Installation of the 346-1467 Mounting Kit for the G3500C and G3500E Throttle and Actuator Control {1265, 1803, 5510} Caterpillar

Installation of the 346-1467 Mounting Kit for the G3500C and G3500E Throttle and Actuator Control {1265, 1803, 5510}

Usage:

Engine:: G3512E (S/N: SSR1-UP); G3516C (S/N: GSB1-UP; TJB1-UP; TJC1-UP; GZZ1-UP); G3516E (S/N: GAS1-UP; SLY1-UP); G3520C (S/N: GZB1-UP; MAD1-UP; GZJ1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP); G3520E (S/N: GZG1-UP; GZH1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

The 346-1467 Mounting Kit provides isolator mounting for the electronic portions of the throttle actuator and for the bypass actuator. The kit helps to reduce vibration on the electronics.

The kit contains 12 small O-rings, 4 larger O-rings, 4 small bushings, and 4 larger bushings. The kit is for use with the following components:

313-6079 Throttle
304-9395 Bypass Actuator and Mounting Gp
304-9396 Actuator Gp
304-9398 Actuator

Required Parts and Tools

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Table 1
Required Parts	Qty
346-1467 Mounting Kit	1
360-2176 Adapter Cable As	1
Required Tools
3/16 inch hex driver	1
Small flat head screwdriver	1
8 mm socket	1
Ability to torque 2.26 N·m (20 lb in) to 7.9 N·m (70 lb in)
Small steel pick	1
Needle nose pliers	1
Petroleum jelly
Proper grounding of tools and technician (grounding wristband)

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NOTICE

If your unit has a throttle body, DO NOT remove the actuator from the valve housing. DO NOT attempt this replacement with the unit still on the engine.

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NOTICE

ALWAYS use proper grounding precautions when handling the electronics to prevent damage to the board due to static discharge. Always wear an appropriate grounding strap.

Replacement Process

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Illustration 1	g02181077

Remove 7.62 cm (3/16 inch) bolts (4) that hold the electronics package to the actuator.

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Illustration 2	g02181099

Loosen the grounding strap screws for easy removal of the bolts.

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Illustration 3	g02181137

Separate the electronics package from the actuator. Do not remove the electronics package completely. Proper grounding is required in steps 3,4,5,18,19 and 20.

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Illustration 4	g02181156

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NOTICE

Do not pull directly up on the connector, grab the connector as shown using the pliers as a lever on the side of the housing

Remove the harness cables from the electronics package.

Set the electrical board away from anything that may produce a static discharge. Proper grounding of the board is required.

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Illustration 5	g02181175

Turn the grounding straps or remove the grounding straps from the actuator so the ground straps are out of the way of the bushings.

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Illustration 6	g02181197

Remove the bushings from the housing.

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Illustration 7	g02181215

Remove the exposed isolator o-rings from internal grooves in the housing

Lubricate all new o-rings with petroleum jelly.

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Illustration 8	g02181235

Prepare the new bushings for installation. Combine the four small bushings with small o-rings and combine the four large bushings with the large o-rings.

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Illustration 9	g02181294

Install eight small o-rings into the groves in the housing by hand.

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Illustration 10	g02181314

Press the small prepped bushings into the new board side isolator o-rings.

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Illustration 11	g02181353

Reinstall the grounding straps. Align the hole in the strap so the bolt can pass through without catching. Torque the grounding screw to 2.26 N·m (20 lb in).
Note: There is a flat washer between the screw and the strap.

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Illustration 12	g02181426

Align the electronics package with the actuator. Align the ribs along the housing.
Note: Proper grounding is required.

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Illustration 13	g02181446

Attach the stator harness connectors to the electronic package board terminals. The white wire connects to the inside terminal and the black wire connects to the outside terminal. An ESD grounding strap is required.

Bring the actuator and board together. Be careful not to pinch the harness wires between the two housings. Use 76.2 mm (3/16 inch) hex head screws (4) to reattach the board. Torque the bolts to 7.9 N·m (70 lb in).

Reinstall on engine and test functionality, if any problems occur refer to Calibration.

Procedure for Downloading the Woodward PISC Service Program

Use the laptop or computer that you will be connecting to the throttle on the engine. Go to www.woodward.com.

Click on "Gas Engine Systems".

Click on "Woodward Software".

Choose "ProAct ISC Tools" on the pulldown menu below Download Software Products.

Click the "Go" button.

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Illustration 14	g02181461

You will see a screen like the one above. Click "Download" and follow the instructions to download the program

Calibration

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Illustration 15	g02181464

Note: Engine battery power must be "ON" in order to power the actuator and calibrate the throttle.

Connect the fully assembled actuator to a computer running the ProACT service tool utilizing the 360-2176 Adapter Cable As . Run the "End Point Auto-Calibration" program within the service tool.