3508, 3512 and 3516 Generator Set Engines Caterpillar

Disassembly Procedure

Start By:

1. Remove the air starting motor.

Note: Several different air starting motors are available for use. An example of disassembling a typical air starting motor gp is described below.

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Illustration 1	g00925011

1. Remove elbow (1) and bracket (2) from motor housing (3).
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   Illustration 2	g00925012

2. To ensure correct assembly, mark the position of motor housing (3) in relation to gear case (6). Remove bolts (4). Remove gear case (6) and drive housing (5) as a unit.
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   Illustration 3	g00925015

3. Use Tooling (A) to remove retaining ring (8) from drive gear (7).
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   Illustration 4	g00925059

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   Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

   Note: Bolt (9) has left hand threads.

4. Remove bolt (9) and washer (10). Remove drive pinion (11), the spring sleeve, and the pinion spring.

   To ensure correct assembly, mark the position of drive housing (5) in relation to gear case (6). Remove bolts (12) and drive housing (5) from gear case (6).

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   Illustration 5	g00925061

5. Remove O-ring seal (13) from drive housing (5).
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   Illustration 6	g01142879

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   The drive shaft, the piston, and the drive gear are under a spring force. Slowly release the spring force before you remove these components.

6. Place Tooling (B) between drive gear (7) and piston (14). Use a suitable press to compress the return spring. Remove retaining ring (15) that holds the drive shaft and the piston in drive housing (5).
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   Illustration 7	g00925068

7. Slowly release the suitable press in order to remove the force of return spring (16). Remove Tooling (B). Remove retaining ring (15). Remove the drive gear, piston (14), and the drive shaft from drive housing (5) as a unit. Remove return spring (16).
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   Illustration 8	g00925083

8. Loosen the bolt for the drive gear with a 5/16 inch hex wrench until the bolt moves freely. Remove drive shaft (17) and piston (14) from drive gear (7) as a unit.
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   Illustration 9	g01143104

9. Remove bulkhead (18) from piston (14). Remove O-ring seals (19) from bulkhead (18).
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   Illustration 10	g00925092

10. Remove retaining ring (20) from piston (14). Remove the piston from drive shaft (17).
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    Illustration 11	g00925095

11. Remove O-ring seal (22) and lip seal (21) from piston (14).
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    Illustration 12	g01052459

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    Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

12. Remove retaining ring (31), cup (30), spring (29), driven clutch jaw (28), driving clutch jaw (27), bearing (26), washer (25), lockwasher (24), and bolt (23) from drive shaft (17).
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    Illustration 13	g00925104

13. Remove retaining ring (32) and bearing (33) from drive shaft (17).

    Note: Do not reuse retaining ring (32).

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    Illustration 14	g00925105

14. Use Tooling (C) to remove lock ring (35). Remove bearing (34) from gear case (6).
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    Illustration 15	g00925107

15. Remove spring seat (36) and bearing (37) from drive housing (5).
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    Illustration 16	g00925110

16. Remove lip seal (38) from drive housing (5).
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    Illustration 17	g00925114

17. To ensure correct assembly, mark the position of cover (39) in relation to motor housing (3). Remove cover (39) and remove the O-ring seal from motor housing (3).
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    Illustration 18	g00925116

18. Remove bolt (41) and rotor pinion (40) from the rotor in the motor housing.
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    Illustration 19	g00925149

19. Loosen hex socket head bolt (43) and remove rotor clamp nut (42). Remove bearing (44) from rear end plate (45).
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    Illustration 20	g00925151

20. Remove O-ring seal (46) and rear end plate (45).
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    Illustration 21	g00925152

21. Remove vanes (47) from rotor (48).

22. Remove rotor (48) from the motor housing.
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    Illustration 22	g00925156

23. Use a suitable press to remove bearing (49) and front end plate (50) from rotor (48) as a unit.
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    Illustration 23	g00925157

24. Remove bearing (49) from front end plate (50).
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    Illustration 24	g00925210

25. Remove washers (51) from front end plate (50).
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    Illustration 25	g00925216

26. Remove O-ring seals (52) from rotor cylinder (53).
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    Illustration 26	g01142915

27. Remove rotor cylinder (53) from motor housing (3). Remove O-ring seals (54) from the rotor cylinder.