3508, 3512 and 3516 Generator Set Engines Caterpillar

Assembly Procedure

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Illustration 1	g00925323

1. Install O-ring seals (54) on rotor cylinder (53). Install the rotor cylinder in motor housing (3). Orient pin (55) of the rotor cylinder with slot (56) in the motor housing.
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   Illustration 2	g00925216

2. Install O-ring seals (52) onto rotor cylinder (53).
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   Illustration 3	g01142958

3. Install rear end plate (45) on the shaft of rotor (48).

4. Install O-ring seal (46) over the shaft of the rotor.
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   Illustration 4	g01142960

5. Apply Tooling (F) to bearing (44). Install bearing (44) into rear end plate (45) and over the shaft of rotor (48).

6. Install rotor clamp nut (42) on the shaft of the rotor. Orient the shoulder of the nut toward the bearing.
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   Illustration 5	g01142961

7. Tighten rotor clamp nut (42) in order to obtain a clearance of 0.03 to 0.08 mm (0.001 to 0.003 inch) between the rear end plate (45) and rotor (48). Measure the clearance with a feeler gauge. Tighten hex socket head bolt (43) to secure rotor clamp nut (42). Measure the clearance again.
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   Illustration 6	g00925356

8. Install rotor (48) into motor housing (3). Align pin (57) into the slot of the rear end plate.
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   Illustration 7	g01142988

9. Thoroughly lubricate vanes (47) with SAE 10W oil and install vanes (47) into the rotor.

10. Install front end plate (50) onto the rotor. Align small hole (58) of front end plate onto rotor pin (59).
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    Illustration 8	g00925361

11. Install washers (51) over the shaft of the rotor onto the front end plate.
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    Illustration 9	g00925366

12. Apply Tooling (F) to bearing (49). Use Tooling (E) and a suitable press to install bearing (49) in the front end plate.
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    Illustration 10	g00925116

13. Install rotor pinion (40). Install bolt (41). Tighten the bolt to a torque of 120 N·m (90 lb ft).
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    Illustration 11	g00925384

14. Install O-ring seal (60). Install cover (39) onto motor housing (3).
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    Illustration 12	g00925390

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    Illustration 13	g00925391

15. Apply Tooling (F) to bearing (33). Install bearing (33) and new retaining ring (32) onto drive shaft (17). Use Tooling (D) and a suitable press to complete the installation of the new retaining ring.

    Note: Do not reuse retaining ring (32).

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    Illustration 14	g01052459

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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.

16. Install retaining ring (31). Install bolt (23), lockwasher (24), and washer (25) into drive shaft (17). Apply Tooling (F) to bearing (26) and install bearing (26) into the drive shaft. Install bolt (23), lockwasher (24), and washer (25) into drive shaft (17). Apply Tooling (F) to bearing (26) and install the bearing into the drive shaft. Install driving clutch jaw (27), driven clutch jaw (28), spring (29), and cup (30) into the drive shaft. Install retaining ring (31). Thoroughly lubricate the drive assembly with SAE 10W oil.
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    Illustration 15	g01143059

17. Use Tooling (E) to install lip seal (21) into piston (14). Install O-ring seal (22).
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    Illustration 16	g00925419

18. Install piston (14) onto the drive shaft (17). Install retaining ring (20) onto the piston.
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    Illustration 17	g01143104

19. Install O-ring seals (19) onto bulkhead (18). Install bulkhead (18) onto piston (14).
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    Illustration 18	g01143117

20. Install drive gear (7) onto drive shaft (17). Use a 5/16 inch hex wrench to tighten the bolt of the drive gear to 77 N·m (57 lb ft).
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    Illustration 19	g01143120

21. Use Tooling (E) to install lip seal (38) into drive housing (5).
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    Illustration 20	g01143123

22. Apply Tooling (F) to bearing (37) and install the bearing into the drive housing.

23. Install spring seat (36) into the drive housing.
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    Illustration 21	g00925068

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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.

24. Install return spring (16) onto the spring seat inside drive housing (5).

25. Install the drive gear, the piston, and the drive shaft onto the return spring as a unit.

    Install retaining ring (15) over the piston. Place Tooling (B) between the drive gear and piston (14). Use a suitable press to compress return spring (16). Install retaining ring (15) into the groove of the drive housing. Slowly release the press and remove Tooling (B).

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    Illustration 22	g00925061

26. Install O-ring seal (13) to drive housing (5).
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    Illustration 23	g00925105

27. Apply Tooling (F) to bearing (34) and install bearing (34) into gear case (6). Use Tooling (C) to install lock ring (35).
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    Illustration 24	g01143454

28. Install drive housing (5) on gear case (6). Make sure that the shaft on the end of the drive gear is correctly engaged with the bearing in the gear case. Install bolts (12) and tighten to a torque of 36 N·m (27 lb ft).
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    Illustration 25	g00925470

29. Use Tooling (A) to install retaining ring (8).
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    Illustration 26	g01143442

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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.

    Note: Bolt (9) has left hand threads.

30. Install pinion spring (62), spring sleeve (61), and drive pinion (11). Install washer (10) and bolt (9). Tighten bolt (9) to a torque of 110 N·m (80 lb ft).

    Note: Bolt (9) has left hand threads.

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    Illustration 27	g00925012

31. Install gear case (6) and drive housing (5) onto motor housing (3). Install bolts (4) and tighten evenly to a torque of 80 N·m (60 lb ft).
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    Illustration 28	g00925011

32. Install the gasket, elbow (1), and bracket (2) on motor housing (3).

33. After you verify that the starting motor operates properly, attach the air lines to the starting motor.

Verify the Operation of the Air Starting Motor

Use the following procedure to verify that the air starting motor is operating correctly:

1. Turn the drive pinion by hand in the direction of the rotation of the starting motor. The drive clutch must operate smoothly with a clicking sound.

2. Turn the drive pinion in the opposite direction of the rotation of the starting motor. The drive pinion must turn by hand.

3. Apply 345 kPa (50 psi) of air pressure in the inlet of the drive housing. The drive pinion must move away from the drive housing and air must come out of the outlet of the drive housing.

4. Plug the outlet of the drive housing. Apply 1034 kPa (150 psi) of air pressure in the inlet of the drive housing. Ensure that no air is leaking. Measure the dimension from the face of the drive pinion to the mounting face of the drive housing. The dimension must be 73.00 ± 2.0 mm (2.874 ± 0.08 inch). Remove the air pressure. Measure the dimension again. The dimension must be 44.5 ± 2.0 mm (1.75 ± 0.08 inch). Remove the plug from the outlet of the drive housing.

5. Apply 620 kPa (90 psi) of air pressure in the inlet of the drive housing. The starting motor must run smoothly.

End By:

1. Install the air starting motor.