HARNESS AS-PLATFORM 4212680 - Caterpillar

Image1.3.1
9. Remove bracket from turbocharger. (Image 1.4.1)
Image1.4.1
10. Mount new bracket on turbocharger and tighten bolts (Image 1.5.1). Tighten to 13.4Nm +/- 1.3Nm. (119 lbin +/- 12 lbin).
Image1.5.1
11. Mount new actuator with old heat shield on bracket; actuator and heat shield orientation to be respected (Image 1.6.1). Fit nuts by a few threads to ensure wastegate does not fall out of bracket.
Image1.6.1
12. Connect wastegate service tool to actuator and pressurize actuator to 90kPa (13psi) to move rod to extended position (Image 1.7.1).
Image1.7.1
13. Mount rod to pin and fit new circlip, supplied with service kit (5209956), with flat side of circlip against the rod (Image 1.8.1).
Image1.8.1
14. Reduce pressure from actuator to 0kPa (0psi). Crank will move as per Image 1.9.1.
Image1.9.1
15. Pressurize actuator at pre-calibration pressure (55kPa +/- 1kPa) (8psi +/- 0.15psi).
16. Push crank to wastegate closed position (Image 1.10.1) ? wastegate must be fully closed ? gap between actuator and bracket will appear (Image 1.10.2).
Image1.10.1
Image1.10.2
17. Spacers need to be fitted into the gap between the heat shield and the bracket. DO NOT force larger spacers into the gap. Apply a suitable cleaning fluid to the spacers.
17.1 Start by fitting the thickest possible spacer. Once no more spacers of this thickness can be fitted, moved to step 17.2.
17.2 Fit the next size down spacer. Once no more spacers of this thickness can be fitted, continue with the next smaller spacer and repeat, until no more spacers can be fitted freely.
17.3 If there is not enough spacers to fill in the gap, this means that the pressure pump is not calibrated properly. Please ensure that the pump is calibrated properly, i.e. within +/- 1kPa (+/- 0.15psi).
The spacer thicknesses are 2mm (0.07874in)(twin circle marking), 1mm (0.03937in)(no marking on spacer), 0.5mm (0.01968in)(triangle marking), and 0.2mm (0.00787in)(square marking).
Image1.11.1
Image1.11.2
Image1.11.3
Image1.11.4
18. Reduce pressure to 0kPa (0psi).
19. Tighten nuts to secure actuator on bracket (Image 1.12.1). Tighten to 2.5Nm +/- 0.5Nm (22 lbin +/- 4 lbin).
Image1.12.1
20. The First check-point: Pressurize actuator to pre-calibration pressure (55kPa (8psi)) and check that crank/wastegate does not move.
If the wastegate moved, please return to Step 15 as a bigger shim may be needed.
21. The Second check-point: Pressurize actuator to calibration pressure (60kPa (8.7psi)) and check that crank/wastegate does move. Actual travel measurements not required but, for information, travel of the rod should be 1mm (0.0394in) @ 60kPa (8.7psi).
22. Once both check points have been successfully complete, reconnect the hose assembly to the wastegate actuator.