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

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

Usage:

REBE8659-00

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28Aug2012

U-456

D-389

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AIR SHUTOFF PROXIMITY SENSORS ON CERTAIN 3512C OIL WELL SERVICE ENGINES
1408 7418		PI32088

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32088" 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 "PI32088" 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
28Feb2013	31Aug2013

PROBLEM

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The engine currently does not have proximity sensors installed.

AFFECTED PRODUCT

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Model

Identification Number

3512C HD

R1S00100-00102, 104-128, 130-137, 139-144, 146-159, 161-168, 170-175, 177-178, 180-185, 187-195, 197-201, 203-216, 218, 220, 222-224, 230, 237-238, 240-241, 244, 246-253, 256-272, 274-276, 278-280, 282, 284-285, 287, 289-290, 292-293, 296-299, 303, 306, 309-310, 312, 314-315, 319, 321-323, 325-327, 330-331, 335-336, 338-339, 343, 348-349, 351-373, 376-385, 387-388, 390-394, 396-402, 404-409, 413, 415-419, 421, 434, 436-437, 440, 443, 445-448, 450-453, 455-461, 463-476, 478-490, 492-497, 499-501, 503-505, 507, 509-512, 515-532, 534-538, 540-543, 545-546, 548-550, 552, 556, 560-563, 565-566, 568-569, 573, 579, 581-587, 590-591, 593, 595, 598-599, 601, 605, 607, 609, 614-615, 617-622, 624-627, 629-630, 633-634, 636-638, 640, 644, 646-651, 653-661, 664-666, 673, 675-683, 685-688, 690-691, 693, 695-698, 702, 708, 712-713, 717, 721-722, 725, 732, 734, 738, 740, 744-749, 751-759, 762-765, 767-770, 772-777, 780, 785-786, 788-790, 793-794, 796, 798-803, 808, 810-811, 813-815, 817-819, 822, 825, 827-828, 831-833, 837-839, 841, 844, 871-873

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 16% 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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OWNER NOTIFICATION

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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%	100%	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.

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

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

MODELS INVOLVED - 3512C

Dear Caterpillar Product Owner:

The air shutoff valves need to be updated with proximity sensors on the products listed below. The existing air shutoff valve does not have the proximity sensors installed from the factory.

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 28Aug2012 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 28Aug2012 Service Letter

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."