0381815 JOHNSON FUEL PUMP ASSEMBLY

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PSP FOR EXCESSIVE OIL CONSUMPTION IN CERTAIN 3406B TRUCK ENGINES - PS0392 - MAILED US AND CANADA, COFA, TRUCK TEPS
  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.
U-110 AU-76 TT-6 1318, 1214, 1215 PS0392 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 "PS0392" as Part Number, "7755" as Group Number, and "96" as Description Code. This Program cancels and replaces the April 21, 1988 Service Letter - PS0349. Termination Date
May 31, 1991
Problem
***** Group 1 ***** Some 310 hp 3406B Truck Engines equipped with 7W3668 or 7C3496 Pistons have experienced excessive oil consumption. Engines with higher ratings using the 1W9372 Pistons have not had this problem. ***** Group 2 ***** Some engines which were built with the 7C3496 Piston and chrome top ring may experience piston seizure.
Affected Product
Model Identification Number Group 1 3406B (310 hp only) 7FB27302 - 99999 8TC1 - 1412 4MG1 - 3599 Group 2 3406B (310 hp only) 7FB73753 - 87310
Parts Needed
***** U.S. and Canadian Dealers ***** Groups 1 and 2 6 - 0R2413 Cylinder Kit 1 - 8T6678 Gasket Kit 1 - 8T6677 Gasket Kit 6 - 9Y9497 Bearing (connecting rod) If 0R2413 Cylinder Kits are not available, the individual parts listed under CofA Dealers can be used. ***** CofA Dealers ***** Groups 1 and 2 6 - 9Y3116 Piston 1 - 8T6677 Gasket Kit 6 - 7N7078 Ring (oil) 1 - 8T6678 Gasket Kit 6 - 2P2817 Ring (intermediate) 6 - 1W9460 Ring (top) 6 - 9Y9497 Bearing (connecting rod)
Action Required
***** Group 1 ***** If oil consumption is reported, document oil consumption using the information in Warranty Bulletin No.16 (SEBF 5116-04). Verify that at least the minimum recommended maintenance has been performed by the customer. If excessive oil consumption has been documented and at least the minimum recommended maintenance has been performed, repair the engine using the new parts. ***** Preventive Action For Excessive Oil Consumption ***** Evaluate the engine application for needed corrections. A. Do not overcool jacket water. The jacket water temperature must be kept above 79 deg. C (175 deg. F). Check thermostat for leakage, install orifice or 8N9071 Check Valve in radiator vent line, if needed. A 7C3095 Thermostat (no-leak) can also alleviate over cooling. B. Check air system for leaks. Abrasive wear can be a factor in excessive oil consumption. Evaluate the engine maintenance for needed corrections. A. It is recommended that only superior quality CD lubrication oils be used. See "EMA Lubricating Oils Data Book" Form SEBU5939 or "Oil And Your Engines" Form SEDB0640. C of A dealers should also refer to "Caterpillar Heavy Duty Engine Oils for Australia", MEHQ1178. B. Oil change intervals are important. The oil should be changed at the intervals shown in the Operation and Maintenance Guide or at intervals that are consistent with your fuel usage compared to oil sump capacity. C. Ensure that the correct Caterpillar oil filter is used. ***** Group 2 ***** If a single piston seizure occurs, install the new parts. WARRANTY ALLOWANCES Caterpillar's contribution for this Program will be a percentage of the total allowable parts and labor. Calculate the cost of the listed parts at consumer list. A maximum of 20 hours labor at dealer selling rate will be claimable for installing the 6-0R2413 Kits. If individual parts are installed, a maximum of 23 hours at dealer selling rate will be allowed. Other costs, if allowable under standard warranty, can also be claimed. Use the information in the following example to determine Caterpillar's contribution. Calculate the total cost of claimable parts. Assume the cost to be $1200.00 for the example. Calculate the total cost of claimable labor. Assume the cost to be $600.00 for the example. Calculate the total cost of parts and labor. For the example the total would be $1800. 00. Assume there are no other allowable costs. Obtain the mileage and time in service for the engine. Round