PRODUCT IMPROVEMENT PROGRAM FOR UPDATING AIR SHUTOFF VALVES ON CERTAIN 3512B OIL WELL SERVICING ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING AIR SHUTOFF VALVES ON CERTAIN 3512B OIL WELL SERVICING ENGINES

Usage:

SEBE8323-06

March 23, 2003
(Revised April 2004)
U-74
A-55
D-57
O-68

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING AIR SHUTOFF VALVES ON CERTAIN 3512B OIL WELL SERVICING ENGINES
1078		PI10222

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10222" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10222" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the March 23, 2003 (Revised February 2004) Service Letter. Changes have been made to the Affected Product.

PROBLEM

The air shutoff valves need to be updated on certain 3512B oil well servicing engines. Air shutoff valves on 3512B oil well servicing engines can be operated with one air shutoff valve in the closed position, which may result in air cleaner fires and turbocharger damage.

AFFECTED PRODUCT

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Model

Identification Number

3512B

2AF194-315

3ZW312, 321-323, 343, 349-351, 358-359

5XZ1018-1026

6RZ150-207, 356-426

PARTS NEEDED

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Qty	Part Number	Description
2	2277483	Switch
2	2296252	Stud
1	2296247	Gate (Right hand)
1	2296249	Gate (Left hand)
2	1507915	Retainer
2	2152711	Retainer
2	2155517	Knob
1	2152590	Screw (Spare)

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	3.0	0	0	0	0
NOTE: This is a 3.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

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

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR UPDATING AIR SHUTOFF VALVES

MODELS INVOLVED - CERTAIN 3512B OIL WELL SERVICING ENGINES

Dear Caterpillar Product Owner:

The air shutoff valves will need to be updated on the products listed below. Air shutoff valve gates may fail after repeated activations. Engines can be operated with one air shutoff valve in the closed position, which may result an air cleaner fire and turbocharger damage. This update will be performed in conjunction with the installation of air shutoff limit switches. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated March 23, 2003 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.

Caterpillar Inc.

Identification #(s)

Attached to March 23, 2003 Service Letter

Rework Procedure

Illustration 1

Illustration 2

Utilizing Illustrations 1 and 2 complete the following rework procedure

Tools needed: 5/32 allen wrench, 3/16 allen wrench, needle nose pliers, soft mallet, flat screwdriver, putty knife, 9/16 wrench, 3/4 wrench and flashlight. Suggested additional tools for use if the 1/4" manual pull shaft is broken off in the hydraulic piston; hand drill, EZ outs and a 1/4" x 28 tap. NOTE: All bolts are to be reassembled using a small amount of removable grade thread locker (Loctite 242 or equivalent).

NOTE: In most cases the air shutoff rework can be completed with the air shutoff valves in place (on the engine). If you choose to remove the air shutoff valves you will need to order the following seals:

Make sure air shutoff?s are in the closed position.
Remove two allen head bolts retaining the hydraulic cylinder to the upper housing (be sure that o-ring seal between cylinder assy. and housing is retained.
Remove the four allen head bolts that holds the two aluminum housings together.
After bolts are removed, tap the outer aluminum housing with a soft mallet to break loose.

NOTE: Housings use two alignment dowels.

Remove spring housing cover.
Remove spring tensioning bolt.
Remove "C" clip from hex reset shaft.

NOTE: Shaft spacer will fall when shaft is removed, before removing hex shaft from housing use needle nose pliers to hold and remove spacer.

Remove gate assembly from valve.
Remove "C" clip and spring shaft from gate.
Reassemble spring shaft to new "one piece" gate using a new "C" clip.

NOTE: Ensure that the proper gate is used 2296247 for the right hand and 2296249 for the left hand. Valve offset should be towards after cooler on both the old gate and the New Gate. Refer to Illustration 3.

Illustration 3

Place new gate as. into housing.
Insert hex shaft through the gate, leaving enough room to install spacer on hex shaft, use needle nose pliers to place spacer onto the shaft.
Using fingers, push hex shaft in fully, install new "C" clip Note; make sure that hex shaft pointer is in alignment with the words "OPEN" or "CLOSED".
With gate pivoted out, align spring shaft with spring shaft opening and allow gate to hang freely.
Apply thread locker onto the spring retaining bolt. Install spring, washer and hex head bolt into housing. Holding gate in closed position, turn bolt by hand until bolt threads engage with spring shaft.
Tighten spring shaft bolt (with gate in fully closed position) until spring washer is flush with O-ring groove. Tighten one additional turn or until gold colored washer is about .010" below the housing surface. See Illustration 4.

Illustration 4

Reinstall spring cover applying thread locker to the hardware and tighten.
Clean the mating surfaces of both housings.
Apply a thin coating of high temperature RTV (Permatex 26B or equivalent) to one housing.
Reinstall housing applying thread locker to the hardware and tighten.
Remove manual trip pull knob and shaft by gently holding shaft and tuning pull knob or stud counter clockwise. A vise with brass jaw protectors may be necessary to hold shaft. See Illustration 5.

Illustration 5

Apply thread locker to both ends of the new (stainless steel) stud, screw knob on one end and reassemble into hydraulic cylinder and tighten.
Apply thread locker to the cylinder mounting bolts and reattach hydraulic cylinder assy. to air shutoff valve and tighten.
SWITCH INSTALLATION ? Remove existing bolt plug and any existing washer/shims from ASO Valve. Apply anti seize to threaded portion of the 2277483 switch and install into air shutoff valve torquing switch to 10 ft lb.

NOTE: No washers or shims are needed with this switch. Refer to Illustration 6 for visual differences in the switches.

Illustration 6

Latch both air shutoffs in the open position. If air shutoff would not latch, review spring bolt adjustment procedure outlined in step #16 and illustration 4.
Reconnect switches into harness.
If jumper plug was not installed when switches were originally removed you will need to reconnect the air shutoff limit switch wiring in the customer connection box.

NOTE: Switch harness needs to be wired in series to the emergency stop circuit. Due to the various methods used in disconnecting the original switches i.e. wires cut, jumper plugs installed etc. rewiring instructions will not be detailed.

Using ET, Verify that the engine ECM has the correct flash file "software" installed. The new software extends the amount of time that the air shutoff activation cylinders receive oil pressure.

2AF serial number engines (Halliburton) should have 2155810 software.
Dowell etc. should have 2243067 software.

AIR SHUTOFF SWITCH TESTING PROCEDURE

NOTE: After checking engine fluids, ensure that both air shutoff valves are latched in the open position. Start the engine and operate at 1500 RPM allowing the fluids to warm up before proceeding with the air shutoff valve testing.

Manually trip one air shutoff valve, this should cause an emergency stop condition and the remaining air shutoff valve should close. If both valves closed testing is complete.

If the engine experienced an emergency stop condition but the remaining valve did not close, bleed the air from the line going to the air shutoff hydraulic cylinder.
If the engine did not initiate an emergency stop condition the switches are not correctly wired into the emergency stop circuit.

NOTE: Both switches should be in a closed state (show continuity) when the air shutoffs are latched in the open position. After the wiring issue has been resolved repeat step 1.

Close one air shutoff valve and attempt to start the engine. If engine cranks but will not start the switches are performing correctly and the testing is complete (ET will also show an active emergency stop condition).
If engine starts with one air shutoff closed check the switch on the valve that is closed (switch should not have continuity). If the switch has continuity remove the switch and inspect. If the switch doesn?t show continuity further troubleshoot the switch wiring.

NOTE: Testing is only complete when engine successfully passes both steps one and four.