Product Support Program For Increasing The Top Engine Limit Up To 2120 RPM And Installing A Viscous Damper On Certain 435 HP Rated 3406E Truck Engines Caterpillar

Product Support Program For Increasing The Top Engine Limit Up To 2120 RPM And Installing A Viscous Damper On Certain 435 HP Rated 3406E Truck Engines

Usage:

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Caterpillar: Confidential Yellow

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 "PS0861" 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 program can only be administered if the customer has returned after PS0843 and PS0858 have been performed or in conjunction with both programs if the first-time complaint is:

1. The engine histograms indicate higher than normal vehicle speeds.

and/or

2. The engine RPM histograms indicate significant time is spent at or above 1900 RPM.

NOTE: This Revised Service Letter replaces the September 11, 1995 (Revised September 1996) Service Letter. Changes have been made to the Termination Date.

Termination Date

April 30, 1998

Problem

Low power complaints may persist on 435 HP rated 3406E Truck Engines when customers operate the engine at high RPM (above 1800 RPM) and high speed or heavily loaded conditions.

Affected Product
Model & Identification Number

3406E (5EK1185-53003)

NOTE: This Program only applies to 3406E Truck Engines within the above serial number range that are rated at 435 HP.

Parts Needed

1 - 7E9520 Damper Assembly-Viscous

1 - 9Y8870 Plate

Action Required

See the attached Rework Procedure.

Service Claim Allowances

NOTE: If this Program is done in conjunction with PS0843 and PS0858, submit only one claim against PS0861 and claim 2.9 hours total time unless TRG allows more. If this program is done in conjuction with only PS0858, submit one claim against PS0861 and claim 1.9 hours total time unless TRG allows more. The SIMS reports will be automatically generated for PS0843 and PS0858.

NOTE: If R&I Radiator is required, add 1353-010. If S&C Radiator is required, add 1353-029. If R&I Fan Drive is required, add 1359-010.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach.

(1-Rework Procedure)

Rework Procedure

NOTE: PS0843 or equivalent must be performed before this Program can be performed. If PS0843 or equivalent and PS0858 has been performed, proceed with Steps 1 through 5. If PS0843 or equivalent has been performed but PS0858 has not been performed, proceed with Steps 1 through 7. If PS0843 or equivalent has not been performed, perform PS0843 first, then complete steps 1 through 7.

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 is set above 1900 RPM.

2. Set the TEL (Top Engine Limit) at any RPM up to 2120 RPM.

3. If the engine already has a 7E9520 viscous damper and 9Y8870 plate, skip step 4. Remove the 4P4297 or 1084096 rubber damper assembly and six 4D3704 washers.

4. Install a new 7E9520 Viscous Damper Assembly and a new 9Y8870 Plate.

5. Add the final TEL setting in the comments section of the warranty claim.

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