PRODUCT SUPPORT PROGRAM FOR REPAIRING A BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING A BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES

Usage:

SEBE8846-01

July 7, 2004
(Revised July 2004)
U-211
A-144
D-163
O-180
TT-16

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING A BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES
5331		PS50839

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 "PS50839" 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: 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 Revised Service Letter replaces the July 7, 2004 Service Letter. Changes have been made to the Action Required Section.

TERMINATION DATE

July 31, 2006

PROBLEM

Broken crankshaft needs to be repaired on certain 3406E Truck Engines. Failures normally occur at #1 or #6 rod fillet.

AFFECTED PRODUCT

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Model	Identification Number
3406E	1LW9548-32089

PARTS NEEDED

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Qty	Part Number	Description
1	0R3973	CRANKSHAFT

NOTE: Letter does not cover the additional cost of an Upgrade to New REMAN crankshaft. Customers choosing to use the 0R3972 Upgrade to New crankshaft are responsible for the additional cost.

ACTION REQUIRED

Follow the Special Instruction REHS1653-00 when determining possible repair options. The dealer and customer can then agree on which option to use. NOTE: A Service Rep. Authorization will have to be submitted in the claim story for repair option 2 and REMAN Engine repairs. Letter does not cover Upgrade to New REMAN short block.

NOTE: Participation depends on mileage, time, and option chosen. Verify the engine mileage using Cat Electronic Technician, and print a copy of the ECM Life Time Totals.

NOTE: A copy of the ECM life time totals is required and should not exceed the published limits in this service letter.

If the engine is repaired using the Inspection and Repair Procedure repair option or alternative repair options 1 or 2 in special instruction REHS1653-00 and engine has:

0-500,000 miles (0-800,000 KM) and less than 96 months.

Caterpillar pays 100% Parts & Labor to repair with REMAN crankshaft (not upgrade to new) and contingent damage.

500,001 ? 550,000 miles (800,001-880,000 KM) and less than 96 months.

Caterpillar pays 70% Parts & Labor to repair with REMAN crankshaft (not upgrade to new) and contingent damage.

550,001 ? 600,000 miles (880,001-960,000 KM) and less than 96 months.

Caterpillar pays 50% Parts & Labor to repair with REMAN crankshaft (not upgrade to new) and contingent damage.

600,001 ? 750,000 miles (960,001-1,200,000 KM) and less than 96 months.

Caterpillar pays for REMAN Crank ONLY (not upgrade to new). Labor and all other parts are not covered.

0-750,000 miles (0-1,200,000KM), less than 96 months, and less than 20,000 hours

If the customer elects to pay for an OPT overhaul, Caterpillar will pay for a REMAN crankshaft (not upgrade to new) and the OPT coverage fee only (no labor is covered for OPT overhaul repair option).

If the customer elects to purchase a REMAN engine, Caterpillar will pay $2,000 to be applied to the purchase price of the REMAN engine. No additional handling fee will be allowed.

750,001 ? 1,000,000 miles (1,200,001-1,600,000 KM) and less than 96 months

Caterpillar will pay $1500 per failure. Customer can apply to repair, overhaul, or REMAN engine.

SERVICE CLAIM ALLOWANCES

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-500,000 mi (0-800,000 KM) 0-96 mos	100%	100%**	0	0	0	0
500,001-550,000 mi (800,001-880,000 KM) 0-96 mos	70%	70%**	0	0	30%	30%
550,001-600,000 (880,001-960,000 KM) 0-96 mos	50%	50%**	0	0	50%	50%
NOTE: Participation above, up to 600,000 miles(960,000 KM) and less than 96 months and 20,000 hours, is based on using either the low cost repair or Optional repair #1 in Special Instruction REHS1653-00. For OPT overhaul, Caterpillar will pay for a REMAN crankshaft (not upgrade to new) and the OPT coverage. For a REMAN engine purchase, Caterpillar will pay $2000 to be applied to the REMAN engine purchase. NOTE: For engines within the 600,001-750,000 mile (960,001-1,200,000 KM) range Cat will pay for REMAN Crank only (not upgrade to new). Labor and all other parts fall under Customer. File for REMAN crankshaft only. NOTE: For engines within the 750,001-1,000,000 mile (1,200,001-1,600,000 KM) range Cat will pay $1500 which can be applied to repair, overhaul or REMAN engine.

**Labor Hour/Supplement Breakdown by Cab Type

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SMCS Code	SC	MC	CV	CO	Description
REHS1653-00 Inspection and repair procedure repairs 0-600,000 miles (0-960,000Km)
1202-000	33.4	31.4	30.6	28.8	Crankshaft R&I (without piston/rod damage)
1202-000-WX	36.9	34.9	34.1	32.3	Crankshaft R&I (with piston/rod damage) Combined time
Add if required:
1119-010-ES-S	0.6	0.5	0.5	0.5	Jake Brake R&I
1302-010-PH	0.9	0.9	0.9	0.9	Oil pan plate R&I
1240-010	0.3	0.3	0.3	0.3	Block under frame ( ladder)
1302-010-S1	0.3	0.3	0.3	0.3	Oil pan sound suppression panel
7050-010-S4	0.3	0.3	0.3	0.3	Frame support R&I
1000-002					Transfer engine components (use if REMAN engine is used
For Alternative repair option 1 repairs 0-600,000 miles (1-960,000 km)
SMCS Code	SC	MC	CV	CO	Description
1201-035	1	1	1	1	Troubleshoot
1201-030	1	1	1	1	Test After Repair
1201-074	0.5	0.5	0.5	0.5	Wash
1000-010	18.6	16.6	15.8	12.3	Engine remove & install
1201-010	21.6	21.6	21.6	23.1	Cylinder block (strip for line bore)
Add if required
1119-010-ES-S	0.6	0.5	0.5	0.5	Jake Brake R&I
1302-010-PH	0.9	0.9	0.9	0.9	Oil pan plate R&I
1240-010	0.3	0.3	0.3	0.3	Block under frame ( ladder)
1302-010-S1	0.3	0.3	0.3	0.3	Oil pan sound suppression panel
7050-010-S4	0.3	0.3	0.3	0.3	Frame support R&I
For OPT Overhaul repairs 0-750,000 miles (0-1,200,000 km)
	$750	$750	$750	$750	Sublet OPT Overhaul coverage fee
For repairs with 750,001-1,000,000 miles (1,200,001-1,600,000KM)
	$1500	$1500	$1500	$1500	Claim as sublet