
Complete and submit Label Request Form

Upgrade from Electronic Engine (Unregulated, IMO I or Tier 1) to Tier 2

The steps that are required to upgrade the engine from unregulated electronic, IMO I or Tier 1 to Tier 2 emissions are listed in this section. Additional upgrades are covered in other sections.

The kit needed for the needed upgrade is serial number specific. Contact the ASC for more information.

New and/or remanufactured Cat replacement parts
Cat parts that have been approved by the Reuse/Salvage guidelines

Reference Refer to Disassembly and Assembly manual for the engine that is being overhauled.

Before beginning this procedure, document all customer specified parameters from the ECM.

Reference Troubleshooting, KENR5404, "3500C Marine Propulsion Engines"

Follow the steps that are listed below in order to complete the emissions upgrade.

Remove the harness assembly from the engine.
Reference Schematic, RENR1297, "3500B Engine for Marine Propulsion Electrical System"

Show/hide table




Illustration 96	g01937305
View of ECM at the front housing

Remove ECM from the front left front cover of engine.

Show/hide table




Illustration 97	g01937795
View of ECM on the left side of the engine

Remove the ECM from left side of the engine.
1. Remove the bracket for the ECM in Step 3.
  Reference Disassembly and Assembly, SENR6564, "3500B Engines", "Electronic Control Module (Engine) - Remove and Install"
  Reference Troubleshooting, SENR1008, "3500B Marine Engines", "Replacing the ECM"

Remove the lines groups for the fuel, oil, air, and the coolant.

Remove the air cleaner assemblies.
Reference Disassembly and Assembly, SENR6564, "Air Cleaner - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 98	g01937236
View of the removal of the turbochargers

Remove the turbochargers from the exhaust elbow.
Reference Disassembly and Assembly, SENR6564, "Turbocharger - Install - Rear Mounted Turbocharger", "Installation Procedure"

Remove the coolant tube for the aftercooler.

Show/hide table




Illustration 99	g01937253
View of removed exhaust elbow

Remove the exhaust elbow for the turbochargers.
Reference Disassembly and Assembly, SENR6564, "Exhaust Elbow - Remove and Install", "Installation Procedure"

Remove the exhaust manifolds and the heat shields.

Remove the aftercooler assembly and the housings.

Remove the oil cooler.

Show/hide table




Illustration 100	g01944754
Typical example of engine with removed covers from the cylinder head and block

Remove the covers from both the left and the right side of the engine.

Show/hide table




Illustration 101	g01944738
Typical view of removed valve covers

Remove the valve covers.
Reference Disassembly and Assembly, SENR6564, "Valve Cover - Remove and Install", "Removal Procedure"

Remove the rocker shaft assemblies.
Reference Disassembly and Assembly, SENR6564, "Rocker Shaft and Push Rods - Remove", "Removal Procedure"

Remove the unit injectors.
Reference Disassembly and Assembly, SENR6564, "Electronic Unit Injector - Remove", "Removal Procedure"

Remove the valve cover bases.
Reference Disassembly and Assembly, SENR6564, "Valve Cover Base - Remove and Install", "Removal Procedure"

Remove the cylinder heads.
Reference Disassembly and Assembly, SENR6564, "Cylinder Head - Remove", "Removal Procedure"

Remove the camshafts.
Reference Disassembly and Assembly, SENR6564, "Camshaft - Remove", "Removal Procedure"

Remove the camshaft bearings.
Reference Disassembly and Assembly, SENR6564, "Camshaft Bearings - Remove", "Removal Procedure"

Remove the piston and rods.
Reference Disassembly and Assembly, SENR6564, "Pistons and Connecting Rods - Remove", "Removal Procedure"

Install the new camshaft bearings.
Reference Disassembly and Assembly, KENR6055, "Camshaft Bearings - Install", "Installation Procedure"

Install the new camshafts.
Reference Disassembly and Assembly, KENR6055, "Camshaft - Install", "Installation Procedure"

Show/hide table




Illustration 102	g01938154
Typical example of cover with sensor

Install original covers and the new cover with the sensor port to the left side of the engine.

Show/hide table




Illustration 103	g01938115
Typical example of cover with sensor

Install the original covers and the new cover with the sensor port to the right side of the engine.

Install the new piston and rod group.
Reference Disassembly and Assembly, KENR6055, "Pistons and Connecting Rods - Install", "Installation Procedure"

Show/hide table




Illustration 104	g01944793
Typical example of cover

Install the original access covers to both the left side and the right side of the block.

Install the new cylinder heads.
Reference Disassembly and Assembly, KENR6055, "Cylinder Head - Install", "Installation Procedure"

Record the trim codes and install the new electronic fuel injectors.
Reference Disassembly and Assembly, KENR6055, "Electronic Unit Injector - Install", "Installation Procedure"

Install the valve cover bases.
Reference Disassembly and Assembly, KENR6055, "Valve Mechanism Cover Base - Remove and Install", "Installation Procedure"

Assemble and install the new rocker shaft assemblies.
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft - Assemble", " Assembly Procedure"
Reference Disassembly and Assembly, KENR6055, "Rocker Shaft and Pushrod - Install", "Installation Procedure"

Set the injector height.
1. For the correct injector settings refer to the reference test specification and the service manual for the reference serial number.

Set the valve lash.

Install the valve covers.
Reference Disassembly and Assembly, KENR6055, "Valve Cover - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 105	g01897334
Typical example of the installed exhaust elbow (1) Exhaust elbow (2) Mounting bracket for the exhaust elbow (3) Coolant tube for the aftercooler

Install the new exhaust elbow for the turbochargers.
Note: Exhaust elbow (1) must be installed before the coolant tube for the aftercooler (3) .
Reference Disassembly and Assembly, SENR6564, "Exhaust Elbow - Remove and Install", "Installation Procedure"

Install coolant tube (3) for the aftercooler.

Install the new turbochargers to the exhaust elbow.
Reference Disassembly and Assembly, SENR6564, "Turbocharger - Install - Rear Mounted Turbocharger", "Installation Procedure"
1. Install the new turbocharger oil lines.
1. Install the new coolant lines for the turbocharger.

Install the remaining lines groups for the fuel, oil, air, and the coolant.

Install the air cleaner assemblies.
Reference Disassembly and Assembly, SENR6564, "Air Cleaner - Remove and Install", "Installation Procedure"

Show/hide table




Illustration 106	g01937283
Typical example of ECM bracket location

Show/hide table




Illustration 107	g01937795
Typical example of ECM

Install the new ECM and the bracket to left side of engine.

Show/hide table




Illustration 108	g01937305
Typical example of ECM

Install the second ECM to the mounting bracket on the front housing.
Reference Disassembly and Assembly, SENR6564, "Electronic Control Module (Engine) - Remove and Install", "Installation Procedure".

Show/hide table




Illustration 109	g01937307
Typical example of control box

Install the control box to the right rear mounting blocks.
1. Install the new rigid wire harness assemblies on both the left and the right sides of the engine.

The following requirements are to be completed after the upgrade is complete:

Complete the required software flash. Refer to the reference test spec for file number.
Prepare the engine for service.
Complete the required performance checks.
Complete the sea trial.
Complete the CAMPAR report.
Register the retrofit
Complete and submit Label Request Form