0379539 JOHNSON COVER & BI-METAL, Choke

October 20, 2000
(Revised May 2001)
U-280
TM-5
beforeor
after failure PRODUCT SUPPORT PROGRAMFOR REPLACING THE TURBOCHARGER MOUNTING STUDS THAT MAY FAIL ON CERTAIN3176C AND 3196 ENGINES
1059 PS40317
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS40317"as the Part number and "7755" as the Group Number. If adminstered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If adminstered after failure, use "96" as theWarranty Claim Description Code 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 October 20, 2000 (Revised October 2000) Service Letter. Changes havebeen made to the Service Claim Allowances, and to the Action Required.TERMINATION DATE
October 31, 2001PROBLEM
The turbocharger mounting studs may fail and needto be replaced on certain 3176C and 3196 engines. This failure may causean exhaust leak that can soot up the engine compartment.AFFECTED PRODUCT
3176C 6BW1-4773196 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 Exclude engine serial numbers showing priorrepairs with 1860870, PS40197, PS40317, or PS50054 as the part causingfailure 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 StudACTION REQUIRED
Run oil analysis to check for high Na, and Saltin the oil. If Na is above 18, or salt test is positive, refer to TIB datedJanuary 10, 2001 for recommended action. THE SALT TEST IS COVERED UNDER SEBF3114-01.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-750 / 0-60 mo 100% 8.5 0 0 0 0
This is a 8.5-hour job. U.S. and Canadian Dealers Only - Dealers may enter a Type 2 SIMS report. Travel time and mileage will be paidas if the engine were under warranty.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure1. Begin the repairs and updates by removingthe turbocharger from one engine that has not failed.2. Apply 1U8265 liquid Penetrating Oil (orequivalent) to the turbocharger mounting studs of that engine. Repeat atintervals during the repair of the other engine. This will make eventualremoval 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 turbochargermounting studs of that engine.4. Continue with the update of the turbochargermounting studs on the first engine. Make every attempt to remove thesestuds 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 using8T3087 (M10-1.5) Tap (or equivalent) as necessary.7. In the event in-hull broken stud removalis not possible due to accessibility problems, remove the exhaust manifold.Remove the broken studs.8. Complete the assembly of both engines withnew stronger 1860870 Studs. Use l43973O Turbo Nut wrench to tighten thenuts to a torque of 55 N.m (41 lb-ft).