O16143 Force SPRING, THROTTLE RETURN

Table 1
Diagnostic Codes
CDL Code Code Description Comments
3409-5 Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid : Current Below Normal The Electronic Control Module (ECM) detects a low current in the circuit for the balance valve solenoid.
3409-6 Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid : Current Above Normal The ECM detects a high current in the circuit for the balance valve solenoid. The balance valve actuator and balance valve solenoid are integral components. The valve is designed with a normally open position. As the solenoid is energized, the valve is closed. Air flow to the diaphragms of the balance valves at the turbochargers is restricted. The valve vents residual air pressure that is in the air lines to the atmosphere.In order to test the balance valve actuator, a test apparatus that consists of the following tooling will be required:
Table 2
Required Tooling
Quantity Part Number
1 215-2592 Wastegate Kit
1 65120 7/16"-20 JIC to hose barb
1 93215 9/16"-20 JIC to hose barb
Illustration 1 g02140483
Schematic for the balance valve solenoid
Test Step 1. Check for Diagnostic Trouble Codes
Establish communication between Caterpillar Electronic Technician (ET) and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
Determine if a code is active or logged. Results:
No Active Codes - No codes are active for the balance valve solenoid at this time, but operation of the balance valve actuator is suspect. Proceed to Test Step 2.
3409-5 Active - A 3409-5 is active or logged. There is a low current in the circuit for the balance valve solenoid. Proceed to Test Step 9.
3409-6 Active - A 3409-6 is active or logged. There is a high current in the circuit for the balance valve solenoid. Proceed to Test Step 8.Test Step 2. Inspect the Air Lines from the Balance Valve Actuator to the Balance Valves at the Turbochargers
Illustration 2 g02139266
Inspection points for the balance valve air lines
Inspect the air lines from the outlet of the balance valve actuator to the inlet of each of the balance valves. Check the lines for any signs of leakage.Expected Result:The lines are in good repair.Results:
OK - The lines are not damaged. All of the line fittings are clean and tight. Proceed to Test Step 3.
Not OK - Damage to the lines is discovered.Repair: Repair the line or replace the line. Return the unit to service.STOPTest Step 3. Inspect the External Linkage for the Balance Valves at each Turbocharger
Illustration 3 g02139372
Inspection points for the balance valve linkage
Inspect the balance valve linkage from each of the canisters to the housing. Also, inspect the connection point from the canister to the valve. Inspect the linkage for the following issues.
Dirt buildup
Rubbing
DamageExpected Result:The linkage from the canister to the valve is in good repair.Results:
OK - The linkage is not damaged. Proceed to Test Step 4.
Not OK - The linkage is damaged.Repair: Replace the turbocharger. Return the unit to service.STOPTest Step 4. Install the Test Apparatus and Check the System with Pressurized Air
Illustration 4 g02139379
(1) Pressurized air supply
(2) Pressure regulator
(3) Gate valve
(4) Pressure gauge
(5) Balance valve solenoid
(6) Turbocharger balance valve
(7) Gate valve
Use the parts that are listed in Table 2 to assemble the test apparatus. Refer to Illustration 4 for the proper assembly.
Illustration 5 g02139660
Test apparatus that is fully assembled
Connect the test apparatus between the inlet of the regulated air supply and inlet of the balance valve canister. Note: Do not exceed 138 kPa (20 psi) of air pressure to the balance valve canister. Damage to the balance valve diaphragm may occur if this pressure is exceeded.
Regulate the supply air pressure for the test apparatus to 138 kPa (20 psi).
Loosen the line fitting on the line that exits the balance valve actuator.
Check for pressurized air that is leaking from the loose fitting. If pressurized air is leaking from the fitting, the balance valve actuator is not stuck in the closed position.
Tighten the line fitting.
Visually inspect each of the balance valve linkages at the turbocharger for activation. While the pressurized air is applied to the system, the balance valve linkage will be fully extended.Expected Result:Pressurized air leaks through the fitting during the test and the balance valve linkage is fully extended.Results:
OK - Pressurized air leaks through the fitting and the balance valve linkage are fully extended during the test. The valve actuator is not stuck in the closed position. The balance valve linkage is operating correctly. Proceed to Test Step 5.
Not OK - Pressurized air did not leak from the line at the balance valve actuator and/or the balance valve linkage did not extend fully.Repair: If pressurized air did not leak from the line at the balance valve actuator during the test, replace the faulty balance valve actuator. Return the unit to service.If the balance valve linkage did not extend fully during the test, there may be a problem with the valve. Proceed to Test Step 7.Test Step 5. Use the Override to Test for Proper Operation of the Balance Valve Actuator
Connect Cat ET. Procee