2005/03/01 Caterpillar

Engine:

3406E (S/N: 2WS1-UP)

C-15 (S/N: 6NZ1-UP)

Truck Engine News SEBD6742, February 2002, "Check the Calibration of the Wastegate Actuator in order to Diagnose a Low Boost Condition". Disregard this article. See the article that follows.

The calibration of the wastegate actuator should be checked when a low boost condition is suspected. After the calibration has been checked, the proper course of resolution may be determined.

The following items are necessary in order to check the calibration of the wastegate actuator.

• An air pressure regulator

• An air pressure gauge for 0 kPa (0 psi) to 207 kPa (30 psi) with 1.72 kPa (0.25 psi) graduations

• A tee or a cross

• A hose barb coupler

• An air valve

• An air supply

• A fitting for connection to the air supply

• A dial indicator with base that can be attached to the engine

• A test hose with a 6.35 mm (0.250 inch) inner diameter for connection to the wastegate actuator

• Two 4P-5866 Clamps

Illustration 1	g00867065
Tools that are required in order to measure the air pressure during the calibration of the wastegate actuator (A) Air pressure regulator (B) Air pressure gauge (C) Tee or cross (D) Hose barb coupler (E) Valve for use with cross (F) Valve (G) Fitting for connection to the air supply (H) Test hose with a 6.35 mm (0.250 inch) inner diameter for connection to the wastegate actuator (J) 4P-5866 Clamps (Hose)

The following part will be required in order to replace the wastegate actuator, if necessary.

• A 214-3451 Repair Kit

A crimping tool will also be required at final installation.

Determine the Actuation Calibration Reading

1. Allow the turbocharger to cool.

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Illustration 2	g00867029

2. Install dial indicator (1) on the engine. The travel of the dial indicator must align with the travel of the rod (2) or an error in the measurement will occur. Refer to Illustration 2.

3. Remove the hose (4) from the actuator (3) .

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Illustration 3	g00867484

4. Connect the air supply to the air pressure regulator (A) .

5. Set the air pressure regulator (A) to 0 kPa (0 psi).

6. Connect the test hose (H) to the actuator (3) with hose clamps (J) .

7. Turn the knob on air pressure regulator (A) and slowly increase the air pressure while you observe the dial indicator (1). Increase the air pressure until the travel of the rod (2) is 1.00 mm (0.039 inch). Observe the pressure gauge (B) and record the pressure reading.

8. Turn the knob on air regulator (A) and slowly decrease the pressure to 0 kPa (0 psi). Repeat Step 7. Observe the pressure gauge (B) and record the pressure reading.

9. This pressure reading is the Actuation Calibration Reading.

The Actuation Calibration Reading is Above 114 kPa (16.5 psi)

No further action is necessary if the actuation calibration reading is above 114 kPa (16.5 psi). Remove the test hose and all test equipment. Install the hose for the actuator. Be sure that the hose is not kinked. Be sure that the hose does not rub at any point. Continue with an alternate diagnosis.

The Actuation Calibration Reading is Below 90 kPa (13 psi)

The turbine housing must be replaced if the actuation calibration reading is below 90 kPa (13 psi). Remove the test hose and all test equipment and replace the turbine housing. Refer to Disassembly and Assembly, "Turbocharger - Disassemble" and Disassembly and Assembly, "Turbocharger - Assemble".

The Actuation Calibration Reading is Between 90 kPa (13 psi) and 114 kPa (16.5 psi)

The actuator must be replaced and recalibrated if the actuation calibration reading is between 114 kPa (16.5 psi) and 90 kPa (13 psi). Replace the wastegate actuator with a 214-3451 Repair Kit. Refer to "Installation and Calibration of a New Wastegate Actuator".

Installation and Calibration of a New Wastegate Actuator

Use the following procedures in order to install a 214-3451 Repair Kit and calibrate the new wastegate actuator.

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Illustration 4	g00867487

1. Apply 138 kPa (20 psi) of air pressure to the actuator (3). Remove the clip (5) from the crank pin. Discard the clip (5) .

2. Reduce the air pressure to 0 kPa (0 psi) and remove the test hose (H) from the actuator (3) .

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Illustration 5	g00867502

3. Note the orientation of the hose nipple (6) on the actuator (3). Measure dimension (X) and record dimension (X) for the existing wastegate actuator. Refer to Illustration 6.

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Illustration 6	g01148512

4. Remove the nuts (7) that fasten the actuator to the bracket and remove the actuator. Do not remove the bracket.

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Illustration 7	g01148513
214-3451 Repair Kit (8) New actuator (9) Nut (10) Jam nut (11) Rod end (12) Clip

5. Assemble the new actuator (8), jam nut (10), and rod end (11) that is included in the 214-3451 Repair Kit. Adjust the length of the new rod to the previously measured dimension (X) .

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Illustration 8	g00867509

6. Be sure that the hose nipple (6) is oriented in the same position as the original actuator. Install the new actuator (8) on the turbocharger. Fasten the new actuator to the bracket with the nuts (9) that are included in the 214-3451 Repair Kit .

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Illustration 9	g00867583

7. Connect the test hose (H) to the new actuator (8). Apply 138 kPa (20 psi) of air pressure to the new actuator. Place the rod end of the new actuator over the crank pin. Reduce the air pressure to 0 kPa (0 psi).

8. Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.

9. Install the new clip (12) from the 214-3451 Repair Kit on the crank pin if the actuation calibration reading from Step 8 is 125 ± 3 kPa (18 ± 0.5 psi). Tighten the jam nut (10) against the rod end (11) of the actuator. Crimp the rod end (11) to the actuator rod. If the actuation calibration reading from Step 8 is above 127.5 kPa (18.5 psi), refer to "The Actuation Calibration Reading for the New Wastegate Actuator is Above 127.5 kPa (18.5 psi)". If the actuation calibration reading from Step 8 is below 120.7 kPa (17.5 psi) refer to "The Actuation Calibration Reading for the New Wastegate Actuator is Below 120.7 kPa (17.5 psi)".

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Illustration 10	g00867592

10. Remove the test hose and all test equipment. Install the hose (4) on the actuator. Make sure that hose (4) is not kinked. Make sure that the hose does not rub at any point.

11. Record the original actuation calibration reading and record the new actuation calibration reading in the appropriate entry of the Service Information Management System (SIMS).

The Actuation Calibration Reading for the New Wastegate Actuator is Above 127.5 kPa (18.5 psi)

Use the following procedure if the actuation calibration reading is above 127.5 kPa (18.5 psi).

1. Remove the rod end from the crank pin. Turn the rod end in a counterclockwise direction. The actuation calibration reading will decrease approximately 4 kPa (0.6 psi) for every one half turn of the rod end.

2. Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.

3. If the actuation calibration reading is above 127.5 kPa (18.5 psi) repeat Step 1 and Step 2.

4. Install the new clip from the 214-3451 Repair Kit on the crank pin if the actuation calibration reading from Step 2 is 125 ± 3 kPa (18 ± 0.5 psi). Tighten the jam nut against the rod end of the actuator. Crimp the rod end to the actuator rod.

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Illustration 11	g00867592

5. Remove the test hose and all test equipment. Install hose (4) on the actuator. Make sure that the hose is not kinked. Make sure that the hose does not rub at any point.

6. Record the original actuation calibration reading and record the new actuation calibration reading in the appropriate entry of the Service Information Management System (SIMS).

The Actuation Calibration Reading for the New Wastegate Actuator is Below 120.7 kPa (17.5 psi)

Use the following procedure if the actuation calibration reading is below 120.7 kPa (17.5 psi).

1. Remove the rod end from the crank pin. Turn the rod end in a clockwise direction. The actuation calibration reading will increase approximately 4 kPa (0.6 psi) for every one half turn of the rod end.

2. Determine the actuation calibration reading. Refer to "Determine the Actuation Calibration Reading" in this article.

3. If the actuation calibration reading is below 120.7 kPa (17.5 psi) repeat Step 1 and Step 2.

4. Install the new clip from the 214-3451 Repair Kit on the crank pin if the actuation calibration reading from Step 2 is 125 ± 3 kPa (18 ± 0.5 psi). Tighten the jam nut against the rod end of the actuator. Crimp the rod end on the actuator rod.

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Illustration 12	g00867592

5. Remove the test hose and all test equipment. Install hose (4) on the actuator. Make sure that the hose is not kinked. Make sure that the hose does not rub at any point.

6. Record the original actuation calibration reading and record the new actuation calibration reading in the appropriate entry of the Service Information Management System (SIMS).