PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR SHUTOFF PROXIMITY SENSORS ON CERTAIN 3512C OIL WELL SERVICE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR SHUTOFF PROXIMITY SENSORS ON CERTAIN 3512C OIL WELL SERVICE ENGINES

Usage:

REBE7518-03

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04Jan2012

(Revised 18Jul2012)

U-5

D-5

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING AIR SHUTOFF PROXIMITY SENSORS ON CERTAIN 3512C OIL WELL SERVICE ENGINES
1078		PS43477

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43477" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 04Jan2012 (Revised 03Feb2012) Service Letter. A change has been made to the Termination Date.

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TERMINATION DATE

31Jul2012

PROBLEM

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This engine currently does not have proximity sensors installed.

AFFECTED PRODUCT

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Model	Identification Number
3512C HD	R1S00100-00876

PARTS NEEDED

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Qty	Part Number	Description
2	5P9757	SEAL-O-RING
2	3719531	SENSOR GP-ENGINE
1	3727324	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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1.) Remove the ECM cover on left J1 connector by removing four screws. (Image1.1.1)

2.) Expose the wires and remove the rubber grommet. (Image1.1.2) and (Image1.1.3)

3.) Use a long allen wrench tool to remove the 70 pin connector from the ECM. (Image1.1.4)

4.) Pull the entire connector away from the ECM so the wires can be removed and added. Remove wires from pin location 55 and 56 with a wire removal tool. (Image1.1.5)

5.) Remove the plug from pin location 67 using an allen wrench tool to by gently pushing through the front of the connector and pushing the plug out of the back. (Image1.1.6)

6.) Tape off loose the wires that were just removed from pin location 55 and 56 and push the wires back into wire bundle. Use UL rated electrical tape. (Image1.1.7)

7.) Route the new jumper harness along the existing engine harness from front to back. Stay clear of all tubes and parts. String the jumper with the three sockets toward the ECM and the two connectors towards the air shutoff valves on the air inlet. (Image1.1.8)

8.) Insert the red wire into pin location 55, the black wire into pin location 67 and the orange wire into pin location 56. Insert the wires completely until they click. Then tug the wires gently to ensure the sockets are locked into place.

9.) Assemble the connector with the rubber grommet and cover and attach the connector to the ECM. Please note the jumper harness will not fit inside the rubber grommet. (Image1.1.9) There are no clearance issues with fastening the cover to the ECM connector. (Image1.1.10)

10.) Remove the plug from the air shutoff valves. (Image1.1.11) Please note that the plug is located on the bottom of the air shutoff valve on the left hand side of the engine, and on the top of the air shutoff valve on the right hand side of the engine.

11.) Install 5P-9757 O-ring over the threads of the sensor. Apply petroleum jelly on the O-ring and screw the 371-9531 Sensor into the port. The sensor will have a pigtail with a 3 pin connector. (Image1.1.12 and Image1.1.13)

12.) Connect sensor pigtails to the jumper harness and zip tie accordingly. Use the existing ladder clips and add ladder clips if necessary.

13.) Zip tie the jumper harness to the existing engine harness placing zip ties every 12 inches. The jumper harness is longer than required. Look for an area to bundle the jumper harness together. (Image1.1.14)

14.) Connect to the engine's ECM via CAT ET and navigate to the configuration screen. Select expand all and move to "Air Intake Shutoff Detection Installation Status." Double click on "Not Installed" and change it to "Installed."