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


Flywheel Housing - Install
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1.1. Installation Procedure

Installation Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     138-7573     Link Bracket     2    
C     -     Guide Stud
1 - 14 by 6 inch    
2    
H     138-7573     Link Bracket     2    
J     -     Guide Stud
5/8 - 11 by 6 inch    
2    
L     6V-4003  (1)     Seal Locator As     1    
2N-5006  (1) Bolt     1    
M     8T-3099  (1)     Seal Installer     1    
N     9S-8858  (1)     Nut     -    
P     -     Loctite 5127     -    
R     447-6264  (2)     Tool As     1    
( 1 ) For installation of seals 113-8432 and 113-8433
( 1 ) For installation of seals 113-8432 and 113-8433
( 1 ) For installation of seals 113-8432 and 113-8433
( 1 ) For installation of seals 113-8432 and 113-8433
( 2 ) For Installation of seals 436-1478 and 436-1479


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



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.


    Note: Refer to Engine News27 March 2006, "Sealing and Installing the Flywheel Housing" for more information.

  1. Ensure that the mating surface of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (P) is applied.



    Illustration 1g01259961

  1. Apply a 6.0 mm (0.25 inch) bead of Tooling (P) to the mating surface of the flywheel housing. Refer to Illustration 1.



    Illustration 2g01127018

  1. Install Tooling (J) into the cylinder block.

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

  1. Lift the flywheel housing into position onto Tooling (J) .

  1. Install bolts (21) and the hard washers that secure the flywheel housing to the cylinder block. Remove Tooling (J) and install remaining bolts (21) and the hard washers.

    Note: Refer to Parts Manual for the correct positions for bolts that secure the flywheel housing to the cylinder block.

  1. Tighten bolts (21) evenly. Tighten the 1/2 - NC bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

  1. Tighten plugs (19) to a torque of 70 ± 15 N·m (50 ± 11 lb ft).

  1. Before installation of the crankshaft rear seal and the wear sleeve, inspect the crankshaft for scratches. Also, inspect the crankshaft for any distortion on the surface that may lead to an out of round condition. Use a polishing cloth in order to remove any imperfections on the crankshaft.

    Note: The crankshaft rear seal and the wear sleeve must be replaced at the same time. Once the crankshaft rear seal and the wear sleeve are separated, these components cannot be used again.

    Note: Do not use any type of lubricant during the installation of the crankshaft rear seal and the wear sleeve.

  1. Perform the following steps to install 113-8432113-8433 Crankshaft Seals :



      Illustration 3g01140254

    1. Clean the outside diameter of crankshaft (22) and the inside diameter of the new wear sleeve (12) . Clean the bore for the crankshaft rear seal in flywheel housing (20) .

    1. Install Tooling (L) on crankshaft (22) .

    1. Place crankshaft rear seal (11) and wear sleeve (12) onto Tooling (L) .

    1. Position Tooling (M) onto Tooling (L) . Lubricate the face of the washer on Tooling (N) . Install Tooling (N) onto Tooling (M) . Tighten Tooling (N) until Tooling (M) contacts Tooling (L) .

    1. Remove the tooling from the crankshaft. Check the crankshaft rear seal and the wear sleeve for the correct installation.



    Illustration 4g03796702

  1. Using Tooling (R) , perform the following steps to install 436-1478436-1479 Crankshaft Seals :

    1. Install pilot (23) to the crankshaft and install bolts (4) .

    1. Position front seal (11) onto pilot (23) .

    1. Install driver (25) onto the shaft of pilot (3) . Mark driver (25) at the 12 O' Clock position. Install bearing (26) and nut (27) .

    1. Tighten nut (27) until the base of driver (25) contacts the skirt of pilot (23) . Loosen nut (27) and rotate driver (25) 90°. Retighten nut (27) until driver (25) contacts the skirt of pilot (23) .

    1. Remove Tooling (R) from the crankshaft.



    Illustration 5g01139900

  1. Install Tooling (C) in the end of the crankshaft.

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

  1. Lift the flywheel into position onto Tooling (C) . Ensure that the mark on the flywheel is aligned with the mark on the crankshaft.

  1. Apply clean engine oil to the threads of bolts (10) . Install bolts (10) .

  1. Remove Tooling (B) and Tooling (C) . Install remaining bolts (10) . Tighten bolts (10) to a torque of 1150 ± 60 N·m (848 ± 44 lb ft).



    Illustration 6g01140296

  1. Install timing bolt (5) in the flywheel. Ensure that timing pin (2) is installed in each camshaft. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".



    Illustration 7g01127078



    Illustration 8g01127072

  1. Use the following procedure in order to install camshaft drive gear (15) and camshaft drive gear (18) .

    1. Clean the taper of the camshaft and the tapered bore of the camshaft gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. The alcohol wipe will dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe.

      Note: The taper of the camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue before assembly.

    1. Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.

    1. Place camshaft drive gear (15) and camshaft drive gear (18) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation.

      Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.

    1. Install bolt (13) and plate (14) .

    1. Install bolt (16) and ring (17) . Ensure that the hole in the ring is properly seated on the locating pin.

    1. Tighten the bolt to a torque of 360 N·m (265 lb ft).

    1. Place a Mark on the bolt.

    1. Place a driver against the retaining plate of the camshaft drive gear. Strike the driver solidly with a hammer 3 to 4 times.

    1. Tighten the bolt again to a torque of 360 N·m (265 lb ft).

    1. Repeat Steps 18.h and 18.i until the Mark has turned at least 90 degrees.



    Illustration 9g01126909

  1. Remove the timing pin from the camshafts. Install timing pin (2) in the storage position. Install rear camshaft covers (1) .

  1. Remove the timing bolt from the flywheel. Install plug (4) in the timing hole. Install cover (3) and timing bolt (5) in the storage position on the flywheel housing.



    Illustration 10g01126908

  1. Install tube (6) .

  1. Install the gaskets on the elbows. Install drain tubes (7) for the turbochargers.

  1. Install the gasket and covers (8) on the flywheel housing.

End By:

  1. Install the engine speed/timing sensor. Refer to Disassembly and Assembly, "Engine Speed/Timing Sensor - Remove and Install".
  2. Install the engine speed sensor. Refer to Disassembly and Assembly, "Engine Speed Sensor - Remove and Install".
  3. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".
  4. If the exhaust elbow was removed, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
  5. Install the starting motors. Refer to Disassembly and Assembly, "Air Starting Motor - Install". Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".

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