PRODUCT IMPROVEMENT PROGRAM TO RELOCATE LIMIT SWITCHES AND ADD VIBRATION DAMPERS TO THE AUTOMATIC AIR SHUTOFFS(ASOS) ON CERTAIN 3508, 3512, AND 3516 ENGINES
Usage:
REBE2257-00
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| 09Aug2007 |
U-388
A-323
D-320
O-345
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| Priority | PRODUCT IMPROVEMENT PROGRAM TO RELOCATE LIMIT SWITCHES AND ADD VIBRATION DAMPERS TO THE AUTOMATIC AIR SHUTOFFS(ASOS) ON CERTAIN 3508, 3512, AND 3516 ENGINES |
|
| 1078 | PI31322 |
|
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31322" 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 "PI31322" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE |
TERMINATION DATE |
| 29Feb2008 | 31Aug2008 |
PROBLEM
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| Relative motion between the air shutoff gate and the housing may cause a wear-step in the housing. The limit switches can wear and fail as well. Either of these actions can prevent the gate from closing and can lead to engine damage if the engine is operated with one gate opened and one gate closed. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| 3516 | 2TS00001-00007 3JS00001-00008 |
| DV-3508B | BAG00024 LPD00001-00002 |
| DV-3512 | NSC00001-00006 |
| DV-3512B | 4DR00001-00007 AAG00001-00005 |
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| *******Group 2******* | |
| 3508B | 1TW00272, 275, 317-318, 320-321, 347 2BM00151-00154, 157-158 2HW00100-00101, 104-116, 124, 134-135, 138-140, 142-146, 148, 152-157, 159-161, 164, 169-179, 185-188, 190-198, 201-205, 208, 211, 214-216, 218-219, 221, 223-237, 239-250, 252-253, 255, 258-261, 263-264, 266-267, 269-271, 273-274, 276, 279, 281-286, 289-292, 296-300, 302-306, 308-309, 315, 325, 329, 331 3DM00082, 86, 90-91, 94-95, 98-100, 102-103, 105, 107, 112-113, 118, 120-122, 132, 134-135, 139-141, 144-146, 152-154, 165, 169, 173, 176, 178-179, 184, 186-188, 190-191, 193, 195-196, 199-200, 212-213, 224, 227, 230, 253-254, 256-257, 261-264, 272-275, 284, 287-294, 296-297, 299-307, 313-318, 320, 325-326, 328, 344-345, 347-350, 352, 362-364, 367-368, 370, 372, 374-375, 377-378, 380, 385, 403, 410-418, 429, 433, 445-446, 449-450, 465, 471-473, 491, 497, 499, 507-509 3DW00144-00149, 152, 154-162, 164, 166-171, 175-177, 179 5KW00918, 1790, 1792, 2062 6PN00801 7SM00038, 40-41, 43, 113-116, 118-120, 126-130, 134, 148, 150, 159, 168, 174-175, 184, 202, 204, 251, 253, 264, 356-357, 369-370, 375-376, 378, 380-381, 476, 479-480, 488, 539-540, 571-572, 586, 648-649, 656, 662-663, 689-690, 692-693, 695-696, 702-703, 708-710, 723-726, 735, 746-747, 753, 757-759, 762-766, 772-776, 779-780, 782, 787-789, 797-801, 803, 843-844, 855, 862, 935-936, 951-952, 986-987, 1013-1014 BGX00109-00110, 112-113 BPX00094, 97, 106-108, 114 CBB00111-00115, 117-118, 121, 123-127, 131-132, 134, 138-140, 142-143, 145, 147-164, 168, 170-171, 173-175, 177, 179-190, 193, 196, 199, 201-202, 204-207, 210, 212, 217-221, 224-228, 231, 236-238, 240-243, 245, 247, 250-253, 259-261, 266-271, 276, 278-280, 283, 285-290, 292, 294-295, 297, 299, 301-302, 304-305, 307, 310-317, 321, 323-325, 327-328, 330, 332, 334, 339, 343-344, 346-350, 354-357, 360-361, 363, 365-371, 375-378, 380, 382-383, 385-386, 389-393, 395, 397, 400, 402, 404-405, 407-413, 415-416, 420-421, 427, 430, 434-439, 441, 443 CNB00596-00598, 600, 602-604, 611, 634-635, 650, 652, 703, 718, 720, 953-954, 1321-1323, 1331, 1490, 1582, 1586, 1593 S2A00100-00101, 120 S2B00105, 148-149, 151, 172-173, 230-231, 233-234, 243-244 S2E00112-00113, 243, 245, 249-250, 299, 321, 324 S2F00111, 117 |
| 3508C | LLC00100-00102 |
| 3512 | 50Y01664 |
| 3512B | 1PW00321-00334, 337-339, 345, 349-353, 356, 361, 363-367, 373-396, 407-412, 418-419, 422-426, 442-444, 446 2AF00200, 203-204, 208, 212, 214, 222-224, 228, 231-236, 240, 244-245, 252, 255-256, 259, 261-262, 265-266, 268, 276-278, 285-286, 290-291, 293-294, 297, 299, 301, 315-317, 334, 340, 342, 344, 367, 369, 379, 381, 383, 391, 394-395, 399-403, 411-413, 416, 418-422, 424, 426-427, 429-430, 434-435, 437, 439-440, 444-446, 451-452, 475, 479-481, 484-485, 490-502, 505, 508-511, 517-518, 520-522, 525, 529-531, 535, 539-542, 544 2EZ00233-00234, 241-244, 264-265, 267-268 2GW00313-00316, 333 3ZW00131, 133-135, 140-141, 147, 151, 160, 163, 167, 175, 177, 185-186, 198-201, 203, 205-207, 211-212, 216, 219, 229, 231, 233, 237, 239-240, 244, 248, 263, 266-267, 279-280, 282-287, 290, 293-298, 303-307, 310, 314-316, 320-323, 493-494, 503, 538, 549, 552, 570, 579-580, 589, 594, 659, 662, 664, 701-702 4AW00171, 173-174, 176-177, 179-182, 190-192, 194-195, 197-203, 206-213, 215-219, 222-242, 244-245, 248, 252, 255, 259-266, 269-273, 275-282, 285-291, 293, 295, 297-300, 306-311, 315-317, 319-322, 326-362, 364-368, 370, 373-374, 376-379, 381, 383-388, 390-406, 408-410, 414-428, 430, 433-437, 439-440, 443-448, 450-465, 468-469, 471-472, 476, 478, 481, 483-484, 486, 488-495, 497-500, 502-530, 532-541, 545-580, 585, 595, 602-605, 608-613, 615, 618-627, 629-649, 653-655, 657-661, 663, 665, 668, 670-682, 691-693, 696-697, 701, 704, 706-710, 716-720, 723, 725, 728-731, 733-738, 740-741, 744, 747-748, 750-752, 754-756, 761-762, 765-767, 769-771, 773-774, 778-779, 788, 790-792, 798-807, 815-820, 827-832, 834, 836-851, 860, 862-864, 868-870, 873-875, 877, 881-882, 887, 892, 896-898, 903-908, 912, 914, 917-918, 920-924, 926-928, 930-932, 934-940, 942, 944, 946, 948-949, 951-953, 955-961, 969, 973, 977-980, 988-989, 991, 994-995, 997-998, 1015, 1024-1026, 1029, 1033-1035, 1047-1049, 1051-1052, 1055, 1059-1060, 1062-1064, 1082, 1090-1092, 1096, 1107, 1126-1127, 1129-1132, 1134-1138, 1145, 1150-1151, 1153-1154, 1168-1171, 1173-1175, 1181, 1187, 1189, 1194-1195, 1198-1200, 1204-1205, 1209, 1211, 1228, 1230-1233, 1235-1237, 1239-1244, 1249-1250, 1252, 1254-1255, 1257-1261 4TN00048-00049, 53-54, 59-60, 69-70, 75-78, 99, 101, 128, 130-131, 137, 141, 144-146, 149, 197-198, 201, 207-210, 215, 217-218, 227-228, 563-565, 581, 593, 595, 597, 605, 607-608, 610-612, 614, 617-622, 629, 649, 651, 654-657, 659, 661, 699-700, 702-703, 726, 765-766, 774-775, 780-783, 805, 810, 821-822, 831-832, 839-840, 859, 861, 864-865 5AW00081-00082 7HM00173-00175, 188, 191, 201-202, 207-208, 257 8EM00247, 260-268, 270-272, 274-275, 277-279, 282-283, 285-298, 301, 303-308, 311-312, 317-320, 324, 334-336, 401, 415, 445-446, 450, 452, 465, 467-468, 470-472, 482-484, 514, 527-531, 535, 538-553 BLF00158, 166, 174-175 BRK00284-00285, 347-348 FDE00297-00300, 302-303, 306, 309 FFG00001, 10-13, 19, 22, 27, 36-39, 43 PTF00124, 130, 137-142, 147-148, 150, 154-164, 166-169 S2G00100, 103-107 S2H00138, 142-143, 150, 156 S2J00155 S2K00106-00107, 180-182 S2L00229-00230 S2M00114-00115, 117-118, 120-121 S2N00100, 103, 107-110 |
| 3512C | LLA00100-00102 |
| 3516B | 1NW00120, 130, 135-137, 141-144, 149, 151, 153-154 2FW00117-00124, 128-133, 138-151, 155, 157, 162-166, 173-182, 195-206, 213-221, 223-236, 238-263, 267, 269-273, 275-277, 281-297, 299, 303-304, 306, 308, 310-311, 313-317, 322-328, 334-337, 343-358, 366-378, 385-390 3CW00247 4BW00336-00339, 353, 355, 358-359, 399, 401, 412-414, 419, 428, 432-435, 443-444, 448-456, 459-460, 463-464, 468-473, 479-482, 494-495, 519-520 8CN00148-00151, 164-165, 168-169, 174, 193-195, 206-209 8KN00083, 98-102, 105, 107, 110-115, 121-122, 129-142, 155, 160, 162, 178, 198, 200-201, 219-221, 231-233, 236-237, 242, 246, 249, 253, 260-261, 268-269, 280, 283-286, 289, 291, 295, 297-298, 300-302, 310, 330-331, 346-347, 361, 366-367, 370-372, 374, 376-377, 390, 393-395, 423-424, 436-441, 455-456, 484-485, 493-494, 497-498, 508, 516, 518, 520-521, 525-526, 538, 563-564 9AN00105-00109, 118, 121, 123, 125, 127, 130-131, 135-137, 140-142, 145-150, 158-168, 171-174, 181-183, 186-190, 192, 194-197, 200-201, 206-208, 215, 219-223, 225-226, 239-240, 243-244, 246-252, 264-269, 271, 273, 280-282, 291, 305, 307-308, 314, 317, 327, 329-331, 334, 337-339, 341-343, 347, 355, 357, 362, 370-374, 385, 388-390, 395-396 BMB00130-00131 CBN00256, 259-261, 263-295, 302, 304-309, 317, 324, 330-331, 352-358 CPA00174-00181 FDN00445-00446 LEK00112-00126 S2R00137, 147-149, 166, 178 S2X00136, 138, 272-273, 276-277 |
| SPF343 | 6RZ00150, 152-156, 158-159, 165-168, 170-175, 179, 181-182, 184-189, 191, 195-207, 356-361, 365-373, 375, 377-378, 380-384, 386-387, 389-396, 400-402, 405-410, 412-414, 416-425, 427-428, 431-440, 442-443, 445-483, 486-487, 491-495 |
| SPS343 | 8ZZ00303-00309, 510-517 |
| SPT343 | 5XZ01018-01028, 1030, 1032 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 4 | 0S1588 | BOLT |
| 4 | 4P8134 | CLIP-LADDER |
| 12 | 9X6772 | STRAP-CABLE |
| 2 | 1790133 | FILM-AIR SHUTOFF |
| 2 | 2632905 | SWITCH AS |
| 2 | 2727102 | CAP-END |
| 2 | 2898498 | DAMPER AS |
| *******Group 2******* | ||
| 4 | 0S1588 | BOLT |
| 4 | 4P8134 | CLIP-LADDER |
| 12 | 9X6772 | STRAP-CABLE |
| 2 | 1790133 | FILM-AIR SHUTOFF |
| 2 | 2632905 | SWITCH AS |
| 2 | 2727102 | CAP-END |
| 2 | 2898498 | DAMPER AS |
ACTION REQUIRED
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| Refer to the attached Rework Procedure. |
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OWNER NOTIFICATION
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| U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | |||||
| NOTE: This is a 3.0-hour job for Group 1 | |||||
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| *******Group 2******* | |||||
| NOTE: This is a 3.0-hour job for Group 2 | |||||
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. |
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| XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM TO RELOCATE LIMIT SWITCHES AND ADD VIBRATION DAMPERS TO AUTOMATIC AIR SHUT OFFS MODELS INVOLVED - Certain 3508, 3512, and 3516 Engines Dear Caterpillar Product Owner: New parts need to be installed on the engines listed. 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. It is VERY IMPORTANT that your Automatic Air Shut Offs (ASOs) be tested every 500 operating hours and the vibration dampers installed on the ASOs need to be inspected/serviced every 6000 operating hours. Please contact your Caterpillar Dealer for a copy of Caterpillar Special Instruction REHS3005, which details this procedure. A COPY OF THIS DOCUMENT SHOULD BE PLACED IN THE APPLICABLE Operating and Maintenance Manuals. Please refer the dealer to their Service Letter dated 09Aug2007 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime. Caterpillar Inc. Identification #(s) Attached to 09Aug2007 Service Letter |
| 1. On each of the two Air Shut Off assemblies, un-plug from wiring harness and remove existing 227-7483 indicator switch (Image 1.1.1) and discard. Replace the indicator switch with new 289-8498 Vibration Damper (Image 1.1.2), insuring that the threads are coated with Thread Lock P/N 9S-3263 or 4C-4030 and torque damper to 16(+/-2) Nm. |
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| Image1.1.1 |
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| Image1.1.2 |
| 2. Remove existing 215-2705 cap (Image 1.2.1), and replace with new 272-7102 cap, utilizing the existing cap screws (Image 1.2.1). Ensure that threads are coated with Thread Lock P/N 9S-3263 or 4C-4030 and torque cap screws to 7(+/-1) Nm. |
|
| Image1.2.1 |
| 3. Install new 263-2905 switches (Image 1.3.1) into caps insuring that threads are coated with P/N 4C-5598 High temperature Anti-Seize and torque to 16(+/-2) Nm. |
|
| Image1.3.1 |
| 4. Connect new switch to the applicable wiring harness. Install ladder clips as shown (Image 1.4.1), using 0S-1588 Bolts coated with P/N 4C-5598 High Temperature Anti-Seize to replace the top two existing bolts as shown. Torque these bolts to 47 (+/-9) Nm. |
|
| Image1.4.1 |
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| Image1.4.2 |
| 5. IMPORTANT - Tie-wrap new switch wiring to existing solenoid wiring as shown (Images 1.4.1 & 1.4.2), to prevent thermal damage to wiring. |
| Install information films P/N 179-0133 on electrically actuated Air Shut Offs over the existing films on the solenoids as shown in (Image 1.6.1) or install information films for hydraulically actuated Air Shut Offs over the existing films on the valve covers as shown in (Image 1.6.2). Films in languages other than English are available under the following part numbers: -Arabic 297-2613 -French 297-2614 -German 297-2615 -Spanish 297-2616 -Portuguese 297-2617 -Russian 297-2618 |
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| Image1.6.1 |
|
| Image1.6.2 |
| Important Notes: 1. If a new switch is to be painted, mask the vent holes around the perimeter of the switch before painting and be sure to remove the masking after the paint dries. 2. Test completed modifications as detailed below for the specific ECM installed on the engine (ADEM 2 or ADEM 3). OPERATIONAL TEST - ADEM II Engine Control Modules ONLY Note: (For Troubleshooting purposes) The ASO switches are normally closed switches that are in the closed state when the air shutoff valves are latched in the open ("Run") position. If the air shutoff valves are in the closed ("Stop") position, the switch will be in the open state, causing an emergency stop and shutting the engine down. This also prevents the engine from starting. 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 for the right side air shutoff and check the wiring for the right side air shutoff. 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. Operate the engine normally. Ensure that the air shutoff gates continue to be latched. |
| OPERATIONAL TEST - ADEM III Engine Control Modules ONLY 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 completed 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 completed 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 the switch for the right side air shutoff. Both air shutoff gates should close and 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 completed and the test is 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 the switch for the left side air shutoff. Both air shutoff gates should close. The engine should shut down. If the engine does not shutdown, 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 test is successful, reconnect the left side air shutoff. Reset both air shutoffs. 7. Testing is complete only when the engine successfully passes steps 1 through 6. 8. Reset both air shutoffs. Ensure that the "EMERGENCY STOP" switch has been reset. Operate the engine normally. |
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PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600 PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN C9 ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN C9 ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING INTERNAL INJECTOR HARNESS TRAYS ON 2007 C9 ENGINES PRODUCT SUPPORT PROGRAM FOR REWORKING INTERNAL INJECTOR HARNESS TRAYS ON 2007 C9 ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE FUEL INJECTION PUMPS ON CERTAIN C7 ON-HIGHWAY TRUCK ENGINES INSTALLED IN BLUEBIRD CHASSIS PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE FUEL INJECTION PUMPS ON CERTAIN C7 ON-HIGHWAY TRUCK ENGINES INSTALLED IN BLUEBIRD CHASSIS
PRODUCT SUPPORT PROGRAM FOR CALIBRATING THE OIL LEVEL GAUGE (DIPSTICK) ON CERTAIN C32 MARINE ENGINES INSTALLED IN HATTERAS YACHTS PRODUCT SUPPORT PROGRAM FOR CALIBRATING THE OIL LEVEL GAUGE (DIPSTICK) ON CERTAIN C32 MARINE ENGINES INSTALLED IN HATTERAS YACHTS