KIT-REGULATOR 1006534 - Caterpillar

Caterpillar: Confidential Yellow
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4602" as the Part Number and "1119" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the October 25, 1998 (Revised April 1999) Service Letter. Changes have been made to the TERMINATION DATE.
Termination Date
October 31, 2000Problem
The Jake Brake master piston pushrod may contact the retaining washer and cause the retaining washer to fracture. This would allow the master piston pushrod assembly to fall out of the housing and may cause damage to the unit injector rocker arm.
Affected Product
Model & Identification Number
3406E (6TS2844-27000, 1LW1-21163, 5DS1-758
Reman 4AS1-245
Before failure repair can only be administered if the engine has at least one of the Jake Brake housings removed.
Parts Needed
6 - 1642025 KIT-RETAINERAction Required
BEFORE FAILURE REPAIR
A before failure repair can only be performed if one or more of the Jake Brake housings are removed because of another repair (other than a washer breaking). If this is the case, follow the repair procedure below and complete all 3 housings, but make sure that the housing(s) that was removed for the original failure is claimed against the original repair, and not this Service Letter.The labor to remove and replace the washers as well as the labor to R & I the remaining housing(s) is to be claimed against this Service Letter.
AFTER FAILURE REPAIR
Repair all damage caused by the failure and complete the repair procedure below on all 3 Jake Brake housings, the complete failure and the installation of the new kits are to be claimed against this Service Letter.
Repair Procedure
1. Remove the existing single master piston retaining washer and discard (2 per housing, see Figure 1).2. Install the new two-washer system (164-2025 Kit-Retainer, 6 per engine, see Figure 2). Be sure to follow the Jacobs 340 Series Installation Manual, p/n 019950B (12/97). This installation manual is included in the Jake Brake retarders product reference guide, Caterpillar manual form number RENR1370. The master piston retaining washer (143-6586 Washer), will remain available as a service part for models 340 and 340A housing which use the older, heavyweight casting (5EK1-Up and 6TS1-2843).
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.