0312653 JOHNSON EXHAUST COVER, Outer

December 15, 2002
(Revised September 2006)
U-324
A-226
AU-239
S-238
H-237
O-262
TM-10
Safety PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGAIR SHUTOFF SYSTEM FROM CERTAIN 3508B, 3512B, AND 3516B ENGINES
1078 PI10201
This Program must be administered assoon as possible. When reporting the repair, use "PI10201" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI10201" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. This Revised Service Letter replacesthe December 15, 2002 (Revised June 2006) Service Letter. Changes havebeen made to the Affected Product.PROBLEM
In some instances, the air shutoff valves malfunctionon 3508B, 3512B, and 3516B Engines. Malfunctions include failure to closewhen required or inadvertent valve closure. This Service Letter authorizesthe removal of the air shutoff valves from 3500B series MARINE enginesand the installation of a redundant electronic overspeed protection system.The new system satisfies marine society requirements to have a primaryand secondary overspeed shutdown system without the use of an air shutoff. If applicable, PI10060 (E-Stop circuitchange) needs to completed prior to performing the following procedure. Engines operating in a combustibleenvironment or in accordance with a sanctioning body requiring ASO's shouldnot have the ASO's removed!AFFECTED PRODUCT
Model Identification Number
***Group 1***
Use Rework Procedure 3
3512B 2EZ221, 233, 234, 255-257,260, 264, 265, 267-2724AW206, 512
3516B 3CW228-231, 244, 245,247
***Group 2***
Use Rework Procedure 3
3512B 4TN99, 101, 102, 104,105, 109, 116-118, 127-131, 137, 141, 144-146, 149-153, 160, 161, 192-198,201, 207-212, 215-218, 220-223, 227, 228, 234, 235, 238, 239, 608, 610,611, 612, 774, 775, 780, 7817HM178-188, 191, 198-208, 212, 213
3516B 8CN144-155, 158-165,168-174, 178-180, 193-1958KN146-149, 155, 156, 159-162, 175-186, 194,195, 198, 200, 201, 204, 207-213, 219-222, 226, 229, 231-233, 235-237,242, 246, 249-251, 253, 260-264, 266, 268-271, 277-292, 295-298, 300-304,308-315, 318, 319, 323, 325-331, 339, 341, 346, 347, 352, 353, 361, 363,364, 366, 367, 370-374, 376-379, 388-399, 408, 409, 421-424, 426, 427,432, 434, 436-441, 448, 455, 456, 467-4744BW333-334, 336-337
***Group 3***
Use Rework Procedure 3
3508B 1TW250-252, 258, 260,261, 264, 270-272, 275, 279, 280, 282, 283, 288-291, 2982BM125-129, 133, 146-151, 155-157, 159, 167,170, 1713DW144-152, 154-1627SM86, 94, 97, 98, 111-116, 118-120, 126-130,134, 138, 140, 141, 148, 150, 154, 155, 159, 160, 168, 174, 175, 184-186,190, 191, 195, 202, 204, 290, 293, 295, 303, 306, 356, 369, 370, 375, 376,378, 476, 480, 488, 499, 508, 519, 524, 529-531, 536-540, 571, 572, 637,640, 641, 644, 648, 656, 662, 663, 665, 667, 676-678
3512B 2GW219, 264, 297-298,313-316, 328, 333, 349
***Group 4***
Use Rework Procedure 3
3516B 4BW338, 339, 351-353,355, 358-361, 373, 374, 377, 378, 399, 401, 408-415, 419-421, 424-427,432-435
***Group 5***
Use Rework Procedure 4
3508B 1TW300, 302, 3032BM145, 152-154, 158, 1607SM251, 253, 264, 357, 380, 381, 479, 601,602, 604, 607, 609-612, 649, 666, 668
3512B 2EZ241-244, 276, 2774TN188, 1897HM173-175
***Group 6***
Use Rework Procedure 1
3516B 2FW117-190, 192-221,223-263, 267, 269-306CBN256-286
***Group 7***
Use Rework Procedure 1
3512B 8EM260-268, 270-272,274-298, 300-312, 317-320, 324, 336, 338, 401
3516B 9AN121, 123-131, 135,140-144, 149, 150, 152-157, 164-168, 171-174, 178, 179, 181-190, 192, 194,195, 197, 200, 208, 215, 219, 221-226, 239, 240, 243, 244, 246-253, 264,266-269, 271, 280, 282, 287-292, 305, 307, 308
***Group 8***
Use Rework Procedure
3512B 1PW321-341, 343-345,349-356, 361, 363-367, 369-400
3508 3DM82, 93-95, 97-105,107, 112-123, 127-129, 132-135, 139-141, 143-146, 152-154, 157-161, 165,166, 169, 173, 176-179, 181, 183-188, 190, 191, 193-196, 199, 200, 203-206,212, 213, 227, 228, 230, 236, 239, 249, 252, 254-258, 262-264, 273-275,278, 279, 284, 287-307, 310-312, 378, 386-388
***Group 9***
Use Rework Procedure 1
3512B 4DR1
***Group 10***
Use Rework Procedure 2
3516B 9AN136-139, 145-148,158-163, 196, 201, 206, 207, 220, 265, 273, 281
***Group 11***
Use Rework Procedure 5
3512B 4TN48-51, 53, 54, 59,60, 63, 64, 66-70, 75-808EM247, 249-250, 252, 402
3516B 8KN81, 83-88, 93, 94,98-108, 110-117, 121-126, 129-1429AN105-109, 114-120