Product Support Program For Routing Fuel Flow Hoses And Flashing The ECM With Updated Software On Certain 3406E Engines Rated At 410 Horsepower And Below 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 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 "PS8748" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the July 31, 1996 (Revised July 1997) Service Letter. Changes have been made to the Termination Date.

Termination Date

Problem

Certain 3406E Engines rated at 410 HP and below needs the fuel hose routed so that the fuel enters the front of the cylinder head instead of the rear of the cylinder head and also flash the Electronic Control Module (ECM) with updated software to improve reliability and durability.

Affected Product
Model & Identification Number

3406E (5EK1-80006)

Parts Needed

Order The Flash Software According to the Horse Power Rating and Serial Number. Multitorque (MT) and Brakesaver (BS) Engines have separate software as indicated below.

Serial Numbers 5EK26875-80006

2 - 7K4129 Union

2 - 6N4461 Hose Assembly

^*1 - 0680009 Coupling

^*1 - 9X2373 16 inches Hose

^*1 - 0016268 Coupling

1 - 0016286 Coupling

Serial Numbers 5EK1-26874 Only

1 - 6N4461 Hose Assembly

^*1 - 0680009 Coupling

^*1 - 9X2373 16 inches Hose

^*1 - 0016286 Coupling

1 - 7K4129 Union

1 - 9X2373 Hose (51 inches)

1 - 0307937 Connector

1 - 0336042 Seal-O-Ring

2 - 0672551 Clamp (Navistar Chassis needs 1 additional Clamp)

1 - 0680599 Coupling

1 - 0016286 Coupling

NOTE: Dealers may choose to assemble the hose assembly with parts listed.

NOTE: If Flash Programming fails at 20% to 25% completion, replace the personality module with a 1069184 Module.

Action Required

See the attached rework procedure.

Service Claim Allowances

Labor Breakdown By Cab Type

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

NOTE: This service letter is for routing fuel lines and flashing the software. However, since it has been determined that flashing to improve reliability and durability, this service letter is allowing, with the approval of the Caterpillar Service Representative, the flashing to be completed prior to installing the hoses on fleets (5 or more units).

For fleets (5 or More units), contact your Caterpillar Service Representative for authorization. The representative will give instructions as to the best time to complete the flashing, how to claim and if travel and overtime can be paid.

NOTE: Check SIMS before flashing the ECM to verify that the ECM has not been flashed previously. The service letter can be claimed once for flashing the ECM and once for routing hoses if the flashing is completed at a time different than the hose routing.

NOTE: For Engines with serial numbers 5EK1-268742 that have either the 1034666 or 1142557 Tube Assembly (steel tube), use Steps 1 through 7. For the remaining engines that have the 1188103 Hose Assembly (flex hose), use Steps 1 through 6 on Page 2 of 2 for Serial Numbers 5EK26875-80006.

1. At the front of the head, remove the 1034666 or 1142557 Tube Assembly, 2R6806 Connector, 6V5049 Seal-O-Ring, and (2) 8S8820 Clips. Install the 0307937 Connector and 0336042 Seal to the head at the location where the 2R6806 Connector was removed.

2. Disconnect the hose assembly at the ECM that is routed to the rear of the engine. Remove the 0680009 Coupling and replace with a 0016286 Coupling.

3. Assemble a 0680599 Coupling and a 0680009 Coupling removed in Step 2 to the ends of a 51 inch piece of 9X2373 Hose.

4. Install the 51 inch piece of 9X2373 Hose with the 45 degree coupling at the front of the engine (attach to the 0307937 Connector) and attach the 90 degree coupling to the ECM. Install the (2) 0672551 Clamps to the hose assembly and attach the hose assembly to the same mounting points from which the 8S8820 Clips were removed.

5. Join the 1013123, 1305180, or 1013124 Hose Assembly coming from the rear of the engine with a 7K4129 Union and 6N4461 Hose Assembly. Attach the 90 degree end to the 2R6806 Connector at the fuel manifold.

6. Secure the hoses using tie straps.

7. Download the appropriate flash software file from the electronic bulletin board and flash the engines ECM.

For Serial Numbers 5EK26875-80006

1. At the fuel manifold, disconnect the 1188103 Hose Assembly from the 2R6806 Connector.

2. At the ECM, disconnect the 1013123, 1305180, or 1013124 Hose Assembly, remove the 0680009 Coupling and replace with a 0016286 Coupling.

3. Join the 1013123, 1305180, or 1013124 Hose Assembly coming from the rear of the engine with a 7K4129 Union and 6N4461 Hose Assembly. Attach the 90 degree end to the 2R6806 Connector at the fuel manifold.

4. Join the 1188103 Hose Assembly coming from the front of the engine with a 7K4129 Union and 6N4461 Hose Assembly. Attach the 90 degree end to the ECM.

5. Secure the hoses using tie straps.

6. Download the appropriate flash software file from the electronic bulletin board and flash the engine's ECM.