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Installation Of The Hydraulic Actuator System (Hydrax System) on G3606 and G3608 Engines {1050, 1250, 1908, 1915} Caterpillar


Installation Of The Hydraulic Actuator System (Hydrax System) on G3606 and G3608 Engines {1050, 1250, 1908, 1915}

Usage:

G3606 3XF
Engine
G3606 (S/N: 3XF1-UP)
G3608 (S/N: 4WF1-UP)

Introduction

This Special Instruction describes the installation of the Hydrax system on G3606 and on G3608 Engines. The Hydrax system replaces the electronic actuators that control the fuel, the wastegate, and the choke. The Hydrax system improves the reliability of the engine and the system reduces maintenance costs.

Whenever questions arise about this product or about this Special Instruction, consult your local Caterpillar dealer for the latest available information.

Do not perform any procedure that is outlined in this Special Instruction and do not order any parts until the entire instruction has been read and understood.

References

The following reference materials may be necessary for this procedure:

Specifications, SENR4257

Troubleshooting, SENR6510

Disassembly And Assembly Manual, SENR4259

Systems Operation/Testing and Adjusting, SENR4258

System Description

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Illustration 1g01025726
Hydraulic Actuator System
(1) Position feedback sensor
(2) Fuel actuator
(3) Pressure relief valve
(4) Wastegate actuator
(5) Box for the hydrax driver modules
(6) Hydraulic pump
(7) Hydraulic tank
(8) Hydraulic oil filter
(9) Accumulator
(10) Check valve
(11) Pressure switch
(12) Air choke actuator

The Hydrax system controls fuel actuator (2), wastegate actuator (4), and air choke actuator (12) by using individual electronically controlled hydraulic actuators.

The system uses engine oil or hydraulic oil for the hydraulic fluid. Hydraulic pump (6) is driven by the engine. The pump provides the required fluid pressure. The pump is gear-driven from the engine front gear train. The pump is mounted behind the engine oil pump. The pump will provide hydraulic fluid at approximately 8 gpm at 1000 rpm engine speed.

Hydraulic tank (7) stores the hydraulic fluid. Check valve (10) keeps the oil from draining from the system. This provides better response characteristics.

Accumulator (9) is a nitrogen charged bottle which helps maintain the system pressure. The accumulator maintains the system pressure for a short period of time after an engine shutdown condition is requested. This allows the occurrence of a proper shutdown sequence.

Pressure switch (11) protects the engine in case of a reduction in the system pressure. The switch activates a warning if the system pressure drops below 1207 kPa (175 psi). An engine shutdown will occur if the system pressure drops below 690 ± 103 kPa (100 ± 15 psi).

A hydraulic oil filter is inside housing (8).

Pressure relief valve (3) is in parallel with the three actuators. The pressure relief valve is manually adjusted at rated engine speed in order to obtain a system pressure of 1550 kPa (225 psi).

The actuators are electronically controlled. The engine's control system sends commands to three hydrax driver modules inside box (5). The modules convert the signals for use by the actuators.

Position feedback sensors (2) are connected to the linkage for each of the actuators. The feedback signals are sent to the hydrax driver modules. The signals from the driver modules are monitored by the Electronic Control Module.

Note: The hydrax driver modules, the position feedback sensors, and the accumulator are not required if the engine will be equipped with the ADEM III control system.

The hydraulic actuators, the position feedback sensors, and the driver modules are interchangeable. This simplifies troubleshooting the system.

Parts List

The parts that are required for installation of the hydrax system are listed in Table 1.

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Table 1
Parts List For the Hydraulic Actuator System 
Part Number  Quantity  Description 
G3606 Engine  G3608 Engine  G3606 Engine  G3608 Engine 
8T-9580  2  Hydraulic Oil 
125-3891  142-1583  1  Hydraulic Tank and Mounting Group 
142-4238  1  Exhaust Bypass Group 
142-4239  1  Air Lines (Choke) 
142-4240  1  Fuel Control 
4C-4030  1  Thread Lock Compound 
142-5067  141-9902  1  Engine Oil Lines 
142-2055  1  Tube 
6L-7817  1  O-Ring Seal 
2W-7817  1  Gasket 
Pump and Hardware for the Pump 
290-9753  1  Gear Pump Gp 
1W-3389  1  Gear 
1W-3390  1  Gear 
1B-7182  1  Bolt 
0L-1143  6  Bolt 
0S-1585  2  Bolt 
5D-5957  1  O-Ring Seal 
6V-3964  1  Hard Washer 
8T-6764  1  Pipe Plug 
Hardware for the Fuel Shutoff Valve 
140-1736  1  Bracket As 
0S-1588  2  Bolt 
107-8480  1  U-Bolt 
3V-3308  4  Hard Washer 
5P-8245  2  Hard Washer 
1F-7958  2  Full Nut 
9S-8752  2  Full Nut 
Pressure Switch and Mounting Hardware 
140-9669  1  Hydrax Oil Pressure Switch 
3K-0360  1  O-Ring Seal 
Position Sensors, Relay Driver Module, Wiring Harnesses, and Mounting Hardware (1) 
0S-1590  9  5  Bolt 
0S-1594  2  Bolt 
0S-1619  0  1  Bolt 
0T-0573  0  6  Bolt 
110-8714  36  Wire End 
129-3543  1  Junction Box Gp 
135-0784  1  Tag 
141-6403  1  Tag 
135-6656  1  Harness for the Connection Between the Engine's Junction Box and the Relay Driver Module 
135-6657  142-5008  1  Harness for the Fuel Actuator 
135-6658  142-5009  1  Harness for the Fuel Actuator's Position Sensor 
135-6659  142-5010  1  Harness for the Air Choke Actuator 
135-6660  142-5011  1  Harness for the Air Choke Actuator's Position Sensor 
135-6661  142-5012  1  Harness for the Wastegate Actuator 
135-6662  142-5013  1  Harness for the Wastegate Actuator's Position Sensor 
135-6663  142-5014  1  Harness for the Hydrax Oil Pressure Switch 
138-3132  1  Bracket 
138-4409  0  2  Spacer 
141-6403  1  Tag 
1A-2029  1  Bolt 
1B-4971  0  2  Spacer 
3V-3308  13  16  Hard Washer 
4P-7581  3  1  Clip 
4P-8134  1  Clip 
5P-7854  0  1  Clip 
5P-9297  1  4  Clip 
7D-1553  1  Clip 
7D-7233  5  6  Clip 
7E-7731  4  Mount 
8H-0707  4  Bolt 
8T-1887  1  Clip 
8T-1888  1  Clip 
9M-4594  4  5  Spacer 
9S-8752  1  2  Full Nut 
9X-6772  17  20  Cable Strap 
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(1) The position sensors, the relay driver module, the wiring harnesses, and the mounting hardware are not required if the engine will be converted to the ADEM III system.

Order a New Personality Module

A new personality module is required in order to make the engine compatible with the new actuators. In ordertoproperly define the configuration for the new personality module, a "Personality Module Request Form" must be submitted to the Service Center at Caterpillar Diversified Power Products. The Service Center will respond with the appropriate part number that can be ordered through the parts system.

Illustration 2 is the "Personality Module Request Form". The form includes all of the information that is required in order to process your request.

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Illustration 2g01056605

Prepare the Engine

Illustration 3 is the "Performance Data Sheet" for the Engine Supervisory System (ESS). Use the sheet in order to record the engine data from these systems:

  • Digital Diagnostic Tool (DDT)

  • Caterpillar Monitoring System (CMS)

  • Status Control Module (SCM)

  • Electronic Control Module (ECM)

  • Pyrometer

Use an emission analyzer tool in order to test the engine's emissions. Record the results of the test onto the sheet.

This information serves as a reference in order to ensure that engine performance is maintained after the Hydrax system is installed.

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Illustration 3g01056776
Performance data sheet

Ensure that the manual shutoff valve for the fuel supply is closed.

Ensure that the manual shutoff valve for the pressure for the starting system is closed.

Remove all electrical power from the engine.

Drain the coolant below the level of the coolant inlet line for the turbocharger.

Replace the Coolant Inlet Line for the Turbocharger

  1. Remove the existing coolant inlet line for the turbocharger.
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    Illustration 4g01025030
    Top view of the engine
    (1) 2W-4026 Gasket
    (2) 142-2055 Tube As
    (3) 6L-7817 O-Ring Seal

  2. Install tube (2) by using gasket (1) and O-ring seal (3).

  3. Check the level of the coolant according to the engine's Operation and Maintenance Manual. Fill the system with coolant, as needed. Check for any coolant leaks and correct any coolant leaks.

Remove the Existing Components

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    Illustration 5g01021804
    Left side view of the air choke
    (1) Typical electrical actuator
    (2) Bracket
    (3) Linkage
    (4) Lever

  1. Remove electrical actuator (1), bracket (2), linkage (3), and lever (4).
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    Illustration 6g01020690
    Top view of the rear of the engine
    (5) Lines for the pressure module
    (6) Fuel metering valve
    (7) Pressure module
    (8) Typical electronic actuator
    (9) Linkage
    (10) Bracket for the fuel metering valve
    (11) Bracket for the fuel shutoff valve
    (12) U-clamp assembly

  2. Remove the following items: lines (5) for the pressure module, pressure module (7), actuator (8), linkage (9), U-clamp assembly (12) and brackets (10) and (11). Save the nut that is used to attach fuel metering valve (6) to bracket (10). The nut will be used during installation of the new bracket.
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    Illustration 7g01021834
    Rear view of the components for the wastegate
    (13) Typical electrical actuator
    (14) Linkage
    (15) Bracket for the linkage
    (16) Bracket for the actuator

  3. Remove electrical actuator (13), linkage (14), and brackets (15) and (16).

  4. Inside the engine junction box, disconnect the wiring for the electrical actuators. Remove the wiring harnesses that connect the engine junction box to the electrical actuators. Completely remove the harnesses from the engine.

  5. Remove all of the clips that were securing the harnesses to the engine.

Install The Components

Drive Gear and Hydraulic Oil Pump

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Illustration 8g01021847
Left side view
(1) 1W-3389 Gear
(2) 0S-1585 Bolt
(3) 0L-1143 Bolt
(4) 5D-5957 O-Ring Seal
(5) 290-9753 Gear Pump Gp
(6) 1B-7182 Bolt
(7) 6V-3964 Hard Washer
(8) 1W-3390 Gear

  1. Remove the engine oil pump.

    Reference: Refer to Disassembly And Assembly Manual, SENR4259 for additional information.

  2. Install hydraulic pump drive gear (1) to the engine oil pump drive gear. Tighten six bolts (3) to the appropriate torque according to the specifications.

  3. Reinstall the engine oil pump.

  4. Remove the front housing cover on the opposite side of the engine oil pump.

  5. Install O-ring seal (4) to the hydraulic oil pump.

  6. Install gear (8) to the hydraulic oil pump by using washer (7) and bolt (6).

    Torque bolt ... 30 N·m (22 lb ft)

  7. Install hydraulic oil pump (5) by tightening two bolts (2) to the standard torque.

Air Choke Actuator

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Illustration 9g01021891
View of the aftercooler
(1) 196-9529 Electronic Actuator
(2) 5M-2894 Hard Washer
(3) 0S-1588 Bolt
(4) 8H-3390 Full Nut
(5) Aftercooler
(6) 130-3357 Bracket As

  1. Install bracket (6) to aftercooler (5) by using three washers (2) and three nuts (3).

  2. Install actuator (1) to bracket (6) by using nut (4). Ensure that the actuator is properly oriented. Do not tighten the nut firmly. The nut will be tightened after the hydraulic lines are connected.

Turbo Wastegate Actuator

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Illustration 10g01022319
Rear view
(1) 141-9885 Bracket As
(2) 8H-3390 Full Nut
(3) 5P-8245 Hard Washer
(4) 6V-8675 Bolt
(5) 196-9529 Electronic Actuator

  1. Install bracket (1) to the turbocharger by using six washers (3) and six bolts (4).

  2. Install actuator (5) to bracket (1) by using nut (2). Ensure that the actuator is properly oriented. Do not tighten the nut firmly. The nut will be tightened after the hydraulic lines are connected.

Fuel Actuator

  1. Vertically align the fuel valve.
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    Illustration 11g01022349
    Rear view
    (1) 131-7750 Bracket As
    (2) 0S-1591 Bolt
    (3) 3V-3308 Hard Washer
    (4) 169-2521 Plate
    (5) 169-2522 Gasket

  2. Ensure that the top surface of the rear housing is clean. Install bracket (1) by using the following items: gasket (5), plate (4), eight washers (3) and eight bolts (2).
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    Illustration 12g01022357
    Right side view
    (6) 140-1736 Bracket As
    (7) 0S-1588 Bolt
    (8) 9S-8752 Full Nut
    (9) 107-8480 U-Bolt
    (10) 5P-8245 Hard Washer
    (11) 1F-7958 Full Nut

  3. Install bracket (6) by using the following items: two bolts (7), two washers (3) and two nuts (8). Install U-bolt (9) by using two washers (10) and two nuts (11).
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    Illustration 13g01020739
    Rear view
    (12) 131-7751 Bracket As
    (13) Nut

  4. Install bracket (12) by using the following items: four bolts (2), eight washers (3) and four nuts (8). Attach the fuel valve to the bracket with the nut (13) that was originally installed on the valve.
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    Illustration 14g01025516
    Rear view
    (14) 131-7749 Bracket As
    (15) 118-6663 Bracket As

  5. Install each bracket (14) and (15) by using the following items: four bolts (2), eight washers (3) and four nuts (8).
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    Illustration 15g01022458
    Rear view
    (16) 196-9529 Electronic Actuator
    (17) 8H-3390 Full Nut

  6. Install actuator (16) by using nut (17). Ensure that the actuator is properly oriented. Do not tighten the nut firmly. The nut will be tightened after the hydraulic lines are connected.

Hydraulic Oil Filter

    Note: Ensure that the O-ring seals are properly installed prior to making the tube connections. A damaged O-ring seal will result in a leak. Pieces of the broken O-ring seal can cause malfunctioning of the hydraulic actuators.

    Note: Overstressing or forcing a tube connection may cause an oil leak or a premature failure.

    Note: Wait until all of the tubes are loosely installed before tightening the tubes.

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    Illustration 16g01028149
    Components for the oil filter
    (1) 0S-1588 Bolt
    (2) 3V-3308 Hard Washer
    (3) 8C-5053 Adapter
    (4) 198-7778 Bracket As
    (5) 3J-1907 O-Ring Seal
    (6) 9S-4191 Plug
    (7) 0S-1590 Bolt
    (8) 138-6144 Engine Oil Filter Gp
    (9) 131-9370 Tube As
    (10) 7M-8485 O-Ring Seal
    (11) 6V-9182 Elbow
    (12) 6V-9746 O-Ring Seal
    (13) 8C-0569 O-Ring Tee
    (14) 3D-2824 O-Ring Seal
    (15) 6V-9832 Cap As
    (16) 6V-8733 Face Seal Union
    (17) 125-3902 Tube As
    (18) 6V-8637 Connector
    (19) 138-6158 Check Valve
    (20) 6V-8784 Face Seal Tee
    (21) 5K-9660 Clip
    (22) 0L-1143 Bolt
    (23) 9C-5344 Spacer
    (24) 131-9371 Tube As
    (25) 141-9812 Tube As

  1. Install the oil filter by performing these steps:

    1. Attach oil filter group (8) to bracket (4) by using four bolts (1) and four washers (2).

    2. Attach bracket (4) to the engine by using three bolts (7) and three washers (2).

    3. Install an O-ring seal (14) and an O-ring tee (13) into the oil filter's inlet.

    4. Install an O-ring seal (14) and an O-ring tee (13) into the oil filter's outlet.

    5. Install an O-ring seal (9) and an O-ring plug (10) into each O-ring tee.

  2. Apply 4C-4030 Thread Lock Compound to the threads of adapter (3). Install the adapter into the pump.

  3. Install an O-ring seal (10) and elbow (11) into adapter (3).

  4. Install an O-ring seal (12) and tube (9) into elbow (11). Attach the tube to the side of the engine by using two bolts (23), two washers (2), two clips (22), and two spacers (24).

  5. Install an O-ring seal (12) and union (16) into tube (9).

  6. For the G3606, install an O-ring seal (12) and tube (24) to union (16). Attach the tube to the engine at two locations by using two bolts (22), two washers (2), two clips (21), and two spacers (23). Tighten the tube after you place an O-ring seal (12) between the end of the tube and the O-ring tee on the oil filter's inlet.

  7. For the G3608, install an O-ring seal (12) and tube (25) to union (16). Attach the tube to the engine at four locations by using four bolts (22), four washers (2), four clips (21), and four spacers (23). Tighten the tube after you place an O-ring seal (12) between the end of the tube and the O-ring tee on the oil filter's inlet.

  8. Install an O-ring seal (14) and tube (17) to the end of O-ring tee (13).

  9. Install an O-ring seal (12) and connector (18) to the end of tube (17).

  10. Install an O-ring seal (14) and check valve (19) into connector (18). Be sure to orient the check valve correctly.

  11. Install an O-ring seal (14) and tee (20) into check valve (19).

  12. Install cap assembly (15) into the top port of tee (20).

Hydraulic Tank

    Note: The mounting location for the hydraulic tank might have an explosion relief valve that is mounted to the crankcase cover. Rearrange the crankcase covers on the left side of the engine in order to install the hydraulic tank and the mounting group.

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    Illustration 17g01021255
    Components for the hydraulic tank
    (1) 8C-6875 Connector
    (2) 5K-9090 O-Ring Seal
    (3) 6V-9854 Elbow
    (4) 3V-3308 Hard Washer
    (5) 0S-1571 Bolt
    (6) 143-4770 Hydraulic Tank Gp
    (7) 0S-1588 Bolt
    (8) 9S-8752 Full Nut
    (9) 143-4773 Bracket As
    (10) 140-0970 Hose As
    (11) 0S-1590 Bolt
    (12) 5P-7854 Clip
    (13) 5G-4313 Spacer
    (14) 7M-8485 O-Ring Seal
    (15) 140-0971 Hose As
    (16) 6V-9008 Elbow
    (17) 6V-7238 Shutoff Valve
    (18) 8L-2786 O-Ring Seal
    (19) 2M-9780 O-Ring Seal
    (20) 8T-5389 Elbow
    (21) 6V-9746 O-Ring Seal
    (22) 142-1584 Hose As

  1. Install bracket (9) by using six bolts (5) and six washers (4).

  2. Install tank (6) to the bracket by using four bolts (7), eight washers (4) and four nuts (8).

  3. Install O-ring seal (2) and elbow (16). Orient the elbow toward the hydraulic pump.

  4. Install O-ring seal (18) and shutoff valve (17).

  5. Apply 4C-4030 Thread Lock Compound to the threads of connector (1). Install connector (1) into the pump.

  6. Install an O-ring seal (2) and elbow (3) into the connector.

  7. Install seal (14) and hose (15) to elbow (3).

  8. Install O-ring seal (14) and the opposite end of the hose to elbow (16).

  9. Install an O-ring seal (19) and elbow (20).

  10. For the G3606, install an O-ring seal (21) and one end of hose (10) to elbow (20). Secure the hose to the engine by using two bolts (11), two washers (4), two clips (12), and one spacer (13). Be sure to locate the spacer at the appropriate location. Orient hose (10) and elbow (20) so that the hose does not contact an explosion relief valve.

  11. For the G3608, install an O-ring seal (21) and one end of hose (22) to elbow (20). Secure the hose to the engine by using four bolts (12), four washers (4), four clips (11), and three spacers (13). Orient hose (22) and elbow (20) so that the hose does not contact an explosion relief valve.

Lines Group

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Illustration 18g01021523
Components for the lines group
(1) 121-6750 Manifold
(2) 3B-1915 Bolt
(3) 3V-3308 Hard Washer
(4) 9S-8752 Full Nut
(5) 138-6261 Bracket
(6) 0S-1588 Bolt
(7) 131-7747 Bracket As
(8) 0S-1594 Bolt (3/8-16X1 inch)
(9) 6V-9746 O-Ring Seal
(10) 6V-8637 Connector
(11) 3D-2824 O-Ring Seal
(12) 131-9376 Tube As
(13) 8T-1887 Clip
(14) 8T-1888 Clip
(15) 0S-0509 Bolt
(16) 6V-8784 Face Seal Tee
(17) Air choke
(18) 131-9372 Tube As
(19) 9C-5344 Spacer
(20) 0L-1143 Bolt
(21) 5K-9660 Clip
(22) Hose
(23) 6V-8733 Face Seal Union

  1. Attach bracket (7) to air choke (17) by using four bolts (6) and four washers (3).

  2. Attach two brackets (5) to bracket (7) by using two bolts (2), four washers (3), and two nuts (4).

  3. Attach manifolds (1) to brackets (5) by using two bolts (8) and two washers (3).

  4. Install an O-ring seal (11) and a connector (10) onto each manifold.

  5. Install an O-ring seal (9) and a union (23) into the end of hose (22).

  6. Connect the appropriate end of tube (12) to union (23) after you place an O-ring seal (9) between the end of the tube and the union.

  7. Connect the opposite end of tube (12) to connector (10) after you place an O-ring seal (9) between the end of the tube and the connector. Secure tube (12) to the bracket for the air choke actuator by using two bolts (15), two washers (3), two clips (13), and two clips (14).

  8. Attach clip (21) to the engine by using bolt (20), washer (3), and spacer (19).

  9. Connect the appropriate end of tube (18) onto tee (16) after you place an O-ring seal (9) between the end of the tube and the tee.

  10. Connect the opposite end of tube (18) onto connector (10) after you place an O-ring seal (9) between the end of the tube and the connector. Secure tube (18) to the bracket for the air choke actuator by using two bolts (6), two washers (3), two clips (13), and two clips (14).

Tubing for the Air Choke Actuator

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    Illustration 19g01024050
    Tubing for the air choke actuator
    (1) 3K-0360 O-Ring Seal
    (2) 9S-4185 Plug
    (3) 3J-1907 O-Ring Seal
    (4) 6V-9873 Connector
    (5) 6V-8398 O-Ring Seal
    (6) 131-9373 Tube As
    (7) 147-0529 Tube As

  1. Install an O-ring seal (5) and a connector (4) into each port of the air choke actuator.

  2. Install O-ring seal (1) and plug (2).

  3. Install an O-ring seal (3) and a connector (4) into the appropriate port of each manifold.

  4. Connect tubes (6) and (7) according to Illustration 19. Use an O-ring seal (1) at the end of each tube.

Tubing for the Wastegate Actuator

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    Illustration 20g01024075
    Left side view
    (1) 0S-1594 Bolt (3/8-16X1 inch)
    (2) 3V-3308 Hard Washer
    (3) 176-3591 Bracket As
    (4) 6V-8629 Elbow
    (5) 2M-9780 O-Ring Seal
    (6) 6V-8638 Connector
    (7) 9S-4190 Plug

  1. Apply 4C-4030 Thread Lock Compound to the threads of bolt (1).

  2. Attach bracket (3) to the engine by using bolt (1) and washer (2).

  3. Install an O-ring seal (5) and an elbow (4) into each manifold.

  4. Install an O-ring seal (5) and a connector (6) into each manifold.

  5. Install an O-ring seal (5) and a plug (7) into each manifold.
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    Illustration 21g01024093
    Rear view
    (8) 131-9379 Tube As
    (9) 8T-1887 Clip
    (10) 8T-1888 Clip
    (11) 9S-8752 Full Nut
    (12) 6V-9746 O-Ring Seal
    (13) 184-5287 Tube As

  6. Connect tubes (8) and (13) according to Illustration 21. Use an O-ring seal (12) at the end of each tube.

  7. Attach each tube to the bracket by using bolt (1), washer (2), clip (9), clip (10), and nut (11).
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    Illustration 22g01024118
    Rear view
    (14) 141-9904 Tube As
    (15) 7C-8246 Spacer
    (16) 6V-8398 O-Ring Seal
    (17) 6V-9873 Connector
    (18) 3J-1907 O-Ring Seal
    (19) 184-5288 Tube As

  8. Connect tubes (14) and (19) to the manifolds. Use an O-ring seal (16) at the end of each tube.

  9. Install two O-ring seals (18) and two connectors (17) into the actuator for the wastegate.

  10. Connect tubes (14) and (19) to the actuator according to Illustration 22. Use an O-ring seal (16) at the end of each tube.

  11. Attach each tube to the bracket by using bolt (1), washer (2), clip (9), clip (10), spacer (15), and nut (11).

Tubing for the Fuel Actuator

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    Illustration 23g01024213
    Left side view
    (1) 6V-9873 Connector
    (2) 3J-1907 O-Ring Seal
    (3) 8T-6876 Elbow
    (4) Actuator for the fuel metering valve

  1. Install an O-ring seal (2) and a connector (1) to actuator (4).

  2. Install an O-ring seal (2) and an elbow (3) into actuator (4).
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    Illustration 24g01024240
    Rear view
    (5) 171-5858 Tube As
    (6) 6V-8398 O-Ring Seal
    (7) 131-9381 Tube As
    (8) 121-7697 Face Seal Tee
    (9) 6V-9746 O-Ring Seal

  3. Install an O-ring seal (9) and a tee (8) into each tube.

  4. Connect tube (5) to the actuator and to the tee according to Illustration 24. Use an O-ring seal (6) at each end of the tube.

  5. Connect tube (7) to the actuator and to the tee according to Illustration 24. Use an O-ring seal (6) at each end of the tube.
    Show/hide table
    Illustration 25g01024258
    Rear view
    (10) 125-3902 Tube As
    (11) 6V-9007 Elbow
    (12) 3D-2824 O-Ring Seal
    (13) 4B-9365 Bolt
    (14) 5P-0537 Hard Washer
    (15) 6V-7646 Hard Washer
    (16) 9S-8750 Nut
    (17) 6V-8637 Connector
    (18) 176-3586 Relief Valve As

  6. Install an O-ring seal (12) and elbow (11) into relief valve (18).

  7. Install an O-ring seal (12) and connector (17) into relief valve (18).

  8. Connect tubes (10) to elbow (11) and to connector (17). Use an O-ring seal (6) at the end of each tube.

  9. Connect tubes (10) to the tees. Use an O-ring seal (9) on the end of each tube.

  10. Attach relief valve (18) to the bracket by using two bolts (13), two washers (14), two washers (15), and two nuts (16).

  11. Tighten all of the connections for all of the tubing.

  12. Tighten the nut for each actuator to 200 ± 20 N·m (148 ± 15 lb ft).

Hydrax Oil Pressure Switch

    Show/hide table
    Illustration 26g01026472
    Top view of the manifolds
    (1) 3K-0360 O-Ring Seal
    (2) 140-9669 Switch

  1. Install O-ring seal (1) onto pressure switch (2).

  2. Install pressure switch (2) into the manifold. Torque the switch to 82 ± 8 N·m (60 ± 6 lb ft).

Linkage for the Air Choke Actuator

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    Illustration 27g01024394
    Top view
    (1) 4W-7394 Gasket
    (2) Air choke
    (3) 130-3359 Shaft
    (4) 193-7879 Boot
    (5) 176-3587 Clevis
    (6) 9S-8752 Full Nut
    (7) 3V-3308 Hard Washer
    (8) 0S-1590 Bolt
    (9) 8M-9024 Hard Washer
    (10) 130-3356 Bracket As
    (11) 031-0214 Locking Bolt
    (12) 8C-7321 Rod End
    (13) 1S-3584 Full Nut
    (14) 4P-0391 Rod
    (15) 3S-2713 Full Nut
    (16) 8C-7315 Rod End
    (17) 4P-0394 Lever
    (18) 5H-2532 Woodruff Key

  1. Remove air choke (2). Replace shaft (3) with a new shaft. Reinstall the air choke. Use two new gaskets (1).

    Reference: Refer to the appropriate Disassembly and Assembly Manual for the procedures for removing, for disassembling, for assembling, and for installing the air choke.

  2. Attach lever (17) by using woodruff key (18), bolt (11), two washers (7), and nut (6).

  3. Install bracket (10), by using four bolts (8) and four washers (7).

  4. Extend the rod from the actuator. Attach boot (4) to the nut for the actuator.

  5. Apply 4C-4030 Thread Lock Compound to the actuator rod's threads. Thread clevis (5) onto the end of the actuator rod.

  6. Preassemble rod (14) by threading nuts (13) and (15) onto each end of the rod. Thread rod ends (12) and (16) onto each end of the rod. Leave the nuts loose in order to align the linkage.

  7. Place washer (9) between lever (17) and rod end (16). Use bolt (11), washer (7) and nut (6) in order to secure the assembly.

  8. Use bolt (8), washer (7) and nut (6) in order to fasten rod end (12) to clevis (5).

Linkage for the Wastegate Actuator

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    Illustration 28g01024852
    Linkage for the wastegate actuator
    (1) 8M-9024 Hard Washer
    (2) 0S-1571 Bolt
    (3) 3V-3308 Washer
    (4) 9S-8752 Nut
    (5) 8C-7315 Rod End
    (6) 5L-3291 Ball Bearing Assembly
    (7) 0S-1591 Bolt
    (8) 0S-1588 Bolts
    (9) 5L-3291 Ball Bearing Assembly
    (10) 3S-2713 Full Nut
    (11) 8M-9024 Hard Washer
    (12) 4P-0394 Lever
    (13) 5H-2532 Woodruff Key
    (14) 4P-0394 Lever
    (15) 8M-9024 Hard Washer
    (16) 8M-9024 Hard Washer
    (17) 039-9895 Rod
    (18) 1S-3584 Nut
    (19) 8C-7321 Rod End
    (20) 118-4736 Wastegate Shaft
    (21) 8C-7321 Rod End
    (22) 1S-3584 Full Nut
    (23) 4P-0391 Rod
    (24) 3S-2713 Full Nut
    (25) 8C-7315 Rod End
    (26) 7C-1178 Clevis
    (27) 193-7879 Boot

  1. Install ball bearing assembly (6) by using four bolts (7), eight washers (3), and four nuts (4). Orient the bearing assembly so that the lube fitting is easily accessible. Leave the bearing assembly loose. The assembly will be tightened after shaft (20) is installed.

  2. Install ball bearing assembly (9) by using four bolts (8), and four washers (3). Orient the bearing assembly so that the lube fitting is easily accessible. Leave the bearing assembly loose. The assembly will be tightened after shaft (20) is installed.

  3. Lubricate each bearing assembly with the appropriate amount of bearing grease.

  4. Install wastegate shaft (20) through the bracket and bearing assembly (9).

    Note: Orient the shaft end that is marked "w/g end" toward the wastegate's housing.

  5. Slide lever (14) onto shaft (20). Slide the shaft through bearing assembly (6). Slide lever (12) onto the end of the shaft. Secure each lever to the shaft with woodruff key (13), bolt (2), two washers (3) and nut (4).

  6. Securely tighten both of the bearing assemblies.

  7. Extend the rod from the actuator. Attach boot (27) to the nut for the actuator.

  8. Apply 4C-4030 Thread Lock Compound to the actuator rod's threads. Thread clevis (26) onto the end of the actuator rod.

  9. Preassemble rod (23) by threading nuts (22) and (24) onto each end of the rod. Then thread the appropriate rod ends (21) and (25) onto each end of the rod. Leave the assembly loose in order to align the linkage.

  10. Place washer (15) between lever (14) and rod end (21). Use bolt (2), two washers (3) and nut (4) in order to secure the assembly.

  11. Use bolt (2), two washers (3) and nut (4) in order to fasten rod end (25) to clevis (26).

  12. Preassemble rod (17) by threading nuts (10) and (18) onto each end of the rod. Then thread the appropriate rod end (5) and (19) onto each end of the rod. Leave the assembly loose in order to align the linkage later.

  13. Install lever (16) onto the wastegate's shaft by using the following items: woodruff key (13), bolt (2), two washers (3) and nut (4).

  14. Place washer (1) between lever (16) and rod end (5). Use bolt (2), two washers (3) and nut (4) in order to secure the assembly.

  15. Place washer (11) between rod end (19) and lever (12). Use bolt (2), two washers (3) and nut (4) in order to secure the assembly.

Linkage for the Fuel Actuator

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    Illustration 29g01020777
    Right side view
    (1) 0S-1588 Bolt
    (2) 3V-3308 Hard Washer
    (3) 5L-3291 Ball Bearing Assembly
    (4) 5L-3291 Ball Bearing Assembly
    (5) 0S-1591 Bolt
    (6) 9S-8752 Full Nut

  1. Install ball bearing assembly (3) by using four bolts (1) and four washers (2). Install ball bearing assembly (4) by using the following items: four bolts (5), eight washers (2) and four nuts (6). Orient each bearing assembly so that the lube fitting is easily accessible. Leave the bearing assemblies loose.

  2. Lubricate each bearing assembly with the appropriate amount of bearing grease.
    Show/hide table
    Illustration 30g01020828
    Right side view
    (7) 0S-1571 Bolt
    (8) 4D-8532 Lever
    (9) 5H-2532 Woodruff Key
    (10) 118-6665 Shaft
    (11) 115-7768 Lever

  3. Slide the narrow end of shaft (10) through ball bearing (4). Slide lever (8) onto the shaft. Slide lever (11) onto the shaft. Slide the shaft through ball bearing (3). Secure each lever to the shaft with the following items: woodruff key (9), bolt (7), two washers (2) and nut (6).
    Show/hide table
    Illustration 31g01020924
    Top view
    (12) 193-7879 Boot
    (13) 0S-1590 Bolt
    (14) 8C-7321 Rod End
    (15) 176-3587 Clevis
    (16) 1S-3584 Nut
    (17) 4P-0391 Rod
    (18) 3S-2713 Full Nut
    (19) 8C-7321 Rod End
    (20) 8M-9024 Hard Washer

  4. Preassemble rod (17) by threading nuts (16) and (18) onto each end of the rod. Thread clevis (15) onto the appropriate end of the rod. Thread rod end (19) onto the other end of the rod. Leave the nuts loose in order to align the linkage.

  5. Place washer (20) between lever (8) and rod end (19). Use bolt (7), washer (2), and nut (6) in order to secure the assembly.

  6. Extend the rod from the actuator. Attach boot (12) to the nut for the actuator.

  7. Apply 4C-4030 Thread Lock Compound to the actuator rod's threads. Thread rod end (14) onto the end of the actuator rod.

  8. Use bolt (13), two washers (2), and nut (6) in order to fasten clevis (15) to rod end (14).
    Show/hide table
    Illustration 32g01020985
    Left side view
    (21) 8C-6971 Rod End

  9. Install nut (18) and clevis (15) onto the end of the fuel metering valve's rod. Connect rod end (19) to the clevis by using bolt (13), two washers (2), and nut (6). Thread nut (16) onto rod end (21). Thread rod end (21) into rod end (19). Place washer (20) between lever (11) and rod end (21). Use bolt (1) and washer (2) in order to fasten the rod end to the lever.

Pressure Module

Reinstall the pressure module. Refer to Disassembly and Assembly, SENR4259, "Air/Fuel Pressure Sensor Module - Remove and Install".

Adjust the Linkage

Linkage for the Air Choke

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Illustration 33g01025120
Adjustment of the linkage for the air choke
(X) Locations for the disconnection of the connecting rod assembly
(1) Bolt
(2) Locknut
(3) Stop plate

Note: All dimensions are for reference.

  1. Remove the connecting rod assembly by disconnecting the assembly at locations (X).

  2. Loosen nut (2).

  3. Loosen bolt (1) so that the bolt does not interfere with the closing of the choke plate. Fully close the choke plate. Carefully tighten bolt (1) until the bolt makes contact with stop plate (3).

  4. Tighten bolt (1) for an additional full turn. Carefully tighten nut (2) to the required torque. The choke plate is now at the proper setting.

  5. Fully close the choke plate. Fully retract the actuator. Adjust each end of the connecting rod assembly so that the assembly can be reinstalled. Adjust each rod end in order to provide equal thread engagement on each rod end.

  6. Reinstall the connecting rod assembly.

  7. Extend the actuator in ordertofully open the choke plate. While the actuator is fully extended and the plates are in contact, shorten the length of the connecting rod by half a turn. This will create a small gap between the two full open stop plates. Tighten the nuts on the connecting rod assembly in order to lock the length of the assembly.

  8. Move the linkage through the entire range. Ensure that the choke plate can reach the full closed stop. Make sure that the actuator does not force the plate past the full open stop when the choke is fully open.

Linkage for the Wastegate

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Illustration 34g01025345
Adjustment of the linkage for the wastegate
(X) Location for the disconnection of the linkage

Note: All dimensions are for reference.

  1. Disconnect the linkage from the wastegate's lever arm at location (X).

  2. Fully close the wastegate. Fully extend the actuator. Reinstall the linkage. Remove all of the slack in the linkage. Adjust each rod end in order to provide equal thread engagement on each rod end.

  3. Turn a rod end on the upper linkage rod by two full turns in ordertoslightly open the wastegate's plate. Tighten the nuts on the connecting rods in order to lock the lengths of the assemblies.

    Note: The wastegate may stick if the plate touches the housing.

  4. Move the linkage through the entire range. Ensure that the wastegate's plate does not touch the housing when the wastegate is fully closed.

Linkage for the Fuel Actuator

    Show/hide table
    Illustration 35g01025455
    Adjustment of the linkage for the fuel valve
    (X) Location for the disconnection of the linkage

    Note: All dimensions are for reference.

  1. Disconnect the linkage at location (X).

  2. Fully close the fuel valve. Fully extend the actuator. Adjust each connecting rod assembly so that all of the slack is removed. Adjust each rod end in order to provide equal thread engagement on each rod end. Reconnect the linkage.

  3. Move the linkage through the entire range. Ensure that the fuel valve can fully open and fully close. Make additional adjustments in order to ensure that the fuel valve will fully open and fully close.

  4. Perform the following procedure in order to ensure that the actuator is not pushing rod (2) too far into the fuel valve.

    1. Fully extend the actuator in order to close the valve. Disconnect the linkage at location (X). Rotate clevis (1) half of a turn so that the clevis pulls rod (2) out of the valve.

    2. Reconnect the linkage.

    3. Ensure that the metering valve can still reach the full open position.

  5. If the engine will not be converted to the ADEM III system, continue with this Special Instruction. Refer to "Install the Electrical Components". If the engine will be converted to the ADEM III system, discontinue this Special Instruction and refer to the Special Instruction, REHS1708 for instructions on the installation of the ADEM III system.

Install the Accumulator and Charge the Accumulator

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    Illustration 36g01028276
    Installation of the accumulator
    (1) 170-0990 Clamp
    (2) 1A-5183 Bolt
    (3) 3V-3308 Hard Washer
    (4) 9S-8752 Full Nut
    (5) 3D-2824 O-Ring Seal
    (6) 6V-8637 Connector
    (7) 6V-9746 O-Ring Seal
    (8) 131-9382 Tube As
    (9) 201-9561 Accumulator Gp
    (10) 126-3005 Pipe
    (11) Bracket
    (12) Tee

  1. Remove the cap from the top of tee (12).

  2. Use two clamps (1) in order to fasten accumulator (9) to bracket (11). Fasten the clamps to the bracket by using four pipes (10), four bolts (2), eight washers (3) and four nuts (4). Do not tighten the nuts completely.

  3. Install O-ring seal (5) and connector (6) into the accumulator.

  4. Install O-ring seal (7) and tube (8) to connector (6).

  5. Install O-ring seal (7) and tube (8) onto tee (12).

  6. Tighten nuts (4) in order to secure the accumulator to the bracket.

  7. Use the 175-5507 Nitrogen Charging Group in order to charge the accumulator. Charge the accumulator with nitrogen to 825 kPa (120 psi).

Install the Electrical Components

Position Sensor for the Air Choke

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    Illustration 37g01025843
    Linkage for the air choke
    (1) Shaft for the air choke
    (2) Coupling hub (Part of 176-3572 Shaft Coupling Gp)
    (3) 9S-8750 Nut
    (4) 5P-0537 Hard Washer
    (5) Spider (Part of 176-3572 Shaft Coupling Gp)
    (6) Coupling hub (Part of 176-3572 Shaft Coupling Gp)
    (7) 6D-3025 Ball Bearing
    (8) 7E-1630 Gasket
    (9) 8C-5607 Mount
    (10) 4E-2250 Housing
    (11) 8M-2337 Washer
    (12) 8C-5608 Spacer
    (13) 6D-3025 Ball Bearing
    (14) 127-1573 Shaft
    (15) 2H-3429 Retaining Ring
    (16) 2L-6726 Retaining Ring
    (17) 8B-2377 Bolt

  1. Attach coupling hub (2) to shaft (1).

  2. Attach coupling hub (6) to the appropriate end of shaft (14).

  3. Insert ball bearing (7) into housing (10).

  4. Place gasket (8) on top of ball bearing (7).

  5. Insert ball bearing (13) into housing (10).

  6. Secure the ball bearings by installing retaining ring (16).

  7. Carefully slide shaft (14) through ball bearings (7) and (13).

  8. Secure shaft (14) by installing retaining ring (15).

  9. Install six mounts (9) and three spacers (12) into housing (10).

  10. Install three bolts (17) and six washers (11) into housing (10).

  11. Place spider (5) onto the end of shaft (1).

  12. Align the shafts and carefully insert housing (10) onto the bracket.

  13. Attach housing (10) to the bracket by using three washers (4) and three nuts (3). Do not tighten the nuts completely.

  14. Rotate the linkage through the entire range while you carefully position housing (10). Position the housing in order to eliminate binding of the coupling and of the shafts. Tighten nuts (3) when the housing is correctly positioned.
    Show/hide table
    Illustration 38g01025989
    Installation of the position sensor for the air choke
    (18) Set screw
    (19) Shaft Coupling Gp
    (20) 4B-4274 Washer
    (21) 6V-2313 Bolt
    (22) Tang
    (23) 219-2388 Position Sensor

  15. Loosen set screw (18).

  16. Rotate the shaft coupling gp (19) until tang (22) that extends from the fuel control shaft is aligned with the slot in position sensor (23).

  17. Install the position sensor by using two washers (20) and two bolts (21).

  18. Tighten set screw (18).

  19. Move the linkage through the entire range. Verify that there is no binding of the linkage or of the shafts. Reposition the sensor's mount, if necessary.

Position Sensor for the Wastegate

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    Illustration 39g01026079
    Linkage for the wastegate
    (1) Coupling hub (Part of 176-3572 Shaft Coupling Gp)
    (2) 7E-1630 Gasket
    (3) 9U-3300 Spacer
    (4) 8M-2337 Washer
    (5) 8F-6302 Bolt
    (6) Shaft for the linkage
    (7) 2L-6726 Retaining Ring
    (8) 2H-3429 Retaining Ring
    (9) 127-1573 Shaft
    (10) 6D-3025 Ball Bearing
    (11) 8C-5608 Spacer
    (12) Coupling hub (Part of 176-3572 Shaft Coupling Gp)
    (13) Spider (Part of 176-3572 Shaft Coupling Gp)
    (14) 6D-3025 Ball Bearing
    (15) 8C-5607 Mount
    (16) 4E-2250 Housing

  1. Attach coupling hub (12) to shaft (6).

  2. Attach coupling hub (1) to the appropriate end of shaft (9).

  3. Insert ball bearing (14) into housing (16).

  4. Place gasket (2) on top of ball bearing (14).

  5. Insert ball bearing (10) into housing (16).

  6. Secure the ball bearings by installing retaining ring (7).

  7. Carefully slide shaft (9) through ball bearings (14) and (10).

  8. Secure shaft (9) by installing retaining ring (8).

  9. Install six mounts (15) into housing (16).

  10. Install three bolts (5) and six washers (4) into housing (16).

  11. Slide three spacers (3) onto the bolts.

  12. Place spider (13) onto the end of shaft (6).

  13. Align the shafts and carefully insert housing (16) onto the bracket.

  14. Attach housing (16) to the bracket by tightening three bolts (5). Do not tighten the bolts completely.

  15. Rotate the linkage through the entire range while you carefully position housing (16). Position the housing in order to eliminate binding of the coupling and of the shafts. Tighten bolts (5) when the housing is correctly positioned.
    Show/hide table
    Illustration 40g01026332
    Installation of the position sensor for the wastegate
    (17) Set screw
    (18) Shaft Coupling Gp
    (19) 4B-4274 Washer
    (20) 6V-2313 Bolt
    (21) Tang
    (22) 219-2388 Position Sensor

  16. Loosen set screw (17).

  17. Rotate the shaft coupling gp (18) until tang (21) that extends from the fuel control shaft is aligned with the slot in position sensor (22).

  18. Install the position sensor by using two washers (19) and two bolts (20).

  19. Tighten set screw (17).

  20. Move the linkage through the entire range. Verify that there is no binding of the linkage or of the shafts. Reposition the sensor's mount, if necessary.

Position Sensor for the Fuel Valve

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    Illustration 41g01026361
    Linkage for the fuel valve
    (1) 8M-2337 Washer
    (2) 9U-3300 Spacer
    (3) 7E-1630 Gasket
    (4) Coupling hub (Part of 176-3572 Shaft Coupling Gp)
    (5) 8F-6302 Bolt
    (6) 2L-6726 Retaining Ring
    (7) Shaft for the linkage
    (8) 2H-3429 Retaining Ring
    (9) 127-1573 Shaft
    (10) 6D-3025 Ball Bearing
    (11) 8C-5608 Spacer
    (12) 4E-2250 Housing
    (13) 8C-5607 Mount
    (14) 6D-3025 Ball Bearing
    (15) Spider (Part of 176-3572 Shaft Coupling Gp)
    (16) Coupling hub (Part of 176-3572 Shaft Coupling Gp)

  1. Attach coupling hub (16) to shaft (6).

  2. Attach coupling hub (4) to the appropriate end of shaft (9).

  3. Insert ball bearing (14) into housing (12).

  4. Place gasket (3) on top of ball bearing (14).

  5. Insert ball bearing (10) into housing (16).

  6. Secure the ball bearings by installing retaining ring (6).

  7. Carefully slide shaft (9) through ball bearings (14) and (10).

  8. Secure shaft (9) by installing retaining ring (8).

  9. Install six mounts (13) into housing (12).

  10. Install three bolts (5) and six washers (1) into housing (12).

  11. Slide three spacers (2) onto the bolts.

  12. Place spider (15) onto the end of shaft (7).

  13. Align the shafts and carefully insert housing (12) onto the bracket.

  14. Attach housing (12) to the bracket by tightening three bolts (5). Do not tighten the bolts completely.

  15. Rotate the linkage through the entire range while you carefully position housing (12). Position the housing in order to eliminate binding of the coupling and of the shafts. Tighten bolts (5) when the housing is correctly positioned.
    Show/hide table
    Illustration 42g01026366
    Installation of the position sensor for the fuel valve
    (17) Shaft Coupling Gp
    (18) Set screw
    (19) 4B-4274 Washer
    (20) 6V-2313 Bolt
    (21) Tang
    (22) 219-2388 Position Sensor

  16. Loosen set screw (18).

  17. Rotate the shaft coupling gp (17) until tang (21) that extends from the fuel control shaft is aligned with the slot in position sensor (22).

  18. Install the position sensor by using two washers (19) and two bolts (20).

  19. Tighten set screw (18).

  20. Move the linkage through the entire range. Verify that there is no binding of the linkage or of the shafts. Reposition the sensor's mount, if necessary.

Box for the Hydrax Driver Modules

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    Illustration 43g01026595
    Left side view of the engine

  1. Remove the four bolts and the four washers from the locations that are shown in Illustration 43.

  2. Remove the lid from the 129-3543 Junction Box Gp. Remove the 135-0784 Tags that were shipped inside the box. Keep the tags for use when the wiring is terminated inside the box.
    Show/hide table
    Illustration 44g01026608
    Mounting hardware for the relay driver module
    (1) 129-3543 Junction Box Gp
    (2) 138-3132 Bracket
    (3) 8H-0707 Bolt
    (4) 7E-7731 Mount
    (5) 0S-1590 Bolt
    (6) 3V-3308 Hard Washer
    (7) 9M-4594 Spacer

  3. Install bracket (2) by using four bolts (5), four washers (6) and four spacers (7).

  4. Thread four mounts (4) into bracket (2).

  5. Place box (1) into position and secure the box to the mounts with four bolts (3).

Wiring Harnesses for the G3606

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    Illustration 45g01026982
    Box for the hydrax driver modules
    (1) 135-6657 Harness (Actuator for the fuel valve)
    (2) 135-6658 Harness (Position sensor for the fuel valve)
    (3) 135-6659 Harness (Air choke actuator)
    (4) 135-6660 Harness (Position sensor for the air choke)
    (5) 135-6661 Harness (Wastegate Actuator)
    (6) 135-6662 Harness (Position sensor for the wastegate)
    (7) Box for the hydrax driver modules

  1. Install six wiring harnesses into box (7). Be sure to install each harness into the correct location.
    Show/hide table
    Illustration 46g01027016
    Left side view
    (X) Clamp for the 135-6656 Harness.
    (Y) Clamps for the harnesses for the actuators, for the position sensors, and for the pressure switch
    (Z) Location for connecting the harness for the pressure switch
    (8) 1A-2029 Bolt
    (9) 3V-3308 Hard Washer
    (10) 5P-9297 Clip
    (11) 8T-1887 Clip
    (12) 0S-1590 Bolt
    (13) 7D-1553 Clip
    (14) 0S-1594 Bolt
    (15) 9S-8752 Full Nut
    (16) 8T-1888 Clip
    (17) 7D-7233 Clip
    (18) 135-6656 Harness
    (19) 9X-6772 Cable Strap

  2. Install harness (18) into the left side of the box for the hydrax driver modules.

  3. Attach harness (18) to the engine at location (X) by using bolt (8), washer (9), and clip (13).

  4. Install harness (18) into an open location on the bottom of the engine terminal box.

  5. Attach the six harnesses from the box for the hydrax driver modules to the engine at location (Y) on the left side of the engine terminal box. Use one bolt (12) and one washer (9) in order to fasten clip (17) to the engine.

  6. Install the 135-6663 Harness for the pressure switch into an open location on the bottom of the engine terminal box.

  7. Attach the seven harnesses to the engine at the remaining locations (Y). Use one bolt (12) and one washer (9) in order to fasten each clip (17) to the engine. Do not route the harness for the air choke actuator through the last clip.

  8. Route the harness for the air choke actuator through clip (10). Attach the clip to the oil line by using clip (11), clip (16), bolt (14), two washers (9), and nut (15).

  9. Secure the wiring harnesses with cable straps (19) at the appropriate locations.
    Show/hide table
    Illustration 47g01027099
    Rear view
    (20) 4P-8134 Clip
    (21) 4P-7581 Clip

  10. Install clip (20) by using one bolt (14), two washers (9), and one nut (15).

  11. Attach two clips (21) to the air inlet elbow by using two of the elbow's bolts.

  12. Attach one clip (21) to the camshaft cover by using one of the cover's bolts.

  13. Route the harnesses to the individual connectors. Secure the harnesses by using tie straps (19) at the appropriate locations.

  14. Connect all of the connectors for the harnesses. Verify that all of the clips are securely installed to the engine. All of the harnesses must be securely fastened to the engine and to other harnesses in order to prevent damage that is caused by vibration.

  15. Terminate each wire for the hydrax system by performing the following procedure.
      Show/hide table
      Illustration 48g01027151
      Typical wire termination
      (22) Paper tag
      (23) 135-0784 Tag or 141-6403 Tag
      (24) 110-8714 Wire End

      Note: Paper tag (22) indicates the wire number.

      Note: Tag (23) indicates the wire number and the termination for the wire. For example, T12/C221A/BK indicates that the wire number is C221. Connect this wire to terminal 12 on the terminal strip.

    1. Remove paper tag (22) from the wire. Install the appropriate tag (23) onto the end of the wire.

    2. Cut the wire to the appropriate length.

    3. Crimp a wire end (24) onto the end of the wire.

    4. Install the wire into the appropriate terminal on the terminal strip. Refer to the engine's electrical schematic, if necessary.

  16. Installation of the electrical components is complete. Proceed to "Prepare the Engine for Initial Start-up".

Wiring Harnesses for the G3608

    Show/hide table
    Illustration 49g01026982
    Box for the hydrax driver modules
    (1) 142-5008 Harness (Actuator for the fuel valve)
    (2) 142-5009 Harness (Position sensor for the fuel valve)
    (3) 142-5010 Harness (Air choke actuator)
    (4) 142-5011 Harness (Position sensor for the air choke)
    (5) 142-5012 Harness (Wastegate Actuator)
    (6) 142-5013 Harness (Position sensor for the wastegate)
    (7) Box for the hydrax driver modules

  1. Install six wiring harnesses into box (7). Be sure to install each harness into the correct location.
    Show/hide table
    Illustration 50g01027499
    Left side view
    (X) Location for the cable strap
    (Y) Location for connecting the harness for the pressure switch
    (8) 0S-1590 Bolt
    (9) 9M-4594 Spacer
    (10) 0S-1619 Bolt
    (11) 3V-3308 Hard Washer
    (12) 1B-4971 Spacer
    (13) 5P-7854 Clip
    (14) 7D-1553 Clip
    (15) 135-6656 Harness
    (16) 9X-6772 Cable Strap
    (17) 1A-2029 Bolt
    (18) 8M-2773 Clip
    (19) 4P-7581 Clip

  2. Install harness (15) into the left side of the box for the hydrax driver modules.

  3. Attach harness (15) to the engine at location (X) by using one cable strap (16).

  4. Install clip (19) to the engine with bolt (17) and washer (11).

  5. Attach seven harnesses to clip (19) with one cable strap (16).

  6. Thread six harnesses through clip (13). Attach the clip to the engine by using one bolt (8), one washer (11), and one spacer (9).

  7. Install the 142-5014 Harness for the pressure switch into an open location on the bottom of the engine terminal box at location (Y).

  8. Install harness (15) into an open location on the bottom of the engine terminal box.

  9. Thread seven harnesses through clip (14). Attach the clip to the engine by using one bolt (10), one washer (11), and two spacers (12).
    Show/hide table
    Illustration 51g01027608
    Left side view
    (20) 0T-0573 Bolt
    (21) 138-4409 Spacer
    (22) 5P-9297 Clip
    (23) 8T-1887 Clip
    (24) 7D-7233 Clip
    (25) 0S-1594 Bolt
    (26) 9S-8752 Full Nut
    (27) 8T-1888 Clip

  10. At two locations, attach the seven harnesses to the engine by using one bolt (20), one washer (11), one clip (24) and one spacer (21).

  11. At four locations under the aftercooler, use one bolt (20), one washer (11), and one clip (24) in order to fasten the harnesses to the engine. Do not route the harness for the air choke actuator through the last clip.

  12. Route the harness for the air choke actuator through clip (22). Attach the clip to the oil line by using clip (23), clip (27), bolt (25), two washers (11), and nut (26).

  13. Secure the wiring harnesses with four cable straps (16) at the appropriate locations.
    Show/hide table
    Illustration 52g01027659
    Rear view
    (28) 4P-8134 Clip

  14. Install clip (28) by using one bolt (25), two washers (11), and one nut (26).

  15. Attach two clips (19) to the air inlet elbow by using two of the elbow's bolts.

  16. Attach one clip (19) to the camshaft cover by using one of the cover's bolts.

  17. Route the harnesses to the individual connectors. Secure the harnesses by using tie straps (16) at the appropriate locations.

  18. Connect all of the connectors for the harnesses. Verify that all of the clips are securely installed to the engine. All of the harnesses must be securely fastened to the engine and to other harnesses in order to prevent damage that is caused by vibration.

  19. Terminate each wire for the hydrax system by performing the following procedure.
      Show/hide table
      Illustration 53g01027820
      Typical wire termination
      (29) Paper tag
      (30) 135-0784 Tag or 141-6403 Tag
      (31) 110-8714 Wire End

      Note: Tag (29) indicates the wire number.

      Note: Tag (30) indicates the wire number and the termination for the wire. For example, T12/C221A/BK indicates that the wire number is C221. Connect this wire to terminal 12 on the terminal strip.

    1. Install the appropriate tag (30) onto the end of the wire.

    2. Cut the wire to the appropriate length.

    3. Crimp a wire end (31) onto the end of the wire.

    4. Install the wire into the appropriate terminal on the terminal strip. Refer to the engine's electrical schematic, if necessary.

Prepare the Engine for Initial Start-up

Restore electrical power to the engine.

Adjust the Position Sensor for the Air Choke

  1. Turn the engine control switch to the STOP position.
    Show/hide table
    Illustration 54g01026805
    Terminal strip inside the box for the hydrax driver modules

  2. Verify that the hydraulic actuator system is receiving electrical power. Connect a voltmeter between terminals 1 and 4 in the box for the hydrax driver modules. The voltage between the terminals must be approximately +24 VDC.

    Note: If the voltage is incorrect, there could be a problem with the wiring. Check the connections of the wiring for the hydrax system. Correct any errors. Refer to the engine's troubleshooting manual, if necessary.

  3. Fully open the air choke. Connect the voltmeter between terminals 4 and 14. The voltage must be between 1.6 VDC and 1.8 VDC. Perform the following procedure if the voltage is incorrect.

    1. Verify that the air choke is fully open.
      Show/hide table
      Illustration 55g01026765
      Top view of the position sensor for the air choke
      (1) Set screw
      (2) Coupling

    2. Loosen set screw (1).

    3. While you are monitoring the voltage, rotate coupling (2) in order to obtain a voltage measurement between 1.6 VDC and 1.8 VDC.

    4. Carefully tighten the set screw.

  4. Fully close the air choke. The voltage measurement must be greater than 8.0 VDC. Move the linkage from the full closed position to the full open position a few times. Verify that the voltages remain within the specifications in the closed position and in the open position. If necessary, perform this procedure again until the readings are correct.

Adjust the Position Sensor for the Wastegate

  1. Fully close the wastegate. Connect the voltmeter between terminals 4 and 21 in the box for the hydrax driver modules. The voltage must be between 1.6 VDC and 1.8 VDC. Perform the following procedure if the voltage is incorrect.

    1. Verify that the wastegate is fully closed.
      Show/hide table
      Illustration 56g01026765
      Top view of the position sensor for the wastegate
      (1) Set screw
      (2) Coupling

    2. Loosen set screw (1).

    3. While you are monitoring the voltage, rotate coupling (2) in order to obtain a voltage measurement between 1.6 VDC and 1.8 VDC.

    4. Carefully tighten the set screw.

  2. Fully open the wastegate. The voltage measurement must be greater than 8.0 VDC. Move the linkage from the full closed position to the full open position a few times. Verify that the voltages remain within the specifications in the closed position and in the open position. If necessary, perform this procedure again until the readings are correct.

Adjust the Position Sensor for the Fuel Valve

  1. Fully close the fuel valve. Connect the voltmeter between terminals 4 and 7. The voltage must be between 1.6 VDC and 1.8 VDC. Perform the following procedure if the voltage is incorrect.

    1. Verify that the fuel valve is fully closed.
      Show/hide table
      Illustration 57g01026765
      Top view of the position sensor for the fuel valve
      (1) Set screw
      (2) Coupling

    2. Loosen set screw (1).

    3. While you are monitoring the voltage, rotate coupling (2) in order to obtain a voltage measurement between 1.6 VDC and 1.8 VDC.

    4. Carefully tighten the set screw.

  2. Move the linkage from the full closed position to the full open position a few times. Verify that the voltage remains within the specification when the fuel valve is closed. If necessary, perform this procedure again until the reading is correct.

    Note: The fuel valve does not require a specific voltage setting for the full open position. Only the voltage setting for the full closed position is required. However, the expected voltage reading in the full open position is between 5.0 VDC and 6.0 VDC.

Prime the Hydraulic System

  1. Ensure that the manual gas shutoff valve is OFF.

  2. Fill the hydraulic tank. Refer to Operation and Maintenance Manual, SEBU6278, "Refill Capacities".

  3. Install a pressure gauge in the oil lines near the hydrax oil pressure switch. The gauge must have a range of 0 to 2068 kPa (0 to 300 psi).

    Note: Step 4 may take more than a total of 50 seconds of cranking. Do not crank the engine more than 15 seconds at a time.

  4. In order to prime the hydraulic circuit, the engine must be cranked with the manual gas shutoff valve in the OFF position. Crank the engine in order to build the pressure of the oil to a value between 1034 kPa (150 psi) to 1379 kPa (200 psi). This is adequate pressure in order to attempt a start.

Initial Start-up of the Engine

  1. Turn the manual gas shutoff valve to the OPEN position.

  2. Start the engine. Bring the engine up to high idle (900 rpm to 1000 rpm).

  3. Inspect the hydrax system for oil leaks. Make repairs, if necessary.

Adjust the Hydraulic Pressure

Note: The hydraulic oil must be near the operating temperature prior to making this adjustment.

Operate the engine at the rated speed. No load on the engine is required for an accurate pressure setting. Adjust the hydraulic pressure by performing the following procedure.

    Show/hide table
    Illustration 58g01027372
    Adjustment of the hydraulic pressure
    (1) Locknut
    (2) Adjustment screw

  1. Loosen locknut (1).

  2. Turn adjustment screw (2) in order to obtain a system pressure of 1550 kPa (225 psi).

  3. Tighten the locknut. Verify that the pressure has not drifted.

  4. Shut down the engine. Remove the oil pressure gauge from the system.

Final Adjustments

Verify that the engine operates correctly across the entire range of speeds and of loads. Compare the operation of the engine with the information that was recorded on the "Performance Data Sheet". Adjust the governor gains, if necessary.

Required Maintenance

  • Service the hydrax system according to the engine's Operation and Maintenance Manual.

  • Adjustments to the linkages, to the position sensors, and to the system pressure are required only if a fault code indicates a possible problem.

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