- 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)
- 2670C (S/N: W671-154; B3E1-171,1470-1470)
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
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
Required Parts
The 508-1306 Actuator As is required.
Installation Procedure
Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | Wastegate Tool | 1 | |
B | Hose (Internal Diameter of |
1 |
- Disconnect the hose assembly from the wastegate actuator.
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Illustration 1 g06114236 Typical example - Remove circlip (1) from pin (2). Retain circlip.
- 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.
- Remove rod (3) from pin (2). Ensure that the rod or the pin are not subjected to any undue stress.
- 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 - 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 - 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.
- 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.Show/hide tableIllustration 4 g06114253 Typical example - 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.
Show/hide tableIllustration 5 g06114255 Typical example - 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 - Pressurize the wastegate actuator to a pressure of
95 kPa (14 psi) . Refer to Illustration 6.Show/hide tableIllustration 7 g06114259 Typical example - 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 Show/hide tableIllustration 9 g06114265 Typical example - 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:
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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)
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- Reduce the pressure from the wastegate actuator.
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Illustration 10 g06114267 Typical example - Tighten nuts (5) that secure wastegate actuator to bracket (4) to a torque of
6.8 N·m (60 lb in) . - 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. - Pressurize the wastegate actuator to a pressure of
100 kPa (14.5 psi) . The movement for the rod actuator is1 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 not1 mm (0.0394 inch) , repeat Step 13 as a thinner spacer (12) may be required. - Remove Tooling (A) and Tooling (B) from the wastegate actuator.
- 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.