G3516B and G3520B Generator Set Engines Caterpillar

Installation Procedure

Show/hide table

Illustration 1	g01227873

1. The following steps are for the installation of a camshaft in the G3516 Engines. The camshaft is in two pieces.

   1. Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).

   2. Install Tooling (C) on the end of the front half of the crankshaft.

   3. Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.

   4. Attach a suitable lifting device to the front half of camshaft (17). The weight of one-half of the camshaft is approximately 41 kg (90 lb). Position the front half of camshaft (17) in the engine until Tooling (C) is in the first camshaft bearing.

   5. Rotate camshaft (17) and tighten the bolts for Tooling (D).

   6. Rotate camshaft (17) and insert camshaft (17) until camshaft (17) is slightly protruding from Tooling (D).
      Show/hide table

      Illustration 2	g00759639

      Show/hide table

      Illustration 3	g00759550

   7. If the dowel was removed from the front half of camshaft (17), install the dowel. The dowel should be 22.0 ± 0.5 mm (0.87 ± 0.02 inch) from the surface of the camshaft.

      Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.

   8. Attach a suitable lifting device to the rear half of camshaft (18). Install spacer (20) and the rear half of camshaft (18) onto the front half of camshaft (17). Install bolts (19) and tighten to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

   9. Install Tooling (C) and Tooling (E) on the end of camshaft (18).

   10. Rotate camshaft (18) and insert the camshaft into the engine.

   11. Remove all Tooling. Repeat Steps 1.a through 1.j for the camshaft on the opposite side of the engine. Go to Step 2.
   Show/hide table

   Illustration 4	g00759543

2. Install thrust washers (15) and bolts (14) that fasten the camshaft to the engine.
   Show/hide table

   Illustration 5	g00759656

   Show/hide table

   NOTICE
   If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.

3. Remove timing pin (21) from the storage position on the side of the engine.

4. Turn the camshaft until timing pin (21) can be installed through the cylinder block and into groove (22) that is in the camshaft.

5. Repeat Steps 3 and 4 for the camshaft on the opposite side of the engine.
   Show/hide table

   Illustration 6	g00759684

   Show/hide table

   Illustration 7	g01227880

6. Remove bolts (24), cover (23), and plug (25).

7. Install one bolt (24) into the flywheel housing through the hole for plug (25). Use Tooling (A) and a ratchet to turn the flywheel until bolt (24) can be installed through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top center. Refer to the Testing and Adjusting Module for more information.
   Show/hide table

   Illustration 8	g00759687

   Show/hide table

   Illustration 9	g00759548

   Show/hide table

   Illustration 10	g00759492

8. Use the following procedure in order to install camshaft drive gears (13).

   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.

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

   3. Place camshaft drive gears (13) 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.

   4. Install the bolt and plate (12).

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

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

   7. Place a Mark on the bolt.

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

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

   10. Repeat Steps 8.h and 8.i until the Mark has turned at least 90 degrees.

9. Remove the timing pins from the camshafts. Install the timing pins in the original locations.
   Show/hide table

   Illustration 11	g00759456

10. Install cover (7). Install filter base (3) and tube assemblies (4), (5), and (6).
    Show/hide table

    Illustration 12	g00759477

11. Install cover (8) on the front housing. Connect hose assembly (9) and harness assembly (10).
    Show/hide table

    Illustration 13	g00759510

12. Install cover (11) on the flywheel housing.
    Show/hide table

    Illustration 14	g00759684

13. Remove bolt (24) from the flywheel. Install plug (25) in the timing hole. Remove Tooling (D) and install cover (23) with bolts (24) on the flywheel housing.
    Show/hide table

    Illustration 15	g00579090

14. Remove the O-ring seals from valve lifters (2). Push valve lifters (2) against the camshaft.
    Show/hide table

    Illustration 16	g00579084

15. Install access covers (1) on the side of the engine.

16. Install the engine speed/timing sensor. Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".

End By:

1. Install the rocker shaft assemblies and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rod - Install".

2. Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".