204476
Expansion Plug
Cummins®

Introduction

The Expansion Plug 204476, manufactured by Cummins, is a critical component in maintaining the integrity and efficiency of truck operations, particularly within the engine and cooling systems.

Basic Concepts of Expansion Plugs

An expansion plug is a mechanical device designed to seal openings in various automotive components. It functions by expanding upon insertion into a pre-drilled hole, creating a secure and tight seal. This mechanism is commonly used in engine blocks, radiators, and other components where sealing is necessary to prevent leaks and maintain system pressure ¹.

Purpose of the 204476 Expansion Plug

The 204476 Expansion Plug plays a role in the operation of a truck by sealing specific openings within the engine or cooling system. Its function is to prevent coolant or other fluids from leaking out, thereby maintaining the system’s pressure and efficiency. This plug ensures that the engine operates within optimal parameters, contributing to overall vehicle performance and longevity ².

Key Features

The 204476 Expansion Plug is characterized by several primary features that enhance its performance. It is made from high-quality materials that offer durability and resistance to corrosion. The design includes a threaded section that allows for easy installation and removal when necessary. Additionally, the plug features an expansion mechanism that ensures a tight and reliable seal once installed.

Benefits

Using the 204476 Expansion Plug offers several advantages. It contributes to improved engine performance by maintaining system pressure and preventing leaks. The plug’s durable construction ensures longevity, reducing the need for frequent replacements. Its reliable sealing capability enhances the overall reliability of the truck’s engine and cooling system, even under various operating conditions ³.

Installation Process

Installing the 204476 Expansion Plug requires careful attention to detail to ensure a proper fit. The process involves cleaning the installation site to remove any debris or old sealant. Using the appropriate tools, the plug is then screwed into the pre-drilled hole until it reaches the desired depth. Upon reaching this point, the expansion mechanism is activated, securing the plug in place. It is important to follow manufacturer guidelines to ensure correct fitting and optimal performance.

Common Issues and Troubleshooting

Typical problems associated with expansion plugs include leaks due to improper installation or wear over time. Diagnosing these issues involves inspecting the plug and surrounding area for signs of fluid leakage or corrosion. Recommended troubleshooting steps may include re-tightening the plug, ensuring it is correctly seated, or replacing it if damage is detected.

Maintenance Tips

To ensure the optimal performance of the 204476 Expansion Plug, regular inspections are advised. This includes checking for signs of wear, corrosion, or leaks around the plug. If any issues are detected, prompt action should be taken to address them, which may involve tightening or replacing the plug. Adhering to these maintenance practices helps maintain the integrity of the engine and cooling system.

Cummins Overview

Cummins Inc. is a global power leader that designs, manufactures, and distributes a wide range of power solutions. With a history spanning over a century, Cummins has established a strong reputation in the commercial truck industry for producing reliable and high-performance components. Their product range includes engines, filtration systems, and aftermarket parts, all designed to meet the demanding requirements of commercial vehicle operations.

Compatibility of Expansion Plug 204476 with Cummins Engines

The Cummins Expansion Plug 204476 is designed to fit a variety of Cummins engines, ensuring a secure and reliable seal. Below is a detailed description of its compatibility with different engine models:

GTA38 G CMEICS G116C

The Expansion Plug 204476 is compatible with the GTA38 G CMEICS G116C engine, providing an essential seal that maintains system integrity.

ISM Series

• ISM CM570
• ISM CM570/870
• ISM CM876
• ISM11 CM876 SN
• ISX CM570

The Expansion Plug 204476 fits seamlessly with all ISM series engines, including the CM570, CM570/870, CM876, ISM11 CM876 SN, and ISX CM570. This ensures optimal performance and longevity of the engine’s cooling system.

K Series

• K38
• K50

The part is also compatible with the K38 and K50 engines, providing a critical seal that prevents leaks and maintains system pressure.

KTA38GC CM558

The Expansion Plug 204476 is suitable for the KTA38GC CM558 engine, ensuring that the cooling system remains sealed and efficient.

L10 Series

• L10 CELECT
• L10 MECHANICAL

Both the L10 CELECT and L10 MECHANICAL engines are compatible with the Expansion Plug 204476, offering a reliable seal for the engine’s cooling system.

M11 Series

• M11 CELECT
• M11 CELECT PLUS
• M11 MECHANICAL

The Expansion Plug 204476 fits the M11 CELECT, M11 CELECT PLUS, and M11 MECHANICAL engines, ensuring a secure seal that is essential for maintaining system pressure and efficiency.

NH/NT 855

The part is also compatible with the NH/NT 855 engine, providing a reliable seal for the cooling system.

QSK19 Series

• QSK19 CM2350 K105
• QSK19 CM2350 K114
• QSK19 CM2350 K144G
• QSK19 CM500
• QSK19 CM850 MCRS
• QSK19G

The Expansion Plug 204476 is compatible with all QSK19 series engines, including the CM2350 K105, CM2350 K114, CM2350 K144G, CM500, CM850 MCRS, and QSK19G, ensuring a secure seal for the cooling system.

QSK50 Series

• QSK50 CM2150 K107
• QSK50 CM2150 MCRS

The part fits the QSK50 CM2150 K107 and QSK50 CM2150 MCRS engines, providing a reliable seal for the cooling system.

QSK78 CM500

The Expansion Plug 204476 is also compatible with the QSK78 CM500 engine, ensuring a secure seal for the cooling system.

QSM11 CM570

The part fits the QSM11 CM570 engine, providing a reliable seal for the cooling system.

Role of Part 204476 Expansion Plug in Engine Systems

The Expansion Plug, part number 204476, is integral to maintaining the integrity and functionality of various engine components. Its role is to seal and pressurize specific areas within the engine system, ensuring optimal performance and longevity of the parts it interfaces with.

In the Cylinder Block, the Expansion Plug is used to seal off unused passages or ports, preventing coolant or oil leaks that could compromise engine performance. This ensures that the cylinder block maintains consistent pressure and temperature, which is vital for the efficient operation of the engine.

Within the Turbocharger Arrangement, the Expansion Plug helps to maintain the pressure differential necessary for the turbocharger to function correctly. By sealing off certain areas, it ensures that the turbocharger can build the required boost pressure without leaks, which is essential for enhancing engine power output and efficiency.

In the Thermostat Housing (THM Housing), the Expansion Plug plays a role in regulating the flow of coolant. It ensures that the housing can withstand the pressures generated during engine operation, thus maintaining a stable engine temperature.

For the Cooler LO & TC and Lubricating Oil Cooler, the Expansion Plug is used to seal off sections of the cooler that are not in use. This prevents any potential leaks of lubricating oil, ensuring that the cooler can effectively manage the temperature of the oil, which is critical for reducing friction and wear within the engine.

In the context of the Lubricating Oil Filter Head and Lubricating Pump Flange, the Expansion Plug ensures that these components remain sealed, preventing any loss of lubricating oil. This is important for maintaining the proper lubrication of moving parts within the engine, which reduces wear and tear.

The Exhaust Assembly also benefits from the use of the Expansion Plug. By sealing off certain areas, it helps to maintain the pressure within the exhaust system, ensuring efficient expulsion of gases and reducing the risk of backpressure, which can affect engine performance.

In the Flywheel and Torque Converter, the Expansion Plug is used to seal passages that are not in use, ensuring that these components can operate under the correct pressure conditions. This is important for the smooth transfer of power from the engine to the transmission.

Finally, in the Oil Pan and Oil Filter Conversion Kit, the Expansion Plug ensures that these components remain sealed, preventing any leaks that could lead to a loss of oil and subsequent engine damage.

Overall, the Expansion Plug, part number 204476, is a vital component in ensuring the sealing and pressurization of various engine systems, contributing to the overall efficiency and reliability of the engine.

Conclusion

The 204476 Expansion Plug by Cummins is a vital component in maintaining the integrity and efficiency of truck engine and cooling systems. Its role in sealing and pressurizing various engine components ensures optimal performance and longevity. Regular maintenance and proper installation are key to maximizing the benefits of this part.