C18 Generator Set Engines Caterpillar

Removal Procedure

Start By:

1. Remove the front housing.

2. Remove the air compressor, if necessary.

3. Remove the water pump, if necessary.

Note: Be sure to mark the orientation of each of the gears for installation purposes.

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Illustration 1	g01008429

1. Remove bolts (2) and thrust plate (1).
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   Illustration 2	g01008430

2. Remove sealing plate (3) and adapter (4).
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   Illustration 3	g01008431

3. Remove O-ring seal (5) and O-ring seal (6) from sealing plate (3).
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   Illustration 4	g01101536

4. Remove bolts (8), plate (9), and adjustable idler gear assembly (7).

5. Use Tooling (A) and remove the sleeve bearing from adjustable idler gear assembly (7).
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   Illustration 5	g01101045

6. Remove bolts (11), plate (12), and idler gear assembly (10).

7. Use Tooling (A) and remove the sleeve bearing from idler gear assembly (10).
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   Illustration 6	g01101048

8. Remove bolts (14), plate (15), and cluster gear assembly (13).

9. Use Tooling (A) and remove the sleeve bearing from cluster gear assembly (13).
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   Illustration 7	g01101050

   Note: Stub shaft assembly (16) must be removed to remove plate (22). The backlash for the camshaft gear and the adjustable idler gear assembly will need to be readjusted at assembly.

10. Remove nuts (17) and remove stub shaft assembly (16).

    Note: Stub shaft (18) must be removed to remove plate (22).

11. Remove nuts (19) and remove stub shaft (18).

12. Remove bolts (21) and remove stub shaft (20).

13. Remove bolts (23) that hold plate (22) to the cylinder block. Remove plate (22).

14. If studs (24) are loose or the threads are damaged, remove the studs from the front plate.
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    Illustration 8	g01101052

15. Remove integral seal (25) from the cylinder block.

Installation Procedure

1. Thoroughly clean the gasket material from the cylinder block and both sides of the plate.
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   Illustration 9	g01101567

2. If studs (24) are loose or the threads are damaged, install new studs (24) in the front plate. Apply Tooling (D) to the serrations of studs (24). Install studs (24) in the front plate.

3. Install integral seal (25) on the dowel pins on the cylinder block.

   Note: Apply Tooling (C) to the bottom of integral seal (25) to fill the space at the cylinder block, the front housing, and the engine oil pan.

4. Install plate (22) on the dowel pins on the cylinder block. Install new locking bolts (23) (Marked "X") to fasten the front plate to the cylinder block. Tighten locking bolts (23) to a torque of 55 N·m (41 lb ft).

   Note: Clean the old sealant from the bolts and apply Tooling (D) to the bolts.

5. Tighten locking bolts (23) again to a torque of 55 N·m (41 lb ft).
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   Illustration 10	g01101565

6. Install stub shaft (18). Apply Tooling (D) to the studs and the bolt for stub shaft (18). Tighten nuts (19) and the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

7. Install stub shaft assembly (16). Apply Tooling (D) to the studs and the bolt for stub shaft assembly (16). Do not tighten nuts (17) and the bolt for stub shaft assembly (16) now. Nuts (17) and the bolt for stub shaft assembly (16) will need to be tightened when the backlash is adjusted.

8. Adjust the backlash between the camshaft gear and the adjustable idler gear assembly. The backlash should be 0.356 ± 0.254 mm (0.014 ± 0.010 inch). Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the backlash adjustment procedure. Tighten nuts (17) and the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

9. Install stub shaft (20). Apply Tooling (D) to bolts (21). Install bolts (21) and tighten in a numeric sequence 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 11	g01101161

10. Use Tooling (A) to install the sleeve bearing in cluster gear assembly (13).

11. Put cluster gear assembly (13) on the stub shaft. Ensure that Timing Marks (V) are aligned on the cluster gear assembly and the crankshaft gear.

12. Position plate (15) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (14). Install bolts (14). Tighten bolts (14) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
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    Illustration 12	g01101045

13. Use Tooling (A) to install the sleeve in idler gear (10).

14. Put idler gear assembly (10) on the stub shaft. Install plate (12) with the oil groove toward the gear face. Apply Tooling (D) to bolts (11). Install bolts (11). Tighten bolts (11) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
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    Illustration 13	g01008436

15. Use Tooling (A) to install the sleeve bearing in adjustable idler gear (7).

    Note: Align the oil hole in the bearing with the oil hole in the adjustable idler gear.

16. Put adjustable idler gear assembly (7) on the stub shaft assembly. Position plate (9) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (8). Install bolts (8). Tighten bolts (8) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

    Note: Check the backlash for the camshaft gear and the adjustable idler gear assembly. The camshaft gear must be installed and the adjustable idler gear assembly must be removed to perform the backlash adjustment procedure. Refer to Testing and Adjusting, "Gear Group (Front) - Time".

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    Illustration 14	g01008431

17. Install O-ring seal (5) and O-ring seal (6) in sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
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    Illustration 15	g01008430

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    Illustration 16	g01010256

18. Install adapter (4). Ensure that the dowel in the adapter engages the hole in the camshaft.

19. Install sealing plate (3) and thrust plate (1). Ensure that the dowel in the adapter engages the hole in the thrust plate. Apply Tooling (D) to bolts (2). Install bolts (2). Evenly tighten bolts (2) to ensure that sealing plate (3) and O-ring seal (5) are seated against the cylinder head.

20. Adjust the backlash for the camshaft gear and the adjustable idler gear, if necessary. Refer to Testing and Adjusting, "Gear Group (Front) - Time".

    Note: The camshaft gear must be installed and the adjustable idler gear must be removed to perform the backlash adjustment procedure.

End By:

1. Install the water pump.

2. Install the air compressor, if necessary.

3. Install the front housing.