WRENCH FUEL 5P5195 - Caterpillar

EngineG3606 (S/N: JFE1-800; 4ZS1-80003)G3608 (S/N: XH71-701; BEN1-579)G3612 (S/N: BB21-701; BKE1-1)G3616 (S/N: BLB1-557; ZZY1-701)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
The coating on the wastegate (WG) shaft is known to swell. The resulting decrease in bushing clearance may cause valve to stick, or seize.Solution
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.
Speed instability at several sites has been successfully resolved without having to rebuild the WG.The procedure described here is intended as a troubleshooting guide to find true root cause of engine instability, and provide alternative solutions to rebuilding the WG.The coating on the WG shaft is known to swell. The resulting decrease in bushing clearance may cause valve to stick, or seize. The current ECA / ICA is to rebuild the valve with new replacement shaft and bushings. If parts are not available and coating on shaft is still intact, the excess swollen shaft material at the bushing interfaces can be machined back to Cat specification of 19.5 0.013 mm.Cat is investigating alternative material wear-pairs as potential PCAs.Diagnostic List
Verify that waste gate linkage is set correctly per instructions below. This is the preferred method to ensure that the plate does not contact the housing at initial setup.
Adjustment of the linkage is required to ensure that in the closed position, the WG plate does not contact the housing during operation. With the WG plate touching the housing in the closed position and the actuator fully extended, shorten the length of the WG rod by turning the rod 2 full turns and secure in place. Verify that plate is not touching housing when actuator is at full extension.
Final adjustment of the WG rod length is verified when the commanded position of the WG is approximately 40% at rated speed and load. Shorten or lengthen the overall rod length to achieve this commanded position of 38% +/- 2%.
Verify that compressor outlet bellows are intact and there are no other boost leaks in the intake air system.
Verify that the IMAP Sensor or Pressure Module is working correctly.Note: 16 Cylinder ONLY: Check Pressure Module lines for condensation.
Verify condition of hydrax oil and possible contamination of system. Document hydrax pressure.If above steps do not resolve issue, follow the procedure below and take Cat® Electronic Technician (ET) data log during entire procedure.
Set all needle valve to 2.5 turns open.
Disable NOx feedback.
Input fuel quality and specific gravity.
Load engine in PC cal to 100% speed and load (or highest stable point) and verify that problem still exists outside of feedback with no known good value stored in NOx sensor. Install calibrated emissions analyzer to verify tune up.
Physically look at WG lever arm at highest stable rating – if