PRODUCT IMPROVEMENT PROGRAM FOR REMOVING AIR SHUTOFF SYSTEM FROM CERTAIN 3508B, 3512B, AND 3516B ENGINES Caterpillar

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

1. Engines operate in a combustible environment i.e. well service or drill rig application.
2. Air shutoff valves are specifically required by a sanctioning society.

When installing new air shutoff valves, use existing support brackets and hardware (except for 3516B engines with ABB turbos, order the brackets listed in chart above). After installation of the air shutoff valves is completed, apply a coating of anti-seize to the threaded portion of the 2277483 switches, install and torque to 10 lbs ft.

1. Find the 40 pin "Customer connector" on the engine being serviced
2. Remove the two jumper wires from pins 33, 34, 20 and 21.
3. From the 2110194 switch harness, insert wire labeled "Shutdown C IN" into the 40 pin connector at location #33.
4. From the 2110194 switch harness, insert wire labeled "Shutdown D IN" into the 40 pin connector at location #34.
5. From the 2110194 switch harness, insert wire labeled "Shutdown C OUT" into the 40 pin connector at location #20.
6. From the 2110194 switch harness, insert wire labeled "Shutdown D OUT" into the 40 pin connector at location #21.

1. With engine operating at low idle and no load, unplug the right hand switch. Engine should shutdown and both air shutoffs should close. If engine did not shutdown check switch wiring, if engine did shutdown proceed to step 2.
2. Reconnect right hand switch and reset air shutoffs to the open position, restart engine and then unplug left hand switch. Engine should shutdown and both air shutoffs should close. If engine did not shutdown check switch wiring, if engine did shutdown proceed to step 3.
3. Reconnect left hand switch and reset both air shutoffs into the open position, testing is complete.

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure 1)
        (3-Rework Procedure 2)
        (4-Rework Procedure 3)
        (5-Rework Procedure 4)
        (6-Rework Procedure 5)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REMOVING AIR SHUTOFF SYSTEM

MODELS INVOLVED - CERTAIN 3508B, 3512B, AND 3516B ENGINES

Dear Caterpillar Product Owner:

New electronic overspeed protection device needs to be installed on the products listed below. Air shutoff valves on 3500B marine propulsion and auxiliary have experienced inadvertent closure or failure to close when required. Operating the engine with one air shutoff valve in the closed position may result in damage to the turbocharger and/or the air cleaner catching fire. All 3500B engines utilize the Engine Control Module (ECM) to monitor engine speed. In the event of an engine overspeed the ECM disables power to the electronic fuel injectors stopping the engine. With the removal of the air shutoff devices, Caterpillar will install a redundant electronic overspeed protection solution. This electronic overspeed protection solution contains no moving parts resulting in enhanced reliability and durability. In the event of an engine overspeed the newly installed electronic overspeed protection solution will provide redundant capability to interrupt all battery power to the ECM resulting in engine shutdown.

Contact your Caterpillar dealer if your engine operates in a combustible environment or regulations specifically require air shutoffs and new air shutoff devices will be installed. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter December 15, 2002 date when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.
 
 

Identification #(s)

Attached to December 15, 2002 Service Letter
 
 

Apply to Group 6, 7, 8, and 9 Engines:

Background: The current wiring for the 3500B Marine Auxiliary Standard Wiring control panel uses a partially effective method to shutoff the engine when the backup Electronic Speed Switch is required to act in place of the primary engine control. Currently, when the independent speed switch detects an overspeed event, the air shutoffs are activated but fuel from the ECM is not shut off. The procedure listed below will completely disable fuel injection by removing power from the engine control module. The change detailed in the procedure will also continue to shut the air doors if they are present. The wiring change takes less than 15 minutes and can be performed with basic hand tools and commonly available components.

Procedure:

1. Obtain a copy of 1328269?Diagram?Wiring Marine Aux, for reference to complete this modification.
2. In the control panel, locate the E-Stop switch contacts E-5 and E-7.
3. Using harness part number 2287319 connect between E-Stop Switch contact E-5 and the E-Stop Switch contact E-7.
4. Unplug and remove one-shot timer (part number 9X3207). See Photo 1 for details.

6. Check all wiring and install tie wraps as appropriate to restrain harness wire bundles.
7. Perform a system check by starting the engine and allowing the engine to reach operating RPM. Activate the electronic speed switch by pressing the Overspeed Verify button on the Electronic Speed Switch. The air shutoffs should activate if they are present and power will be removed from the ECM, disabling fuel injection.

Illustration 1 (Excerpt from 1328269)

Illustration 2 (Excerpt from 1328269)

Rework Procedure 2

Apply to Group 10 Engines:

Background: The current wiring for the 3500B Marine Auxiliary Premium Wiring control panel uses a partially effective method to shutoff the engine when the backup Electronic Speed Switch is required to act in place of the primary engine control. Currently, when the independent speed switch detects an overspeed event, the air shutoffs are activated but fuel from the ECM is not shut off. The procedure listed below will completely disable fuel injection by removing power from the engine control module. The change detailed in the procedure will also continue to shut the air doors if they are present. The wiring change takes less than 15 minutes and can be performed with basic hand tools and commonly available components.

Procedure:

1. Obtain a copy of 1336501 (12/16 cylinder) or 1417043 (8 cylinder)?Diagram (Premium Wiring)?Marine Aux, for reference to complete this modification.
2. In the control panel, locate the E-Stop switch contacts E-5 and E-8.
3. Using harness part number 2287320, connect between E-Stop Switch contact E-5 and the E-Stop Switch contact E-8.
4. Locate wire (F708-A119) installed on the Emergency Stop switch terminal E-5. Disconnect wire and cut off terminal. Install heat shrink 6V2690 and secure wire to harness. See Photo 1 and 2 for details.

Photo 1
 
 

Photo 2

6. Check all wiring and install tie wraps as appropriate to restrain harness wire bundles.
7. Perform a system check by starting the engine and allowing the engine to reach operating RPM. Activate the electronic speed switch by pressing the Overspeed Verify button on the Electronic Speed Switch. Power will be removed from the ECM, disabling fuel injection.

Engine Control Switch?E-Stop Switch, Premium Wired Marine Aux, 3500B Series Engine?Excerpt from 1477043.

Engine Control Switch-E-Stop Switch, Premium Wired Marine Aux, 3500B Series Engine?Excerpt from 1477043.

Apply to Group 1, 2, 3, and 4 Engines:

Background: The current wiring for the 3500B Marine Prop Standard Wiring control panel uses a partially effective method to shutoff the engine when the backup engine control is required to act in place of the primary engine control. Currently, when the independent backup engine control detects an overspeed event, the air shutoffs are activated but fuel control from both of the ECM?s is not shut off. The procedure listed below will completely disable fuel injection by removing power from the primary and secondary engine control modules. The change detailed in the procedure will only by applicable if the air doors are to be removed. The wiring change takes approximately one hour and can be performed with basic hand tools and commonly available components.

Procedure:

1. Obtain a copy of 1328103?Diagram?Wiring Marine Prop, for reference to complete this modification.
2. Locate the wire F708 YL installed in the Instrument Box Connector ?A? pin 15.
3. Remove the F708 YL wire from the connector and cut socket off of the wire.
4. Cover end of wire with heat shrink part number 6V2690 and secure wire to harness. As shown in Photo 1.

Photo 1

Photo 2

5. Install wire part number 2287321 from Instrument Box Connector ?A? pin 15 to the Emergency Stop switch terminal E-7. Also shown in Photo 1.
6. Disconnect wire F708?YL from the Emergency Stop switch terminal E-5. Cut off terminal and install heat shrink 6V2690 over end of wire. See Photo 2.

Illustration 1 (Excerpt from 1328103-Existing Wiring)

Illustration 2 (Excerpt from 1328103?Modified with changes)

7. Locate the E-Stop Lockout Relay (ESLR) and the E-Stop Relay (ESR).
8. Disconnect wires connected to ESR-86, ESLR-86, and ESLR-30.
9. Remove last two wires on the strand and install heat shrink part number 6V2690 to cover the exposed wire. Relabel remaining wire at both ends with Tag Wire Indent part number 2287324. For further details see Photo 3.

Photo 3

10. Install diode assembly part number 2287322 as shown in Photo 4.


NOTE: The diode should be installed with the bar (anode side) of the diode symbol on ESLR-86.
 
 




Photo 4

11. Install wire part number 2292852 from ESLR-30 to ESR-86.
12. Reattach wire from step 8 to the ESLR-86 terminal.

Illustration 1 (Excerpt from 1328103?Existing Wiring)

Illustration 2 (Excerpt from 1328103?Modified with changes)

13. Check all wiring and install tie wraps as appropriate to restrain harness wire bundles.
14. Perform a system check by starting the engine and allowing the engine to reach operating RPM. Activate the electronic speed switch by switching the Overspeed Verify switch located inside the control panel. Proper operation will remove power from both the primary and secondary ECM?s until the Engine Control switch is cycled to OFF/RESET. Power loss to the ECM"S can be detected easily be monitoring the ECM lights on the from of the instrument panel. Both of the lights will be off when the power is lost to the ECM?s.

Apply to Group 5 Engines:

Background: The current wiring for the 3500B Marine Prop Premium Wiring control panel uses a partially effective method to shutoff the engine when the backup engine control is required to act in place of the primary engine control. Currently, when the independent backup engine control detects an overspeed event, the air shutoffs are activated but fuel control from both of the ECM?s is not shut off. The procedure listed below will completely disable fuel injection by removing power from the primary and secondary engine control modules. The change detailed in the procedure will only by applicable if the air doors are to be removed. The wiring change takes approximately one hour and can be performed with basic hand tools and commonly available components.

Procedure:

1. Obtain a copy of 1336499?Diagram?Wiring Marine Prop 3512/16 or 1417042?Diagram?Wiring Marine Prop 3508, for reference to complete this modification.
2. Locate the wire (F708-A119) installed on the Emergency Stop switch terminal 5.
3. Remove the wire from the connector and cut terminal off of the wire.
4. Cover end of wire with heat shrink part number 6V2690 and secure wire to harness. For further details see Photos 1 and 2.

5. Install wire part number 2287320 from Emergency Stop switch terminal E-5 to the Emergency Stop switch terminal E-8. See Photo 3.

Photo 3

6. Locate the E-Stop Lockout Relay (ESLR) and the E-Stop Relay (ESR).
7. Disconnect wires connected to ESR-86, ESLR-86, and ESLR-30.
8. Remove wire (103A240) from the strand and install heat shrink part number 6V2690 to ends to cover the exposed wires. For further details see Photos 4 and 5.

Photo 4

Photo 5

9. Install diode assembly part number 2287322 as shown in photo 6.


NOTE: The diode should be installed with the bar (anode side) of the diode symbol on ESLR-86.

10. Install wire part number 2292852 from ESLR-30 to ESR-86.
11. Reattach wires (103A242) and (103A239). See Photos 6 and 7.

Illustration 3 (Excerpt from 1328103?Modified with changes)
 
 

Photo 6

12. Check all wiring and install tie wraps as appropriate to restrain harness wire bundles.
13. Perform a system check by starting the engine and allowing the engine to reach operating RPM. Activate the electronic speed switch by switching the Overspeed Verify switch located inside the control panel. Proper operation will remove power from both the primary and secondary ECM?s until the Engine Control switch is cycled to OFF / RESET. Power loss to the ECM"S can be detected easily be monitoring the ECM lights on the from of the instrument panel. Both of the lights will be off when the power is lost to the ECM?s.

Apply to Group 11 and 12 Engines:

Background: The current wiring for the 3500B Marine Auxiliary Standard Wiring control panel uses a partially effective method to shutoff the engine when the backup Electronic Speed Switch is required to act in place of the primary engine control. Currently, when the independent speed switch detects an overspeed event, the air shutoffs are activated but fuel from the ECM is not shut off. The procedure listed below will completely disable fuel injection by removing power from the engine control module. The change detailed in the procedure will also continue to shut the air doors if they are present. The wiring change takes less than 15 minutes and can be performed with basic hand tools and commonly available components.

Procedure:

1. Obtain a copy of 1269193?Diagram?Wiring Marine Prop, for reference to complete this modification. Sheet 2 of this procedure shows a partial drawing of sheet 1 of 1269193. Locate the E-Stop switch contact E-3.
2. Locate the E-Stop switch contact E-5 and E-6 that was added in PI10060. If this E-stop switch contact block does not exist, perform PI10060 before proceeding.
3. Locate the wire that connects the Emergency Stop Latching Relay (ESLR)?30 to terminal E-5 or E-6 of the Emergency Stop Switch contact.
4. Using harness 2287323, connect wire from E-3 to E-5 as shown in Illustration 1.
5. Unplug and remove one-shot timer (part number 9X3207). See Photo 1 for details.

7. Check all wiring and install tie wraps as appropriate to restrain harness wire bundles.
8. Perform a system check by starting the engine and allowing the engine to reach operating RPM. Activate the electronic speed switch by pressing the Overspeed Verify button on the Electronic Speed Switch. The air shutoffs should activate if they are present and power will be removed from the ECM, disabling fuel injection.