3508, 3512 and 3516 Generator Set Engines Caterpillar

Removal Procedure

Start By:

1. Remove the flywheel housing.

Note: The following Step is for a 3508 Engine.

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Illustration 1	g01056631

1. The engine must be put in time before the flywheel housing is removed. This is done in order to make sure that the rear gear group is in alignment with the rotation of the engine, as shown.
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   Illustration 2	g02033554

2. Remove bolts (1), plate (2), and gear assembly (3).
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   Illustration 3	g02033555

3. Use Tooling (A) and a suitable press to remove bearing (4) from gear assembly (3). Use Tooling (A) and a suitable press to separate gear assembly (3).
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   Illustration 4	g02033556

4. Remove bolts (6), bolts (7), and camshaft idler gears (5).
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   Illustration 5	g02033557

5. Remove shafts (8) and the thrust washers from camshaft idler gears (5).

6. Use Tooling (A) and a suitable press to remove the bearings from camshaft idler gears (5).
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   Illustration 6	g02033558

7. Remove bolts (9) and shaft (10).

8. Remove bolts (12) and crankshaft gear (11).

Installation Procedure

1. Install camshaft idler gears (5) and gear assembly (3) in the reverse order of removal.

   1. Tighten bolts (9) to a torque of 140 ± 10 N·m (105 ± 7 lb ft).

   2. Tighten bolts (6) and bolts (7) to a torque of 240 ± 20 N·m (175 ± 15 lb ft).

   3. The bore in the bearings in camshaft idler gears (5) should be 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch) after installation. The bearings should be installed to a depth of 1.00 ± 0.25 mm (0.039 ± 0.010 inch).

   4. The bore in the bearing in gear assembly (3) should be 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch) after installation. The bearings should be installed to a depth of 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

   5. Apply clean engine oil to the bearings prior to assembly.

   6. Raise the temperature of the larger gear in order to assemble gear assembly (3).