3512C Generator Set Engine Caterpillar

Installation Procedure

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Illustration 1	g03856103
Installation procedure is the same for both the left side and right side camshafts.

1. Attach a suitable lifting device to the rear half of the camshaft. The weight of the rear half of the camshaft is approximately 38 kg (84 lb).

2. Attach a suitable lifting device to the front half of the camshaft. The weight of the front half of the camshaft is approximately 33 kg (73 lb).

3. Install spacer (25) and the rear half of the camshaft onto the front half of the camshaft. Install bolts (26) and tighten to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

   Note: Ensure that the camshafts are assembled according to the marks on the ends of the camshafts. If the dowel was removed from the front half of the camshaft, install the dowel. Install the dowel to 22 ± 0.5 cm (9 ± 0.20 inch) from the surface of the camshaft.

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   Illustration 2	g01123198

4. Install Tooling (C) on the front housing. Do not tighten the bolts on Tooling (C).

   Note: Tooling (C) can be installed on the flywheel housing in order to install the camshaft from the rear of the engine.

5. Install Tooling (B) on the ends of the camshaft. Install Tooling (D) on Tooling (B) which is installed on the front of the camshaft.

6. 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.

7. Rotate the camshaft and insert the camshaft in the engine. Position the camshaft in the engine until Tooling (B) is in the front camshaft bearing. Rotate the camshaft in order to align Tooling (C) and the camshaft bores. Tighten the bolts for Tooling (C).

8. Rotate the camshaft and insert the camshaft into the engine. Remove Tooling (B) from the camshaft. Remove Tooling (C) from the front housing.
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   Illustration 3	g03856042

9. Install thrust washer (22), plate (24), and bolts (23).
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   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.

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   Illustration 4	g03856567

10. Remove bolt (38), plate (36), and timing pin (37).

11. Turn the camshaft until the timing pin can be installed through the cylinder block and into the groove that is in the camshaft. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
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    Illustration 5	g03856588

12. Remove bolts (40), cover (41), and plug (39).

13. Install one bolt (40) into the flywheel housing through the hole for plug (39). Use Tooling (E) and a ratchet to turn the flywheel until bolt (40) can be install through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top dead center. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for more information.
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    Illustration 6	g03855987

14. Use the following procedure in order to install camshaft drive gear (21).

    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 be 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 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 gear (21) in position. Remove the backlash by rotating the gears in the opposite direction of the camshaft rotation.

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

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       Illustration 7	g03855940

    4. Install ring (20) and bolt (19). Ensure that the hole in the ring is properly seated on the locating pin.

    5. Tighten bolt (19) to a torque of 360 ± 40 N·m (266 ± 30 lb ft).

    6. Place a Mark on bolt (19).

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

    8. Tighten bolt (19) again to a torque of 360 ± 40 N·m (266 ± 30 lb ft).

    9. Repeat Steps 14.g and 14.h until the Mark has turned at least 90°.
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    Illustration 8	g03856567

15. Remove timing pin (37) from the camshaft. Install timing pin (37), plate (36), and bolt (38) in the storage position under the rear camshaft cover.
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    Illustration 9	g03856425

16. Remove the O-ring seals form valve lifters (35). Push valve lifters (35) against the camshaft.
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    Illustration 10	g03856410

17. Install cover (33) and bolts (34).
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    Illustration 11	g03856343

18. Install cover (32) and bolts (31).
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    Illustration 12	g03856336

19. Install covers (30) and bolts (29).
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    Illustration 13	g03856332

20. Install cover (28) and bolts (27).
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    Illustration 14	g03855925

21. Lubricate the O-ring seal on speed sensor (18) with the fluid that is being sealed. Install speed sensor (18) and tighten to a torque of 40 ± 5 N·m (30 ± 4 lb ft).
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    Illustration 15	g03855898

22. Install cover (17) and bolts (16).
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    Illustration 16	g03855866

23. Install bracket (14), bolts (15), and bolts (13).
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    Illustration 17	g03855761

24. Remove the O-ring seals form valve lifters (12). Push valve lifters (12) against the camshaft.
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    Illustration 18	g03855740

25. Install covers (11) and bolts (10).
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    Illustration 19	g03855733

26. Install cover (9) and bolts (8).
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    Illustration 20	g03855730

27. Install bracket assembly (7) and bolts (6).
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    Illustration 21	g03855720

28. Install plate (4) and bolts (5).
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    Illustration 22	g03855715

29. Install box assembly (3), bolts (2), and bolts (1).

End By:

1. Install rocker shafts and pushrods.

2. Install valve mechanism covers.

3. Install radiator group.

4. Install electronic control module.