PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER WASTEGATE CANISTER ON CERTAIN C13 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER WASTEGATE CANISTER ON CERTAIN C13 INDUSTRIAL ENGINES

Usage:

REBE6292-01

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03Jan2011

(Revised 18Jan2011)

U-2

A-2

D-2

O-2

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER WASTEGATE CANISTER ON CERTAIN C13 INDUSTRIAL ENGINES
1052 1053 1940 1057 7557		PS43214

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NOTE:

This Program must 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 "PS43214" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 03Jan2011 Service Letter. Changes have been made to the Affected Product and Service Claim Allowances.

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TERMINATION DATE

31Jan2012

PROBLEM

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The existing wastegate diaphragms can have holes worn through them by the actuator piston on certain C13 Industrial Engines. If the existing wastegate diaphragm rips or cracks it can result in high turbo speed and compressor wheel failure.

AFFECTED PRODUCT

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Model

Identification Number

C13

LGK00687-00693, 695-712, 714-717, 722, 3668, 3670, 3680, 3685, 3700, 3702, 3718, 3721, 3728, 3758, 3786, 3814, 3821, 3844, 3854, 3860, 3864, 3870-3871, 3887, 3899, 3923, 3940, 3955, 3967, 3983, 3993, 4017, 4035, 4042, 4066, 4085, 4105, 4114, 4116, 4150, 4161, 5386-5387, 5393, 5401, 5412, 5416-5417, 5419, 5421, 5432, 5798, 5861, 5873-5874, 5877, 5880-5882, 5885, 5887, 5889-5891, 5896-5897, 5899-5900, 5902-5904, 5906-5910, 5912-5914, 5916-5917, 5921-5922, 5927-5928, 5932-5933, 5943-5944, 5949-5950, 5956, 5997, 5999, 6250, 6268, 6298, 6333, 6365, 6368, 6373, 6412, 6426, 6430-6431, 6447, 6455, 6470, 6473, 6475, 6484, 6709, 6728, 6751, 6771, 6783, 6795, 6797-6798, 6815, 6825, 6872-6873, 6885, 6891, 6922, 6936, 6972, 6977, 7016, 7019, 7231, 7235, 7240, 7244, 7251-7252, 7272, 7274, 7276, 7281, 7331, 7357, 7366, 7390, 7400, 7402, 7413, 7416, 7430, 7441, 7697, 7699, 7701, 7704, 7708, 7713, 7832-7833, 7836-7837, 7839, 7879, 7884-7887, 7915, 7917-7918, 7920-7921, 7980, 7982-7983, 7986, 7988, 8016-8017, 8019-8021, 8096, 8098, 8101, 8103, 8112, 8147, 8158-8160, 8165, 9118-9119, 9132, 9136-9137, 9295, 9306, 9312, 9318-9320, 9413, 9416, 9419-9420, 9422, 9425, 9427, 9431, 9468, 9474-9475, 9477, 9482-9483, 9485-9486, 9519, 9525-9526, 9529, 9532, 9539-9541, 9543, 9545, 9591-9593, 9598, 9634, 9637, 9643, 9646, 9774, 9777, 9783-9784, 9786, 9804, 9806, 9808, 9814-9815, 10430-10431, 10439, 10452, 10459, 10474, 10479, 10494, 10497, 10500, 10511, 10520, 10523, 10533, 10539, 10651, 10663, 10673-10674, 10677, 10754, 10759-10760, 10763, 10766, 10787-10788, 10806, 10814, 10918, 10920-10921, 10930, 10933, 10995-10996, 11001, 11005, 11007, 11119, 11121-11122, 11126, 11130, 11152, 11156, 11162, 11165, 11178, 11180, 11182-11183, 11189, 11192, 11194, 11196, 11198, 11200-11201, 11207, 11209-11210, 11212, 11218, 11221, 11224-11225, 11227, 11261, 11263, 11266, 11278, 11286, 11390, 11393, 11395, 11403, 11407, 11409, 11412-11413, 11477-11478, 11480, 11482-11483, 11486, 11500-11502, 11505, 11514, 11516, 11520, 11522, 11524-11525, 11527-11528, 11532, 11534, 11540-11542, 12091, 12117-12120, 12122-12123, 12178, 12180, 12182, 12184, 12187-12188, 12238, 12241, 12244, 12247-12248, 12251, 12315, 12319-12320, 12322-12324, 12403-12404, 12408, 12410, 12413-12414, 12485-12486, 12489-12490, 12492-12493, 12572-12577, 12585, 12591, 12593, 12596, 12598, 12600, 12604-12606, 12610-12611, 12615, 12618, 12631-12632, 12635-12637, 12640, 12699-12704, 12745-12747, 12751-12752, 12759-12760, 12762-12763, 12765, 12768, 12815, 12819, 12821, 12833-12834, 12836, 12961, 12963, 12967, 12970, 12977-12982, 13109, 13111, 13113-13114, 13119, 13178, 13180, 13184, 13186, 13188, 13191, 13198, 13208, 13210, 13212, 13215, 13217, 13329, 13335, 13337, 13340-13341, 13345, 13348, 13350-13353, 13385, 13387, 13391, 13395, 13397-13399, 13405, 13845, 13848, 13851, 13853, 13856, 13858, 13862, 13865-13866, 13869-13870, 13872-13874, 13897-13902, 13904-13905, 20114-20125, 20127-20135, 20137-20140, 20142, 20504, 20506-20507, 20513, 20519-20520, 20525, 20527, 20531, 20656, 20660-20661, 20666, 20668, 20671, 20685-20687, 20690, 20692-20693, 20695, 20792-20794, 20796-20798, 20801, 20804-20805, 20808, 20810-20811, 20817-20819, 20823, 20827, 21722

PARTS NEEDED

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Qty	Part Number	Description
1	3624782	KIT-ACTUATOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Rework the turbocharger wastegate canister and change the turbocharger part number label.

Refer to the attached rework procedure.

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SERVICE CLAIM ALLOWANCES

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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%
0-4500 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Turbocharger Part Number Rework

1. Remove the part number tag from the turbocharger with appropriate tooling. Make sure both rivet heads are sheered off during removal. See image 1.1.1 below for tag and rivet head location.

Image1.1.1

2. Use the blank name plate included in the 362-4782 Actuator Kit; stamp the new 362-3145 Turbocharger part number on the plate if it has not already stamped. Also, transfer the turbocharger serial number.

3. Clean the part number tag area on turbocharger using a file, emery cloth, and 222-3117 Caterpillar Brake Cleaner.

4. Install new turbocharger part number tag using 266-3144 Caterpillar Epoxy Kit.
- One Epoxy Kit will service 10 engines.

NOTE: Only charge 1 Kit per 10 engines to this repair, if possible.

5. Follow instructions on Epoxy Kit and allow epoxy to harden before returning the machine to service.

Wastegate Canister (362-4782) Removal/Installation/Calibration

Introduction:

Do not perform any procedure in the removal/installation/calibration portion of the rework until you read this information and you understand this information completely.

NOTICE:

Caterpillar continues to provide engines that meet the regulations of various agencies around the world. Each engine is certified to meet emission regulations by using the proper iron, software (flash files),and fuel settings. Unauthorized changes to any of these components may cause an engine to not be compliant with emission regulations. This is considered as tampering. Tampering with an engine can make
the reliability and durability of the engine decrease.

Required Tooling:

Use the 362-4782 Kit (Wastegate) in order to calibrate the new actuator kit properly.

Removal Procedure for the Old Wastegate Actuator:

Image1.3.1

(10) Heat shield for the turbocharger (if equipped)
(11) Support bracket

1. Remove heat shield (10) from the turbocharger and support bracket (11). Also remove the hose that goes from the turbocharger compressor housing to the wastegate actuator. Reference Image 1.4.1

Image1.4.1

Image1.5.1

(5) Test hose
(12) Clip that secures the crank pin
(13) Wastegate actuator

2. Apply 186 kPa (27 psi) of air pressure to actuator (13).

3. Remove clip (12) from the crank pin. Discard the clip. Reference Image 1.4.1

Image1.6.1

(14) Mounting nuts for the wastegate actuator

Image1.7.1

(5) Test hose
(13) Wastegate actuator
(14) Mounting bolts for the wastegate actuator

4. Relieve all the air pressure from the actuator. Remove test hose (5) from actuator (13).

Note: Make sure that you note the orientation of the hose nipple on the actuator before removing the actuator. Make sure that the new actuator is installed in the same position as the old actuator.

5. Remove nuts (14) from the mounting studs on actuator (13). Remove the actuator. Refer to Illustration 1.6.1

Reference Image 1.7.1

Note: Remove old bracket and install with new bracket included in kit. Bracket mounting bolt torque is 20.3-24.9 Nm (3 mounting bolts). Put appropriate amount of high-temp antisieze on bolts.

Assembly of the 362-4782 Actuator Kit:

Image1.8.1

(A) Measurement of the Rod
(12) Clip for the crank pin
(13) Wastegate actuator
(14) Mounting nuts for the actuator
(15) Jam nut
(16) Rod end

1. Put heat shield onto actuator, make sure that heat shield orientation matches what it was previously.

2. Assemble jam nut (15) and rod end (16) onto the new actuator. Use the parts that came with the 362-4782 Actuator Kit . Refer to Illustration 1.8.1.

Installing the Actuator:

Image1.9.1

(13) Actuator
(14) Mounting Nuts
(18) Hose nipple

1. Install the new actuator to the mounting bracket. Make sure that the hose nipple on the new actuator is oriented in the same position as the old actuator. Secure the actuator to the mounting bracket with mounting nuts (14)A & 14B. Make sure that the actuator mounting nuts that are included in the 362-4782 Actuator Kit are used. Torque the actuator mounting nut 14A to 5.7-7.9 Nm/50-70 LBF-In of Torque.

Reference Image 1.9.1

Image1.10.1

(5) Test hose
(13) Wastegate actuator

3. Connect test hose (5) to the hose nipple on the new actuator.

4. Apply 186 kPa (27 psi) of air pressure to the new actuator. Place the rod end of the new actuator over the crank pin.

5. Relieve all the air pressure from the actuator.

Reference Image 1.10.1

Procedure to Calibrate the Actuator:

Image1.11.1

B) Dial indicator
(13) Actuator
(18) Actuator Rod

1. Install a dial indicator (B) on the engine. The travel of the rod on the dial indicator must be in-line with the travel of the rod on the actuator. Misalignment between the dial indicator and rod may cause the reading to be incorrect.

(B) Dial indicator
(1) Air pressure regulator
(2) Air pressure gauge
(3) 4P-5866 Clamp
(5) Test hose
(13) Wastegate actuator
(18) Actuator Rod

2. Connect the air supply to air pressure regulator (1) .

3. Connect test hose (5) to actuator (13). Use hose clamps (3) to secure the test hose to the actuator.

4. Slowly apply air pressure. Make sure to watch the dial indicator.

5. Increase air pressure until the rod on the actuator has traveled 1 mm (0.039 inch).

6. Observe pressure gauge (2). Record the pressure reading. This is the calibration value.

7. Slowly relieve all the air pressure.

8. Repeat Steps 4 through 7. Record the pressure reading again.

Reference Image 1.11.1

Image1.12.1

(12) Clip that secures the crank pin

9. Install new clip (12) on the crank pin in order to secure the rod end of the actuator if the value of the calibration is 186 +/- 3 kPa (27 +/- 0.5 psi). Use the clip that was supplied with the 362-4782 Actuator Kit.

Note: Follow the appropriate procedure below if the calibration value is not 186 +/- 3 kPa (27 +/- 0.5 psi).

Procedure for the Actuator if the Calibration Value is above 186kPa (27 psi)

1. Remove the rod end from the crank pin. Turn the rod end in a counterclockwise direction. If pressure is off by more than 2 PSI turn rod end 1 full turn, if off by less than 1 PSI then turn 1/2 rotation at a time.

2. Perform the calibration test again. Refer to the "Procedure to Calibrate the Actuator" above.

3. Install new clip (12) on the crank pin in order to secure the rod end of the actuator if the actuator calibration value is 186 +/- 3 kPa (27 +/- 0.5 psi). Use the clip that was supplied with the 3624782 Actuator Kit.

4. Perform Steps 1 through 3 if the actuator calibration value is still above 186 kPa (27 psi).

Reference Image 1.12.1

Procedure for the Actuator if the Calibration Value is below 186kPa (27 psi):

1. Remove the rod end from the crank pin. Turn the rod end in a clockwise direction. If pressure off by more than 1 PSI; turn rod end 1 full turn. If off by less than 1 PSI; turn 1/2 rotation at a time. Adjust the rod end accordingly to the last actuator calibration value.

2. Perform the calibration test again. Refer to the "Procedure to Calibrate the Actuator" above.

3. Install new clip (12) on the crank pin in order to secure the rod end of the actuator if the actuator calibration value is 186 +/- 3 kPa (27 +/- 0.5 psi). Use the clip that was supplied with the 362-4782 Actuator Kit .