PRODUCT SUPPORT PROGRAM FOR INSTALLING A CAMSHAFT KIT ON CERTAIN 3406E TRUCK ENGINES WITH MILEAGE UP TO 500,000 Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A CAMSHAFT KIT ON CERTAIN 3406E TRUCK ENGINES WITH MILEAGE UP TO 500,000

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR INSTALLING A CAMSHAFT KIT ON CERTAIN 3406E TRUCK ENGINES WITH MILEAGE UP TO 500,000

SEBE6584-04

August 2, 1998
(Revised April 2001)
U-215
A-198
AU-162
O-189
TT-12

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR INSTALLING A CAMSHAFT KIT ON CERTAIN 3406E TRUCK ENGINES WITH MILEAGE UP TO 500,000
1210		PS5444

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 "PS5444" 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 Service Letter replaces Service Letters PS0874 and PS0982. It is effective for all repairs after September 1, 1999.

NOTE: This Revised Service Letter replaces the August 2, 1998 Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

March 31, 2002

PROBLEM

A camshaft lobe failure may occur due to rocker arm roller skidding and/or an unsatisfactory cam lobe profile.

AFFECTED PRODUCT

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Model	Identification Number
3406E	5EK1-55087

PARTS NEEDED

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Quantity	Part Number	Description
NOTE: *If the camshaft, injector arms and/or rocker arms have been previously replaced with updated parts, either by a previous Service Letter (PS0899, PS0874 or PS0982) or a previous repair, only replace the parts that were damaged using the individual parts list below.
NOTE: The speed timing sensor and the air compressor relief valve have been removed from the 0R8449 and 0R8450 kits and are not claimable under this service letter.
Engines Rated at 410 HP or Below**
1	0R8449	Camshaft Kit (includes low Hp camshaft, 6-EUI rocker arms and 12-valve rocker arms)
1	6V1197	Seal-O-Ring
1	5E8771	Seal-O-Ring
1	1036045	Seal
1	1178801	Seal-O-Ring
4	1190036	Screw
1	1288853	Adaptor Assembly
NOTE: **For engines with serial numbers 5EK1-1821, use the High Hp camshaft kit (0R8450) or 0R8452 camshaft for all ratings.
-OR-
Engines Rated at 435 HP or Higher
1	0R8450	Camshaft Kit (includes low Hp camshaft, 6-EUI rocker arms and 12-valve rocker arms)
1	6V1197	Seal-O-Ring
1	5E8771	Seal-O-Ring
1	1036045	Seal
1	1178801	Seal-O-Ring
4	1190036	Screw
1	1288853	Adaptor Assembly
-OR-
Individual Parts List* Engines Rated at 410 HP or Below** Engines Rated at 435 HP Up

0R8451 Camshaft 0R8452 Camshaft

0R9546 Arm As. (EUI) 0R9546 Arm As. (EUI)

0R9544 Arm As. (Int Valve) 0R9544 Arm As. (Int Valve)

0R9545 Arm As. (Exh Valve) 0R9545 Arm As. (Exh Valve)

6V1197 Seal-O-Ring 6V1197 Seal-O-Ring

5E8771 Seal-O-Ring 5E8771 Seal-O-Ring

1036045 Seal 1036045 Seal

1178801 Seal-O-Ring 1178801 Seal-O-Ring

1190036 Screw 1190036 Screw

1288853 Adapter Assembly 1288853 Adapter Assembly

ACTION REQUIRED

Camshaft Failure Definition
When evaluating 3406E camshaft lobe wear, use the following pictures/diagram/flowchart to help determine a claimable repair.
Extensive testing has shown the current camshaft design will give excellent service life, even with minor pitting on the backside of the lobes. If a camshaft has some pitting on the backside of one or two lobes (either unit injector or intake/exhaust), and the flowchart directs you to reuse the cam, replace the rocker arm/arms associated with the pitted lobes. The flowchart must be used to determine whether the cam is claimable. There will be a 100% recall of claimed camshafts to monitor the use of the flowchart.
Remove the camshaft and replace it with either an 0R8449 or an 0R8450 Camshaft Kit or individual parts as listed in the "PARTS NEEDED" section of the Service Letter.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
	Parts (D/N)	Labor Hrs (Cost)	Parts	Labor Hrs	Parts (C/L)	Labor Hrs (Sell)
0-500,000 0-806,500 Km 0-60 Mo	100%	100%*	0	0	0	0
*Labor Hour Breakdown SMCS CODE SC MC CV CO Description 1000-074 .5 .5 .5 .7 Engine Wash 1000-035 1.0 1.0 1.0 1.0 Troubleshooting 1210-010 9.0 8.4 8.1 5.9 Camshaft R&I 1123-017-S .5 .5 .5 .5 D&A Rocker Arms (includes transfer of adjuster screws) 1000-530-MJ 1.0 1.0 1.0 1.0 Test After Repair ___ ___ ___ ___ _________________ 12.0 11.4 11.1 9.1 Totals Additional Labor may be claimed for the following: 1802-045-ES .6 .6 .6 .6 A/C System; Recover, Recycle and charge With Refrigerant 1119-010-S .3 .3 .3 .3 Jake Brakes (set) 1353-010-S4 .3 .3 .3 .3 Radiator Top Support Bracket
NOTE: Repair times are for this repair only - if any other repairs are completed at this time (or on the same work order) and there is duplicate labor, it can not be claimed.