Inspection and Testing of the Air Shutoff{1078} Caterpillar

Generator Set:

3512B (S/N: ZAH1-UP; ZAJ1-UP)

3516B (S/N: ZAP1-UP)

Engine:

3508 (S/N: 8TL1-UP; 3HM1-UP; 9WN1-UP)

3508B (S/N: S2A1-UP; CBB306-UP; CNB1189-UP; S2B1-UP; ZAC1-UP; S2D1-UP; ZAD1-UP; S2E1-UP; S2F1-UP; 6PN1-UP; 5PS344-UP; 2HW286-UP; BGX120-UP; BPX103-UP)

3512 (S/N: 65Z1-UP; 66Z1-UP; 67Z1-UP)

3512B (S/N: BRC160-UP; CMC1241-UP; NSC1-UP; BLF166-UP; 2AF463-UP; PWG157-UP; S2G1-UP; ZAG1-UP; S2H1-UP; S2J1-UP; YAJ1-UP; BRK287-UP; S2K1-UP; S2L1-UP; S2M1-UP; 8EM1-UP; 8RM1-UP; S2N1-UP; 3ZW672-UP; 4AW952-UP)

3512C (S/N: R3A1-UP)

3516 (S/N: ZAK1-UP; ZAL1-UP; 3JS1-UP)

3516B (S/N: CPA192-UP; BMB132-UP; B5G1-UP; BPJ477-UP; ZAM1-UP; CAN1-UP; CBN1-UP; FDN1599-UP; ZAN1-UP; 7RN1-UP; 9AN1-UP; S2P1-UP; S2R1-UP; ZAR1-UP; S2S1-UP; S2T1-UP; S2W1-UP; 2FW1-UP; S2X1-UP; S2Y1-UP; 6HZ100-UP)

3516C (S/N: PAG1-UP; T2X1-UP)

Pumper:

SPF343C (S/N: R2A1-UP)

Petroleum Engine:

3508C (S/N: LLC1-UP; LLE1-UP)

3512C PETROLEUM (S/N: LLA1-UP; R1A1-UP; LLB1-UP; LLF1-UP)

Power Module:

PM3508 (S/N: BLM1-UP)

PM3512 (S/N: BNR1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

The above engines are equipped with two air shutoffs. Ensure that both air shutoffs are reset to the open position before operation in order to prevent engine damage. The air shutoffs must be tested for every 500 operating hours. The air shutoffs must be inspected and serviced for every 6000 operating hours. This Special Instruction provides details for the inspection and testing of air shutoffs.

There are two separate testing procedures. One procedure is for engines with an ADEM II Electronic Control Module (ECM) and the other procedure is for engines with an ADEM III ECM.

Illustration 1	g01290429
Typical air shutoffs on a 3500B engine (top view)

Illustration 2	g01285609
Left side air shutoff in the OPEN position

Illustration 3	g01285610
Right side air shutoff in the OPEN position

Engines that are Equipped with an ADEM II ECM

This procedure verifies the following conditions:

• The air shutoffs close when the emergency stop is activated.

• If one of the gates is closed, the other gate will close when the ECM is powered up.

Note: Do not start the engine. Ensure that the engine control is in the "OFF" position.

1. Ensure that both air shutoff gates are latched in the OPEN position and ensure that both air shutoff switches are connected. Turn on the power to the engine control panel. Both air shutoff gates should remain open. If both air shutoff gates do not remain open, check the wiring for the air shutoff switches.

2. With the power for the engine control panel in the ON position, activate the "EMERGENCY STOP" switch. Both of the air shutoff gates should close. If both air shutoff gates close, proceed to step 3. If both air shutoff gates do not close, check the wiring for the air shutoff switches and check the wiring for the solenoids. Activate the "EMERGENCY STOP" switch again. When both air shutoff gates close, proceed to step 3.

3. Turn the power to the engine control panel to the OFF position. Ensure that the "EMERGENCY STOP" switch is in the RUN position. Latch only the right side air shutoff gate to the OPEN position. Turn the power for the engine control panel to the ON position. The right side air shutoff gate should close. If the right side air shutoff gate closes, proceed to step 4. If the right side air shutoff gate does not close, check the air shutoff switch and check the wiring. When the right side air shutoff closes, proceed to step 4.

4. Turn the power for the engine control panel to the OFF position. Latch only the left side air shutoff gate to the OPEN position. Turn the power for the engine control panel to the ON position. The left side air shutoff gate should close. If the left side air shutoff gate closes, the test is complete. If the left side air shutoff gate does not close, check the switch and the wiring for the left side air shutoff .

   Note: Testing is only complete when the engine successfully passes step 1 through step 4.

5. Reset both air shutoffs. Ensure that the "EMERGENCY STOP" switch has been reset. Operate the engine normally.

Engines that are Equipped with an ADEM III ECM

This procedure verifies the following conditions:

• The air shutoffs close when the emergency stop is activated.

• The engine fails to start when only one of the gates closes.

• The engine fails to start if either one of the solenoids is disconnected.

Note: Do not start the engine. Ensure that the engine control is in the "OFF" position.

1. Ensure that both air shutoff gates are latched in the OPEN position. Ensure that both air shutoff switches are connected. Turn the power for the engine control panel to the ON position. The air shutoff gates should remain in the OPEN positions. If the air shutoff gates do not remain in the OPEN positions, check the wiring for the air shutoffs. When step 1 has been successfully completed, proceed to step 2.

2. While the power for the engine control panel is in the ON position, activate the "EMERGENCY STOP" switch. Both air shutoff gates should close. If the air shutoff gates do not close, check the wiring for the air shutoffs and the wiring for the solenoids. Both air shutoff gates must close before proceeding to step 3.

3. Turn the power for the engine control panel to the OFF position. Reset the "EMERGENCY STOP" switch to the RUN position. Reset the right side air shutoff to the OPEN position. Turn the power for the engine control panel to the ON position. Select "Run/Start" on the engine control panel. The engine should fail to start. If the engine does not start, proceed to 4. If the engine starts, turn off the engine. Check the right side air shutoff. Check the wiring for the right side air shutoff. Retest the air shutoff. When the procedure in 3 is followed and the engine fails to start, proceed to 4.

4. Reset the "EMERGENCY STOP" switch to the RUN position. Set the power for the engine control panel to the ON position. Activate the"EMERGENCY STOP" switch. Both air shutoff gates should close. Set power for the engine control panel to the OFF position. Reset the "EMERGENCY STOP" switch to the RUN position. Reset the left side air shutoff to the OPEN position. Turn the power for the engine control panel to the ON position. Select "START/RUN" on the engine control panel. The engine should fail to start. If the engine does not start, proceed to 5. If the engine starts, turn off the engine. Check the left side air shutoff. Check the wiring for the left side air shutoff. Retest the left side air shutoff. When the procedure in step 4 is followed and the engine fails to start, proceed to 5.

5. Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start the engine. Disconnect only the right side air shutoff switch that is located on the solenoid. Both air shutoff gates should close. The engine should shut down. If the engine does not shut down, use the "EMERGENCY STOP" switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in order to retest the right side air shutoff. When the procedure in step 5 is followed and results of the test are successful, reconnect the right side air shutoff. Reset both air shutoffs.

6. Turn the power for the engine control panel to the ON position. Reset both air shutoffs. Start the engine. Disconnect only the left side air shutoff switch that is located on the solenoid. Both air shutoff gates should close. The engine should shut down. If the engine does not shut down, use the "EMERGENCY STOP" switch to stop the engine. Check the wiring for both air shutoffs. Use the above procedure in order to retest the left side air shutoff. When the procedure in 6 is followed and the results of the test are successful, reconnect the right side air shutoff. Reset both air shutoffs.

   Note: Testing is only complete when the engine successfully passes Step 1 through Step 6.

7. Reset both air shutoffs. Ensure that the "EMERGENCY STOP" switch has been reset. Operate the engine normally.

Removing and Checking the Damper for the Air Shutoff

Illustration 4	g01286554
Typical air shutoff (back view) (1) Gate (2) Damper assembly

The air shutoff vibration damper minimizes the vibration of the gate when the engine is operating and the gate is latched open. The components of the damper assembly must be inspected in order to ensure correct performance of the damper.

Illustration 5	g01286567
Damper assembly (3) Plug (4) Seal ring (5) Housing (6) Spring (7) Plunger

1. Do not loosen or do not remove the body of the damper from the air shutoff when the plunger is removed. In order to remove the plunger without loosening or removing the damper, unscrew plug (3) with a6.35 mm (0.25 inch) allen wrench and an open-end wrench.

2. Check seal ring (4) for damage or wear. If necessary, replace the seal ring.

3. Inspect the internal parts of the vibration damper for wear or damage. Clean the components with 138-8440 Component Cleaner .

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Illustration 6	g01286606
Plunger

4. Remove plunger (7) from the spring. Visually inspect the exposed end of the plunger for dirt, fouling, damage, and wear. If distance "A" is less than 18.3 mm (0.72 inch) or if a visual inspection reveals dirt, fouling, damage, or wear on the active end of the plunger, replace the plunger. Insert the tapered end of a clean, undamaged plunger into the spring. Install the open end of the spring into the plug. Apply 9S-3263 Thread Lock Compound or apply 9S-4030 Thread Lock onto the threads of the plug. Screw the assembly into the damper body. Allow the thread lock to cure for a minimum of 1 hour before the air shutoff is used.