Installation and Adjustment Procedure for the 332-8662 Actuator Kit (Wastegate){1052, 1053, 1057, 1940} Caterpillar

Industrial Engine:

C13 INDUSTRIAL (S/N: LGK1-UP)

Introduction

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

Required Tooling

Use the 215-2592 Kit (Wastegate) in order to calibrate the new actuator kit properly.

Illustration 1 shows the 215-2592 Kit (Wastegate). However, the 213-4269 Adapter As (Crimping) is not shown in Illustration 1.

Illustration 1	g01580494
(1) Air pressure regulator (2) Air pressure gauge (3) Two 4P-5866 Clamps (4) A tee or a cross (5) A test hose (6) A hose barb coupler (7) An air valve (8) Valve (9) A fitting that is used to make a connection to the air supply

Note: The air pressure gauge must have a minimum pressure rating of 207 kPa (30 psi). The gauge must also have graduations of 1.72 kPa (0.25 psi).

Note: Test hose (5) must have a 6.35 mm (0.25 inch) inside diameter. This will allow the test hose to connect to the wastegate actuator properly.

You will also need a dial indicator with a base that can be attached to the engine.

Removal Procedure for the Old Wastegate Actuator

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Illustration 2	g01580714
(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 tube that goes from the turbocharger compressor housing to the wastegate actuator.

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Illustration 3	g01580733
(12) Clip that secures the crank pin

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Illustration 4	g01581155
(5) Test hose (12) Clip that secures the crank pin (13) Wastegate actuator

2. Apply 165 kPa (24 psi) of air pressure to actuator (13) .

3. Remove clip (12) from the crank pin. Discard the clip. Refer to Illustrations 3 and 4.

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Illustration 5	g01708775
(14) Mounting nuts for the wastegate actuator

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Illustration 6	g01581176
(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 bolts on actuator (13). Remove the actuator. Refer to Illustrations 5 and 6.

   Note: Do not remove the mounting bracket for the actuator.

Assembly of the 332-8662 Actuator Kit

Illustration 7	g01580736
(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

Note: Measure the length of the rod on the old actuator. Rod length (A) on the new actuator must be the same length as the rod on the old actuator.

1. Assemble jam nut (15) and rod end (16) onto the new actuator. Use the parts that came with the 332-8662 Actuator Kit . Refer to Illustration 7.

Installing the Actuator

Illustration 8	g01580753
(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.

2. Secure the actuator to the mounting bracket with mounting nuts (14). Make sure that the mounting nuts that are included in the 332-8662 Actuator Kit are used. Torque the mounting nuts to 8 ± 1 N·m (6 ± 0.7 lb ft).

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Illustration 9	g01580755
(5) Test hose (13) Wastegate actuator

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

4. Apply 165 kPa (24 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.

Procedure to Calibrate the Actuator

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Illustration 10	g01580758
(B) Dial indicator (13) Actuator (18) Rod on the actuator

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.

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Illustration 11	g01580760
(B) Dial indicator (1) Air pressure regulator (2) Air pressure gauge (3) 4P-5866 Clamp (5) Test hose (13) Wastegate actuator (18) Rod on the actuator

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 travelled 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.

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Illustration 12	g01580733
(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 165 ± 3 kPa (24 ± 0.5 psi). Use the clip that was supplied with the 332-8662 Actuator Kit .

Note: Follow the appropriate procedure below if the calibration value is not 165 ± 3 kPa (24 ± 0.5 psi).

Procedure for the Actuator if the Calibration Value is above 165 kPa (24 psi)

1. Remove the rod end from the crank pin. Turn the rod end in a counterclockwise direction. The actuator calibration value will decrease approximately 4 kPa (0.6 psi) for every one and a half turns of the rod end. 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 165 ± 3 kPa (24 ± 0.5 psi). Use the clip that was supplied with the 322-9352 Actuator Kit .

4. Perform Steps 1 through 3 if the actuator calibration value is still above 165 kPa (24 psi).

Procedure for the Actuator if the Calibration Value is below 165 kPa (24 psi)

1. Remove the rod end from the crank pin. Turn the rod end in a clockwise direction. The actuator calibration value will increase approximately 4 kPa (0.6 psi) for every one and a half turns of the rod end. 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 165 ± 3 kPa (24 ± 0.5 psi). Use the clip that was supplied with the 332-8662 Actuator Kit .

4. Perform Steps 1 through 3 if the actuator calibration value is still below 165 kPa (24 psi).

Final Assembly

After the actuator has been calibrated properly, perform the following steps.

1. Make sure that you tighten the locknut (15) in Illustration 7 after the actuator has been calibrated.

2. Use the 213-4269 Adapter As (Crimping) in order to crimp the threads on the locknut (15). This will prevent the locknut from becoming loose.

3. Reinstall the support bracket and the heat shield for the turbocharger.

4. Reattach the hose between the turbocharger compressor housing to the wastegate actuator.