G3516B and G3520B Generator Set Engines Caterpillar

Assembly Procedure

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

Note: Thoroughly clean all of the parts. Use a 2S-3230 Grease Cartridge in order to apply grease to all of the bearings and to the drive assembly. Before assembly, coat all of the other parts with an SAE 10 grade of oil.

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Illustration 1	g00598178

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	g00598181

2. Install O-ring seal (52) onto rotor cylinder (53).
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   Illustration 3	g00598221

3. Install rear end plate (45) on the shaft of rotor (48).
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   Illustration 4	g00598222

4. Install O-ring seal (46) over the shaft of the rotor.
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   Illustration 5	g00598197

5. Install bearing (44) over the shaft of the rotor. The bearing will fit into the rear end plate.
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   Illustration 6	g00598200

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 7	g00598201

7. Tighten the rotor clamp nut in order to obtain a clearance of 0.03 to 0.08 mm (0.001 to 0.003 inch) between the rear end plate and the rotor. Measure the clearance with a feeler gauge. Tighten hex socket head bolt (43) into the rotor clamp nut. Measure the clearance again.
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   Illustration 8	g00598207

8. Install rotor (48) into motor housing (3). Align pin (57) into the slot of the rear end plate.
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   Illustration 9	g00598208

9. Install vanes (47) into the rotor.
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   Illustration 10	g00598223

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 11	g00598420

11. Install washers (51) over the shaft of the rotor onto the front end plate.
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    Illustration 12	g00598225

12. Place bearing (49) onto the front end plate.
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    Illustration 13	g00598445

13. Use Tool (E) and a press in order to complete the installation of bearing (49).
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    Illustration 14	g00598227

14. Install rotor pinion (40) with the hex head bolt. Tighten the bolt to 120 N·m (90 lb ft).
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    Illustration 15	g00598230

15. Install O-ring seal (60) onto the rotor bearing that is on the rear end plate. Install cover (39) onto motor housing (3).
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    Illustration 16	g00598232

16. Install bearing (33) and new ring (32) onto drive shaft (17).
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    Illustration 17	g00598234

17. Use Tool (D) with a press in order to complete the installation of the new ring.
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    Illustration 18	g00598241

18. Install these parts into drive shaft (17): bolt (23), lockwasher (24), washer (25), bearing (26), driving clutch jaw (27), driven clutch jaw (28), spring (29) and cup (30). Install ring (31).
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    Illustration 19	g00598242

19. Use Tool (E) in order to install the seal into piston (14). Ensure that the lip of the seal is oriented toward the outside of the piston. Install O-ring seal (22).
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    Illustration 20	g00598244

20. Install piston (14) onto the drive shaft (17). Install ring (20) onto the piston.
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    Illustration 21	g00598246

21. Install O-ring seals (19) onto bulkhead (18).
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    Illustration 22	g00598261

22. Install bulkhead (18) onto piston (14).
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    Illustration 23	g00598263

23. Install drive gear (7) onto drive shaft (17). Use an Allen wrench in order to tighten the bolt of the drive gear to 77 N·m (57 lb ft).
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    Illustration 24	g00598264

24. Use Tool (E) in order to install the seal into drive housing (5). Ensure that the lip of the seal is oriented toward the outside of the housing.
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    Illustration 25	g00598267

25. Install bearing (37) into the drive housing.
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    Illustration 26	g00598268

26. Install spring seat (36) into the drive housing.
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    Illustration 27	g00598269

27. Install return spring (16) onto the spring seat inside the drive housing.
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    Illustration 28	g00598270

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

    Install ring (15) over the piston. Place Tool (B) between the drive gear and the piston. Use a press in order to compress the return spring. Install ring (15) into the groove of the drive housing. Slowly release the press. Remove Tool (B).

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    Illustration 29	g00598272

29. Install bearing (34) into gear case (6). Use Tool (C) in order to install the ring that retains the bearing in the gear case.
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    Illustration 30	g00598274

30. Install drive housing (5) in 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. Tighten the bolts to a torque of 36 N·m (27 lb ft).
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    Illustration 31	g00598276

31. Use Tool (A) to install ring (8).
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    Illustration 32	g00598277

    Note: Bolt (9) has left hand threads.

32. Install these parts on the end of the drive shaft: pinion spring (62), spring sleeve (61), drive pinion (11), bolt (9) and the washer. Tighten the bolt to 110 N·m (80 lb ft).
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    Illustration 33	g00598278

33. Install gear case (6) and drive housing (5) onto cover (3) as a unit. Tighten bolts (4) evenly to a torque of 80 N·m (60 lb ft).
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    Illustration 34	g00597693

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

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) 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 ± 2 mm (2.874 ± 0.08 inch). Remove the air pressure. Measure the dimension again. The dimension must be 44.5 ± 2 mm (1.75 ± 0.08 inch).

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

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1. Install the air starting motor.