SPRING 1S5646 - Caterpillar

Caterpillar: Confidential Yellow
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.
This Program must be administered as soon as possible. When reporting the repair, use "PI3576" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3576" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Revised Service Letter replaces the April 22, l992 (Revised May 1992) Service Letter. Changes have been made to the Affected Product, Action Required, Service Claim Allowances, and Parts Disposition.
Completion Date
October 31, 1992Termination Date
April 30, 1993Problem
The control group (personality module) needs to be replaced on certain 460 Hp 3406B Engines to improve performance and response.
Affected Product
Model & Identification Number
3406B (5YG1-393, 5YG395-407, 5YG409, 5YG411-421, 5YG424, 5YG426, 5YG427, 5YG429-444, 5YG447-452, 5YG454-458, 5YG460-476, 5YG478-486, 5YG488-492, 5YG494, 5YG495, 5YG497-504, 5YG506-512, 5YG514-519, 5YG521-561, 5YG563-586, 5YG588-613, 5YG615-627, 5YG629-634, 5YG636-642, 5YG644-656, 5YG658-688, 5YG690-701, 5YG703, 5YG705-726, 5YG728-731, 5YG735-757, 5YG759-768, 5YG770-779, 5YG781-783)
Several of the engines listed above were already updated with all of the new parts from the control group kit except for the new 0R6495 Control Group (Personality Module).
Parts Needed
1 - 0R6497 Control Group Kit Unused parts from kit are to be returned.
Action Required
Parts Stock
Remove all 0R6269 Control Group Modules from parts stock.
Affected Product
1. Replace the existing control group (personality module) with a 0R6495 Control Group from the 0R6497 Control Group Kit. Some engines may have already have been partially updated to detect coolant temperature. If not, remove the plug located in the side of the regulator housing. Install a 3J1907 Seal and 9X3271 Adapter into the housing. Install a 9X5370 Control Group into the adapter. Remove the existing main harness assembly and install the new 6I2382 Harness Assembly. Route and secure the new harness assembly as described on page 9 of the trouble shooting section of the Service Manual (SENR5503). Connect all plugs and receptacles that were attached to the former harness assembly in addition to connecting the 9X5370 Control Group to the harness assembly.2. Program Full Load Setting (FLS) and Full Torque Setting (FTS) to zero (0) and zero (0). Install the new 9L6531 Engine Information Plate.3. Program low idle to 700 RPM or higher.4. Program Top Engine Limit to 2120 RPM. Program the values for the TEL after the engine is out of the "Cold Mode" (Coolant temperature is greater than 65° F).Owner Notification
Not Applicable.
Service Claim Allowances
Parts Stock
Submit one claim for all 0R6269 Control Group Modules removed from parts stock.
Affected Product
Labor segment for steam cleaning not allowed for this repair.
Parts Disposition
U.S. and Canadian Dealers
Return all parts removed from parts stock; return all parts removed from the engines; and return all parts from the kits that were not installed on the engines.