MANIFOLD-EXHAUST 1078109 - Caterpillar

SEBE6135-06 July 4, 1997
(Revised August 2003)
U-180
A-155
AU-138
O-152
TT-13
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPAIRINGFRONT COVER OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS
1162 PS5292
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS5292" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode 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. Complete PS5291 before administeringthis program. However, at the dealers discretion, if it is concluded thatthe engine is also leaking on the left side at or behind the air compressor,this program may be applied at the same time as PS5291. Up to 60 months or 500,000 miles, thisProgram covers this repair. This is 36 months longer than the 3406 On-HighwayVehicle standard warranty. If for any reason this repair is not successful,please call your Caterpillar Service Representative to discuss this matter. This Revised Service Letter replacesthe July 4, 1997 (Revised August 2001) Service Letter. Changes have beenmade to the Termination Date.TERMINATION DATE
July 31, 2004PROBLEM
The front cover plate to block gasket may leakoil on the left side at or behind the air compressor. If a leak is foundat the top of the plate to block gasket, refer to PS5291.AFFECTED PRODUCT
Model Identification Number
3406E 5EK1-Up4AS1-Up5DS1-Up6TS1-Up1LW1-Up2WS1-Up1MM1-UpPARTS NEEDED
Claimable Parts
Qty Part Number Description
1 8T9527 Power Steering AdaptorO-Ring
2 1100004 Air Compressor MountingO-Ring
1 1439508 Epoxy
1 1439509 Mixing Nozzle (oneper engine repair)
1 1075769 Seal
Non-Claimable Parts
Qty Part Number Description
1 4C4079 Cleaner-(Aerosol Can)or 9U6346 (Pump Spray)(16 oz. will clean approximately 2 engines)
1 Vinyl Tube (7 cm or 2 1/2 incheslong, 5/16 inch ID)(Caterpillar P/N 5P5995 or equivalent)
Service Tools
Qty Part Number Description
1 1439510 Applicator (includes1435911 Plunger)ACTION REQUIRED
See the attached rework procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-500,000 hrs0-60 Mo 100% 100% 0 0 0 0Labor Hour BreakdownLaborSMCS Code Hours Description1000-074 0.3 Wash1000-035 0.2 Troubleshoot1803-010 D 1.3 R&I Air Compressor (2 Cyl)1803-010-04 1.6 R & I Air Compressor (4 Cyl)4306-010-PD 0.5 R & I Power Steering Pump and Drive1801-560 0.2 Cut Sound Suppression Panel1162-079-MN 0.2 Tighten Bolts1162-005 0.5 Epoxy1000-031 0.3 Test After Repair times are for this repair only - if any duplicaterepairs are completed at this time (same work order), they cannot be claimed.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)REWORK PROCEDURE
Repair Procedure with Front Cover NOT Removed
If access to bolt heads is difficult,a hand wrench is recommended.
Remove air compressor.
Cut approximately 2 inches of sound suppressionpanel along the left side of the block and front plate joint, this willallow application of epoxy along the entire length of the left side ofthe plate/block joint.
Remove the power steering pump/adaptor.
Tighten the two 3/8 inch bolts. The use of a handwrench is recommended. See Illustration 1.
Clean the top and left joint area of the enginewhere the front cover/plate meet the block with 4C4079 Cleaner. A smallbrass/wire brush may be needed to remove excessive amounts of oil/dirtbuild-up. Be sure no oil is left on the