G3516B and G3520B Generator Set Engines Caterpillar

Removal Procedure

1. Remove the magnetic pickups.
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   Illustration 1	g00911678

2. Attach Tooling (A) and a suitable lifting device to flywheel (1). The weight of flywheel (1) is approximately 170 kg (375 lb).

3. Remove two bolts (2) on each side of the crankshaft.

4. Install Tooling (B).

5. Remove remaining bolts (2).

6. Remove flywheel (1).

   Use the following procedure if flywheel (1) is not easily separated from the crankshaft:

   1. Install Tooling (C) in each side of flywheel (1).

   2. Use a prybar to remove flywheel (1) from the crankshaft.

Installation Procedure

1. Inspect the condition of the ring gear. Use the following procedure in order to replace the ring gear, if necessary.

   1. Remove the damaged ring gear from the flywheel.

   2. Raise the temperature of the new ring gear.

   3. Install the ring gear on the flywheel. Ensure that the chamfer of the gear teeth will be toward the pinion of the starting motor.
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   Illustration 2	g00911678

2. Install Tooling (B) in the end of the crankshaft.

3. Attach Tooling (A) and a suitable lifting device to flywheel (1). The weight of flywheel (1) is approximately 170 kg (375 lb).

   Note: Ensure that the mark on flywheel (1) is aligned with the mark on the crankshaft.

4. Lift flywheel (1) into position onto Tooling (B).

5. Apply clean engine oil to bolts (2) and install bolts (2).

6. Remove Tooling (A) and Tooling (B). Install remaining two bolts (2). Tighten bolts (2) to a torque of 1150 ± 60 N·m (850 ± 44 lb ft).

7. Install the magnetic pickups.