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Rebuild Instructions for the High Temperature Throttle Used on Certain G3500C and G3500E Engines {1269} Caterpillar


Rebuild Instructions for the High Temperature Throttle Used on Certain G3500C and G3500E Engines {1269}

Usage:

G3520C B9P
Gas Engine
G3516C (S/N: F6J1-UP)
Generator Set
G3516C (S/N: GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; F6D1-UP; F6E1-UP; F6F1-UP; GZZ1-UP)
G3516E (S/N: F6G1-UP; GAS1-UP; SLY1-UP)
G3520C (S/N: FZA1-UP; GZA1-UP; FZB1-UP; GZB1-UP; FZC1-UP; FZD1-UP; MAD1-UP; FZE1-UP; FZF1-UP; FZG1-UP; GZK1-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)
Power Module
PMG3516 (S/N: JKK1-UP)

Introduction

This Special Instruction provides clear instructions to a field technician who is servicing the 180 mm Extra High Temperature Throttle with Slow Dynamics.

Safety Section

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------ WARNING! ------

Serious injury can result from failure to use personal protective equipment. Wear the appropriate personal protective equipment that is required for the tasks that are being performed.

General Information

Serviceable Parts

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Table 1
Part Number  Description  Qty 
1L-8490  Retaining Ring  1 
2N-5749  O-Ring Seal  1 
3H-5840  Bolt  3 
3J-1907  O-Ring Seal  1 
6J-6478  Washer  10 
8T-0908  Bolt  3 
9S-8004  O-Ring Plug  1 
9T-5112  Screw  4 
087-4677  Bolt  6 
196-0346  Washer  3 
288-5476  O-Ring Seal  1 
360-0424  Bearing  2 
360-0425  Seal  2 
346-4897  O-Ring Seal  1 
363-4965  Gasket  1 
363-4990  Coupling  1 
374-4546  Bolt  4 
384-0897  Bushing  4 
493-1028  Actuator  1 

Throttle Inspection and Replacement Requirements

Inspect Unit Serial Number

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Illustration 1g03850745
(1) Serial number plate

  1. Record serial number and submit with order of replacement components.

Inspect Unit for Binding

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    Illustration 2g03850746
    (A) 90 degrees
    (2) 360-0423 Plate

  1. Press plate (2) at 90 degrees (A). If unit is stiff, completely binds, or cogs in its travel, the throttle must be repaired.

Decouple Actuator from Valve

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    Illustration 3g03850747
    (3) 8T-0908 Bolt
    (4) 363-4990 Coupling
    (5) 493-1028 Actuator

  1. Place a solid spacer under actuator (5) to support the weight of the actuator during disassembly.

  2. Loosen the two coupling bolts (3).
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    Illustration 4g03850749
    (5) 493-1028 Actuator
    (6) 363-3152 Housing
    (7) 374-4546 Bolt
    (8) 384-0897 Bushing

  3. Remove the four bolts (7) and four bushings (8) from actuator (5) and housing (6).
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    Illustration 5g03850781
    (5) 493-1028 Actuator
    (6) 363-3152 Housing
    (9) 363-3157 Plate (Manifold)

  4. Lift and slide away actuator (5) from housing (6) and plate (9).

Inspect Valve and Actuator

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    Illustration 6g03850782
    384-0897 Bushing
    (B) Mating surface
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    Illustration 7g03860183
    384-0897 Bushing
    (B) Mating surface
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    Illustration 8g03860184
    374-4546 Bolt
    (B) Mating surface

  1. Inspect the mating surfaces (B) for damage on the 374-4546 Bolts and the 384-0897 Bushings.
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    Illustration 9g03850783
    (A) 90 degrees
    (2) 360-0423 Plate

  2. Press plate (2) at 90 degrees (A).

    If the valve moves freely and there is no evidence of high temperature exposure to the valve or rubbing marks between the plate and bore, measure the gap between the plate and bore (refer to "Verify Plate Clocking Angle", Step 3) and continue with actuator inspection.

    If the valve binds, proceed to "Valve Teardown and Inspection".

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    Illustration 10g03850784
    (4) 363-4990 Coupling
    (5) 493-1028 Actuator
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    Illustration 11g03850786

  3. Rotate coupling (4) on actuator (5) counterclockwise (CCW).

    The shaft should rotate approximately 70 degrees to 75 degrees.

    If the actuator binds, order a complete 493-1028 Actuator. Refer to "Actuator Coupling Assembly".

Valve Teardown and Inspection

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    Illustration 12g03850787
    (2) 360-0423 Plate
    (10) 3H-5840 Bolt

  1. Loosen the three retaining bolts (10) of plate (2).

  2. Recheck to see if any binding of the throttle is relieved by loosening the bolts.

    If binding is eliminated and the part post-dates the serial number cutoff (SN: 16161935), follow the reshimming and clocking process. Refer to "Actuator Coupling Assembly".

    Note: This only applies when there is NO evidence of high temperature exposure. (If there is any question, continue with seal and bearing inspection).

    If binding persists, continue.

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    Illustration 13g03850788
    (2) 360-0423 Plate

  3. Remove the 3H-5840 Bolts and plate (2).
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    Illustration 14g03850789
    (11) 9S-8004 O-Ring Plug
    (12) 9T-5112 Screw
    (13) 6J-6478 Washer
    (14) 363-4964 Cover

    Note: There is spring pressure behind the cap. Remove the cap carefully, following the instructions below.

  4. Remove top cover (14).

    Step bolts (12) slowly out, alternating from one to the other, until the screws are about halfway out. If the cover has not moved with the screws, tap the cover firmly with a dead blow hammer. DO NOT remove bolts completely unless the spring is no longer compressed.

  5. Remove top cap plug (11).
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    Illustration 15g03850790
    (15) 3J-1907 O-Ring Seal

  6. Remove and discard O-ring seal (15).
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    Illustration 16g03850791
    (16) 360-0426 Spring

  7. Remove spring (16) from the 363-3154 Carrier (Outboard) cavity.

  8. Inspect spring (16) for cracking or other abnormalities.
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    Illustration 17g03850793
    (17) 363-3154 Carrier (Outboard)
    (18) 360-0424 Bearing

  9. Remove carrier (17) from the 363-3152 Housing.

  10. Remove and discard bearing (18).
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    Illustration 18g03850796
    (17) 363-3154 Carrier (Outboard)
    (19) 360-0425 Seal

  11. Remove and discard seal (19).
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    Illustration 19g03850800
    (20) 363-4965 Gasket

  12. Remove and discard gasket (20).
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    Illustration 20g03850801
    (6) 363-3152 Housing
    (21) 363-4989 Shaft

  13. Remove shaft (21) from housing (6).
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    Illustration 21g03850803
    (C) Sealing surface
    (21) 363-4989 Shaft
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    Illustration 22g03850805
    (C) Sealing surface
    (21) 363-4989 Shaft

  14. Inspect sealing surfaces (C) on both ends of shaft (21).
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    Illustration 23g03850806
    (D) Threaded hole
    (21) 363-4989 Shaft

  15. Inspect threaded holes (D) in shaft (21). Verify that the Heli-coils are intact and not damaged.
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    Illustration 24g03850807
    (6) 363-3152 Housing
    (13) 6J-6478 Washer
    (22) 363-3155 Carrier (Inner)
    (23) 087-4677 Bolt

  16. Remove four bolts (23) from the inner carrier (22) and housing (6), leaving two bolts 180 degrees apart from each other. Loosen the last two bolts to a couple of threads.
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    Illustration 25g03850809
    (22) 363-3155 Carrier (Inner)
    (24) 1L-8490 Retaining Ring
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    Illustration 26g03860216
    (E) Snap ring pliers
    (24) 1L-8490 Retaining Ring

  17. Use snap ring pliers (E) to remove retaining ring (24).
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    Illustration 27g03860217
    (18) 360-0424 Bearing
    (22) 363-3155 Carrier (Inner)

  18. Remove and discard bearing (18).
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    Illustration 28g03860218
    (22) 363-3155 Carrier (Inner)
    (25) 3/8-18 NPTF pipe plug
    (26) 3/8-18 air fitting

  19. Install plug (25) into one of the housing ports.

  20. Install air fitting (26) into the other housing port.

  21. Pressurize to remove inner carrier (22).

  22. Remove the two remaining 087-4677 Bolts.
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    Illustration 29g03860220
    (19) 360-0425 Seal
    (22) 363-3155 Carrier (Inner)

  23. Inspect inner bearing carrier (22).

  24. Remove and discard seal (19).
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    Illustration 30g03860221
    (22) 363-3155 Carrier (Inner)
    (27) 346-4897 O-Ring Seal
    (28) 2N-5749 O-Ring Seal
    (29) 288-5476 O-Ring Seal

  25. Remove and discard O-ring seals (27), (28), and (29).

  26. Inspect the 363-3152 Housing.

    1. Inspect all the housing threads - if damaged replace or repair the threads.
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      Illustration 31g03860222
      Witness marks

    2. Inspect the housing bore:

      • If there is build-up, the throttle requires cleaning.

      • If there is significant corrosion, the throttle should be replaced.

      • Witness marks from the plate rubbing in the bore are not a problem.

Throttle Rebuild

Bill of Materials

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Table 2
Part Number  Description  Qty 
1L-8490  Retaining Ring  1 
2N-5749  O-Ring Seal  1 
3H-5840  Bolt  3 
3J-1907  O-Ring Seal  1 
6J-6478  Washer  10 
8T-0908  Bolt  3 
9S-8004  O-Ring Plug  1 
9T-5112  Screw  4 
087-4677  Bolt  6 
196-0346  Washer  3 
288-5476  O-Ring Seal  1 
360-0423  Plate  1 
360-0424  Bearing  2 
360-0425  Seal  2 
360-0426  Spring  1 
346-4897  O-Ring Seal  1 
363-3152  Housing  1 
363-3154  Carrier  1 
363-3155  Carrier  1 
363-3157  Plate  1 
363-4964  Cover  1 
363-4965  Gasket  1 
363-4989  Shaft  1 
363-4990  Coupling  1 
374-4546  Bolt  4 
384-0897  Bushing  4 
493-1028  Actuator  1 

Cleaning

  • All components that are being reused during the unit repair/overhaul should be cleaned before attempting assembly.

  • Clean all the parts with isopropyl alcohol and a non-abrasive material.

  • There are several critical surfaces that require cleaning.

Housing

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Illustration 32g03860224
363-3152 Housing
(1) Gasket surface
(2) O-ring sealing surface (Carrier bore)
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Illustration 33g03860225
363-3152 Housing
(3) Port
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Illustration 34g03860226
(1) Gasket surface
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Illustration 35g03860228
(1) Gasket surface
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Illustration 36g03860227
(2) O-ring sealing surface (Carrier bore)
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Illustration 37g03860229
(3) Port

Outer Bearing Carrier

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Illustration 38g03860231
363-3154 Carrier (Outer)
(1) Gasket surface
(3) Port
(4) Bearing seat
(5) Seal seat
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Illustration 39g03860233
(1) Gasket surface
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Illustration 40g03860235
(3) Port
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Illustration 41g03860232
(4) Bearing seat
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Illustration 42g03860234
(5) Seal seat

Top Cap

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Illustration 43g03860236
363-4964 Cover
(6) Plug seat

Manifold

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Illustration 44g03860237
363-3157 Plate (Manifold)
(3) Port
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Illustration 45g03860238
(3) Port

Inner Bearing Carrier

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Illustration 46g03860239
363-3155 (Inner)
(4) Bearing seat
(5) Seal seat
(7) O-ring grooves
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Illustration 47g03860240
(4) Bearing seat
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Illustration 48g03860241
(5) Seal seat
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Illustration 49g03860242
(7) O-ring grooves

Shaft

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Illustration 50g03860243
363-4989 Shaft
(8) Shaft bearing and sealing surface
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Illustration 51g03850803
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Illustration 52g03850805

A light abrasive pad can be used to remove seal material.

Ensure that the shaft bearing and sealing surface has no burrs or debris.

Coupler

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Illustration 53g03860244
363-4990 Coupling
(9) Smooth bore
(10) Splined bore

Assembly

Required Chemicals

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Illustration 54g03860230
(11) Loctite® 246 Thread Locker Medium Strength/High Temperature
(12) MOLYKOTE® G-N Paste
(13) Loctite® Silver Grade Anti-Seize
(14) Petroleum jelly

O-ring Preparation

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Illustration 55g03860430
(15) 288-5476 O-Ring Seal
(16) 2N-5749 O-Ring Seal
(17) 346-4897 O-Ring Seal
(18) 3J-1907 O-Ring Seal

  1. Apply a light coat of petroleum jelly to O-rings (15), (16), (17), and (18).

Fastener Preparation

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Illustration 56g03860431
(19) 9T-5112 Screw
(20) 6J-6478 Washer

  1. Install four washers (20) one per bolt onto four bolts (19).

  2. Apply a small drop of Loctite 246 Thread Locker Medium Strength/High Temperature to the threads of bolts (20).
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    Illustration 57g03860434
    (20) 6J-6478 Washer
    (21) 087-4677 Bolt

  3. Install six washers (20) one per bolt onto six bolts (21).

  4. Apply a small drop of Loctite 246 Thread Locker Medium Strength/High Temperature to the threads of bolts (21).
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    Illustration 58g03860436
    (22) 374-4546 Bolt
    (23) 384-0897 Bushing

  5. Install four bushings (23) one per bolt onto four bolts (22).

  6. Apply a small drop of Loctite 246 Thread Locker Medium Strength/High Temperature to the threads of bolts (21).
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    Illustration 59g03860439
    (24) 3H-5840 Bolt
    (25) 196-0346 Washer

  7. Install three washers (25) one per bolt onto three bolts (24).

  8. Apply Loctite Silver Grade Anti-Seize 360 degrees around bolts (24) covering approximately 10 to 12 threads.

Top Cap Assembly

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Illustration 60g03860440
(18) 3J-1907 O-Ring Seal
(26) 9S-8004 O-Ring Plug

  1. Install lubricated O-ring (18) onto plug (26).
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    Illustration 61g03860441
    (26) 9S-8004 O-Ring Plug
    (27) 363-4964 Cover

  2. Install plug (26) into cover (27).

    Note: The plug will be torqued after pressure test.

Inner Bearing Carrier Assembly

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Illustration 62g03860443
(29) 363-3155 Carrier (Inner)
(30) 360-0425 Seal
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Illustration 63g03860444
(29) 363-3155 Carrier (Inner)

  1. Install seal (30) into the inner carrier (29). This seal can be installed by hand.

    Note: The seal should snap into the groove.

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    Illustration 64g03860446
    (15) 288-5476 O-Ring Seal
    (16) 2N-5749 O-Ring Seal
    (17) 346-4897 O-Ring Seal
    (29) 363-3155 Carrier (Inner)

  2. Install O-rings (15), (16), and (17) onto inner carrier (9).
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    Illustration 65g03860447
    (29) 363-3155 Carrier (Inner)

  3. Apply MOLYKOTE G-N or equivalent to the bearing bore of inner carrier (29).
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    Illustration 66g03860457
    (29) 363-3155 Carrier (Inner)
    (30) 360-0424 Bearing

  4. Install bearing (30) into the inner carrier (29).
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    Illustration 67g03860448
    (29) 363-3155 Carrier (Inner)
    (31) 1L-8490 Retaining Ring

  5. Install retaining ring (31) into the inner carrier (29). Once installed, rotate the retaining ring to ensure that the retaining ring is seated into the groove.
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    Illustration 68g03860460
    (A) 10.54100 ± 0.25400 mm (.415 ± 0.01 inch)
    (31) 1L-8490 Retaining Ring

  6. Measure the distance between the two arms of retaining ring (A).

    If the measurement is not 10.54100 ± 0.25400 mm (.415 ± 0.01 inch), remove the retaining ring and reinsert.

Valve Assembly

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Illustration 69g03860484
(29) 363-3155 Carrier (Inner)
(32) 363-3152 Housing

  1. Insert inner carrier (29) into housing (32). Align indent on the carrier with indent on the housing.
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    Illustration 70g03863860
    (20) 6J-6478 Washer
    (21) 087-4677 Bolt
    (29) 363-3155 Carrier (Inner)
    (32) 363-3152 Housing

    Note: Verify that the bolts have Loctite 246 Thread Locker Medium Strength/High Temperature applied.

  2. Install inner carrier (29) slowly into housing (32) with two bolts (21) and two washers (20). Alternate from one screw to the other only threading about 2 or 3 threads per side.

    Torque the bolts ... 14 N·m (125 lb in)

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    Illustration 71g03863861
    (20) 6J-6478 Washer
    (21) 087-4677 Bolt
    (29) 363-3155 Carrier (Inner)
    (32) 363-3152 Housing

  3. Install the last four bolts (21) and four washers (20) into inner carrier (29) and housing (32).

    Torque the bolts ... 14 N·m (125 lb in)

  4. Sit housing (32) on the table with feet facing down.
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    Illustration 72g03863862
    (33) 363-3154 Carrier (Outboard)
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    Illustration 73g03863863
    (30) 360-0425 Seal
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    Illustration 74g03863864
    (33) 363-3154 Carrier (Outboard)

  5. Install seal (30) into the inner carrier (29). This seal can be installed by hand.

    Note: The seal should snap into the groove.

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    Illustration 75g03863866
    (33) 363-3154 Carrier (Outboard)

  6. Apply MOLYKOTE G-N or equivalent to the bearing bore of outboard carrier (33).
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    Illustration 76g03863867
    (30) 360-0424 Bearing
    (33) 363-3154 Carrier (Outboard)

  7. Install bearing (30) into the inner carrier (29).
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    Illustration 77g03863868
    (33) 363-3154 Carrier (Outboard)
    (34) 360-0426 Spring

  8. Place spring (34) on top of the bearing in outboard carrier (33).
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    Illustration 78g03863870
    (27) 363-4964 Cover
    (35) 1/4-28 x 3 inch alignment bolt

  9. Place cover (27) onto two alignment bolts (35).

    Note: Top cover plug is facing down.

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    Illustration 79g03863877
    (27) 363-4964 Cover
    (33) 363-3154 Carrier (Outboard)
    (35) 1/4-28 x 3 inch alignment bolt

  10. Place outboard carrier (33) on top of cover (27) with the spring facing down.
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    Illustration 80g03863878
    (33) 363-3154 Carrier (Outboard)
    (36) 363-4965 Gasket

  11. Place gasket (36) on top of outboard carrier (33).
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    Illustration 81g03863879
    (32) 363-3152 Housing
    (37) 363-4989 Shaft

  12. Gently slide shaft (37) into housing (32).

    Note: The threaded end of the shaft is facing up.

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    Illustration 82g03863880
    (27) 363-4964 Cover
    (32) 363-3152 Housing
    (33) 363-3154 Carrier (Outboard)
    (35) 1/4-28 x 3 inch alignment bolt
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    Illustration 83g03863881
    (32) 363-3152 Housing
    (33) 363-3154 Carrier (Outboard)

  13. Place cover (27) and the outboard carrier (33) onto housing (32) with alignment bolts (35). Align outboard carrier port parallel to the housing port. Refer to Illustration 83.
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    Illustration 84g03864045
    (19) 9T-5112 Screw
    (20) 6J-6478 Washer
    (27) 363-4964 Cover
    (32) 363-3152 Housing
    (33) 363-3154 Carrier (Outboard)

    Note: Verify that the bolts have Loctite 246 Thread Locker Medium Strength/High Temperature applied.

  14. Attach cover (27) and the outboard carrier (33) slowly to housing (32) with two bolts (19) and two washers (20). Alternate from one screw to the other only threading about 2 or 3 threads per side.

    Torque the bolts ... 14 N·m (125 lb in)

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    Illustration 85g03864047
    (32) 363-3152 Housing
    (35) 1/4-28 x 3 inch alignment bolt

  15. Remove alignment bolts (35) from housing (32).
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    Illustration 86g03864048
    (19) 9T-5112 Screw
    (20) 6J-6478 Washer
    (32) 363-3152 Housing

  16. Install the last two bolts (19) and two washers (20) into housing (32).

    Torque the bolts ... 14 N·m (125 lb in)

Verify Throttle Leak Rate

Note: This process ensures the throttle leaks less than 15 cm3/min.

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Illustration 87g03866170
(27) 363-4964 Cover

  1. Remove the 9S-8004 O-Ring Plug from cover (27).
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    Illustration 88g03866171

  2. Install leak cover onto both flanges of housing (32)

    Note: Top cover should have pressure gauge and an air inlet.

  3. Pressurize the throttle to 414 kPa (60 psi).

  4. Allow the throttle to sit pressurized for 60 minutes.

    Note: A temperature controlled environment is ideal.

  5. Check the final pressure in the throttle.

    180 mm throttle limit:

    • Maximum pressure loss of 17 kPa (2.5 psi)
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    Illustration 89g03866172
    (26) 9S-8004 O-Ring Plug
    (27) 363-4964 Cover

  6. After the leak testing is complete, install plug (26) into cover (27).

    Torque the plug ... 8.5 N·m (75 lb in)

Plate Installation

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    Illustration 90g03864050
    (A) 90 degree
    (B) 180 degree
    (C) 270 degree
    (D) 360 degree
    (32) 363-3152 Housing

  1. Sit housing (32) on the table with the flow arrow pointing down.
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    Illustration 91g03864052
    (A) 90 degree
    (32) 363-3152 Housing
    (37) 363-4989 Shaft

  2. Install shaft (37) into housing (32).

    Note: The 363-4964 Cover is at 360 degrees.

  3. Turn shaft (37) so that the flat faces 90 degree (A) position.
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    Illustration 92g03864055
    (37) 363-4989 Shaft
    (38) 360-0423 Plate

  4. Install plate (38) onto shaft (37) so that the flat seats into the grove on the plate.
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    Illustration 93g03864057
    (24) 3H-5840 Bolt
    (25) 196-0346 Washer
    (38) 360-0423 Plate

  5. Turn plate (38) 90 degrees so the bolt holes face up.

    Note: Verify that the bolts have Loctite Silver Grade Anti-Seize applied.

  6. Attach plate (38) loosely to shaft (37) with three bolts (24) and three washers (25). Screw the bolts down so that only 2 to 3 turns remain.
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    Illustration 94g03864058
    (A) 90 degree
    (C) 270 degree
    (38) 360-0423 Plate

  7. Angle plate (38) so that the plate slopes down from 270 degree (C) position to 90 degree (A) position.
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    Illustration 95g03864060
    (E) 0.007 inch shim
    (F) 0.015 inch shim
    (G) 0.005 inch shim

  8. Place the centering and clocking shims into the bore.

    1. Place four shims (G) into the bore spaced an inch apart on both sides of the shaft at 360 degree (D) position.

    2. Place four shims (G) into the bore spaced an inch apart on both sides of the shaft at 180 degree (D) position.

    3. Place one shim (E) into the bore at 90 degree (A) position and 270 degree (C) position.
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    Illustration 96g03864061
    (F) 0.015 inch shim
    (38) 360-0423 Plate

  9. Close plate (38) firmly against shims. The plate should jam into shims (F) at the 90 degree position and 270 degree position.

    Note: The plate should be slightly higher at the 270 degree position.

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    Illustration 97g03864062
    (24) 3H-5840 Bolt

  10. Tighten bolts (24).

    Torque the bolts ... 38 N·m (28 lb ft)

  11. Leave the shims in the bore for the coupling process.

Actuator Coupling Assembly

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    Illustration 98g03864064
    (39) 8T-0908 Bolt
    (40) 363-4990 Coupling

  1. Place bolts (9) finger tight into coupler (40).
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    Illustration 99g03864065
    (40) 363-4990 Coupling
    (41) Actuator mounting holes
    (42) 493-1028 Actuator
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    Illustration 100g03864066
    (39) 8T-0908 Bolt

  2. Set actuator (42) onto the table with mounting holes (41) facing up.

  3. Install the splined end of coupler (40) onto actuator (42) and turn clockwise into the stop. Verify that the bolts point up, refer to Illustration 100.
    Show/hide table
    Illustration 101g03864067
    (39) 8T-0908 Bolt
    (40) 363-4990 Coupling
    (42) 493-1028 Actuator
    (43) 13.081 ± 1.270 mm (0.515 ± 0.050 inch) spacer
    Show/hide table
    Illustration 102g03865709
    (H) 13.081 ± 1.270 mm (0.515 ± 0.050 inch)
    (39) 8T-0908 Bolt

  4. Install spacer (43) in between coupling (40) and actuator (42).

    Note: Make sure that dimension (H) is correct.

  5. Press coupling (40) firmly against spacer (43) and tight bolt (39).

    Torque the bolt ... 37.3 N·m (27.5 lb ft)

    Show/hide table
    Illustration 103g03865708
    (32) 363-3152 Housing
    (37) 363-4989 Shaft
    (42) 493-1028 Actuator
    (44) 363-3157 Plate (Manifold)

  6. Place actuator (42) on a block and line up with plate (44) and shaft (7) with the actuator mounting holes facing up.

    Note: A stack of paper works well to level the actuator shaft with the throttle shaft.

    Show/hide table
    Illustration 104g03865712

  7. Align coupling (40) with plate (44) on the block and press close together.
    Show/hide table
    Illustration 105g03865715
    (37) 363-4989 Shaft
    (42) 493-1028 Actuator
    (44) 363-3157 Plate (Manifold)

  8. Align plate (44) and actuator (42) to shaft (37).
    Show/hide table
    Illustration 106g03865717
    (32) 363-3152 Housing
    (42) 493-1028 Actuator
    (44) 363-3157 Plate (Manifold)

  9. Align coupling (40) with shaft (37) and press actuator (42) and plate (44) flush with the feet housing (32).
    Show/hide table
    Illustration 107g03866139
    (22) 374-4546 Bolt
    (23) 384-0897 Bushing
    (32) 363-3152 Housing
    (42) 493-1028 Actuator

    Note: Verify that the bolts have Loctite 246 Thread Locker Medium Strength/High Temperature applied.

    Note: Verify that the bushings have the flange side down.

  10. Secure housing (32) to actuator (42) with four bolts (22) and four bushings (23).

    Torque the bolts in a cross pattern ... 27 N·m (240 lb in)

  11. Verify the 360-0423 Plate is still jamed firmly into the 0.015 inch shims at the 90 degree and 270 degree positions.
    Show/hide table
    Illustration 108g03865751

  12. Press the actuator against its hard stop through the access port. Verify that the coupling bolts are pointing up.

  13. While maintaining pressure on the coupling (against the stop), tighten bolts one at a time.

    Torque the bolts ... 37.3 N·m (27.5 lb ft)

  14. Remove the shims from the housing.

Throttle Build Inspection

Plate-Bore Gap Verification

Note: This process ensures that the plate will not bind in the bore due to thermal expansion.

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Illustration 109g03866158
(H) 85 degrees to 95 degrees
(J) 45 degrees
(K) Zone A
(L) Zone B

  1. Measure the gap between the plate and bore while in the fully closed position.

    • Zone A (K) should measure minimum 0.006 inch

    • Zone B (L) should measure minimum 0.004 inch

Verify Plate Clocking Angle

Note: This process ensures that the plate is clocked between 2 to 4 degrees.

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Illustration 110g03866160
(M) Measurement at the 90 degree position
(N) Measurement at the 270 degree position
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Illustration 111g03866167
(P) 6.350 mm (0.250 inch) gap

  1. Measure the depth of the plate fully closed at the 90 degree position and the 270 degree position approximately 6.350 mm (0.250 inch) from the bore wall.

  2. Measurement (M) - measurement (N) = the difference.

    180 mm throttle limits:

    • The difference must be greater than 4.369 mm (0.172 inch)

    • The difference must be less than 10.23620 mm (0.403 inch)
    Show/hide table
    Illustration 112g03866168
    (Q) Open throttle plate measurement

  3. Measure the gap between the fully open plate and the bore.

    180 mm throttle limits:

    • Measurement (Q) must be greater than 63.50 mm (2.50 inch)

    Note: The clocking method is not precise when done without powering the actuator. Using the smaller shims and pressing the actuator into the hard stop is the closest approximation that can be obtained.

    • Standard Clocking: Plate Angle equals 2 degrees to 4 degrees at 0 percent command

    • Powerless Clocking: Plate Angle is approximately 1 degree to 5 degrees at 0 percent command

Engine Assembly Leak Inspection

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Illustration 113g03866192
(3) Port
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Illustration 114g03866193
(45) Weep hole
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Illustration 115g03866196
363-3154 Carrier (Outer)
(3) Port
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Illustration 116g03866195
363-3152 Housing
(3) Port
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Illustration 117g03866198
363-3157 Plate (Manifold)
(3) Port
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Illustration 118g03866199
363-3152 Housing
(45) Weep hole

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