Replacing a Model S2B With a Model S3B Turbocharger on Certain 3176 Truck Engines{1052} Caterpillar

Introduction

This instruction provides the information and parts necessary to replace a Model S2B with a Model S3B turbocharger on 3176 Truck Engines 7LG07500 - 15999.

Reference: Service Manual SEHS9349 ... Tool Operating Manual ... Using the NEXG4522 Truck Engine Functions Dual Service Program Module

Turbocharger Model Identification

The turbocharger Model, that is currently on the engine, MUST be identified as a Model S2B before any parts replacement.

How to Identify the Turbocharger Model

Two methods can be used to identify the turbocharger Model:

Part Number Identification

Side view of typical turbocharger ... 4N8155 Nameplate at location (A).

The Turbocharger Group and Cartridge Group part number (begins with C2B) is on the 4N8155 Nameplate at location (A).

NOTE: The name plate surface may have been painted and should be cleaned to ensure legibility.

The following Turbocharger (Turbo) Group and Cartridge Group part numbers identify the turbocharger as a Model S2B ONLY:

4P2870 Turbo Group ... 4P2880 Cartridge Group

0R6175 Turbo Group ... 0R6179 Cartridge Group

6I3965 Turbo Group ... 6I3990 Cartridge Group

0R6571 Turbo Group ... 0R6572 Cartridge Group

Visual Identification

Side view of typical turbocharger that uses bolts (B) to secure the housings to the center section.

A turbocharger Model S2B uses bolts to secure the housings to the center section.

NOTE: The 3176 Truck Engine also uses turbocharger Models, on earlier models, that use band clamps, rather than bolts, to secure the housings to the center section and are NOT covered by this instruction.

Parts Description List

Model S2B Removal and Inspection

1. Remove (retain fasteners for reuse) the turbocharger and oil lines from the engine.

Inspection

If the turbocharger is being replaced because of a FAILURE:

* Inspect the compressor (cold side) for evidence of oil leaks ... and/or

* Fin damage.

If there are signs of oil leaks:

* Inspect the aftercooler and related hoses for evidence of oil.

If fin damage is evident, remove the air filter and:

* Inspect the air system, DOWNSTREAM and UPSTREAM, for any debris from the damaged wheel's fins.

If debris is present:

* Carefully wipe/flush the debris from the air filter element housing, aftercooler and related hoses.

* Replace air cleaner element if necessary.

Installing the Model S3B

1. Clean the exhaust manifold flange and install the Model S3B turbocharger using a new 1P0451 Gasket and four 9X6620 Nut(s).

NOTE: Use 5P3931 Anti-Seize on studs before installing the 9X6620 Nut(s).

2. Install the 7C1831 Tube Assembly (oil drain line) to the turbocharger using a new 1S7057 Gasket and the original bolts and washers.

3. Lubricate the turbocharger shaft and bearings by pouring CLEAN engine oil into the oil supply hole in the top of the turbocharger center housing.

4. Install the 6I1463 or 4P7566 Tube Assembly (oil supply line) to the turbocharger using a new 1S7057 Gasket and the original bolts and washers.

5. Complete the assembly of air pipes, hoses, etc.

* Check the engine oil level ... and

* Change engine oil and engine oil filter if a serious failure has occurred.

Personality Module

NOTE: All references are found in the Tool Operating Manual:

* SEHS9349 ... Using the NEXG4522 Truck Engine Functions Dual Service Program Module

NOTE: The original Personality Module MUST be interrogated, using the 8T8697 Electronic Control Analyzer Programmer (ECAP), to ensure that the new Personality Module is programmed with the same engine power and contains J1922 Powertrain Data Test Link or Bulk-Hauler if needed.

Original Personality Module

1. Connect ECAP to power and RS-485 Connector.

Refer to:

* Power and RS-485 Connector

2. Read customer specified parameters list.

Refer to:

* Read Customer Specified Parameters List

NOTE: If you are not familiar with the ECAP and/or NEXG4522 Truck Engine Functions Dual Service Program Module, follow the procedures as shown in the reference(s). The procedures will guide you through the various screen displays required to reach and/or review/change the customer specified parameters list.

New Personality Module

The new personality module will have a different Personality Module Code which MUST be transferred to the engine's Electronic Control Module (ECM).

3. Disconnect engine electrical power.

4. Disconnect power to PORT 1 on ECAP.

5. Install the new personality module.

3. Connect engine electrical power.

6. Connect power to PORT 1 on ECAP.

7. Read Customer Specified Parameters List to compare with the original personality module's Customer Specified Parameters List.

Refer to:

* Read Customer Specified Parameters List

NOTE: The Read/Change System Configuration Parameters are protected by factory specified passwords to prevent unauthorized changes.

The factory specified passwords are obtained by contacting your Caterpillar dealer with the following information:

* Engine Serial Number

* Electronic Control Module Serial Number

* ECAP Serial Number

* Total Tattletale.

You will then be provided with a set of two (eight character) passwords that are valid until a parameter is changed in the ECM (indicated by a changed total tattletale number).

Change and Confirm New Personality Module Code

The new personality module will have a different Personality Module Code which MUST be transferred to the engine's Electronic Control Module (ECM).

Refer to all procedures in:

* Read/Change System Configuration Parameters

8. ENTER Personality Module Code (0):

* The ECM will read the new Personality Module and store the new Personality Module Code in the ECM.

4W5140 Parts Service Engine Information Plate, 9L6531 Engine Information Plate and Certification Label

A 4W5140 Parts Service Engine Information Plate MUST be stamped with the new engine Power Rating, Performance Specification number and Fuel Timing value.

Some of the he original plates information block information must also be transferred onto the new plate:

* AR NO. (Arrangement number)

* MAX ALT (Maximum Altitude)

* BARE ENG. HIGH IDLE RPM

* FULL LOAD RPM

The 4W5140 Parts Service Engine Information Plate is then installed (with adhesive) over the original 9L6531 Engine Information Plate.

1. DO NOT remove the original 9L6531 Engine Information Plate.

2. Use the above chart as a reference to stamp the new information on the new 4W5140 Parts Service Engine Information Plate:

* HP (kW)

* Performance Specification number ... and

* Fuel Timing

Use the original plate as a reference to transfer the remaining block information to the new plate.

3. Clean the face of the original 9L6531 Engine Information Plate.

4. Remove the protective backing from the 4W5140 Parts Service Engine Information Plate.

Break off the lower section of the plate at the scribed mark.

5. Use 8T9021 Adhesive (DEPEND® No-Mix Adhesive) to provide a permanent bond between the two plates.

NOTE: Follow the instructions on the adhesive package CAREFULLY. The adhesive and catalyst are applied in sequence from two separate containers and will NOT bond permanently if applied premixed.

6. Position new plate over original plate so that the AR NO. block of each plate are aligned. When positioned correctly press the new plate firmly onto the original plate.

Certification Label

The original Certification Label is located on the engine's valve cover.

The original Certification Label has a hole punched through the Date of Manufacturing Month portion of the label. This information MUST be transferred to the new Certification Label.

1. Clean the surface of the original Certification Label.

2. Punch a hole through the Date of Manufacturing Month portion of the new label to match the original label.

3. Remove the protective backing from new label an install the new label onto the original.