PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER MOUNTING STUDS THAT MAY FAIL ON CERTAIN 3176C AND 3196 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER MOUNTING STUDS THAT MAY FAIL ON CERTAIN 3176C AND 3196 ENGINES

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER MOUNTING STUDS THAT MAY FAIL ON CERTAIN 3176C AND 3196 ENGINES

SEBE7441-02

October 20, 2000
(Revised May 2001)
U-280
TM-5

Show/hide table

*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER MOUNTING STUDS THAT MAY FAIL ON CERTAIN 3176C AND 3196 ENGINES
1059		PS40317

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS40317" as the Part number and "7755" as the Group Number. If adminstered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If adminstered after failure, 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 Revised Service Letter replaces the October 20, 2000 (Revised October 2000) Service Letter. Changes have been made to the Service Claim Allowances, and to the Action Required.

TERMINATION DATE

October 31, 2001

PROBLEM

The turbocharger mounting studs may fail and need to be replaced on certain 3176C and 3196 engines. This failure may cause an exhaust leak that can soot up the engine compartment.

AFFECTED PRODUCT

3176C 6BW1-477 3196 2XR1-593, 596-680, 683-685, 687-897, 899, 901-962, 964-979, 981, 983-1016, 1018-1047, 1049-1051, 1053-1129, 1131-1143, 1145, 1147-1289, 1291-1326, 1328, 1330-1403, 1405-1407, 1409-1422, 1424-1437, 1439-1499, 1501-1530, 1532-1537, 1540-1618, 1620, 1622, 1624-1670, 1672-1701, 1703-1827, 1829-1859, 1861-1869, 1871, 1873-1942, 1945-1972, 1974-1983, 1985-2025, 2027, 2029-2113, 2115-2122, 2124-2159, 2161-2230, 2232-2236, 2238-2243, 2247, 2249-2266, 2268-2273, 2276, 2277, 2279-2281, 2283, 2284, 2286-2294, 2296-2313, 2315, 2317-2339, 2341, 2342, 2344-2355, 2357-2360, 2362, 2364, 2367-2370, 2372, 2373, 2375-2378, 2380, 2383-2391, 2393-2407, 2409-2463, 2465, 2466, 2468-2485, 2488-2496, 2498-2503, 2505-2510, 2512, 2516, 2519, 2522, 2523, 2527-2560, 2562-2564, 2566, 2567, 2569, 2570, 2573, 2575, 2581, 2583, 2586-2591, 2593, 2594, 2604, 2606, 2607, 2613, 2615-2678 NOTE: Exclude engine serial numbers showing prior repairs with 1860870/">1860870, PS40197, PS40317, or PS50054 as the part causing failure in SIMS.

PARTS NEEDED

1 - 7M7273 Gasket - Turbocharger
1 - 1S4810 Gasket - Oil
1 - 1S6595 Gasket
1 - 6V5839 Washer - Hard
4 - 9X6620 Locknut
1 - 1260124 Gasket
4 - 1860870 Stud

ACTION REQUIRED

Run oil analysis to check for high Na, and Salt in the oil. If Na is above 18, or salt test is positive, refer to TIB dated January 10, 2001 for recommended action.

NOTE: THE SALT TEST IS COVERED UNDER SEBF3114-01.

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-750 / 0-60 mo	100%	8.5	0	0	0	0
NOTE: This is a 8.5-hour job. NOTE: U.S. and Canadian Dealers Only - Dealers may enter a Type 2 SIMS report. NOTE: Travel time and mileage will be paid as if the engine were under warranty.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1-Rework Procedure) Rework Procedure 1. Begin the repairs and updates by removing the turbocharger from one engine that has not failed.

2. Apply 1U8265 liquid Penetrating Oil (or equivalent) to the turbocharger mounting studs of that engine. Repeat at intervals during the repair of the other engine. This will make eventual removal of these studs easier and less time consuming.

3. Remove the turbocharger from the other engine, which may or may not have failed. Apply liquid penetrant to the turbocharger mounting studs of that engine.

4. Continue with the update of the turbocharger mounting studs on the first engine.

NOTE: Make every attempt to remove these studs in hull. 5. Remove studs that have not failed.

6. If stud(s) have failed, or break upon removal, drill out and use 4C3367 Extractor (or equivalent) to remove. Re-tap using 8T3087 (M10-1.5) Tap (or equivalent) as necessary.

7. In the event in-hull broken stud removal is not possible due to accessibility problems, remove the exhaust manifold. Remove the broken studs.

8. Complete the assembly of both engines with new stronger 1860870 Studs. Use l43973O Turbo Nut wrench to tighten the nuts to a torque of 55 N.m (41 lb-ft).