3608 Engine Caterpillar

Removal Procedure

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

1. Remove the flywheel guards.

2. Disconnect the drive coupling from the flywheel.

Show/hide table



Illustration 1	g00557125

3. Turn the crankshaft until the dash marks on both the crankshaft and the flywheel face upward. This will put the 3/4 inch tapped hole for Tooling (B) at the top of the flywheel.

Show/hide table

NOTICE
Do not use the timing pin in order to hold the crankshaft while loosening the flywheel bolts. Remove the two front opposite crankcase inspection covers, and place a 102 mm (4 inch) by 102 mm (4 inch) board under the connecting rod in order to keep the crankshaft from turning.

4. Remove two bolts (1). Install Tooling (A) in the open holes.

5. Attach Tooling (B) and a suitable lifting device to the top of the flywheel. The weight of the flywheel is approximately 499 kg (1100 lb).

6. Remove remaining bolts (1) from the flywheel.

7. Raise the suitable lifting device in order to support the weight of the flywheel.

   Note: Do not pry against the aluminum seal.

8. Pry between the rear housing and the back of the flywheel in order to move the flywheel on Tooling (A) .

Show/hide table



Illustration 2	g00557126

9. Use the suitable lifting device in order to remove flywheel (2) from Tooling (A) .

10. Inspect ring gear (3). If ring gear (3) must be replaced, remove bolts (4) that hold ring gear (3) to flywheel (2) .

Installation Procedure

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

1. Ensure that the mounting surface on the flywheel for the ring gear is clean and dry. There should be no nicks or burrs in the mounting face.

Show/hide table



Illustration 3	g00557126

2. Install a new ring gear (3) and bolts (4) on flywheel (2). Install the ring gear with the tooth chamfer toward the front of the engine.

3. Ensure that the timing on the crankshaft is up.

4. Install Tooling (A) in the crankshaft.

5. Attach Tooling (B) and a suitable lifting device to flywheel (2). The weight of flywheel (2) is approximately 499 kg (1100 lb).

Show/hide table

NOTICE
Be sure that the mounting surfaces of the flywheel exhibit the following conditions: clean, dry and free of nicks or burns.

Note: Align the mark on the flywheel with the dash mark on the crankshaft.

6. Put the flywheel on Tooling (A). Check the bolt hole alignment. There are four unequally spaced holes on the back of the flywheel. These holes give clearance for the heads of the bolts that hold the seal adapter to the crankshaft. Ensure that the holes are aligned.

7. Move the flywheel into position on Tooling (A) .

Show/hide table



Illustration 4	g00557125

8. Apply Tooling (C) to the face of the washer and the bolt threads. Install bolts (1). Remove Tooling (A). Install the remaining bolts.

   Note: Do not use the timing pin in order to hold the crankshaft while you tighten the flywheel bolts. Remove the two front crankcase access covers. Place a 102 by 102 mm (4.0 by 4.0 inch) board under the connecting rod in order to keep the crankshaft from turning.

9. Tighten the bolts to a torque of 800 ± 80 N·m (590 ± 60 lb ft). The bolts should then be turned an additional 90 degrees.

10. Connect the drive coupling to the flywheel. Refer to Specifications, "Flexible Coupling" for the correct tightening procedure for your drive coupling.

11. Install the flywheel guards.