TOPIC: Electronic Controls

IDENT NO: 17-4118

DATE: November 2019

275GL+*/VHP* SUPERSEDES: New

SUBJECT: Troubleshooting Steps for Actuators

MODELS AFFECTED: 275GL+ and VHP Engines

The purpose of this bulletin is to provide

information about proper adjustment,
maintenance and troubleshooting of the
actuators used on VHP and 275GL+ engines.
The VHP actuator, P/N 214046B, is used to control
throttle movement (see Figure 1).
The 275GL+ uses actuator P/N 214046B for
throttle control and two actuators, P/N 296515,
for bypass and wastegate movement (see
Figure 2).
VHP Actuator P/N affected: 214046B
275GL+ Actuator P/Ns affected: 214046B, 296515
NOTE: On 275GL+ engines, troubleshooting
guidance regarding ALM324, which may cause
engine shutdowns not seen in the Human Figure 2: 275GL+ Actuator: P/N 214046B and 296515
Machine Interface (HMI), is also included in this
bulletin.
NOTICE
Do not plug or unplug the actuator without
removing power. This causes arcing and burns
connecting pins.
Ensure that proper surge protection is in place
for the engine. Actuators are vulnerable to
surging.

275GL+ ACTUATOR ADJUSTMENT

Figure 1: VHP Actuator: P/N 214046B
Every year or as needed, the throttle actuator
linkage must be inspected.
NOTE: 2-3% play may be found when
attempting to rotate the shaft manually (by
hand). This is considered acceptable for
operation if the actuator is holding the desired
RPM during operation.

* Trademark of INNIO Waukesha Gas Engines, Inc.

All other trademarks are the property of their respective owners.

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Service Bulletin No. 17-4118

275GL+ THROTTLE LINKAGE ADJUSTMENT

! WARNING
1. Position the carburetor lever to the forward
Always stop the unit before stop (closed) position.
cleaning, servicing or
repairing the unit or any 2. Position the actuator lever parallel to the
driven equipment. Be sure to carburetor lever (approximately 15º from
follow the procedures listed vertical) with the actuator position indicator
below and apply site in the closed position (0) (see Figure 3).
Lockout/Tagout
requirements. Failure to
comply may result in death
or serious personal injury.
• Place all controls in the OFF
position and disconnect or
lockout starters to prevent
accidental restarting.
• If possible, lock all controls
in the OFF position and
remove the key.
• Put a sign on the control
panel warning that the
engine is being serviced.
• Close all manual control
valves.
• Disconnect and lock out all
energy sources to the Figure 3: Throttle Actuator End View
engine, including all fuel,
electric, hydraulic and 3. Adjust the length of the throttle rod (if
pneumatic connections. necessary) to span both mounting locations.
Tighten the jam nuts.
• Disconnect or lock out
driven equipment to
prevent the possibility of
the driven equipment
rotating the disabled
engine.

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 Service Bulletin No. 17-4118

4. Apply Loctite® 242 to threads of both flat-

head screws. Attach the throttle rod using NOTICE
the hardware shown in Figure 4.
Throttle rod ends must be free of debris.
Throttle rod ends are not to be manually
greased or oiled.

4 3
6 5
7

2 2

7 6 5 4

Figure 4: Throttle Rod

1 - Throttle Rod 5 - Flat Washer

2 - Jam Nut 6 - Lock Washer
3 - Flat-Head Screw 7 - Hex Nut
4 - Spacer

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Service Bulletin No. 17-4118

BYPASS LINKAGE ADJUSTMENT 2. The bypass lever should be installed in line

and parallel to the actuator lever in the
closed position.
6 5 4 4 3
3. Adjust the length of the linkage rod (if
necessary) to span both lever mounting
locations. Tighten the jam nuts.
4. Attach the rod using the hardware shown in
Figure 5.

2 NOTICE
Throttle rod ends must be free of debris.
1 Throttle rod ends are not to be manually
greased or oiled.

WASTEGATE LINKAGE ADJUSTMENT

2 1. Install the actuator lever inline with the
3
5 actuator position indicator (approximately
135º from vertical) with the actuator position
indicator in the closed position (0º) (see
Figure 7).

6 4 4

Figure 5: Bypass Linkage Adjustment

1 - Control Rod
2 - Jam Nut
3 - Capscrew
4 - Spacer
5 - Lock Washer
6 - Hex Nut
1. Install the actuator lever inline with actuator
position indicator (approximately 35º from
vertical) with the actuator position indicator
in the closed position (0º) (see Figure 6).

Figure 7: Wastegate Actuator End View

2. The wastegate levers should be installed as

shown in the closed position.
3. Adjust length of the linkage rods (if
necessary) to span lever mounting locations.
Tighten the jam nuts.

Figure 6: Bypass Actuator End View

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 Service Bulletin No. 17-4118

4. Attach the rod using the hardware shown in
Figure 8.
3. Verify the rod ends are centered on their
pivots and are free throughout the travel.
Adjust as required.
4. Inspect rod ends. Replace if worn.
5. Inspect actuator rods for straightness and
damage. Repair or replace as necessary.

3 6. Verify proper operation of actuators by

performing a manual calibration of
actuators using ESP.

NOTICE
The rod ends for throttle, wastegate and
bypass must be clean and dry. Application of
grease, oil or dry film lubricant can cause
3 sticking or binding of the linkage and result in
2 erratic performance.
5
6 2
1 7. Inspect wastegate and bypass valve shafts
4
for binding or excessive looseness. Repair or
3 replace as required.
3 Remove the preservative grease applied to the
joints for shipping before running the engine.
5 Use an appropriate solvent, brush and rags to
make sure all grease and paint is removed. Any
6 remaining grease may carburize and cause the
linkage to bind.
Figure 8: Wastegate Linkage Adjustment
275GL+ ACTUATOR TROUBLESHOOTING
1 - Control Rod
2 - Jam Nut Actuator failures may be a surface-level
3 - Spacer symptom of other component issues. Likely,
4 - Capscrew
5 - Lock Washer
exchanging the actuator may not solve the
6 - Hex Nut main issue in the engine.
If alarms activate, check:
NOTICE
• All linkage components, which should be tight
Throttle rod ends must be free of debris. and secure, but not stuck. Linkages should
Throttle rod ends are not to be manually also be able to move smoothly through the
greased or oiled. full range of motion.
• Wireway connections, pins and the integrity of
275GL+ ACTUATOR MAINTENANCE the wireway protection, such as tubing,
conduit, braiding, etc.
Refer to Service Bulletin 9-4075, Rod End
Maintenance Manual Corrections for additional • Wastegate valves for free movement.
information. Disconnect linkage and ensure that the
wastegate’s valves are moving smoothly. If so,
The actuator linkage must be inspected and the fault is not caused by a stuck wastegate. If
cleaned every 4,000 hours. there is no movement, replace the wastegate.
1. Shut down the engine. • Actuator connectors, for signs of burning. This
2. Verify jam nuts on both ends of actuator may be caused by plugging/unplugging
connectors without removing power to the
rods are secure.
engine, or by engine surging.

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Service Bulletin No. 17-4118

If unknown shutdown occurs, and a shutdown VHP ACTUATOR ADJUSTMENT

code cannot be found in the HMI:
Every year or as needed, the throttle actuator
• ALM324 STUCK WG LINKAGE FB results in a
linkage must be inspected.
shutdown (ESD).
This shutdown prevents exhaust and intake NOTE: 2-3% play may be found when
attempting to rotate the shaft manually (by
events in the engine.
hand). This is considered acceptable for
Disparity between the ECU commanded operation if the actuator is holding the desired
position and the position feedback of the RPM during operation.
Wastegate (WG) valve is monitored. A disparity
greater than 5% for more than 5 seconds
triggers this shutdown.
! WARNING
Always stop the unit before
This alarm code is not shown in the HMI, but can
cleaning, servicing or
be found in ESP. ESP should serve as the main
repairing the unit or any
record of all ALMs and ESDs.
driven equipment. Be sure to
NOTE: ALM324 STUCK WG LINKAGE is a distinct follow the procedures listed
and separate fault. This does function as an below and apply site
alarm code, and not a shutdown. Wastegate Lockout/Tagout
position is monitored over time. This may also requirements. Failure to
not be shown in the HMI, but can be found in ESP. comply may result in death
This fault is less likely to occur than the ALM324 or serious personal injury.
STUCK WG LINKAGE FB.
• Place all controls in the OFF
The following eHelp alarm codes are relevant to position and disconnect or
the actuators. Please review for detailed lockout starters to prevent
guidance on troubleshooting. accidental restarting.
• ALM322 Calibrate Actuator • If possible, lock all controls
in the OFF position and
• ALM323 Stuck Throttle Linkage remove the key.
• ALM324 Stuck Wastegate Linkage • Put a sign on the control
• ALM325 Stuck Bypass Linkage panel warning that the
engine is being serviced.
• ALM441 Throttle Actuator
• Close all manual control
• ALM443 Wastegate Actuator valves.
• ALM445 Bypass Actuator • Disconnect and lock out all
NOTE: See eHelp for additional alarm energy sources to the
engine, including all fuel,
information.
electric, hydraulic and
pneumatic connections.
• Disconnect or lock out
driven equipment to
prevent the possibility of
the driven equipment
rotating the disabled
engine.

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 Service Bulletin No. 17-4118

VHP 6- AND 12-CYLINDER ADJUSTMENT

MAX. FUEL NO FUEL

POSITION POSITION

GOVERNOR
LEVER

TOP VIEW OF ACTUATOR

Figure 9: Governor Terminal Shaft Angles

The following steps describe the procedure for

properly setting the governor linkage rod and
levers on the actuator and the throttle shaft.
1. Install governor lever onto governor terminal
shaft at angle shown in Figure 9. Terminal
shaft must be in the NO FUEL position. Secure
with capscrew and nut.
2. Attach left-hand side of governor rod
assembly to lever on butterfly valve. Tighten
nuts on governor rod assembly.
3. With governor terminal shaft in NO FUEL
position and with butterfly valve held
CLOSED, adjust governor rod for length so rod
end and hole in governor lever align.
4. Attach right-hand side of governor rod
assembly to lever on governor terminal
shaft. Tighten nuts on governor rod
assembly.
5. Check for throttle and governor travel to
angles specified in Figure 9.
6. Check to ensure no binding occurs.
7. Check all fasteners on rod and levers for
tightness. Thread engagement on all rod
ends must be at least seven threads.

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Service Bulletin No. 17-4118

L5794LT L7042GSI S4, L7044GSI & L5794GSI

(STANDARD NATURAL GAS APPLICATIONS) (STANDARD NATURAL GAS APPLICATIONS)
SEE NOTES SEE NOTES

THROTTLE
LEVER
BUTTERFLY
VALVE CLOSED 110°
POSITION
BUTTERFLY
VALVE MAX. OPEN 0°
POSITION

35° 56°

0°

THROTTLE
LEVER
124°
BUTTERFLY BUTTERFLY VALVE
VALVE CLOSED MAX. OPEN
POSITION POSITION

L5774LT
(STANDARD NATURAL GAS APPLICATIONS)

L7042GSI S4, L7044GSI, L5794GSI, & L5794LT

(DRAW-THRU APPLICATIONS)
SEE NOTES

BUTTERFLY
BUTTERFLY VALV E MAX. OPEN
VALVE CLOSED POSITION NOTE: For all figures shown, the throttle lever is mounted
POSITION
on the far side of butterfly valve housing.

NOTE: For all figures shown, the butterfly valve is viewed

from the right bank side.
124°

56°

0°

THROTTLE
LEVER

Figure 10: Butterfly Valve Cross-Shaft Angles

The following steps describe the procedure for
properly setting the governor linkage and rod
and levers on the actuator and the throttle
shaft.
1. Install governor lever (see Figure 9) onto
governor terminal shaft at angle shown in
Figure 9. Terminal shaft must be in the NO
FUEL position. Secure with capscrew and nut.
2. Install throttle lever on regulating cross shaft
to angle shown for your engine type in
Figure 10. The butterfly valve must be in the
CLOSED position. Secure with capscrew,
washers and nut.
3. Attach left-hand side of governor rod
assembly to lever on butterfly valve. Tighten
nuts on governor rod assembly.
4. With governor terminal shaft in NO FUEL
position and with butterfly valve held
CLOSED, adjust governor rod for length so rod
end and hole in governor lever align.
5. Attach right-hand side of governor rod
assembly to lever on governor terminal
shaft. Tighten nuts on governor rod
assembly.

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 Service Bulletin No. 17-4118

6. Check for throttle and governor travel to
angles specified in Figure 9 and Figure 10.
7. Check to ensure no binding occurs.
8. Check all fasteners on rod and levers for
tightness. Thread engagement on all rod
ends must be at least seven threads.
VHP 16-CYLINDER ADJUSTMENT
NOTE: The butterfly valve spider is attached to
the butterfly valve shaft in a fixed position
(factory-set) using a capscrew, washer and roll
pin. The butterfly valve should be fully closed
with the throttle actuator indicator in the NO
FUEL position.
1. Verify the butterfly valve spider capscrew is
tight and the roll pin is in place.
2. Position (turn) throttle actuator shaft to align
throttle actuator indicator in the NO FUEL
position (see Figure 11).
2 22°
4. With left and right butterfly valves held in full
CLOSED position, and throttle actuator rod
length adjusted, install throttle actuator pivot
capscrew, locknut, spring-wave washer and
spacers attaching throttle actuator rod pivot
to left bank butterfly valve lever (see
Figure 11).
5. Recheck all jam nuts and throttle actuator
pivot capscrews for tightness.
6. Check throttle butterfly valve lever angles
specified in Figure 11 and Figure 12.
1
2 56°
0°

1 3
124° 1
68°

56° Figure 12: Right Bank Throttle

(Viewed from Front of Engine)

1 - Butterfly Valve CLOSED Position

0° 2 - Butterfly Valve – Right Bank
22° 7. Readjust as required; check to ensure no
binding occurs.

Figure 11: Left Bank Throttle

(Viewed from Rear of Engine)

1 - MAXIMUM FUEL Position

2 - Governor Travel
3 - NO FUEL Position
4 - Butterfly Valve CLOSED Position
3. While holding left and right butterfly valves in
full CLOSED position, adjust throttle actuator
rod length so that a capscrew will pass
through the rod end and the hole in the left
bank butterfly valve lever.

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Service Bulletin No. 17-4118

VHP ACTUATOR MAINTENANCE 1. Shut down engine.

2. Inspect rod ends. If worn, replace.
Every year or as needed, the throttle actuator
linkage must be lubricated. 3. Using a grease gun, lubricate the grease
fittings on the throttle actuator linkage with
NOTE: Do not lubricate fittings in throttle
CITGO Lithoplex Grease NLGI 2 [service
actuator linkage beyond the specifications.
temperature range 20° – 250°F (7° – 121°C)] or
Using unspecified lubricants can cause burning
equivalent (see Figure 13).
and sticking of linkages.

Figure 13: VHP Throttle Actuator Linkage (Grease Fitting)

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 Service Bulletin No. 17-4118

VHP ACTUATOR TROUBLESHOOTING

Actuator failures may be a surface-level
symptom of other component issues. Likely,
exchanging the actuator may not solve the
main issue in the engine.
If alarms activate, check:
• All linkage components, which should be tight
and secure, but not stuck. Linkages should
also be able to move smoothly through the
full range of motion.
• Wireway connections, pins and the integrity of
the wireway protection, such as tubing,
conduit, braiding, etc.
• Wastegate valves for free movement.
Disconnect linkage and ensure that the
wastegate’s valves are moving smoothly. If so,
the fault is not caused by a stuck wastegate. If
there is no movement, replace the wastegate.
• Actuator connectors, for signs of burning. This
may be caused by plugging/unplugging
connectors without removing power to the
engine, or by engine surging.
The following eHelp alarm codes are relevant to
the actuator. Please review for detailed
guidance on troubleshooting.
• ALM323 Stuck Throttle Linkage
• ALM324 Calibrate Actuator
• ALM441 Throttle Actuator
NOTE: See eHelp for additional alarm
information.

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