- Engines:
- G3606 (S/N: 3XF)
- G3608 (S/N: 4WF)
- G3612 (S/N: 1YG)
- G3616 (S/N: 4CG)
Description of Change: A new accumulator is used in the Hydrax System on these engines. The new accumulator includes the improvements that follow:
- A new design for the charging valve
- A variable volume that is controlled by an internal piston
- A larger volume provides hydraulic pressure for a longer period of time.
Adaptable To: The new accumulator can be installed on any G3600 Engine that is currently operating with the Hydrax System.
Instructions For Converting G3606 And G3608 Engines To The New Style Of Accumulator
The table identifies the components that are required to convert a G3606 Engine or a G3608 Engine to the new style of accumulator.
| Components That Are Required For A G3606 Engine Or A G3608 Engine | |||
|---|---|---|---|
| Qty | Part Number | Description | |
| 1 | 201-9561 | Accumulator | |
| 1 | 198-7778 | Bracket | |
| 2 | 170-0990 | Clamp | |
| 4 | 126-3005 | Pipe | |
| 4 | 9S-8752 | Nut | |
| 4 | 1A-5183 | Bolt | |
| 12 | 3V-3308 | Hard Washer | |
| 4 | 0S01590 | Bolt | |
| 1 | 6V-8637 | Seal Connector | |
| 2 | 6V-9746 | O-Ring Seal | |
| 1 | 3D-2824 | O-Ring Seal | |
- Shut down the engine.
 | |
| Illustration 1 | g00807585 |
This view is of the left side of the engine. This view shows the former accumulator. (1) 130-1498 Accumulator (2) Support Clip and Bracket (3) Hardware (4) Tube Assembly (5) 131-7746 Bracket (6) Filter and filter base | |
- Disconnect tube (4) from the end of the accumulator (1) .
- Remove the hardware (3). Remove the support clip and bracket (2). Remove the accumulator (1) .
- Remove the filter and the filter base (6) from the bracket (5) .
- Remove the bracket (5) .
- Install the bracket (15) with the existing hardware.
 | |
| Illustration 2 | g00807610 |
This view is of the left side of the engine. This view shows the new accumulator. (4) Tube Assembly (6) Filter and filter base (7) Charging Valve (8) Protective Cover (9) 201-9561 Turbocharger Oil Accumulator Gp (10) 170-0990 Clamps (11) 1A-5183 Bolts and 3V-3308 Hard Washers (12) 126-3005 Pipes (13) 6V-8637 Seal Connector (14) 9S-8752 Full Nut and 3V-3308 Hard Washers (15) 198-7778 Bracket | |
- Loosely install the filter and filter base (6) with the existing hardware. Loosely connect the lines to the filter base. After the components are in alignment, tighten the filter base in position and tighten the lines in position.
- Install the 3D-2824 O-Ring Seal and Seal Connector (13) in the accumulator (9) .
- Loosely fasten the accumulator (9) to the bracket (15) with the following components:
- Two clamps (10)
- Four bolts and hard washers (11)
- Four pipes (12)
- Four nuts and hard washers (14)
- Two clamps (10)
- Connect the tube assembly (4) to the accumulator (9) .
- After the components are in alignment, tighten the hardware that fastens the accumulator to the bracket (15) .
- Remove the protective cover (8) from the accumulator.
- Use the correct tools to connect the container of dry nitrogen to the charging valve (7). Charge the accumulator with dry nitrogen to a pressure of 690 kPa to 725 kPa (100 psi to 105 psi).
 |
Personal injury or death can result from improper accumulator charging. Dry nitrogen is the only gas approved for use in the accumulator. Charging the accumulator with oxygen gas will cause an explosion. This danger will not happen if nitrogen cylinders with standard CGA Compressed Gas Association, Inc.Number 580 connections are used. When ordering nitrogen gas, be sure that the cylinders are equipped with CGA Number 580 Connections. Do not use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. Never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen or other gas cylinders. Be sure you use dry nitrogen (99.8 % purity). |
 |
- After the accumulator is correctly charged, install the protective cover (8) .
Note: Due to the potential loss of hydraulic fluid during this procedure, the Hydrax System might require one or two cranking cycles in order to fully recharge the hydraulic lines with fluid.
Instruction For Converting G3612 And G3616 Engines To The New Style Of Accumulator
The table identifies the components that are required to convert a G3612 Engine or a G3616 Engine to the new style of accumulator.
| Components That Are Required For A G3612 Engine Or A G3616 Engine | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | 201-9561 | Accumulator |
| 1 | 198-7779 | Bracket |
| 2 | 170-0990 | Clamp |
| 1 | 158-2940 | Hose As |
| 4 | 126-3005 | Pipe |
| 5 | 9S-8752 | Nut |
| 4 | 0S-1608 | Bolt |
| 14 | 3V-3308 | Hard Washer |
| 4 | 0S01590 | Bolt |
| 1 | 6V-8637 | Seal Connector |
| 3 | 6V-9746 | O-Ring Seal |
| 1 | 3D-2824 | O-Ring Seal |
| 1 | 6V-8733 | Union |
| 1 | 7G-4326 | Plate |
| 1 | 5K-9660 | Clip |
| 1 | 0S-1594 | Bolt |
| 1 | 3B-1915 | Bolt |
- Shut down the engine.
- Disconnect the tube assembly (1) from the accumulator (4). Remove the bracket and clip (3) and remove the accumulator (4). Remove the support bracket (2) .
 | |
| Illustration 3 | g00807845 |
This view is of the left side of the engine. This view shows the former accumulator. (1) 148-7610 Tube As (2) 148-7624 Bracket (3) Support Clip and Bracket (4) 130-1498 Accumulator | |
- Install the bracket (6) with four bolts and hard washers (14). The new bracket should be installed to the left of the former bracket. The new bracket is installed on a lower crankcase cover.
 | |
| Illustration 4 | g00807878 |
This view is of the left side of the engine. This view shows the new accumulator. (1) 148-7610 Tube As (5) 6V-8733 Face Seal Union (6) 198-7779 Bracket (7) 0S-1608 Bolts and 3V-3308 Hard Washers (8) 126-3005 Pipes (9) 170-0990 Clamps (10) 158-2940 Hose As (11) Protective Cover (12) Charging Valve (13) 201-9561 Turbocharger Oil Accumulator Gp (14) 0S-1590 Bolts and 3V-3308 Hard Washers (15) 9S-8752 Full Nuts and 3V-3308 Hard Washers (16) 6V-8637 Seal Connector | |
- Install the 3D-2824 O-Ring Seal and Seal Connector (16) in the accumulator (13) .
- Loosely fasten the accumulator (13) to the bracket (6) with the following components:
- Two clamps (10)
- Four bolts and hard washers (7)
- Four pipes (8)
- Four full nuts and hard washers (15)
- Two clamps (10)
- Install the 6V-9746 O-Ring Seal and the face seal union (5) in the tube assembly (1) .
- Use two 6V-9746 O-Ring Seal in order to install the hose assembly (10) .
- Remove the bolt that is in lower right side of the existing bracket (17) .
 | |
| Illustration 5 | g00808059 |
This view is of SECTION A-A. (17) The existing 148-7622 Bracket (18) 3B-1915 Bolt and 3V-3308 Hard Washer (19) 7G-4326 Plate (20) 0S-1594 Bolt (21) 3V-3308 Hard Washers (22) 9S-8752 Full Nut (23) 5K-9660 Clip | |
- Loosely install the plate (19) with the bolt and hard washer (18) .
- Install the clip (23) on the tube assembly (1) .
- Loosely fasten the clip (23) to the plate (19) with the bolt (20), two hard washers (21), and the full nut (22) .
- After the components are in alignment, tighten all of the mounting hardware. Tighten the ends of the hose assembly (10) and the end of the tube assembly (1) .
- Remove the protective cover (11) from the accumulator.
- Use the correct tools to connect the container of dry nitrogen to the charging valve (12). Charge the accumulator with dry nitrogen to a pressure of 690 kPa to 725 kPa (100 psi to 105 psi).
|
Personal injury or death can result from improper accumulator charging. Dry nitrogen is the only gas approved for use in the accumulator. Charging the accumulator with oxygen gas will cause an explosion. This danger will not happen if nitrogen cylinders with standard CGA Compressed Gas Association, Inc.Number 580 connections are used. When ordering nitrogen gas, be sure that the cylinders are equipped with CGA Number 580 Connections. Do not use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. Never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen or other gas cylinders. Be sure you use dry nitrogen (99.8 % purity). |
|
Note: Due to the potential loss of hydraulic fluid during this procedure, the Hydrax System might require one or two cranking cycles in order to fully recharge the hydraulic lines with fluid.