3508, 3512 and 3516 Generator Set Engines Caterpillar

Installation Procedure

1. The following steps are for the installation of a camshaft in the 3512 Engines and 3516 Engines. The camshaft is in two pieces.

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

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   Illustration 1	g02051533

   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 camshaft.

   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 camshaft. The weight of one-half of the camshaft for 3512 Engines is approximately 32 kg (70 lb). The weight of one-half of the camshaft for 3516 Engines is approximately 41 kg (90 lb).

   5. Position front camshaft (13) in the engine until Tooling (C) is in the first camshaft bearing.

   6. Rotate front camshaft (13) and tighten the bolts for Tooling (D).

   7. Rotate front camshaft (13) and insert the camshaft until the camshaft is slightly protruding from Tooling (D).
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      Illustration 2	g02051554

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      Illustration 3	g02050937

   8. If the dowel was removed from front camshaft (13), install the dowel. Install the dowel to 22.0 ± 0.5 mm (0.87 ± 0.02 inch) from the surface of the camshaft.

   9. Attach a suitable lifting device to rear camshaft (14). The weight of one-half of the camshaft for 3512 Engines is approximately 32 kg (70 lb). The weight of one-half of the camshaft for 3516 Engines is approximately 41 kg (90 lb). Install spacer (16) and rear camshaft (14) onto front camshaft (13). Install bolts (15) and tighten to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

   10. Install Tooling (C) and Tooling (E) on rear camshaft (14).

   11. Rotate rear camshaft (14) and insert the camshaft into the engine.

   12. Remove all Tooling. Repeat Steps 1.a through 1.k for the camshaft on the opposite side of the engine. Go to Step 3.

2. The following steps are for the installation of the camshaft in 3508 Engines. The camshaft is one piece.

   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 camshaft.

   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.

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

   4. Attach a suitable lifting device to the camshaft. The weight of the camshaft is approximately 45 kg (100 lb). Insert the camshaft in the engine until Tooling (C) is in the first camshaft bearing.

   5. Install Tooling (E). Rotate the camshaft and tighten the bolts on Tooling (D).

   6. Rotate the camshaft and insert the camshaft into the engine.

   7. Repeat Steps 2.a through 2.f for the camshaft on the opposite side of the engine. Go to Step 3.
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   Illustration 4	g02050934

3. Install thrust washers (12) and bolts (11) that fasten the camshaft to the engine.
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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 5	g02051674

4. Remove timing pin (17) from the storage position on the side of the engine.

5. Turn the camshaft until timing pin (17) can be installed through the cylinder block and into groove (18) that is in the camshaft.

6. Repeat Steps 4 and 5 for the camshaft on the opposite side of the engine.
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   Illustration 6	g02051678

7. Remove bolts (21), cover (20), and plug (19).

8. Install one bolt (21) into the flywheel housing through the hole for plug (19). Use Tooling (A) and a ratchet to turn the flywheel until bolt (21) can be installed through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top center. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for more information.
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   Illustration 7	g02050875

9. Use the following procedure in order to install camshaft drive gears (10).

   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 (10) 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 (9).

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

   6. Place a Mark on the bolt.

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

   9. Repeat Steps 9.g and Step 9.h until the Mark has turned at least 90 degrees.
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   Illustration 8	g02051754

10. Remove the timing pins from the camshafts. Install timing pins (17) in the original locations.
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    Illustration 9	g02050873

11. Install the gaskets and covers (8) over the camshaft drive gears on both sides of the engine.
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    Illustration 10	g02051678

12. Remove bolt (21) from the flywheel. Install plug (19) in the timing hole. Remove Tooling (A) and install cover (20) with bolts (21) on the flywheel housing.
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    Illustration 11	g02050835

13. Remove the O-ring seals from valve lifters (7). Push valve lifters (7) against the camshaft.
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    Illustration 12	g02050814

14. Install cover (6) on the front housing.
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    Illustration 13	g02045599

15. Install rod assembly (2) and lever assembly (4) as a unit. Install bolts (5).
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    Illustration 14	g02045598

16. Connect rod assembly (2) to the fuel control shaft. Install the cap and bolt (3).
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    Illustration 15	g02045597

17. Install covers (1).

End By:

1. Install the governor drive.

2. Install the tachometer drive.

3. Install the rocker shaft and the pushrods.