CHAIN 2988623 - Caterpillar

Image1.2.1
Image1.2.2
3. Connect the wastegate service tool to the wastegate (WG) actuator can, then pressurize actuator at 150 kPa ; the WG crank will move, which will make it easier to disconnect the rod.
Note that if the wastegate actuator has failed, the failed actuator may not move and you should go to next step.
4. Pull the rod carefully from the pin. Take care not to bend or stress the pin (ref. Image 1.3.1).
Image1.3.1
5. Release pressure from pump, i.e. reduce pressure from actuator to 0 kPa. Remove the pump from actuator.
6. Remove retaining nuts and dismount actuator from bracket (ref. Image 1.4.1 & Image 1.4.2).
Keep wastegate actuator available for Send-It-Back requests. See the Parts Disposition.
Image1.4.1
Image1.4.2
7. Mount new actuator with old heat shield on bracket ; actuator and heat shield orientation to be respected (ref. Image 1.5.1). Fit nuts by a few threads to ensure wastegate does not fall out of bracket.
Image1.5.1
8. Connect WG service tool to actuator and pressurize actuator to 150 kPa to move rod to extended position (ref. Image 1.6.1).
Image1.6.1
9. Mount rod to pin and fit new circlip, supplied with service kit (5081306), with flat side of circlip against the rod (ref. Image 1.7.1).
Image1.7.1
10. Reduce pressure from actuator to 0 kPa. Crank will move as per Image 1.8.1.
Image1.8.1
11. Pressurize actuator at pre-calibration pressure (95 kPa +/- 1 kPa). See Image 1.9.1.
12. Push crank @ WG closed position ? WG must be fully closed ? Gap between actuator and bracket will appear (ref. Image 1.9.2).
Image1.9.1
Image1.9.2
13. The spacers need to be fitted like a feeler gauge into the gap between heat shield and bracket, DO NOT force larger washers into the gap. Put the cleaning agent to the spacer (use the SODI35). Fit the spacers into the gap (ref. Image 1.10.1, 1.10.2 & 1.10.3) starting with the thickest and moving to the next thickest when no more spacers of the current thickness can be fitted freely. The washer thicknesses are 2mm (twin circle marking), 1mm (no marking on spacer), 0.5mm (triangle marking), and 0.2mm (square marking).
Image1.10.1
Image1.10.2
Image1.10.3
14. Reduce pressure to 0 kPa
15. Tighten nuts to secure actuator on bracket (ref. Image 1.11.1). Torque setting is 6.8Nm +/-1.1Nm.
Image1.11.1
16. The First check-point: Pressurize actuator @ pre-calibration pressure (95 kPa) and check that crank/ WG does not move.
If the WG moved, please return to step 11 as a bigger shim may be needed.
17. The Second check-point: Pressurize actuator @ calibration pressure (100 kPa) and check that crank /WG does move. Actual travel measurements not required but, for information, travel of the rod should be 1mm @100kPa.