Turbocharger Boost Pressure on Certain C4.4 Machine Engines {1052, 7432} Caterpillar

Turbocharger Boost Pressure on Certain C4.4 Machine Engines {1052, 7432}

Usage:

Excavator: 320 (S/N: YCP1-UP; HEX1-UP); 320F (S/N: NHD1-UP; YBM1-UP); 323F (S/N: FA21-UP; YEC1-UP; MFY1-UP); 325F (S/N: XAA1-UP; YCA1-UP; CPF1-UP; NDJ1-UP; RBW1-UP)
OEM Mobile Hydraulic Power Unit: 323F OEM (S/N: P7P1-UP; RGP1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

There have been instances of the following event codes becoming active leading to an engine derate:

Show/hide table

Table 1
J1939 Code and Description	CDL Code and Description	Customer Action	Clearing Conditions
102–16 Engine Intake Manifold #1 Pressure : High - moderate severity (2)	E1044 (2) High Intake Manifold Pressure	Cycle key OFF for 2 minutes and then run engine to meet Clearing Conditions	Engine Speed >1400/1500 RPM
102-18 Engine Intake Manifold #1 Pressure : Low - moderate severity (2)	E1045 (2) Low Intake Manifold Pressure	Cycle key OFF for 2 minutes and then run engine to meet Clearing Conditions	Engine Speed >1400/1500 RPM

When the operator cycles the keyswitch and meets the clearing conditions for the active event code, the active event is reset.

This issue has been observed on engines with more than 1500 service hours.

Solution

Show/hide table

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Caterpillar is investigating the root cause of the issue. To support the investigation, Caterpillar is requesting that the following procedure is completed, documented, and recorded in "CPI Feedback" within the Service Information Management System (SIMSi).

Use the electronic service tool to download a Product Status Report (PSR) before performing any troubleshooting.
Photograph the turbocharger actuator and actuator rod. Confirm that there is no impact damage to either component.
Review the PSR. If the logged event code is E1044 (102-16), proceed to Test Step 4. If the logged event code is E1045 (102-18), proceed to Test Step 5.
Refer to Troubleshooting, Intake Manifold Air Pressure Is High, starting at Test Step 2.
1. Record the electronic service tool Snapshot.
2. From Troubleshooting, Intake Manifold Air Pressure Is High, Test Step 3c, record the air pressure required to move the actuator rod 1 mm (0.039 inch). If the pressure is outside of the specification of 60 ± 5 kPa (8.7 ± 0.7 psi), replace the high-pressure turbocharger. Refer to Disassembly and Assembly, Turbocharger - Remove (Second Stage Turbocharger) and Disassembly and Assembly, Turbocharger - Install (Second Stage Turbocharger) for the correct procedure.
3. Proceed to Step 7 in this procedure.
Refer to Troubleshooting, Intake Manifold Air Pressure Is Low, Test Step 1 to Test Step 3.
1. Photograph the condition of the air filter elements during inspection.
2. Proceed to Step 6 in this procedure.
If no issues are found during Step 5, troubleshoot the turbocharger wastegate. Refer to Troubleshooting, Intake Manifold Air Pressure Is High, Test Step 2 and Test Step 3.
1. Record the electronic service tool Snapshot.
2. From Troubleshooting, Intake Manifold Air Pressure Is High, Test Step 3c, record the air pressure required to move the actuator rod 1 mm (0.039 inch). If the pressure is outside of the specification of 60 ± 5 kPa (8.7 ± 0.7 psi), replace the high-pressure turbocharger. Refer to Disassembly and Assembly, Turbocharger - Remove (Second Stage Turbocharger) and Disassembly and Assembly, Turbocharger - Install (Second Stage Turbocharger) for the correct procedure.
3. If the high-pressure turbocharger is replaced as a result of an E1045 (102-18), also replace the wastegate solenoid. Refer to Disassembly and Assembly, Wastegate Solenoid - Remove and Install for the correct procedure.
4. Proceed to Step 7 in this procedure.
Photograph all removed parts. Sometimes, returned parts have shown signs of transit damage. Ensure that all parts are packaged to prevent transit damage. Ensure that the part numbers, Works Order number or Service Claim number, and Machine Serial number are recorded in "CPI Feedback" within SIMSi.
In every instance, submit a SIMSi report, complete with TIB media number M0106628 and CPI number 439729. Submit the following information through "CPI Feedback" within SIMSi:
- PSR from before and after troubleshooting. Ensure that the PDF and XML versions of the PSR are downloaded, with the Histogram option selected in the download list
- Photographs from Step 2 and Step 5a. Correctly name the files for easy identification.
- Electronic service tool snapshot (XML)
- Recorded pressure to move the wastegate actuator rod
- Works Order Number or Service Claim Number and Machine Serial Number for generation of Parts Return Request