3508B, 3512B and 3516B Generator Set Engines Flywheel Housing - Remove Caterpillar


Flywheel Housing - Remove
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1.1. Removal Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
238-9586  Camshaft Drive Group 
138-7573  Link Bracket 
Guide Stud
1 - 14 by 6 inch 
1U-7600  Slide Hammer Puller Gp 
1U-7325  Distorter Adapter 
5P-7409  Sleeve Distorter 
8B-7548  Push-Puller Tool Group 
8B-7559 Adapter 
8B-7561 Step Plate 
1P-0820 Hydraulic Puller 
5H-1504 Hard Washer 
9U-6600 Hand Hydraulic Pump 
138-7573  Link Bracket 
Guide Stud
5/8 - 11 by 6 inch 
169-5464  Quick Cure Primer 

Start By:

  1. Remove the starting motor. Refer to Disassembly and Assembly, "Air Starting Motor - Remove". Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".

  2. If the exhaust elbow is attached to the flywheel housing, remove the exhaust elbow and remove the bracket for the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".

  3. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".

  4. Remove the engine speed sensor. Refer to Disassembly and Assembly, "Engine Speed Sensor - Remove and Install".

  5. Remove the engine speed/timing sensor. Refer to Disassembly and Assembly, "Engine Speed/Timing Sensor - Remove and Install".


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.




    Illustration 1g01126909

  1. Remove rear camshaft covers (1).

  2. Remove timing pin (2) from the storage position.

  3. Remove timing bolt (5) from the storage position. Remove cover (3) and plug (4) from the flywheel housing.

  4. Use Tooling (A) to turn the flywheel in order to install timing bolt (5) in the flywheel and timing pin (2) in both camshafts. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

  5. Remove the timing bolt from the flywheel.


    Illustration 2g01126908

  6. Remove tube (6).

  7. Remove drain tubes (7) for the turbochargers. Remove the gaskets from the elbows.

  8. Remove covers (8) and the gasket.


    Illustration 3g01139900

  9. Install Tooling (B) and a suitable lifting device on flywheel (9). The weight of flywheel (9) is approximately 170 kg (375 lb).

  10. Remove two bolts (10) and install Tooling (C).

  11. Remove remaining bolts (10). Remove flywheel (9).


    NOTICE

    Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.




    Illustration 4g01139914

  12. Use Tooling (D) or a punch and hammer in order to puncture three or more holes in crankshaft rear seal (11).

  13. Use Tooling (D) to remove crankshaft rear seal (11).


    Illustration 5g01139915

  14. Insert Tooling (E) between the flywheel housing and wear sleeve (12).


    NOTICE

    The use of excessive force on the sleeve distorter can cause the distorter adapter to crack the housing. To help avoid damage to the engine, do not use excessive force to remove the wear sleeve.


  15. Insert Tooling (F) between Tooling (E) and wear sleeve (12). Carefully turn Tooling (F) until the edge of the tool causes a crease in wear sleeve (12). Repeat this procedure several times around the wear sleeve until the wear sleeve can be removed by hand.


    Illustration 6g01126971

  16. Remove bolt (13) and plate (14). Place the three washers from Tooling (G) behind plate (14) and install bolt (13). Install Tooling (G) on camshaft drive gear (15). Apply 51675 kPa (7500 psi) to the puller. Strike the screw on the puller with a hammer until camshaft drive gear (15) is free from the camshaft. Remove Tooling (G) from the camshaft drive gear. Remove camshaft drive gear (15) from the camshaft.

    Note: Plate (14) must be installed in order to keep camshaft drive gear (15) on the camshaft during the removal procedure.



    Illustration 7g01126997

  17. Remove bolt (16). Remove ring (17).


    Illustration 8g01127005

  18. Place the three washers from Tooling (G) behind plate (14) and install bolt (16). Install Tooling (G) on camshaft drive gear (18). Use Tooling (G) in order to remove camshaft drive gear (18) from the camshaft. Apply 51675 kPa (7500 psi) to the puller. Strike the screw on the puller with a hammer until camshaft drive gear (18) is free from the camshaft. Remove Tooling (G) from the camshaft drive gear. Remove camshaft drive gear (18) from the camshaft.

    Note: Plate (14) must be installed in order to keep camshaft drive gear (18) on the camshaft during the removal procedure.



    Illustration 9g01127018

  19. Install Tooling (H) and a suitable lifting device on flywheel housing (20). The weight of flywheel housing (20) is approximately 235 kg (518 lb).

  20. Remove two bolts (21) and install Tooling (J). Remove the remaining bolts (21) and remove flywheel housing (20) from the cylinder block.

  21. If necessary, remove plugs (19) from the flywheel housing.

  22. After removing flywheel housing (20), clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (K). If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.

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