Turbocharger Wastegate Actuator on Certain C7.1 Engines {1052, 1053} Caterpillar

Electric Power Generation

C7.1 GEN SET (S/N: MRP1-127,129-763,765-765,770-806,808-808,818-818,821-822,830-830,835-837,843-846,848-849)

Excavator

324E (S/N: KTE1-207; TLF1-523; LDG1-682; PNW1-1,176-1640; JCZ1-163)

329E (S/N: RLD1-789; ZCD1-838; WJK1-157; TST1-884; PLW1-1717; RDX1-200; PTY1-124)

Industrial Engine

C7.1 (S/N: 7701-270,272-282,284-294,299-313,315-331,333-382,384-393,395-415,417-876,887-942,948-1173,1176-1205,1207-1326,1328-1365,1367-1796,1799-1807,1810-1876,1879-1969,1971-2022,2024-2030,2032-2041,2045-2236,2238-2247)

Mobile Hydraulic Power Unit

329E MHPU (S/N: K2L1-168; KNR1-155)

Wheel Feller Buncher

2570C (S/N: W571-128; F1B1-202,204-204,206-216)

2670C (S/N: W671-154; B3E1-171,1470-1470)

563C (S/N: W631-317; JCB1-324)

573C (S/N: W731-247; RJT1-1,252-296)

Introduction

This Special Instruction details that procedure to install 508-1306 Actuator As to 359-0125 Turbocharger, 359-0126 Turbocharger, and 359-0127 Turbocharger on certain C7.1 engines.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

Required Parts

The 508-1306 Actuator As is required.

Installation Procedure

1. Disconnect the hose assembly from the wastegate actuator.
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   Illustration 1	g06114236
   Typical example

2. Remove circlip (1) from pin (2). Retain circlip.

3. Connect Tooling (A) and Tooling (B) to the wastegate actuator. Pressurize the wastegate actuator to a pressure of 150 kPa (22 psi). The wastegate actuator shaft should move, which will help with the removal of the rod.

   Note: If there is an issue with the wastegate actuator, the wastegate actuator may not move. Proceed to Step 4.

4. Remove rod (3) from pin (2). Ensure that the rod or the pin are not subjected to any undue stress.

5. Reduce the pressure from the wastegate actuator. Remove Tooling (A) and Tooling (B) from the wastegate actuator.
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   Illustration 2	g06114244
   Typical example

6. Make temporary marks on all components to show correct orientation and alignment. Remove retaining nuts (5) and heat shield (7) from bracket (4). Remove wastegate actuator (6) from bracket (4). Retain nuts, heat shield, and wastegate actuator.
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   Illustration 3	g06114247
   Typical example

7. Position existing heat shield (7) to new wastegate actuator (8). Install new wastegate actuator (8) to bracket (4). Install existing nuts (5) to bracket (4). Engage the first three threads.

8. Connect Tooling (A) and Tooling (B) to the wastegate actuator. Pressurize the wastegate actuator to a pressure of 150 kPa (22 psi). The rod should move to the extended position.
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   Illustration 4	g06114253
   Typical example

9. Install rod (9) to pin (2). Install a new circlip (10) to pin (2).

   Note: Ensure that the flat side of the circlip is against the rod.

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   Illustration 5	g06114255
   Typical example

10. Reduce the pressure from the wastegate actuator. The actuator arm (11) should move. Refer to Illustration 5.
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    Illustration 6	g06114256
    Typical example

11. Pressurize the wastegate actuator to a pressure of 95 kPa (14 psi). Refer to Illustration 6.
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    Illustration 7	g06114259
    Typical example

12. Push actuator arm (11) on the wastegate actuator (8) to the closed position. Ensure that the wastegate is fully closed. A gap between the wastegate actuator (8) and bracket (4) will appear. Refer to Illustration 7.
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    Illustration 8	g06114263
    Typical example

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    Illustration 9	g06114265
    Typical example

13. Use suitable feeler gauges to measure the gap between the wastegate actuator and bracket. Use a suitable cleaning fluid to clean the spacers (12). Install spacers (12) to fill the gap between the bracket (4) and heat shield (7). Install the thickest spacers first, then install the second thickest spacers next. Continue to install spacers until the gap has been filled.

    The spacers are available in the following thicknesses:

    • 0.2 mm (0.00787 inch) (square marking)

    • 0.5 mm (0.01968 inch) (triangular marking)

    • 1 mm (0.03937 inch) (no marking)

    • 2 mm (0.07874 inch) (twin circle marking)

14. Reduce the pressure from the wastegate actuator.
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    Illustration 10	g06114267
    Typical example

15. Tighten nuts (5) that secure wastegate actuator to bracket (4) to a torque of 6.8 N·m (60 lb in).

16. Pressurize the wastegate actuator to a pressure of 95 kPa (14 psi). Ensure that the shaft and the wastegate actuator does not move. If the wastegate moved, repeat Step 13as a thicker spacer (12) may be required.

17. Pressurize the wastegate actuator to a pressure of 100 kPa (14.5 psi). The movement for the rod actuator is 1 mm (0.0394 inch). Ensure that the shaft and the wastegate actuator does move. If the wastegate does not move, or the movement for the rod actuator is not 1 mm (0.0394 inch), repeat Step 13 as a thinner spacer (12) may be required.

18. Remove Tooling (A) and Tooling (B) from the wastegate actuator.

19. Connect hose assembly to the wastegate actuator.

Retain the removed circlip and wastegate actuator. If requested, the circlip and wastegate actuator may be returned using the Send It Back (SIB) process.