13035 Force FITTING

July 7, 2004
(Revised July 2004)
U-211
A-144
D-163
O-180
TT-16
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPAIRINGA BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES
5331 PS50839
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50839" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe July 7, 2004 Service Letter. Changes have been made to the Action RequiredSection.TERMINATION DATE
July 31, 2006PROBLEMBroken crankshaft needs to be repaired on certain 3406E Truck Engines.Failures normally occur at #1 or #6 rod fillet.AFFECTED PRODUCT
Model Identification Number
3406E 1LW9548-32089PARTS NEEDED
Qty
Part Number
Description
1 0R3973 CRANKSHAFT Letter does not cover the additionalcost of an Upgrade to New REMAN crankshaft. Customers choosing to use the0R3972 Upgrade to New crankshaft are responsible for the additional cost.ACTION REQUIRED
Follow the Special Instruction REHS1653-00 whendetermining possible repair options. The dealer and customer can then agreeon which option to use. A Service Rep. Authorization will haveto be submitted in the claim story for repair option 2 and REMAN Enginerepairs. Letter does not cover Upgrade to New REMAN short block. 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. A copy of the ECM life time totals isrequired and should not exceed the published limits in this service letter.If the engine is repaired using the Inspection and Repair Procedure repairoption or alternative repair options 1 or 2 in special instruction REHS1653-00and engine has: 0-500,000 miles (0-800,000 KM) and less than 96 months.
Caterpillar pays 100% Parts & Labor to repairwith 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 repairwith 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 repairwith 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 upgradeto new). Labor and all other parts are not covered.
0-750,000 miles (0-1,200,000KM), less than 96 months, and less than 20,000hours
If the customer elects to pay for an OPT overhaul,Caterpillar will pay for a REMAN crankshaft (not upgrade to new) and theOPT 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 theREMAN 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
Product age Caterpillar Dealer Suggested Customer Suggested
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%
Participation above, up to 600,000miles(960,000 KM) and less than 96 months and 20,000 hours, is based onusing either the low cost repair or Optional repair #1 in Special InstructionREHS1653-00. 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 engin