Product Support Program For Installing An Inlet Air Manifold Heater On Certain 460 H.P. 3406B And 3406C Truck Engines Caterpillar

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 "PS0658" 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 February 20, 1993 Service Letter. Changes have been made to the Affected Product, Action Required, and Service Claim Allowances.

Termination Date

Problem

A 6I3045 Heater Group for the intake air manifold can be installed to improve the starting and cold engine operation of certain 3406B and 3406C Engines while operating in cold weather or in cold climates.

Affected Product
Model & Identification Number

3406B (5YG1-783)

3406B (2EK179, 2EK180, 2EK185, 2EK188, 2EK190, 2EK202-204, 2EK206, 2EK208-211, 2EK214, 2EK216, 2EK217, 2EK219-221, 2EK224, 2EK226, 2EK228-232, 2EK234, 2EK236, 2EK238-240, 2EK243, 2EK246, 2EK251, 2EK255, 2EK264, 2EK272, 2EK273, 2EK285, 2EK287, 2EK288, 2EK290, 2EK292, 2EK294, 2EK300, 2EK302, 2EK304, 2EK316, 2EK333, 2EK334, 2EK339, 2EK357, 2EK392, 2EK393, 2EK399, 2EK409, 2EK426, 2EK430, 2EK431, 2EK445, 2EK446, 2EK483-485, 2EK487, 2EK489, 2EK497, 2EK500, 2EK503, 2EK504, 2EK509, 2EK511, 2EK519, 2EK522, 2EK524, 2EK538, 2EK542, 2EK554, 2EK555, 2EK560, 2EK562, 2EK580, 2EK585, 2EK587, 2EK593, 2EK597, 2EK600, 2EK601, 2EK603, 2EK635, 2EK639, 2EK644, 2EK645, 2EK653, 2EK660, 2EK674, 2EK676, 2EK678, 2EK681-685, 2EK688, 2EK689, 2EK692, 2EK693, 2EK706, 2EK713, 2EK716, 2EK723, 2EK732, 2EK733, 2EK737, 2EK738, 2EK741, 2EK743, 2EK745, 2EK746, 2EK751, 2EK753, 2EK756, 2EK757, 2EK760, 2EK766, 2EK769-771, 2EK773, 2EK779, 2EK784, 2EK787, 2EK794, 2EK796, 2EK800, 2EK804, 2EK805, 2EK839, 2EK845, 2EK862, 2EK872, 2EK886, 2EK887, 2EK889, 2EK904, 2EK918, 2EK919, 2EK921, 2EK931, 2EK933, 2EK934, 2EK938, 2EK940, 2EK942, 2EK944, 2EK945, 2EK957, 2EK961, 2EK965, 2EK966, 2EK968, 2EK971, 2EK982, 2EK994, 2EK1006, 2EK1028, 2EK1036, 2EK1066, 2EK1075, 2EK1078, 2EK1080, 2EK1083, 2EK1087, 2EK1110, 2EK1112, 2EK1116, 2EK1121, 2EK1138, 2EK1140, 2EK1143, 2EK1149-1151, 2EK1154-1156, 2EK1158-1159, 2EK1159, 2EK1161, 2EK1167, 2EK1175, 2EK1210, 2EK1213, 2EK1214, 2EK1216, 2EK1221, 2EK1227, 2EK1240, 2EK1241, 2EK1245, 2EK1279, 2EK1286, 2EK1301, 2EK1332-1334, 2EK1342, 2EK1343, 2EK1351, 2EK1354, 2EK1401, 2EK1412, 2EK1428, 2EK1433, 2EK1436, 2EK1438, 2EK1440, 2EK1441, 2EK1444, 2EK1459, 2EK1476, 2EK1498, 2EK1499, 2EK1503, 2EK1507, 2EK1518, 2EK1519, 2EK1521, 2EK1524, 2EK1537, 2EK1541, 2EK1603, 2EK1606, 2EK1608, 2EK1611, 2EK1624, 2EK1652, 2EK1654, 2EK1657, 2EK1658, 2EK1661, 2EK1669, 2EK1681, 2EK1687, 2EK1702, 2EK1704-1706, 2EK1708, 2EK1711, 2EK1715, 2EK1728, 2EK1729, 2EK1739, 2EK1742, 2EK1750, 2EK1753, 2EK1765, 2EK1767, 2EK1770, 2EK1773-1779, 2EK1793, 2EK1796, 2EK1798, 2EK1799, 2EK1801, 2EK1802, 2EK1823, 2EK1834, 2EK1835, 2EK1848, 2EK1850, 2EK1852, 2EK1856, 2EK1859, 2EK1865, 2EK1916, 2EK1930)

3406C (4CK168, 4CK169, 4CK173, 4CK181, 4CK183, 4CK199, 4CK200, 4CK217, 4CK271, 4CK272, 4CK295, 4CK296, 4CK401, 4CK436, 4CK486, 4CK489, 4CK491, 4CK855, 4CK857, 4CK891, 4CK892, 4CK894, 4CK952, 4CK955, 4CK960, 4CK961, 4CK973, 4CK977, 4CK978, 4CK1011, 4CK1013, 4CK1040, 4CK1088, 4CK1091, 4CK1108, 4CK1124, 4CK1185, 4CK1195, 4CK1196, 4CK1199, 4CK1270, 4CK1313, 4CK1323, 4CK1374, 4CK1378, 4CK1417, 4CK1419, 4CK1433, 4CK1468, 4CK1528, 4CK1534, 4CK1547, 4CK1549, 4CK1550, 4CK1552-1554, 4CK1557, 4CK1558, 4CK1566-1569, 4CK1582, 4CK1584, 4CK1691, 4CK1698, 4CK1724, 4CK1730, 4CK1732, 4CK1735, 4CK1736, 4CK1739, 4CK1741, 4CK1746, 4CK1750, 4CK1754, 4CK1757, 4CK1805, 4CK1807, 4CK1811, 4CK1833, 4CK1836, 4CK1855, 4CK1860, 4CK1865, 4CK1894, 4CK1896, 4CK1898, 4CK1899, 4CK1901, 4CK1904, 4CK1905, 4CK1909, 4CK1915, 4CK1917, 4CK1919, 4CK2082, 4CK2089, 4CK2094, 4CK2097, 4CK2101, 4CK2140, 4CK2157, 4CK2244, 4CK2411, 4CK2478, 4CK2526, 4CK2554, 4CK2571, 4CK2594, 4CK2636, 4CK2660, 4CK2683, 4CK2854, 4CK3096, 4CK3314, 4CK3348, 4CK3432, 4CK3561, 4CK3650, 4CK3825, 4CK3828, 4CK3834, 4CK3886, 4CK3939, 4CK3953, 4CK4140, 4CK4334, 4CK4341, 4CK4385, 4CK4402, 4CK4842, 4CK4991, 4CK5155, 4CK5200, 4CK5243, 4CK5392, 4CK5445, 4CK5485, 4CK5516, 4CK5542, 4CK5558, 4CK5579, 4CK5686, 4CK5687, 4CK5693, 4CK5733, 4CK5786, 4CK5860, 4CK6186, 4CK6482, 4CK6532, 4CK6568, 4CK6611, 4CK6615, 4CK6783, 4CK6815, 4CK6931, 4CK6935, 4CK7067, 4CK7070, 4CK7072, 4CK7076, 4CK7078, 4CK7081, 4CK7083, 4CK7085, 4CK7089, 4CK7090, 4CK7104, 4CK7127, 4CK7231, 4CK7233, 4CK7235, 4CK7252, 4CK7293, 4CK7357, 4CK7360, 4CK7362, 4CK7366, 4CK7368, 4CK7371, 4CK7397, 4CK7408, 4CK7410, 4CK7413, 4CK7416, 4CK7418, 4CK7459, 4CK7460, 4CK7490, 4CK7494, 4CK7525, 4CK7530, 4CK7532, 4CK7534, 4CK7536, 4CK7577, 4CK7581, 4CK7631, 4CK7724, 4CK7727, 4CK7799, 4CK7848, 4CK7865, 4CK7867, 4CK7882, 4CK7888, 4CK7899, 4CK7904, 4CK7909, 4CK7913, 4CK7918, 4CK7944, 4CK7960, 4CK7971, 4CK7974, 4CK7986, 4CK7996, 4CK8030, 4CK8039, 4CK8067, 4CK8170, 4CK8172, 4CK8173, 4CK8175, 4CK8176, 4CK8179, 4CK8183, 4CK8186, 4CK8187, 4CK8218, 4CK8224, 4CK8266, 4CK8269, 4CK8273, 4CK8307, 4CK8310, 4CK8338, 4CK8341, 4CK8362, 4CK8373, 4CK8375, 4CK8376, 4CK8379, 4CK8381, 4CK8384, 4CK8386, 4CK8390, 4CK8395, 4CK8400, 4CK8481, 4CK8488, 4CK8539, 4CK8540, 4CK8545, 4CK8555, 4CK8592, 4CK8623, 4CK8628, 4CK8629, 4CK8641, 4CK8631, 4CK8647, 4CK8652, 4CK8656, 4CK8658, 4CK8693, 4CK8743, 4CK8745, 4CK8747-8749, 4CK8751, 4CK8771, 4CK8804, 4CK8809, 4CK8868, 4CK8871, 4CK8879, 4CK8882, 4CK8919, 4CK8925, 4CK8927, 4CK8931, 4CK8932, 4CK9007, 4CK9009, 4CK9010, 4CK9028, 4CK9045, 4CK9128, 4CK9129, 4CK9131, 4CK9135, 4CK9294, 4CK9296, 4CK9339, 4CK9341, 4CK9342, 4CK9345, 4CK9375, 4CK9384, 4CK9386, 4CK9387, 4CK9390, 4CK9392, 4CK9405, 4CK9413, 4CK9477, 4CK9480, 4CK9482, 4CK9486, 4CK9489, 4CK9499, 4CK9508, 4CK9550, 4CK9553, 4CK9590, 4CK9677, 4CK9678, 4CK9680, 4CK9683, 4CK9684, 4CK9689, 4CK9693, 4CK9746, 4CK9802, 4CK9804, 4CK9821, 4CK9826, 4CK9830, 4CK9832, 4CK9869, 4CK9870, 4CK9872, 4CK9897, 4CK9900, 4CK9902, 4CK9909, 4CK9913, 4CK9915, 4CK9919, 4CK9922, 4CK10008, 4CK10010, 4CK10017, 4CK10021, 4CK10024, 4CK10115, 4CK10159, 4CK10163, 4CK10167, 4CK10171, 4CK10175, 4CK10178, 4CK10179, 4CK10183, 4CK10186, 4CK10187, 4CK10190, 4CK10192, 4CK10193, 4CK10210, 4CK10212, 4CK10214, 4CK10217, 4CK10291, 4CK10296, 4CK10311, 4CK10325, 4CK10336, 4CK10344, 4CK10381, 4CK10382, 4CK10384, 4CK10385, 4CK10402, 4CK10403, 4CK10407, 4CK10410, 4CK10413, 4CK10455, 4CK10484, 4CK10492, 4CK10501, 4CK10508, 4CK10509, 4CK10517, 4CK10540, 4CK10541, 4CK10545, 4CK10555, 4CK10561, 4CK10568, 4CK10604, 4CK10621, 4CK10699, 4CK10860-Up^*)

Parts Needed

1 - 8D8719 Fuse Holder

2 - 3E7437 Connector

1 - 6I3045 Heater Group

1 - 6I3784 Bracket

1 - 3K8782 Fuse

2 - 5P0537 Washer

1 - 3T4418 Switch Assembly

2 - 8T2930 Film

2 - 6V8837 Bolt

Action Required

During cold weather, low intake air temperatures may delay warm-up and cause poor performance immediately after start-up on certain 3406B and 3406C Engines. Following a customer complaint of extended warm-up periods, install a 6I3045 Heater Group following most of the procedures in Special Instructions SEHS9444. Any existing ether starting system must be disabled prior to operation of the intake manifold heater.

NOTE: Use the following to install the temperature sensor. Disregard the section "Installing the 6I3050 Temperature Sensor" contained in Special Instruction SEHS9444. The temperature sensor found in the heater group should be installed on the engine to measure outside air temperature. Sensing outside air temperature instead of coolant temperature will allow system activation in cold weather conditions when coolant temperature is still above 68 ° F.

If the 6I3048 Heater Group is equipped with the 6I3050 Sensor (single terminal), replace it with a new 101-9646 Sensor. The new sensor is of a two post design.

Ground the sensor by crimping a new wire onto one of the posts and connecting it to the common ground at the solenoid mounting bracket. Cut off the boot on the existing harness and crimp the wire onto the remaining post. The connections can be protected by installing plastic shrink wrap to prevent corrosion.

The sensor should be mounted in a protected area on the intake side of the engine so that the end of the sensor is exposed. Attach (tie wrap) the sensor onto the main harness wiring loom between the fuel solenoid and the air inlet pipe.

In some cases, the cooling fan may turn on during the intake air heater cycle. The additional parasitic load of driving the fan will reduce engine warm-up time.

Service Claim Allowances

NOTE: This is a 5.5-hour job.

Parts Disposition

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