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 Caterpillar

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

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Caterpillar: Confidential Yellow

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

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-161
TT-10
1250, 1408  PS4260
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 "PS4260" as Part Number, "7755" as Group Number, and
"96" as Description Code.

Termination Date

October 31, 1989

Problem

a) The wires for the rack position sensor, transducer module, and
engine speed sensor have a tendency to rub against the 4W2283 Cover on
the Governor Group on certain 3406B (PEEC) Engines.
b) Water may accumulate in the boost line or in the transducer module
and indicate that there is no boost on certain 3406B (PEEC) Engines.

Affected Product

Model Identification Number DO

Rework Procedure

 NO.
3406B 8TC976 - 1099 Procedure 1, 3, and 4
8TC1100 - 2687  Procedure 1, 2, 3, and 4
8TC2688 - 3999  Procedure 1, 3, and 4
8TC4000 - 5166  Procedure 3 and 4

Parts Needed

1 - 5P3426 Elbow
1 - 3J7354 Seal
1 - 3V3036 Hose Assembly
1 - 8M2770 Clip
1 - 2D7325 Tee
1 - 4S6399 Fitting - Flared
1 - 5M6214 Plug
1 - 6K0806 Strap - Cable
1 - 4W2283 Cover
1 - 9X1386 Sleeve (Bulk) (Order 1-20 Foot Length)
1 - 0R5630 Control Group (Required Only If Failure Has Occured)

Action Required

See Attached Rework Procedures

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
miles Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(C/L) (Sell)  (C/L) (Sell)
0-300,000 100% 4 0 0 0 0
mi
NOTE: This is a 4-hour job.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
-1 of 3-

Rework Procedure

 1
1. Remove the 4W2283 Cover and 7C2645 Clip Assembly-Governor from the
engine
2. Remove one rivet and rotate the clip on the clip assembly 10 deg.
counterclockwise (move hole approximately 1/8"). Drill a new hole
for the clip assembly and install a new rivet. See Illustration 1.
3. Reinstall the clip assembly on the engine.
****** IMAGE: SEBE3895.00001.001
CAPTION: Illustration 1

Rework Procedure

 2
1. Remove the 4W2283 Cover from the governor. Earlier 4W2283 Covers
had a rougher surface finish than current 4W2283 Covers that are
used in production and in the parts system.
2. Install a new 4W2283 Cover, with a smooth surface finish, on the
governor.

Rework Procedure

 3
1. The wires from the speed sensor should be 160 mm (6.3") long. Cut
off any excess wire from the retainer of the pin connector. The
1U5803 Connector Kit will be needed to service the Deutsch Connector
(J9).
-2 of 3-
2. Install 9X1386 Sleeve on the wires extending from the rack position
sensor, engine speed sensor, and transducer. See Illustration 2
wires J8, J9, P8, and P9. To install the sleeve on wires coming
from the transducer module, remove the shrink wrap holding the seven
wires together (J8 & P9), being careful not to cut the wires or
insulation. Install separate sleeves on the wires leading to the
engine speed sensor and the rack position sensor. (Note: the
transducer must be removed from the engine to install the sleeve.
The transducer must also be removed for Rework Procedure 4.)
****** IMAGE: SEBE3895.00001.002
CAPTION: Illustration 2.

Rework Procedure

 4
1. With the transducer removed from the engine, remove the 3J7352
Connector, and check for any water that could have entered through
the boost line. If water is present, shake out the water from the
transducer as well as possible.
-3 of 3-
2. With the transducer removed from the engine, install a 5P3426 Elbow
and 3J7354 Seal on the boost port of the transducer. Tighten the
locknut on the elbow so that it is in a downward position when
mounted on the engine. Install the transducer but do not connect
the boost line to it. See Illustration 3 for the location of the
parts.
3. Remove the 7W8804 Tube Assembly from the engine and install a 5M6214
Plug in the bottom of the aftercooler housing where the tube
assembly was connected. Install a 3V3036 Hose Assembly by first
connecting the hose to the 5P3426 Elbow on the transducer. Then
connect the other end of the hose th the top of the inlet manifold.
(Note: In some applications the port on the inlet manifold may
already be used. If this is the case, use a 2D7325 Tee on the
inlet manifold rather than the 6K1972 Elbow.)
Instead of the 3V3036 Hose Assembly a fabricated hose can be used.
If a fabricated hose is to be used, fabricate one out of one 7/16 -
20 SAE 37 deg. JIC straight fitting (Aeroquip FC5988-0404S,
Stratoflex JSN 727-4-4SH-4-4, or equivalent), 36" of 3/16" hose
(Aeroquip #4, Stratoflex #4, or equivalent), and one 7/16 - 20 SAE
37 deg. JIC swivel 45 deg. elbow (Aeroquip FC5990-0404S, Stratoflex
J45S 27227-4-4SH-4-4, or equivalent).
****** IMAGE: SEBE3895.00001.003
CAPTION: Illustration 3
4. Stamp the rework number "TM" on the machined pad which is located
between the engine S/N plate and the cylinder head. Do not stamp
the rework number in the old location on the right side of the
engine.