Product Support Program For Flashing 435 Hp (1650 Lb Ft Torque) Rated 3406E Truck Engines In Response To Low Power Complaints Caterpillar

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.

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0858" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the June 23, 1995 (Revised April 1996) Service Letter. Changes have been made to the Termination Date.

NOTE: This Program can only be administered after Program PS0843, Service Letter dated April 25, 1995, has been performed or in conjunction with PS0843 on a first-time complaint if:

1. The engine histograms indicate that the truck is being driven at higher than normal vehicle speed.

and/or

2. The engine RPM histograms show significant time spent at or above 1700 RPM.

Termination Date

Problem

The 3406E 435 HP 1650 lb ft torque Truck Engine performance is widely accepted as the industry standard. In an effort to provide outstanding product support Caterpillar has developed a performance curve which is expected to meet or exceed the expectations of our customers. This new performance rating produces 445 HP at 1900 RPM. See the performance curve comparison between the production 435 HP rating and the 435 HP High RPM Performance rating below. If customers currently operate the engine consistently at or below 1600 RPM, the 435 HP High RPM Performance rating will not provide any noticeable change in performance.

Consistent use of an engine at higher RPM (1700-1900 RPM) may adversly affect fuel economy. Setting the Top Engine Limit (TEL) above 1900 RPM with the 435 HP High RPM Performance rating requires the addition of a viscous damper, and is not authorized under this product support program.

3406E 435 HP Ratings Performance Curves

Affected Product
Model & Identification Number

3406E (5EK1185-53003)

Parts Needed

Not applicable.

Action Required

1. The owner of the truck must be contacted by the repairing dealer and notified of the potential impact on fuel economy if the Top Engine Limit (TEL) is set above 1800 RPM.

2. Flash the engine with the new High RPM Performance rating:

5EK1185-53003 (Flash file 125-3230 for engines with out Brakesaver)

5EK1185-53003 (Flash file 125-3237 for engines with Brakesaver)

3. If the TEL is set above 1900 RPM, reset it to 1900 RPM or less.

4. Record the final TEL setting in the COMMENTS SECTION of the warranty claim. If you are performing this in conjunction with PS0843, record and enter the following information in the COMMENTS SECTION ON THE FRONT PAGE of the warranty claim.

a. FINAL Top Engine Limit (TEL ____)

b. % time 1700 RPM or above (R__)

c. % time 65 MPH or above (M__)

d. % time Idling (I__)

NOTE: When the rating information is displayed on the service tool (ECAP, ET, PROLINK) the rating is described as "434 HP @ 9999".

Service Claim Allowances

NOTE: This is a .5-hour job.

NOTE: If this Program is done in conjunction with PS0843, submit only one claim against PS0858 and claim 1.5 hour total time.The SIMS Report will be generated automatically for PS0843.