G3500 Engines Caterpillar

Air Starting Motor - Assemble

Usage:

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-1855	Retaining Ring Pliers	1
C	1P-0510	Driver Gp	1
D	1P-1861	Retaining Ring Pliers	1
E	1P-1863	Retaining Ring Pliers	1
G	277-7088	Spanner Socket	1
J	9S-3263	Thread Lock Compound	1

Note: The individual parts of the air starting motor are nonserviceable. An overhaul kit must be purchased in order to service the air starting motor.

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Illustration 1	g01172945

Install bearing (52) on turbine shaft (50). Use a suitable press and install turbine shaft (52) and bearing (50) into the housing.
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Illustration 2 g01172024
Position retainer plate (49) and install allen head bolts (48). Tighten allen head bolts (48) to a torque of 5.0 N·m (40.0 lb in).
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Illustration 3 g01172948
Install spacer (51) and spacer (61) on turbine shaft (50). Install O-ring seal (59).
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Illustration 4 g01172618
Use Tooling (C) and install lip seal (60) into nozzle (58).
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Illustration 5 g01172585
Position nozzle (58). Apply Tooling (J) to the threads of allen head bolts (57). Install allen head bolts (57). Tighten allen head bolts (57) to a torque of 3.0 N·m (30.00 lb in).
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Illustration 6 g01173007
Install the woodruff key and rotor (56). Make sure that the woodruff key did not push out during installation of rotor (56). Install spacer (55).
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Illustration 7 g01172628
Use Tooling (C) and install lip seal (62). Install wave washer (64).
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Illustration 8 g01173045
Use Tooling (C) and a suitable press to install bearing (63) into housing (53).
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Illustration 9 g01172212
Install O-ring seal (54). Install housing (53).
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Illustration 10 g01172022
Apply Tooling (J) to the threads of allen head bolts (47). Install allen head bolts (47). Tighten allen head bolts (47) to a torque of 3.0 N·m (30.00 lb in).
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Illustration 11 g01171998
Install the woodruff key and install rotor (45). Make sure that the woodruff key did not push out during installation of rotor (45). Install the washer and allen head bolt (44). Tighten allen head bolt (44) to a torque of 11.0 N·m (100.00 lb in).
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Illustration 12 g01171989
Install O-ring seal (43) onto housing (42).
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Illustration 13 g01171986
Position housing (42). Apply Tooling (J) to the threads of allen head bolts (41). Install allen head bolts (41). Tighten allen head bolts (41) to a torque of 9.0 N·m (80.00 lb in).
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Illustration 14 g01171983
Use Tooling (C) and a suitable press to install bearing (40) into planetary gear (38).
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Illustration 15 g01171812
Install thrust washers (37), planetary gear (38), and pin (39) into the planetary carrier.
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Illustration 16 g01171808
Use Tooling (A) and install retaining ring (36).
Repeat Step 14 through Step 16 for the remaining planetary gears.
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Illustration 17 g01173138
Use Tooling (C) and a suitable press to install bearing (35) onto planetary carrier assembly (29).
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Illustration 18 g01171772
Install spring washers (34), washer (33), and spacer (32).
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Illustration 19 g01171769
Install bearing (31). Use Tooling (D) and install retaining ring (30) into bearing housing (28).
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Illustration 20 g01173235

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install bearing housing (28) onto planetary carrier assembly (29). Install the woodruff key and spur gear (27).
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Illustration 21 g01173238
Install lock washer (26).
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Illustration 22 g01171744
Position planetary assembly (23) into a soft jawed vise. Use Tooling (G) and install spanner nut (25). Tighten spanner nut (25) to a torque of 122 to 136 N·m (90 to 100 lb ft).
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Illustration 23 g01171739
Bend the tab of lock washer (26) into the slot in spanner nut (25).
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Illustration 24 g01171591
Lubricate planetary assembly (23) with the grease that is supplied in the overhaul kit. Install planetary assembly (23). Install O-ring seal (24).
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Illustration 25 g01171580
Install allen head bolts (22). Tighten allen head bolts (22) to a torque of 13 N·m (113 lb in).
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Illustration 26 g01171575
Install ring gear (21).
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Illustration 27 g01171573
Position gearbox housing (3). Install bolts (20). Tighten bolts (20) to a torque of 13 N·m (113 lb in).
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Illustration 28 g01171533
Install bearing (19) into drive housing (2).
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Illustration 29 g01173294
Use Tooling (C) and a suitable press to install bearing (18) onto spur gear (14).
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Illustration 30 g01171531
Use Tooling (C) and a suitable press to install bearing (17).
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Illustration 31 g01171422
Use Tooling (E) and install retaining ring (16). Use Tooling (D) and install retaining ring (15).
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Illustration 32 g01173298
Use Tooling (C) and a suitable press to install spur gear (14) into drive housing (2).
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Illustration 33 g01171415
Use Tooling (C) to install lip seal (13). Install spacer (12).
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Illustration 34 g01173353
Use a suitable press and install bearing (11) onto drive assembly (7).
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Illustration 35 g01171383
Use Tooling (A) and install retaining ring (10) onto drive assembly (7).
Lubricate drive assembly (7) with the grease that is supplied in the overhaul kit.
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Illustration 36 g01170867

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install spring (8), washer (9), and drive assembly (7) into drive housing (2).
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Illustration 37 g01170823

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Illustration 38 g01171324
Position drive housing (2) into a suitable press. Press drive assembly (7) into drive housing (2). Install pinion gear (6), washer (5), and bolt (4). Tighten bolt (4) to a torque of 81 N·m (60 lb ft).
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Illustration 39 g01170843
Position drive housing (2) onto gearbox housing (3). Install bolts (1). Tighten bolts (1) to a torque of 13 N·m (113 lb in).