PRODUCT SUPPORT PROGRAM FOR REPLACING HP TURBO WASTEGATE ACTUATOR ON CERTAIN 324E, 329E EXCAVATORS AND 3570C, 2670C, 563C, 573C WHEEL FELLER BUNCHERS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPLACING HP TURBO WASTEGATE ACTUATOR ON CERTAIN 324E, 329E EXCAVATORS AND 3570C, 2670C, 563C, 573C WHEEL FELLER BUNCHERS
Usage:
TEBE4808-00
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28Jul2016
U-395
A-300
D-345
O-345
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Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING HP TURBO WASTEGATE ACTUATOR ON CERTAIN 324E, 329E EXCAVATORS AND 3570C, 2670C, 563C, 573C WHEEL FELLER BUNCHERS
1058 108A 1088 1052 105H 1057 1081 1053 1071 5506
PS45172
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NOTE:
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
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 "PS45172" 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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TERMINATION DATE
31Jul2018
PROBLEM
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The existing high pressure turbo part number (3590125, 3590126,3590127) can lose wastegate control capability on certain 324E, 324E L, 324 LN, 329E, 329E L, 329E LN, 329E OEM excavators and 3570C, 2670C, 563C, 573C Wheel Feller Bunchers. If the existing high pressure turbo wastegate fails it can lead to the "1044(2) High Intake Manifold Pressure" error code and subsequent machine power derate.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Refer to the attached Rework Procedure. Before completing this rework procedure, review the safety actions in the Operation and Maintenance Manual for the machine.
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SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-5000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-6000 hrs, 49-60 mo
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
NOTE: This is a 1.5-hour job for Group 1
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-5000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-6000 hrs, 49-60 mo
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
NOTE: This is a 1.5-hour job for Group 2
PARTS DISPOSITION
All dealers: Hold all replaced Wastegate Actuators (508-1306) for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
Rework Procedure
Tooling requirements
? Wastegate Tool kit (p/n 215-2592) ? Hose, 6.35mm inside diameter to connect hand pressure pump to WG can.
Rework instructions
1. Prior to accessing and working on the turbo, please make sure that the machine has been shut down for long enough and engine temperature allows for manual work.
2. Dismount circlip from pin (ref. Image 1.2.1 & 1.2.2).
NOTE: Keep circlip available for Send-It-Back requests. See the Parts Disposition.
Image1.2.1
Image1.2.2
3. Connect the wastegate service tool to the wastegate (WG) actuator can, then pressurize actuator at 150 kPa ; the WG crank will move, which will make it easier to disconnect the rod. Note that if the wastegate actuator has failed, the failed actuator may not move and you should go to next step.
4. Pull the rod carefully from the pin. Take care not to bend or stress the pin (ref. Image 1.3.1).
Image1.3.1
5. Release pressure from pump, i.e. reduce pressure from actuator to 0 kPa. Remove the pump from actuator.
6. Remove retaining nuts and dismount actuator from bracket (ref. Image 1.4.1 & Image 1.4.2).
NOTE: Keep WG actuator available for Send-It-Back requests. See the Parts Disposition.
Image1.4.1
Image1.4.2
7. Mount new actuator with old heat shield on bracket ; actuator and heat shield orientation to be respected (ref. Image 1.5.1). Fit nuts by a few threads to ensure wastegate does not fall out of bracket.
Image1.5.1
8. Connect WG service tool to actuator and pressurize actuator to 150 kPa to move rod to extended position (ref. Image 1.6.1).
Image1.6.1
9. Mount rod to pin and fit new circlip, supplied with service kit (5081306), with flat side of circlip against the rod (ref. Image 1.7.1).
Image1.7.1
10. Reduce pressure from actuator to 0 kPa. Crank will move as per Image 1.8.1.
Image1.8.1
11. Pressurize actuator at pre-calibration pressure (95 kPa +/- 1 kPa). See Image 1.9.1.
12. Push crank @ WG closed position ? WG must be fully closed ? Gap between actuator and bracket will appear (ref. Image 1.9.2).
Image1.9.1
Image1.9.2
13. The spacers need to be fitted like a feeler gauge into the gap between heat shield and bracket, DO NOT force larger washers into the gap. Put the cleaning agent to the spacer (use the SODI35). Fit the spacers into the gap (ref. Image 1.10.1, 1.10.2 & 1.10.3) starting with the thickest and moving to the next thickest when no more spacers of the current thickness can be fitted freely. The washer thicknesses are 2mm (twin circle marking), 1mm (no marking on spacer), 0.5mm (triangle marking), and 0.2mm (square marking).
Image1.10.1
Image1.10.2
Image1.10.3
14. Reduce pressure to 0 kPa
15. Tighten nuts to secure actuator on bracket (ref. Image 1.11.1). Torque setting is 6.8Nm +/-1.1Nm.
Image1.11.1
16. The First check-point: Pressurize actuator @ pre-calibration pressure (95 kPa) and check that crank/ WG does not move. If the WG moved, please return to step 11 as a bigger shim may be needed.
17. The Second check-point: Pressurize actuator @ calibration pressure (100 kPa) and check that crank /WG does move. Actual travel measurements not required but, for information, travel of the rod should be 1mm @100kPa.