C18 Generator Set Engines Caterpillar

Removal Procedure

Start By:

1. Remove the camshaft gear.

2. Remove the rocker arms and the rocker shafts.

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Illustration 1	g01056681

1. Remove bolts (2) and thrust plate (1).
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   Illustration 2	g01071487

2. Remove sealing plate (3) from the front housing. Remove adapter assembly (4) from the crankshaft.
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   Illustration 3	g01056684

3. Remove O-ring seal (5) and O-ring seal (6) from sealing plate (3).
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   NOTICE
   Care must be used when removing or installing the camshaft. Do not damage the finished surfaces of the camshaft or the camshaft bearings.

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   Illustration 4	g01056704

4. Use the bolts for the rocker arm shaft assembly to install Tooling (A) at Location (Y).
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   Illustration 5	g01047945

5. Install Tooling (B) on front housing (7). Tooling (B) is used to support camshaft (8). Do not tighten the bolts for Tooling (B) now.
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   Illustration 6	g01056675

6. Remove flat head screws (9) and cover (10). Remove the O-ring seal from the cover.
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   Illustration 7	g01047961

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   Illustration 8	g01047996

   Note: It is necessary to install Tooling (C) on the camshaft. Tooling (C) will support the rear of the camshaft as the camshaft is moved out of the cylinder head and into Tooling (B). Align camshaft (8) with the bore of Tooling (B). Tighten the bolts that hold Tooling (B) to front housing (7).

7. Move camshaft (8) forward and install one Tooling (C) in the end of the camshaft. Again, move the camshaft forward and install remaining Tooling (C) into the back of first Tooling (C).

   Note: Avoid lifting the camshaft with Tooling (D). The camshaft should rest on Tooling (A). Lifting of the camshaft can mis-align the camshaft during removal, which will result in damage to the camshaft bearings.

8. Use Tooling (D) to move camshaft (8) toward the front of the engine. Reposition Tooling (D), as needed.

9. Carefully slide the camshaft to the front of the engine for removal. Use two technicians to remove the camshaft. Keep the camshaft level during removal from the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

   Note: Rotate the camshaft during removal. This will prevent the camshaft from binding in the camshaft bearings.

10. Remove Tooling (C) from the camshaft.

11. Remove Tooling (B) from front housing (7).

12. Remove Tooling (A) from the cylinder head.

Installation Procedure

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (F) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.
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   Illustration 9	g01056704

2. Install Tooling (A) on the cylinder head at Location (Y).
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   Illustration 10	g01056901

3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front housing (7) now.

4. Use Tooling (E) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold Tooling (B) to front housing (7). Remove Tooling (E).

   Note: Tooling (E) should move freely from the bore of Tooling (B).

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   Illustration 11	g01047961

5. Install Tooling (C) on the rear of the camshaft.

6. Use two technicians to install the camshaft. Use Tooling (D) to help with aligning camshaft (8) with the camshaft bearings. Carefully slide the camshaft into the cylinder head from the front of the engine. Keep the camshaft level during installation in the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

   Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.

7. Remove Tooling (C) and finish installing camshaft (8) in the bore.

   Note: Tooling (C) must be removed before the camshaft can be installed in the cylinder head.

8. Remove Tooling (A) from the cylinder head.

9. Remove Tooling (B) from the front housing.
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   Illustration 12	g01056675

10. Install the O-ring seal on cover (10). Position the cover on the rear of the cylinder head. Install flat head screws (9) and tighten to a torque of 13 ± 3 N·m (10 ± 2 lb ft).
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    Illustration 13	g01056684

11. Install O-ring seals (5) and (6) in sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (F) and clean engine oil.
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    Illustration 14	g01056682

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    Illustration 15	g01056681

12. Install sealing plate (3) in front housing (7). Install adapter assembly (4) in the sealing plate. Ensure the dowel in adapter assembly (4) engages the hole in the camshaft.

13. Install thrust plate (1) . Apply Tooling (G) to bolts (2). Hold the thrust plate in position and install bolts (2). Evenly tighten bolts (2) until sealing plate (3) and the O-ring seal are seated against the cylinder head.

    Note: Ensure that the O-ring seal stays in the groove in sealing plate (3).

End By:

1. Install the rocker arms and the rocker shafts.

2. Install the camshaft gear.