Product Support Program For Installing A Wastegate Cover Kit On Certain 3406E, C-15, C-16, And C-12 Engines Caterpillar

Product Support Program For Installing A Wastegate Cover Kit On Certain 3406E, C-15, C-16, And C-12 Engines

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50131" as the Part number and "7755" as the Group Number. 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.

Termination Date

October 31, 2002

Problem

The cover (plug) for the wastegate mechanism on certain 3406E, C-15, C-16, and C-12 Engines can be damaged or missing.

Affected Product
Model & Identification Number

3406E (2WS23000-Up)

C-15 (6NZ1-Up)

C-16 (7CZ1-Up)

C-12 (2KS17000-Up)

Parts Needed

1 - 1927934 Cover Kit - Wastegate

Action Required

Install a 1927934 Cover Kit - Wastegate. See attached Rework Procedure.

Service Claim Allowances

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

(1-Rework Procedure)

Rework Procedure

Introduction

The 192-7934 Cover Kit-Wastegate is designed as a replacement part kit for field repair of turbine housing assemblies which have damaged or missing cup plugs. The kit is used on turbochargers found on C-12, 3406E, C-15, & C-16 Engines.

Part Identification

Part list for 192-7934 Cover Kit-Wastegate

Preparation

1. Check that vehicle ignition is off, wheels blocked, and follow all applicable shop Safety regulations.

2. Allow engine, exhaust, turbocharger, and all other related parts to cool completely.

3. Locate and visually inspect the turbocharger exhaust housing assembly. If the cup plug (press fit freeze plug) is damaged or missing proceed. If cup plug is in tack continue with standard troubleshooting procedures.

Engine components may be extremely hot, and can cause severe injury. Allow to cool completely.

4. Remove the exhaust pipe and other related hardware from the turbine housing outlet.

NOTE: There is no need to disassemble or remove the turbocharger. Only remove the exhaust pipe attached to the turbine outlet.)

5. Verify that there is no other damage to the turbocharger.

NOTE: This program does not cover defective turbochargers not related to damaged or missing plugs.

Installation of Plug (Seal) (Item 1 in part list)

1. Visually inspect the cup plug bore and flat external surface. If staking impressions are large, resulting in excess raised metal, use a die grinder or file to flatten these areas before installation. (See Figure 2) This area needs to be flat for proper settling of Cap (Item 2).

Figure 2. Staking locations

Figure 3. Wastegate cavity.

Figure 4. Inserting Plug (Seal).

2. Insert the Plug (Seal) (Item 1) into turbine housing through the wastegate cavity. (See Figure 3 and 4)

3. Insert the Long Bolt (Item 3) into the Cap (Item 2).

4. With the Long Bolt (3) and Cap (2) together, thread the Long Bolt (3) into the Plug (Seal) (1).

5. Use the bolt from the outside and your hand on the inside of the housing to position the Plug (Seal) so that it seats squarely inside the turbine housing bore.

NOTE: If Plug (Seal) (1) does not seat squarely it will be damaged when pulled into place by the installation bolt (Long Bolt (3)).

6. Continue threading Long Bolt (3) into the Plug (Seal) (1). By tightening, the Plug (Seal) is drawn into the bore. Tighten the Plug (Seal) into the bore until the lip on the Plug (Seal) (1) begins to seat on inside cast surface of the turbine housing.

NOTE: The Long Bolt (3) is only used as an installation bolt for seating the Plug (Seal) (1).It must be replaced by the Short Bolt (4) in order for correct operation of the turbocharger. Discard the Long Bolt (3).

7. Remove the Long Bolt (3). Visually verify that the Plug (Seal) (1) is seated Properly. Discard the Long Bolt (3). (See Figure 5)

Figure 5. Plug (Seal) seated properly.