REHS0385 Installation of The Hydraulic Actuator System (Hydrax System) On G3612 and G3616 Engines PDF

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Special Instruction
Installation Of The Hydraulic Actuator System (Hydrax System) on G3612 and G3616 Engines
{1050, 1250, 1908, 1915}
Media Number -REHS0385-04 Publication Date -07/25/2006 Date Updated -07/25/2006
i02588701
Installation Of The Hydraulic Actuator System (Hydrax System) on

G3612 and G3616 Engines{1050, 1250, 1908, 1915}
SMCS - 1050-012; 1250-012; 1908-012; 1915-012
Engine:
G3612 (S/N: 1YG1-UP)
G3616 (S/N: 4CG1-UP)
Introduction
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.
This Special Instruction describes the installation of the Hydrax system on G3612 and on G3616 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.
References
The following reference materials may be necessary for this procedure:
Specifications, SENR5527
Troubleshooting, SENR6510
Disassembly And Assembly Manual, SENR5535
Systems Operation/Testing and Adjusting, RENR5528
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 8/14/2017
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System Description
Illustration 1 g01028469
Left side view of the engine
(1) Position sensor
(2) Air choke actuator
(3) Hydraulic pump
(4) Hydraulic tank
(5) Hydraulic oil filter
(6) Accumulator
(7) Check valve
Right side view of the engine
(8) Wastegate actuator
(9) Fuel actuator
(10) Pressure relief valve
(11) Pressure switch
(12) Box for the hydrax driver modules
The Hydrax system controls fuel actuator (9), wastegate actuator (8), and air choke actuator (2) by using individual
electronically controlled hydraulic actuators.
The system uses engine oil or hydraulic oil for the hydraulic fluid. Hydraulic pump (3) 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 (4) stores the hydraulic fluid. Check valve (7) keeps the oil from draining from the system. This
provides better response characteristics.
Accumulator (6) is a nitrogen charged bottle which maintains 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 (5) .
Pressure relief valve (10) 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 (12). The modules convert the signals for use by the actuators.
Position sensors (1) 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 sensors, and the accumulator are not required if the engine will be
equipped with the ADEM III control system.
The hydraulic actuators, the position 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.
Table 1
Parts List For the Hydraulic Actuator System
Part Number
Quantity
G3612 G3616 Description
Engine Engine
8T-9580 2 Hydraulic Oil
117-3195 117-3196 1 Hydraulic Tank and Mounting Group
142-4238 1 Exhaust Bypass Group
153-2789 1 Air Lines (Choke)
153-2788 1 Fuel Control
4C-4030 1 Thread Lock Compound
148-7632 148-7633 1 Engine Oil Lines
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
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-1571 4 Bolt
0S-1588 4 Bolt
0S-1594 4 Bolt
0S-1620 2 Bolt
110-8714 40 Wire End
129-3543 1 Junction Box Gp
135-0784 1 Tag
140-9669 1 Harness for the Pressure Switch
141-6380 4 Flexible Mount
Harness for the Connection Between the Engine Junction Box and
147-0114 1
the Box for the Relay Driver Modules
147-0115 1 Harness for the Fuel Actuator
147-0116 1 Harness for the Fuel Actuator's Position Sensor
147-0117 1 Harness for the Air Choke Actuator
147-0118 1 Harness for the Air Choke Actuator's Position Sensor
147-0119 1 Harness for the Wastegate Actuator
147-0120 1 Harness for the Wastegate Actuator's Position Sensor
147-0121 1 Harness for the Pressure Switch
151-6154 2 Bracket As
151-6155 1 Bracket As
3V-3308 17 Hard Washer
153-2792 1 Tag
4B-4274 6 Washer
4D-7388 1 Clip
4L-7124 4 Bolt
4P-7428 2 Clip
4P-7581 4 Clip
4P-8134 5 Clip
5P-8245 2 Hard Washer
5S-0003 8 Nut
6V-2313 6 Bolt
9M-1974 8 Hard Washer
9S-8752 5 Full Nut
9X-3495 3 Clip As
9X-6772 50 Cable Strap
(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 control system.
Order a New Personality Module

A new personality module is required in order to make the engine compatible with the new actuators. In order to
properly define the configuration for the new personality module, a "Personality Module Request Form" must be
submitted to the Service Center at the Caterpillar Diversified Power Products. The Service Center will respond
with the appropriate part number that can be ordered through the parts system.
Illustration 3 is the "Personality Module Request Form". The form includes all of the information that is required
in order to process your request.
Prepare the Engine
Illustration 4 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.
Performance data sheet
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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.
Remove the Existing Components
Rear view of the components for the air choke
(1) Lever
(2) Linkage
(3) Bracket
(4) Typical electrical actuator
1. Remove electrical actuator (4), linkage (2), brackets (3), and lever (1) .
Rear view of the components for the fuel valve
(6) Linkage
(7) Bracket
(8) Nut for the fuel valve
2. Remove electrical actuator (5), linkage (6) and bracket (7). Save the nut (8) that is used to attach the fuel
valve to the bracket. The nut will be used during installation of the new bracket.
Rear view of the components for the wastegate
(10) Linkage
(11) Bracket for the linkage
(12) Bracket for the actuator
3. Remove electrical actuator (9), linkage (10), and brackets (11) and (12) .
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
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.
ReferenceRefer to Disassembly And Assembly Manual, SENR5535 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) .
7. Install hydraulic oil pump (5) by tightening two bolts (2) to the standard torque.
Air Choke Actuator
Left side view of the aftercooler
(1) 196-9529 Electronic Actuator
(2) 5M-2894 Hard Washer
(3) 145-0040 Bracket As
(3) 0S-1588 Bolt
(4) 0S-1587 Bolt
(5) 5P-8245 Hard Washer
1. Install bracket (3) by using one bolt (4) and one washer (5).
2. Attach actuator (1) to bracket (3) 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.
Turbo Wastegate Actuator
Rear view
(1) 141-9885 Bracket As
(2) 8H-3390 Full Nut
(3) 6V-8675 Bolt
1. Install bracket (1) to the turbocharger by using six bolts (3) and six washers (4).
Fuel Actuator
Top view
(2) 0S-1588 Bolt
(4) 118-6664 Bracket As
(5) 1W-3557 Gasket
(6) 8H-3390 Full Nut
(7) 9X-8887 Bolt
(9) 118-6662 Bracket As
(10) Nut
1. Install bracket (9) by using four bolts (7) and four washers (8) .
2. Attach the fuel valve to the bracket with the nut (10) that was originally installed on the valve.
3. Ensure that the top surface of the rear housing is clean. Install gasket (5) and bracket (4) by using four bolts
(2) and four washers (3) .
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.
Components for the oil filter
(1) 8C-5053 Adapter
(2) 7M-8485 O-Ring Seal
(3) 6V-9182 Elbow
(4) 6V-9746 O-Ring Seal
(5) 148-7621 Bracket As
(6) 0L-1143 Bolt
(8) 5K-9660 Clip
(9) 9C-5344 Spacer
(10) 148-7621 Bracket As
(11) 0S-1588 Bolt
(12) 0S-1594 Bolt
(13) 8C-0569 O-Ring Tee
(15) 3J-1907 O-Ring Seal
(16) 9S-4191 Plug
(17) 138-6144 Engine Oil Filter Gp
1. Install the oil filter by performing these steps:
a. Attach bracket (5) to the engine by using four bolts (11) and four washers (7) .
b. Attach oil filter group (17) to bracket (5) by using four bolts (12) and four washers (7) .
c. Install O-ring seal (14) and O-ring tee (13) into the oil filter's inlet.
d. Install O-ring seal (14) and O-ring tee (13) into the oil filter's outlet.
e. Install O-ring seal (15) and O-ring plug (16) into each O-ring tee.
2. Apply 4C-4030 Thread Lock Compound to the threads of adapter (1). Install the adapter into the pump.
3. Install O-ring seal (2) and elbow (3) into adapter (1) .
4. Install O-ring seal (4) and tube (10) onto elbow (3). Attach the tube to the side of the engine by using two
bolts (6), two washers (7), two clips (8), and two spacers (9). Tighten the tube's fitting after you place an O-
ring seal (4) between the end of the tube and the O-ring tee on the oil filter's inlet.
Left side view
(X) Location for 16 cylinder engines
(Y) Locations for 16 cylinder engines and for 12 cylinder engines
(1) 0S-1588 Bolt
(3) 1A-2029 Bolt
(4) 9S-8752 Full Nut
(5) 148-7623 Bracket
(6) 148-7622 Bracket As
5. For 12 cylinder engines, attach two brackets (6) to the engine at locations (Y) by using four bolts (1) and
four washers (2) for each bracket.
6. For 16 cylinder engines, attach three brackets (6) to the engine at locations (X) and (Y) by using four bolts
(1) and four washers (2) for each bracket.
7. Attach bracket (5) to each bracket (6) by using two bolts (3), two washers (2) and two nuts (4) for each
bracket.
Left side view of a 16 cylinder engine
(7) Bracket
(8) 0S-1594 Bolt
(9) 5K-9660 Clip
(10) 6V-9832 Cap As
(12) 148-7606 Tube As (12 cylinder engines)
(12) 148-7620 Tube As (16 cylinder engines)
(13) 6V-8637 Connector
(15) 6V-8784 Face Seal Tee
(16) 138-6158 Check Valve
8. Install an O-ring seal (11) and the appropriate end of tube (12) onto the hydraulic filter's outlet.
9. On a 12 cylinder engine, attach tube (12) to the engine at one location. Use bolt (8), two washers (2), clip
(9), and nut (4) in order to attach the tube to the bottom hole on bracket (7) .
10. On a 16 cylinder engine, attach tube (12) to the engine at two locations. Use bolt (8), two washers (2), clip
(9), and nut (4) in order to attach the tube to the bottom holes of brackets (7) .
11. Install O-ring seal (11) and connector (13) to the end of tube (12) .
12. Install O-ring seal (14) and check valve (16) onto connector (13). Be sure to orient the check valve correctly.
13. Install O-ring seal (14) and tee (15) to check valve (16). Orient the tee according to Illustration 14.
14. Install cap (10) onto the outlet of the tee that points toward the engine.
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.
Components for the hydraulic tank
(1) 8C-6875 Connector
(2) 5K-9090 O-Ring Seal
(3) 6V-9854 Elbow
(4) 0S-1571 Bolt
(6) 143-4770 Hydraulic Tank Gp
(7) 0S-1588 Bolt
(9) 143-4773 Bracket As
(10) 117-3198 Hose As
(11) 0S-1590 Bolt
(12) 5P-7854 Clip
(13) 5G-4313 Spacer
(15) 117-3197 Hose As
(16) 6V-9008 Elbow
(17) 6V-7238 Shutoff Valve
(18) 8L-2786 O-Ring Seal
(20) 8T-5389 Elbow
(22) 117-3199 Hose As
1. Install bracket (9) by using six bolts (4) and six washers (5) .
2. Install tank (6) to the bracket by using four bolts (7), eight washers (5) 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 O-ring seal (2) and elbow (3) into the connector.
7. Install O-ring 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 O-ring seal (19) and elbow (20) .
10. For the G3612, install O-ring seal (21) and one end of hose (10) to elbow (20). Secure the hose to the engine
by using three bolts (11), three washers (5), three clips (12), and three spacers (13). Orient hose (10) and
elbow (20) so that the hose does not contact an explosion relief valve.
11. For the G3616, install an O-ring seal (21) and one end of hose (22) to elbow (20). Secure the hose to the
engine by using six bolts (12), six washers (5), six clips (11), and six spacers (13). Orient hose (22) and
elbow (20) so that the hose does not contact an explosion relief valve.
Lines Group
View of the manifold
(1) 148-7635 Manifold
(2) 8T-6876 Elbow
(6) 6V-9007 Elbow
1. Install the O-ring seals, the connectors, and the elbows according to Illustration 16.
Top view of the engine
(8) 1A-1460 Bolt
(10) 148-7630 Bracket
2. Attach bracket (10) to the engine with two bolts (8) and two washers (9) .
Left side view
(X) Location for the clip
(Y) Location for the clip
(10) 117-3198 Hose As
(11) 0S-1594 Bolt
(13) 5K-9660 Clip
(14) 9S-8752 Full Nut
(15) 148-7608 Tube As
(17) 6V-8733 Face Seal Union
(18) 148-7609 Tube As
(19) 148-7607 Tube As
3. Install O-ring seal (16) and tube (18) to the end of hose (10). Attach the tube to the engine at location (X) by
using bolt (2), two washers (3), clip (13), and nut (4). Be sure to attach the clip to the bracket's upper hole.
4. Install O-ring seal (16) and union (17) to the end of tube (18) .
5. Install O-ring seal (16) and tube (15) to the union (17). Attach the tube to the engine at location (Y) by using
bolt (11), two washers (12), clip (13), and nut (14). Be sure to attach the clip to the bracket's upper hole.
6. Install O-ring seal (16) and tube (19) to the tee. Attach the tube to the engine at location (Y) by using bolt
(11), two washers (12), clip (13), and nut (14). Be sure to attach the clip to the bracket's lower hole.
Top view
7. Attach manifold (1) by using two bolts (11) and two washers (12). Install O-ring seals (5) and tubes (15) and
(19) to the manifold.
Manifold
(20) 121-6750 Manifold
(24) 6V-9004 Elbow
(25) 9S-4191 Plug
8. Install the O-ring seals, the connectors, the elbow, and the plugs according to Illustration 20.
Manifold
(26) 8T-6451 Elbow
(27) 6V-8629 Elbow
(28) 4P-6814 Manifold
9. Install the O-ring seals, the connectors, and the elbows according to Illustration 21.
Top view of the brackets for the manifolds
(29) 148-7625 Bracket As
(30) 1A-2029 Bolt
(31) 148-7626 Bracket
(32) 0S-1591 Bolt
(33) 0S-1588 Bolt
10. Install bracket (29) by using three bolts (33), one bolt (32), six washers (12), and four nuts (14) .
11. Install bracket (31) by using two bolts (30), four washers (12), and two nuts (14) .
Top view of the brackets for the manifolds
(34) 0L-1352 Bolt
12. Install manifold (20) by using two bolts (11) and two washers (12). Install manifold (29) by using two bolts
(34), four washers (12) and two nuts (14) .
Rear view
(35) 1A-5183 Bolt
(36) 148-7627 Clamp
(37) 148-7628 Clamp
(38) 148-7619 Tube As
(39) 148-7618 Tube As
13. Install two O-ring seals (5) and tube (38) .
14. Install O-ring seal (5), O-ring seal (22), and tube (39) .
15. Attach clamps (36) and (37) by using bolt (35) and washer (12) .
Tubing for the Air Choke Actuator
Top view of the air choke actuator
(2) 148-7612 Tube As
(3) 148-7611 Tube As
(4) 8T-6876 Elbow
1. Install O-ring seals (5) and elbows (4) into the actuator's ports.
2. Install O-ring seals (1) and tubes (2) and (3) .
Tubing for the Turbo Wastegate Actuator
Rear view
(1) 8T-1885 Clip
(2) 8T-1886 Clip
(3) 176-3592 Bracket
(4) 0S-1594 Bolt
(10) 148-7614 Tube As
(11) 148-7615 Tube As
1. Install an O-ring seal (9) and a connector (8) into the actuator's ports.
3. Install brackets (3) .
4. Install clips (1) and (2) by using bolts (4), washers (4), and nuts (6) .
Tubing for the Fuel Actuator
Top view
(2) 148-7616 Tube As
(3) 148-7613 Tube As
1. Install an O-ring seal (5) and a connector (4) into each of the actuator's ports.
Rear view
(7) 148-7617 Tube As
(10) 8T-6451 Elbow
(12) 176-3586 Relief Valve As
3. Install O-ring seal (8) and connector (9) into relief valve (12) .
4. Install O-ring (8) and elbow (10) into relief valve (12) .
5. Install O-ring seal (11) between elbow (10) and the connector on the manifold.
6. Install two O-ring seals (6) and tube (7) .
7. Tighten all of the connections for all of the tubing.
8. Tighten the nut for each actuator to 200 ± 20 N·m (148 ± 15 lb ft).
Hydrax Oil Pressure Switch
Top view of the manifolds
(1) 3K-0360 O-Ring Seal
(2) 140-9669 Switch
1. Install O-ring seal (1) and pressure switch (2) .
Linkage for the Air Choke Actuator
Rear view
(1) 8C-7321 Rod End
(3) 145-0041 Rod
(5) 8C-7315 Rod End
(6) 0S-1590 Bolt
(9) 176-3587 Clevis
(10) 193-7879 Boot
1. Extend the rod from the actuator. Attach boot (10) onto the nut for the actuator.
2. Apply 4C-4030 Thread Lock Compound to the actuator rod's threads. Thread clevis (9) onto the end of the
actuator rod.
3. Attach rod end (5) to the clevis by using bolt (6), two washers (7), and nut (8) .
4. Thread nuts (2) and (4) onto rod (3) .
5. Thread rod (3) into rod end (5) .
6. Thread rod end (1) onto the end of rod (3) .
Rear view
(11) 5L-3291 Ball Bearing As
(12) 0S-1594 Bolt
(13) 145-0039 Bracket As
(14) 0S-1588 Bolt
(15) 118-3842 Bracket As
7. Install bracket (13) by using six bolts (14), twelve washers (7), and six nuts (8) .
9. Install ball bearing assembly (11) by using four bolts (12) and four washers (7). Orient the ball bearing
assembly so that the lube fitting is easily accessible. Leave the ball bearing assembly loose.
10. Install ball bearing assembly (11) by using four bolts (14), eight washers (7), and four nuts (8). Orient the
ball bearing assembly so that the lube fitting is easily accessible. Leave the ball bearing assembly loose.
11. Lubricate each ball bearing assembly with the appropriate amount of bearing grease.
Rear view
(X) Ball bearing assembly
(Y) Ball bearing assembly
(16) 4P-0394 Lever
(17) 5H-2532 Woodruff Key
(18) 118-3843 Shaft
(19) 4P-0394 Lever
12. Slide shaft (18) through ball bearing assembly (X). Be sure to orient the shaft correctly.
13. Slide lever (16) onto the shaft. Be sure to orient the lever correctly.
14. Slide the shaft through ball bearing assembly (Y) .
15. Slide lever (19) onto the end of the shaft. Be sure to orient the lever correctly. Install two woodruff keys
(17) .
Rear view
(21) 0S-1571 Bolt
(22) 118-3843 Shaft
(23) 038-7444 Rod (Single-stage aftercooler)
(23) 147-5092 Rod (Two-stage aftercooler)
16. Use bolt (21), two washers (7), and nut (8) in order to secure lever (16) to shaft (22) .
17. Use bolt (21), two washers (7), and nut (8) in order to secure lever (19) to shaft (22) .
18. Place washer (20) between lever (16) and rod end (1). Use bolt (21), two washers (7), and nut (8) in order to
secure the assembly.
20. Securely tighten both of the ball bearing assemblies.
21. Preassemble rod (23) by threading nuts (2) and (4) onto each end of the rod. Then thread the appropriate rod
end (5) and (1) onto each end of the rod. Leave the assembly loose in order to align the linkage later.
Linkage for the Turbo Wastegate Actuator
Linkage for the turbo wastegate actuator
(2) 0S-1571 Bolt
(3) 3V-3308 Washer
(4) 9S-8752 Nut
(5) 8C-7315 Rod End
(7) 0S-1591 Bolt
(8) 0S-1588 Bolts
(10) 3S-2713 Full Nut
(12) 4P-0394 Lever
(14) 4P-0394 Lever
(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 ball
bearing assembly so that the lube fitting is easily accessible. Leave the ball 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 ball bearing
assembly so that the lube fitting is easily accessible. Leave the ball bearing assembly loose. The assembly
will be tightened after shaft (20) is installed.
4. Install wastegate shaft (20) through the bracket and ball 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 ball 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) .
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
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
15. Place washer (11) between rod end (19) and lever (12). Use bolt (2), two washers (3) and nut (4) in order to
Linkage for the Fuel Actuator
Rear view
(2) 0S-1588 Bolt
(4) 118-6665 Shaft
(5) 0S-1571 Bolt
(7) 4D-8532 Lever
(10) 0S-1591 Bolt
(11) 115-7768 Lever
1. Install ball bearing assembly (1) by using four bolts (2) and four washers (3). Install ball bearing assembly
(9) by using four bolts (10), four washers (3), and four nuts (6). Orient the ball bearing assemblies so that the
lube fittings are easily accessible. Leave the ball bearing assemblies loose.
3. Slide the narrow end of shaft (10) through ball bearing assembly (9). Slide lever (7) onto the shaft. Slide
lever (11) onto the shaft. Slide the shaft through ball bearing assembly (1). Secure each lever to the shaft
with the following items: woodruff key (8), bolt (5), two washers (3) and nut (6) .
Rear view
(13) 8C-6971 Rod End
(14) 1S-3584 Full Nut
(15) 8C-7321 Rod End
(16) 176-3587 Clevis
(17) 0S-1590 Bolt
(18) 3S-2713 Full Nut
5. Install nut (18) and clevis (16) onto the end of the fuel valve's rod. Connect rod end (15) to the clevis by
using bolt (17), two washers (3), and nut (6). Thread nut (14) onto rod end (13). Thread rod end (13) into rod
end (15). Place washer (12) between lever (11) and rod end (13). Use bolt (2) and washer (3) in order to
fasten the rod end to the lever.
Top view
(19) 193-7879 Boot
(20) 8C-7315 Rod End
(21) 4P-0391 Rod
6. Preassemble rod (21) by threading nuts (14) and (18) onto each end of the rod. Thread clevis (16) onto the
appropriate end of the rod. Thread rod end (15) onto the other end of the rod. Leave the nuts loose in order to
align the linkage.
8. Extend the rod from the actuator. Attach boot (19) to the nut for the actuator.
9. Apply 4C-4030 Thread Lock Compound to the actuator rod's threads. Thread rod end (14) onto the end of
the actuator rod.
10. Use bolt (17), two washers (3), and nut (6) in order to fasten clevis (15) to rod end (14) .
Adjust the Linkage

Linkage for the Air Choke
Adjustment of the linkage for the air choke
(X) Locations for the disconnection of the connecting rod assemblies
Note: All dimensions are for reference.
1. Remove the connecting rod assemblies by disconnecting the assemblies at locations (X) .
Adjustment of the choke plate
(1) Bolt
(2) Locknut
(3) Stop plate
2. 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 contacts the stop plate (3) .
3. 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.
4. Fully close the choke plate. Fully retract the actuator. Adjust each 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.
5. Reinstall the connecting rod assemblies.
6. Extend the actuator in order to fully open the choke plate. While the actuator is fully extended and the choke
plate is open, shorten the length of a connecting rod by half a turn. This will create a small gap between the
edge of the choke plate and the housing. Tighten the nuts on the connecting rod assemblies in order to lock
the length of the assemblies.
Linkage for the Wastegate
Adjustment of the linkage for the wastegate
(X) Location for the disconnection of the linkage
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 order to slightly 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
Adjustment of the linkage for the fuel valve
(X) Location for the disconnection of the linkage
(1) Clevis
(2) Rod
1. Disconnect the linkage at location (X) .
2. Carefully push the rod (2) into the fuel valve in order to 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.
a. 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.
b. Reconnect the linkage.
c. Ensure that the metering valve can still reach the full open position.
5. If the engine will not be converted to the ADEM III control system, continue with this Special Instruction.
Refer to ""Install the Electrical Components" ". If the engine will be converted to the ADEM III control
system, discontinue this Special Instruction and refer to the Special Instruction, REHS1709 for the
installation of the ADEM III control system.
Install the Accumulator and Charge the Accumulator
Installation of the accumulator
(1) 7G-4326 Plate
(2) Tee
(3) 0S-1594 Bolt
(6) 5K-9660 Clip
(8) 148-7610 Tube As
(9) 6V-8733 Face Seal Union
(10) 0S-1590 Bolt
(11) 199-3141 Turbocharger Accumulator Gp
(12) 0S-1608 Bolt
(13) 170-0990 Clamp
(14) 126-3005 Pipe
(15) 198-7779 Bracket As
(18) 158-2940 Hose As
1. Remove cap (2) from the back of the tee.
2. Install plate (1) by using the existing hardware.
3. Install O-ring seal (7) and tube (8) to the tee.
4. Attach the tube to the plate by using clip (6), bolt (3), two washers (4), and nut (5) .
6. Install O-ring seal (16) and connector (17) into accumulator (11) .
7. Attach the accumulator to the bracket by using two clamps (13), four pipes (14), four bolts (12), four
washers (4), and four nuts (5). Do not tighten the nuts completely.
8. Install O-ring seal (7) and union (9) to the end of tube (8) .
9. Install two O-ring seals (7) and hose (18) .
10. Securely tighten the mounting hardware for the accumulator.
11. 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
Linkage for the air choke
(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
(15) Spider (Part of 176-3572 Shaft Coupling Gp )
1. Attach coupling hub (16) to shaft (7) .
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) .
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.
Installation of the position sensor for the air choke
(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 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.
Position Sensor for the Wastegate
Linkage for the wastegate
(2) 7E-1630 Gasket
(3) 9U-3300 Spacer
(4) 8M-2337 Washer
(5) 8F-6302 Bolt
(9) 127-1573 Shaft
(11) 8C-5608 Spacer
(15) 8C-5607 Mount
positioned.
Installation of the position sensor for the wastegate
(17) Set screw
(19) 4B-4274 Washer
(20) 6V-2313 Bolt
(21) Tang
Position Sensor for the Fuel Valve
Linkage for the fuel valve
(1) 8M-2337 Washer
(2) 9U-3300 Spacer
(3) 7E-1630 Gasket
(5) 8F-6302 Bolt
(9) 127-1573 Shaft
(11) 8C-5608 Spacer
(13) 8C-5607 Mount
positioned.
Installation of the position sensor for the fuel valve
(18) Set screw
(19) 4B-4274 Washer
(20) 6V-2313 Bolt
(21) Tang
Box for the Hydrax Driver Modules
Left side view of the engine
1. Remove the four bolts and the four washers from the locations that are shown in Illustration 49.
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.
Mounting hardware for the box for the relay driver modules
(1) 151-6154 Bracket As
(2) 129-3543 Junction Box Gp
(3) 0S-1594 Bolt
(5) 4L-7124 Bolt
(6) 0S-1571 Bolt
(7) 151-6155 Bracket As
(8) 151-6154 Bracket As
(9) 141-6380 Flexible Mount
(11) 5S-0003 Nut
3. Attach bracket (7) to the engine by using four bolts (6) and four washers (4) .
4. Attach bracket (8) to bracket (7) by using three bolts (3) and three washers (4) .
5. Attach four mounts (9) by using four washers (10) and four nuts (11) .
6. Attach bracket (1) to the mounts by using four washers (`0) and four nuts (4) .
7. Attach box (2) to the bracket by using four bolts (5) .
Wiring Harnesses
Box for the Hydrax driver modules
(A) 147-0118 Harness (Position sensor for the air choke)
(B) 147-0117 Harness (Air choke actuator)
(C) 147-0116 Harness (Position sensor for the fuel valve)
(D) 147-0115 Harness (Actuator for the fuel valve)
(E) 147-0120 Harness (Position sensor for the wastegate)
(F) 147-0119 Harness (Wastegate Actuator)
1. Install six wiring harnesses into box (2). Be sure to install each harness into the correct location.
Rear view and right side view of the engine
(12) 4D-7388 Clip
(13) 0S-1588 Bolt
(14) 9S-8752 Full Nut
(15) 9X-3495 Clip As
(16) 4P-7581 Clip
(17) 9X-6772 Cable Strap
(18) 4P-8134 Clip
(19) 0S-1620 Bolt
(21) 4P-7428 Clip
(22) 147-0121 Harness
(23) 4P-8134 Clip
(24) 147-0114 Harness
2. Install harness (24) into the right side of the box for the Hydrax driver modules.
3. Attach harness (24) to the engine at two locations (X) by using the existing hardware.
4. Attach clip (12) and harness (24) to the engine at location (W) by using the existing hardware.
5. Install harness (24) into an open location on the bottom of the engine terminal box.
6. Install harness (22) into an open location on the bottom of the engine terminal box.
7. Attach clip (23) by using the existing hardware. Attach harness (22) to clip (23) by using a cable strap (17) .
8. Connect the connectors for the Hydrax oil pressure switch.
9. Attach six harnesses to the engine at two locations by using clips (18) and cable straps (17) .
10. Attach six harnesses to the engine at one location by using clip (16) and cable strap (17) .
11. Attach harnesses (C), (E), and (F) to the engine at two locations. Use one bolt (19), one washer (20), one clip
(21) and one cable strap (17) at each location.
12. Connect the connectors for the fuel valve's position sensor. Attach the connectors to the bracket by using
bolt (13), two washers (4), clip (15), and nut (14) .
13. Attach the harnesses for the wastegate to the fuel actuator's bracket by using bolt (3), two washers (4), clip
(18), nut (14), and cable strap (17) .
14. Connect the connectors for the wastegate actuator.
15. Attach the harness for the wastegate's position sensor to the wastegate actuator's bracket by using bolt (13),
two washers (4), clip (16), nut (14), and cable strap (17) .
16. Connect the connectors for the wastegate's position sensors. Attach the connectors for the wastegate's
position sensor to the bracket by using one bolt (13), two washers (4), clip (15), and nut (14) .
17. Secure the wiring harnesses with cable straps (17) at the appropriate locations.
Left side view
18. Route the harnesses for the air choke to the left side of the engine. Connect the connectors for the air choke
actuator and for the actuator's position sensor.
19. Attach the connectors for the position sensor to the bracket by using one bolt (13), two washers (4), one clip
(15), and one nut (14) .
20. Attach clip (15) to the engine by using the existing hardware. Attach the harnesses to the clip by using a
cable strap (16) .
21. Verify that all of the connectors are connected. Verify that all of the clips are securely installed to the engine.
All of the harnesses must be securely fastened to the engine or to other harnesses in order to prevent damage
that is caused by vibration.
22. Terminate each wire for the Hydrax system by performing the following procedure.
Typical wire termination
(25) Paper tag
(26) 135-0784 Tag or 141-6403 Tag
(27) 110-8714 Wire End
Note: Paper tag (25) indicates the wire number.
Note: Tag (26) 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.
a. Remove paper tag (25) from the wire. Install the appropriate tag (26) onto the end of the wire.
b. Cut the wire to the appropriate length.
c. Crimp a wire end (27) onto the end of the wire.
d. 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.
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.
a. Verify that the air choke is fully open.
Top view of the position sensor for the air choke
(1) Set screw
(2) Coupling
b. Loosen set screw (1) .
c. While you are monitoring the voltage, rotate coupling (2) in order to obtain a voltage measurement
between 1.6 VDC and 1.8 VDC.
d. 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.
a. Verify that the wastegate is fully closed.
Top view of the position sensor for the wastegate
(1) Set screw
(2) Coupling
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.
a. Verify that the fuel valve is fully closed.
Top view of the position sensor for the fuel valve
(1) Set screw
(2) Coupling
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, SEBU6496, "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.
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. Check the pressure in order to ensure 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.
Copyright 1993 - 2017 Caterpillar Inc. Mon Aug 14 10:00:37 UTC-0400 2017
All Rights Reserved. r40bvjn
Private Network For SIS Licensees.

REHS0385 Installation of The Hydraulic Actuator System (Hydrax System) On G3612 and G3616 Engines PDF

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Installation Of The Hydraulic Actuator System (Hydrax System) on

Disassembly And Assembly Manual, SENR5535

Systems Operation/Testing and Adjusting, RENR5528

Left side view of the engine

(1) Position sensor

(2) Air choke actuator

(3) Hydraulic pump

(4) Hydraulic tank

(5) Hydraulic oil filter

(7) Check valve

Right side view of the engine

(8) Wastegate actuator

(9) Fuel actuator

(10) Pressure relief valve

(11) Pressure switch

(12) Box for the hydrax driver modules

A hydraulic oil filter is inside housing (5) .

Order a New Personality Module

Prepare the Engine

• Digital Diagnostic Tool (DDT)

• Caterpillar Monitoring System (CMS)

• Status Control Module (SCM)

• Electronic Control Module (ECM)

Performance data sheet

Remove all electrical power from the engine.

Remove the Existing Components

Rear view of the components for the air choke

(4) Typical electrical actuator

Rear view of the components for the fuel valve

(5) Typical electrical actuator

(8) Nut for the fuel valve

Rear view of the components for the wastegate

(9) Typical electrical actuator

(11) Bracket for the linkage

(12) Bracket for the actuator

Install The Components

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.

ReferenceRefer to Disassembly And Assembly Manual, SENR5535 for additional information.

3. Reinstall the engine oil pump.

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

Air Choke Actuator

Left side view of the aftercooler

(1) 196-9529 Electronic Actuator

(2) 5M-2894 Hard Washer

(3) 145-0040 Bracket As

(3) 0S-1588 Bolt

(4) 0S-1587 Bolt

(5) 5P-8245 Hard Washer

Turbo Wastegate Actuator

(1) 141-9885 Bracket As

(2) 8H-3390 Full Nut

(3) 6V-8675 Bolt