PSP FOR DAMAGED BOLTS IN GOVERNOR FLYWEIGHT CARRIER AND AUTO TIMING ADVANCE UNITS IN D8N, 621E, 623E, 627E, 824C TRACTORS; 980 C LOADERS; 245 EXCAVATORS; 16G MOTOR GRADERS; 825C, 826C COMPACTORS; 3406 INDUSTRIAL, MARINE, GEN SET, TRUCK ENGINES - MAIL
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PSP FOR DAMAGED BOLTS IN GOVERNOR FLYWEIGHT CARRIER AND AUTO TIMING ADVANCE UNITS IN D8N, 621E, 623E, 627E, 824C TRACTORS; 980 C LOADERS; 245 EXCAVATORS; 16G MOTOR GRADERS; 825C, 826C COMPACTORS; 3406 INDUSTRIAL, MARINE, GEN SET, TRUCK ENGINES - MAILED US AND CANADA, CACO, CFEL, COSA
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.
U-87 A-39 AU-56 E-37 O-50 1264, 1272 PS4224 NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4224" as Part Number and "7755" as Group Number. Although products are to be administered as described above, parts stock should be purged immediately.
Termination Date
May 31, 1989
Problem
Some 1S5440 Dowels were made with a chamfer on the ends instead of a radius. These dowels are used in certain governor groups and automatic timing advance units. The chamfered dowels may damage the threads of the bolts in the governor flyweight retainer and in the automatic timing advance units.
Affected Product
Model Identification Number Automatic Timing Advance Units Only 3406B 7FB86679 - 95381 2WB4651 - 4919 4TB1106 - 1216 6TB3856 - 4072 621E 6AB810-839, 846 623E 6CB654, 656-679 627E 6EB504, 505 627E 6GB574, 577, 590, 591 245 82X748-752, 754-773, 776, 785, 792 245 84X1061, 1065-1069, 1071-1074, 1083-1085, 1100, 1116, 1118, 1130, 1131, 1133 824C 85X1251-1262 825C 86X771-773 826C 87X687, 688, 690, 692-694, 696-715 980C 63X7398, 7402-7473, 7475-7570, 7573-7576, 7578, 7580, 7583, 7584, 7586, 7630 2XD466, 467, 469, 470, 474-485, 487, 489-494, 496-499, 501, 502, 504-507, 509, 510, 513-515, 518, 519, 521-550, 552-559, 561, 578, 583, 585, 596, 597, 633, 634, 673, 699, D8N 9TC814, 833, 959, 960, 962-964, 966, 969, 973, 975-986, 988-999, 1001-1049, 1051-1086, 1088-1114, 1116-1155, 1157-1215, 1217, 1218, 1222, 1223, 1267, 1286, 1297, 1298, 1346, 1429, 1603, 1801 16G 93U2685-2705, 2730 Automatic Timing Advance Units And Governors 3406B 7FB95382 - 99999 4MG1 - 3599 2WB4920 - 5353 4TB1217 - 1399 6TB4073 - 4467 621E 6AB840, 841-845, 847-916, 926, 929, 931-933, 935 623E 6CB680 - 697, 699-707, 714, 717 627E 6EB508, 509, 514 6GB93, 594 980C 63X7571, 7572, 7577, 7579, 7581, 7582, 7585, 7587-7629, 7631-7761, 7765-7792, 7794-7874, 7898 2XD562, 570-577, 580-582, 584, 586-595, 598-600, 602, 604-606, 609-612, 614-632, 635-642, 644-650, 652, 653, 656-660, 662-665, 667, 668, 670, 678-680, 683, 686, 697, 700 13B787 245 82X774, 775, 777-784, 786-790, 793-820, 823, 831, 832, 835 84X1075, 1077, 1079-1082, 1086-1099, 1101, 1102, 1105-1115, 1117, 1120-1123, 1128, 1134 824C 85X1263 -1285 825C 86X774 - 783 826C 87X716 - 736, 738-779 D8N 9TC1216, 1219-1221, 1224-1266, 1269-1285, 1287-1296, 1299-1345, 1347-1599, 1601, 1602, 1604-1655, 1657-1682, 1684, 1685, 1719, 1728, 1737, 1749, 1755, 1760, 1888, 1892 16G 93U2706 -2743, 2747, 2749-2754 Governors Only 3406B 4MG3600 - 10013
Parts Needed
Parts Stock To rework the following: 2W6179 Pump Group 1N3110 Governor Group 2W7325 Governor Group 4W1628 Governor Group 7C1677 Governor Group 7C4797 Governor Group 7C6576 Governor Group 8N9682 Governor Group 4W2427 Pump and Governor Gp. 4W3897 Pump and Governor Gp. 7C183 Pump and Governor Gp. 8N9675 Pump and Governor Gp. 4 - 9Y7037 Bolt 1 - 335879 Ring 4 - 1S5440 Dowel 1 - 8N9382 Gasket 1 - 4W435 Seal 1 - 8N9384 Gasket 1 - 8M8515 Seal To rework the following: 2W6174 Camshaft As.,9L4990 Weight As. 4 - 9Y7037 Bolt 4 - 1S5440 Dowel Affected Product Automatic Timing Advance Units Only 4 - 1S5440 Dowel 4 - 8T7893 Bolt 1 - 4W435 Seal 1 - 4W4616 Seal 1 - 2W459 Gasket Automatic Timing Advance Units And Governors 4 - 9Y7037 Bolt 1 - 335879 Ring 8 - 1S5440 Dowel 4 - 8T7893 Bolt 1 - 8N9382 Gasket 1 - 4W435 Seal 1 - 8N9384 Gasket 1 - 4W4616 Seal 1 - 8M8515 Seal 1 - 2W459 Gasket Governors Only 4 - 9Y7037 Bolt 1 - 335879 Ring 4 - 1S5440 Dowel 1 - 8N9384 Gasket 1 - 8N9382 Gasket 1 - 8M8515 Seal
Action Required
Parts Stock Check all 1S5440 Dowels in parts stock. Remove all 1S5440 Dowels that have a chamfer on the ends. 1S5440 Dowels with a radius on the ends are good. See the Illustrations. Remove all 1S5440 Dowels from the following groups and assemblies and install new 1S5440 Dowels. Category 1 2W6179 Pump Group 1N3110 Governor Group 2W7325 Governor Group 4W1628 Governor Group 7C1677 Governor Group 7C4797 Governor Group 7C6576 Governor Group 8N9682 Governor Group 2W6174 Camshaft As. 9L4990 Weight As. Category 2 4W2427 Pump and Governor Gp. 4W3897 Pump and Governor Gp. 7C183 Pump and Governor Gp. 8N9675 Pump and Governor Gp. ****** IMAGE: SEBE3818.00001.001 CAPTION: Chamfered End ****** IMAGE: SEBE3818.00001.002 CAPTION: Radius End Affected Product Check the upper rear corner of the right side of the cylinder block for the code "5AX" or "5A". If the code is there, the product has already been reworked. If the code is not there, the product needs to be reworked. Stamp "5AX" on the upper rear corner of the right side of the cylinder block after the product has been reworked. Governor: Remove all 1S5440 Dowels with chamfers from the flyweight carriers. Install the new parts. If the engine is equipped with a tachometer drive, remove the tachometer drive before the governor is installed. Align the slot and the drive tang and install the tachometer drive. Automatic Timing Advance Unit: Remove all 1S5440 Dowels with chamfers. Install the new parts. Ensure that the dynamic timing is correct.
Service Claim Allowances
Submit one claim for all chamfered 1S5440 Dowels removed from parts stock. Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first Automatic Timing Advance Units And Governors 0-4000 100% 4.5 0 0 0 0 0-24 mo 0-150000 mi 4001-6000 33 1/3% 4.5 0 0 50% 0 25-36 mo 150001-300000 mi Automatic Timing Advance Units Only 0-4000 100% 2 0 0 0 0 0-24 mo 0-150000 mi 4001-6000 33 1/3% 2 0 2 50% 0 25-36 mo 150001-300000 mi Governors Only 0-4000 100% 2.5 0 0 0 0 0-24 mo 0-150000 mi 4001-6000 33 1/3% 2.5 0 2 50% 0 25-36 mo 150001-300000 mi Parts Stock - Category 1 100% 1 0 0 0 0 Parts Stock - Category 2 100% 2 0 0 0 0 NOTE: If OEM, parts are at C/L and labor at sell rate.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Caterpillar Information System:
PSP FOR FAILURES OF RETAINERS FOR THE GOVERNOR, FLYWEIGHT DOWELS ON CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COF A, TRUCK TEPS, LIMITED COSA TRUCK TEPS, LIMITED COSA PSP FOR FAILURES OF RETAINERS FOR THE GOVERNOR, FLYWEIGHT DOWELS ON CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COF A, TRUCK TEPS, LIMITED COSA TRUCK TEPS, LIMITED COSA
PSP FOR EXCESSIVE OIL CONSUMPTION IN CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, TRUCK TEPS PSP FOR EXCESSIVE OIL CONSUMPTION IN CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, TRUCK TEPS
PSP FOR INCORRECTLY ADJUSTED AIR FUEL RATIO CONTROL ON CERTAIN 3208 TRUCK ENGINES - MAILED US AND CANADA, TRUCK TEPS PSP FOR INCORRECTLY ADJUSTED AIR FUEL RATIO CONTROL ON CERTAIN 3208 TRUCK ENGINES - MAILED US AND CANADA, TRUCK TEPS
PSP FOR FLUCTUATION OF LOW IDLE RPM ON CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, TRUCK TEPS, LIMITED COSA PSP FOR FLUCTUATION OF LOW IDLE RPM ON CERTAIN 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, TRUCK TEPS, LIMITED COSA
PSP FOR OIL OVER CARRY ON CERTAIN 3208 INDUSTRIAL ENGINES - MAILED US AND CANADA PSP FOR OIL OVER CARRY ON CERTAIN 3208 INDUSTRIAL ENGINES - MAILED US AND CANADA
THROTTLE POSITION SENSOR NEEDS TO BE CHECKED ON CERTAIN 3406B PEEC ENGINES - MAILED US, CANADA, TRUCK TEPS THROTTLE POSITION SENSOR NEEDS TO BE CHECKED ON CERTAIN 3406B PEEC ENGINES - MAILED US, CANADA, TRUCK TEPS
CRANKSHAFT DAMPER BOLTS NEED TO BE RETIGHTENED ON CERTAIN D10N TRACTORS, 992C LOADERS, 773B TRUCKS, 3408, 3412 MARINE ENGINES - M AILED WORLDWIDE EXCEPT BRAZIL. CRANKSHAFT DAMPER BOLTS NEED TO BE RETIGHTENED ON CERTAIN D10N TRACTORS, 992C LOADERS, 773B TRUCKS, 3408, 3412 MARINE ENGINES - M AILED WORLDWIDE EXCEPT BRAZIL.
PSP FOR TURBOCHARGER SURGE AND HIGH EXHAUST TEMPERATURE PROBLEMS ON CERTAIN 3508 GENERATOR SET ENGINES - MAILED US AND CAN ADA, CACO, COFA, LIMITED COSA - REVISED 1/89 PSP FOR TURBOCHARGER SURGE AND HIGH EXHAUST TEMPERATURE PROBLEMS ON CERTAIN 3508 GENERATOR SET ENGINES - MAILED US AND CAN ADA, CACO, COFA, LIMITED COSA - REVISED 1/89
SERVICE LETTER EXTENSION FOR MARCH 30, 1989 SL - PS5991 - PSP FOR RESETTING THE PROGRAMMABLE CUSTOMER SPECIFIED PARAMETERS ON 3406B PEEC TRUCK ENGINES - MAILED US AND CANADA, TRUCK TEPS SERVICE LETTER EXTENSION FOR MARCH 30, 1989 SL - PS5991 - PSP FOR RESETTING THE PROGRAMMABLE CUSTOMER SPECIFIED PARAMETERS ON 3406B PEEC TRUCK ENGINES - MAILED US AND CANADA, TRUCK TEPS
SERVICE LETTER SUPPLEMENT FOR AUGUST 18, 1987 SL - PS0322 - PSP FOR WATER PUMP SEAL FAILURES IN 3406...92U, 3406B...7FB TRU CK ENGINES - MAILED US AND CANADA, COSA, TRUCK TEPS SERVICE LETTER SUPPLEMENT FOR AUGUST 18, 1987 SL - PS0322 - PSP FOR WATER PUMP SEAL FAILURES IN 3406...92U, 3406B...7FB TRU CK ENGINES - MAILED US AND CANADA, COSA, TRUCK TEPS
PSP FOR WATER PUMP SEAL FAILURES IN 3406...92U, 3406B...7FB TRUCK ENGINES - MAILED US AND CANADA, COSA, TRUCK TEPS PSP FOR WATER PUMP SEAL FAILURES IN 3406...92U, 3406B...7FB TRUCK ENGINES - MAILED US AND CANADA, COSA, TRUCK TEPS
PRIORITY - OIL PUMP BOLT NEEDS TO BE RETIGHTENED ON CERTAIN 215B AND 225B EXCAVATORS; 936, 950B AND 966D LOADERS; 3304 AND 330 6 GENERATOR SET ENGINES - MAILED US, CANADA, COSA PRIORITY - OIL PUMP BOLT NEEDS TO BE RETIGHTENED ON CERTAIN 215B AND 225B EXCAVATORS; 936, 950B AND 966D LOADERS; 3304 AND 330 6 GENERATOR SET ENGINES - MAILED US, CANADA, COSA
PSP FOR DAMAGED BOLTS IN GOVERNOR FLYWEIGHT CARRIER AND AUTO TIMING ADVANCE UNITS IN 3406B INDUSTRY, MARINE, GEN SET AND TRU CK ENGINES - MAILED TRUCK TEPS, AGRICULTURE TEPS AND MARINE TEPS PSP FOR DAMAGED BOLTS IN GOVERNOR FLYWEIGHT CARRIER AND AUTO TIMING ADVANCE UNITS IN 3406B INDUSTRY, MARINE, GEN SET AND TRU CK ENGINES - MAILED TRUCK TEPS, AGRICULTURE TEPS AND MARINE TEPS
SOME 3208 REMANUFACTURED SHORT BLOCKS MAY HAVE INCORRECTLY MACHINED THRUST FACES ON THE CRANKSHAFT - MAILED US, CANADA, CAC O, COFA, BRAZIL, CFEL, COSA SOME 3208 REMANUFACTURED SHORT BLOCKS MAY HAVE INCORRECTLY MACHINED THRUST FACES ON THE CRANKSHAFT - MAILED US, CANADA, CAC O, COFA, BRAZIL, CFEL, COSA
SOME OR1744 REMANUFACTURED NOZZLES IN PARTS STOCK MAY LOSE NOZZLE TIPS - MAILED US, CANADA, CACO, COFA, BRAZIL, CFEL, COS A SOME OR1744 REMANUFACTURED NOZZLES IN PARTS STOCK MAY LOSE NOZZLE TIPS - MAILED US, CANADA, CACO, COFA, BRAZIL, CFEL, COS A
PSP FOR CRACKS IN TURBOCHARGER FLANGE OF RIGHT EXHAUST MANIFOLDS ON CERTAIN 3516 MARINE ENGINES - MAILED US AND CAN ADA, CACO, COFA, LIMITED COSA PSP FOR CRACKS IN TURBOCHARGER FLANGE OF RIGHT EXHAUST MANIFOLDS ON CERTAIN 3516 MARINE ENGINES - MAILED US AND CAN ADA, CACO, COFA, LIMITED COSA
POWER TAKEOFF NEEDS TO BE CLEANED AND BEARINGS ADJUSTED AND REPACKED ON CERTAIN 3412 INDUSTRIAL ENGINES - MAILED US, CAN ADA, COSA POWER TAKEOFF NEEDS TO BE CLEANED AND BEARINGS ADJUSTED AND REPACKED ON CERTAIN 3412 INDUSTRIAL ENGINES - MAILED US, CAN ADA, COSA
PRIORITY - FLAME ARRESTORS NEED TO BE INSTALLED TO PREVENT MANIFOLD EXPLOSIONS ON CERTAIN 3512 AND 3516 SPARK IGNITED ENG INES - US, CANADA, LIMITED COSA PRIORITY - FLAME ARRESTORS NEED TO BE INSTALLED TO PREVENT MANIFOLD EXPLOSIONS ON CERTAIN 3512 AND 3516 SPARK IGNITED ENG INES - US, CANADA, LIMITED COSA
PSP FOR INCORRECT STARTING SYSTEM CIRCUIT BREAKER AND/OR WIRE CONNECTION ON CERTAIN 3116 GENERATOR SETS - MAILED US AND CAN ADA, CACO, CFEL, LIMITED COSA PSP FOR INCORRECT STARTING SYSTEM CIRCUIT BREAKER AND/OR WIRE CONNECTION ON CERTAIN 3116 GENERATOR SETS - MAILED US AND CAN ADA, CACO, CFEL, LIMITED COSA
PSP FOR WIRE ABRASION AND/OR WATER IN THE AIR RATIO LINES GROUP BOOST LINE ON CERTAIN 3406B ENGINES EQUIPPED WITH PRO GRAMMABLE ELECTRONIC ENGINE CONTROL (PEEC) - PS4260 - MAILED US AND CANADA, TRUCK TEPS PSP FOR WIRE ABRASION AND/OR WATER IN THE AIR RATIO LINES GROUP BOOST LINE ON CERTAIN 3406B ENGINES EQUIPPED WITH PRO GRAMMABLE ELECTRONIC ENGINE CONTROL (PEEC) - PS4260 - MAILED US AND CANADA, TRUCK TEPS
PRIORITY - ROLLER BEARINGS ON THE IDLER SHAFT OF THE AUXILIARY WATER PUMP NEEDS TO BE REPLACED ON CERTAIN 3408B, 3412 SPARK IGN ITED ENGINES - MAILED CFEL, LIMITED US, CANADA, COSA PRIORITY - ROLLER BEARINGS ON THE IDLER SHAFT OF THE AUXILIARY WATER PUMP NEEDS TO BE REPLACED ON CERTAIN 3408B, 3412 SPARK IGN ITED ENGINES - MAILED CFEL, LIMITED US, CANADA, COSA
PRIORITY - NEW GOVERNOR DRIVE AND HOUSING ASSEMBLY NEED TO BE INSTALLED ON CERTAIN 3612 AND 3616 INDUSTRIAL ENGINES - MAILED BRA ZIL, LIMITED US, CANADA, CACO, CFEL, AND COSA PRIORITY - NEW GOVERNOR DRIVE AND HOUSING ASSEMBLY NEED TO BE INSTALLED ON CERTAIN 3612 AND 3616 INDUSTRIAL ENGINES - MAILED BRA ZIL, LIMITED US, CANADA, CACO, CFEL, AND COSA
PRIORITY - CALIFORNIA AIR RESOURCES BOARD (CARB) CERTIFICATION LABELS NEED TO BE INSTALLED ON CERTAIN 3406B TRUCK ENGINES - MAI LED US, CANADA, TRUCK TEPS PRIORITY - CALIFORNIA AIR RESOURCES BOARD (CARB) CERTIFICATION LABELS NEED TO BE INSTALLED ON CERTAIN 3406B TRUCK ENGINES - MAI LED US, CANADA, TRUCK TEPS
PRIORITY - PARTS STOCK ACTION NEEDED - OIL FILTER BYPASS VALVE NEEDS TO BE CHANGED ON CERTAIN 3606, 3608, 3612 & 3616 ENGINES - M AILED US, CANADA, CFEL, LIMITED CACO, COFA, COSA PRIORITY - PARTS STOCK ACTION NEEDED - OIL FILTER BYPASS VALVE NEEDS TO BE CHANGED ON CERTAIN 3606, 3608, 3612 & 3616 ENGINES - M AILED US, CANADA, CFEL, LIMITED CACO, COFA, COSA