3608 Engine Caterpillar

Air Starting Motor - Assemble

Usage:

3608 1ZD

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-1854	Retaining Ring Pliers	1
B	-	Plate 51.0 by 102.0 by 6.0 mm (2.00 by 4.00 by 0.25 inch)	2
C	1P-1857	Retaining Ring Pliers	1
D	-	Allen Wrench (5/16 inch)	1
E	-	Tube 64.0 by 203.0 by 6.0 mm (2.50 by 8.00 by 0.25 inch)	1
F	1P-0510	Driver Group	1
G	2S-3230	Bearing Lubricant	1
H	4C-5593	Thread Compound	1
J	6V-7030	Micrometer Depth Gauge Group	1
K	8H-8581	Feeler Gauge	1

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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

Note: Apply Tooling (G) to all bearings and the drive assembly. Apply a thin layer of clean engine oil to all other parts before assembly.

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Illustration 1	g01204945

Install the O-ring seals on cylinder (56). Install cylinder (56) in motor housing (3). Ensure that pin (57) is in alignment with slot (58) in motor housing (3) .

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Illustration 2	g00539182

Install O-ring seals (55) on cylinder (56) .

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Illustration 3	g01204950

Install end plate (48) on rotor (51) .

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Illustration 4	g01204952

Install O-ring seal (49) on the rotor shaft.

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Illustration 5	g01204954

Install bearing (47) over the rotor shaft and in the end plate.

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Illustration 6	g01204956

Install nut (45) on the rotor shaft with the shoulder toward the bearing.

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Illustration 7	g01204960

Tighten the nut until there is 0.03 to 0.08 mm (0.001 to 0.003 inch) of clearance between the end plate and the rotor. Use Tooling (K) in order to check the clearance. Tighten bolt (46). Check the clearance again.

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Illustration 8	g01204961

Install rotor (51) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin. Ensure that pin (59) is in alignment with the hole in the end plate.

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Illustration 9	g01204972

Install vanes (50) in the rotor.

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Illustration 10	g01204976

Install end plate (53) on the rotor. Ensure that hole (60) in the end plate is in alignment with pin (61) .

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Illustration 11	g01204978

Install washers (54) in the end plate.

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Illustration 12	g01204980

Put bearing (52) in position on the end plate.

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Illustration 13	g01204984

Use Tooling (F) and a suitable press in order to install bearing (52) on the rotor shaft and in the end plate.

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Illustration 14	g00539147

Install rotor pinion (43) and bolt (44) on the rotor shaft. Tighten the bolt to a torque of 120 N·m (90 lb ft).

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Illustration 15	g00539145

Install the O-ring seal on the motor housing. Position cover assembly (2) on motor housing (3) .

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Illustration 16	g00539088

Put bearing (35) and ring (34) in position on drive shaft assembly (18) .

Use Tooling (E) and a suitable press in order to install the ring on the drive shaft.

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Illustration 17	g00538973

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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.

Put bolt (25), lockwasher (26), washer (27), bearing (28), driving clutch jaw (29), driven clutch jaw (30), spring (31), and cup (32) in position on drive shaft assembly (18). Install ring (33) on the drive shaft assembly.

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Illustration 18	g01204991

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Illustration 19	g00538972

Use Tooling (F) in order to install seal (22) in piston (15). Ensure that the lip of the seal is toward the outside of the piston.

Note: Later air starting motors will not have bumper (23) .

Install O-ring seal (24) and bumper (23) on piston (15) .

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Illustration 20	g00538971

Install piston (15) on drive shaft assembly (18). Install ring (21) that holds the piston to the shaft assembly.

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Illustration 21	g00538970

Install O-ring seals (20) on bulkhead (19) .

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Illustration 22	g00538969

Install bulkhead (19) on piston (15) .

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Illustration 23	g00538968

Install drive gear (8) on piston (15) and drive shaft assembly (18). Use Tooling (D) in order to install the bolt that holds the drive gear to the drive shaft. Tighten the bolt to a torque of 77 N·m (57 lb ft).

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Illustration 24	g01205057

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Illustration 25	g00539144

Use Tooling (F) in order to install seal (42) in drive housing (6). Ensure that the lip of the seal is installed correctly.

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Illustration 26	g00539094

Install bearing (41) and seat (40) in drive housing (6) .

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Illustration 27	g00539092

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Illustration 28	g00539091

Note: Later air starting motors will not have backup ring (39) and bumper (38) .

Install backup ring (39) and bumper (38) in drive housing (6) .

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Illustration 29	g00538966

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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 piston return spring (17) in drive housing (6) .

Put the drive gear, piston (15), and the drive shaft assembly as a unit in position on piston return spring (17) .

Put ring (16) in position over the piston. Install Tooling (B) between the drive gear and the piston. Use a suitable press in order to compress piston return spring (17). Install ring (16) in the groove of drive housing (6). Release the suitable press and remove Tooling (B) .

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Illustration 30	g00538964

Install O-ring seal (14) on drive housing (6) .

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Illustration 31	g00539089

Install bearing (36) in gear case (7). Use Tooling (C) in order to install ring (37) that holds bearing (36) in gear case (7) .

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Illustration 32	g00538963

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Illustration 33	g00538961

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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 drive housing (6) in gear case (7). Ensure that the shaft on the end of the drive gear is correctly engaged with the bearing in gear case (7). Install bolts (13) that hold drive housing (6) to gear case (7). Tighten the bolts to a torque of 38 N·m (28 lb ft).

Use Tooling (A) in order to install ring (9) on the end of the shaft for drive gear (8) .

Note: Air starting motors for standard engine rotation rotate clockwise when the motors are viewed from the pinion end of the air starting motor. Bolt (10) for an air starting motor with clockwise rotation has left hand threads.

Note: Air starting motors for reverse engine rotation rotate counterclockwise when the motors are viewed from the pinion end of the air starting motor. Bolt (10) for an air starting motor with counterclockwise rotation has right hand threads.

Install the spring, the sleeve, drive pinion (12), bolt (10), and washer (11) on the end of the drive shaft. Tighten bolt (10) to a torque of 108 N·m (80 lb ft).

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Illustration 34	g00538960

Install gear case (7) and drive housing (6) as a unit on motor housing (3). Apply Tooling (H) on the threads of bolts (5) that hold the cover and the housing. Install bolts (5). Tighten each bolt alternately to a torque of 81 N·m (60 lb ft).

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Illustration 35	g00538959

Install silencer (4) and the gasket on motor housing (3) .

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Illustration 36	g00538952

Install elbow (1) and the gasket on cover assembly (2) .

In order to check the operation of the air starting motor, use the following procedure:
1. Turn the drive pinion by hand in the direction of the starter's rotation. The drive clutch must operate with a smooth action.
1. Turn the drive pinion in the opposite direction of the starter's rotation. The drive pinion must turn by hand.
1. Put 345 kPa (50 psi) of air pressure in the inlet line of the drive housing. The drive pinion must move away from the drive housing. Air must come out of the outlet opening of the drive housing. Remove the air pressure from the inlet opening.
1. Put a plug in the outlet opening of the drive housing. Put 1034 kPa (150 psi) of air pressure in the inlet line of the drive housing. Ensure that there are no air leaks. Use Tooling (J) in order to measure the dimensions. Measure the dimension from the face of the drive pinion to the mounting face of the drive housing. The dimension must be 74.5 ± 2.0 mm (2.93 ± 0.08 inch). Remove the air pressure from the inlet opening. Measure the same dimension again. the dimension must be 45.0 ± 2.0 mm (1.77 ± 0.08 inch).
1. Put 620 kPa (90 psi) of air pressure in the inlet line of the motor housing. The motor must run smoothly. Remove the air pressure from the inlet opening.

End By: Install the air starting motor. Refer to Disassembly and Assembly, "Air Starting Motor - Install".