G3516C Generator Set GZZ00001-UP(SEBP3864 - 33) - Documentation Page 1 of 8
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Product: GENERATOR SET
Model: G3516C GENERATOR SET GZZ00202
Configuration: G3516C Generator Set GZZ00001-UP
Testing and Adjusting
G3516C and G3516E Engines
Media Number -KENR6834-06 Publication Date -01/08/2013 Date Updated -05/08/2013
i01821606
Camshaft Timing
SMCS - 1210
Timing Check
Table 1
Tools Needed Quantity
9S-9082 Engine Turning Tool 1
Illustration 1 g00284801
Location of timing pins (typical example)
(1) Timing hole
(2) Timing pin
1. Remove rear camshaft covers from both sides of the engine.
2. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
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Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No.
1 valve cover in order to find the compression stroke. Both rear camshaft covers must be
removed in order to check the timing.
3. When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the
timing ring is visible, then the No. 1 piston is on the compression stroke. If the timing ring
is not visible, feel the back of the camshaft for the groove. If the groove is at the back of the
camshaft, the flywheel must be turned by 360 degrees in order to put the No. 1 piston on the
compression stroke.
Illustration 2 g00284802
Installation of timing pins (typical example)
(2) Timing pin
(3) RH Camshaft
4. When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression
stroke, remove timing pins (2) from the storage positions.
5. Install timing pins (2) through timing holes (1) in the engine block. Install timing pins (2)
into the groove in camshaft (3) on each side of the engine. In order to time the engine
correctly, the timing pins must fit into the groove of each camshaft.
If the timing pins do not engage in the grooves of both camshafts, the engine is not in time,
and one or both camshafts must be adjusted.
6. Proceed to the "Timing Adjustment" procedure.
NOTICE
If a camshaft is out of time more than 18 degrees (approximately 1/2
the diameter of timing pin out of groove), the valves can make contact
with the pistons. This will cause damage that will make engine repair
necessary.
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Timing Adjustment
Table 2
Tools Needed Quantity
9S-9082 Engine Turning Tool 1
1P-0820 Hydraulic Puller 1
8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
5H-1504 Hard Washer 3
9U-6600 Hand Hydraulic Pump 1
Note: Before any timing adjustments are made, make sure that adjustments are necessary. Refer to
"Timing Check".
After the timing check procedure is completed, the timing bolt will be engaged in the flywheel
with No. 1 piston at the top center (TC) position.
1. Disconnect the ignition harness from all of the ignition transformers on the side of the
engine with the camshaft that needs adjustment. Remove the ignition transformers.
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Illustration 3 g00930076
(1) Bolt
(2) Rocker Shaft
2. Remove all valve covers on the side of the engine with the camshaft that needs adjustment.
Loosen bolts (1) that hold rocker shaft (2) to the valve cover bases until all rocker arms are
free from the valves.
Note: The above procedure must be done before the camshaft drive gear is pulled off the
camshaft taper.
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Illustration 4 g00662269
Left rear
(3) Cover
(4) Speed/Timing sensor
3. Remove camshaft gear cover (3) from the rear of the engine. If the left rear camshaft gear
must be removed, remove speed/timing sensor (4) first.
Illustration 5 g00662337
Rear gear group
(5) Gear (left camshaft drive)
(6) Idler gear
(7) Speed/Timing ring
(8) Gear (right camshaft drive)
(9) Washer
(10) Bolt
(11) Bolt
(12) Plate
4. To remove the left camshaft drive gear, remove bolt (10) and washer (9). Remove
speed/timing ring (7) from the left camshaft.
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5. To remove right camshaft drive gear, remove bolt (11) and plate (12) from the right
camshaft.
Illustration 6 g00662446
Removing the camshaft drive gear
(A) 1P-0820 Hydraulic Puller
(12) Plate
6. Use tooling (A) to remove camshaft drive gears (5) and (8) .
7. Install the three 5H-1504 Hard Washers behind plate (12). This plate holds the camshaft
drive gear on the camshaft. Install plate (12) and bolt (11) on the camshaft.
NOTICE
Do not apply more than 41,340 kPa (6,000 psi) of pressure to 1P-0820
Hydraulic Puller. 8B-7559 Adapters are rated at 5 ton each and 1P-
0820 Hydraulic Puller is rated at 17 ton at 68,900 kPa (10,000 psi). If
too much pressure is applied, the gear may be damaged.
8. Use the 8B-7559 Adapter and needed parts from the 8B-7548 Push-Puller Tool Group to
install the 1P-0820 Hydraulic Puller on the camshaft drive gear. Apply 41,340 kPa (6,000
psi) to the puller and tap the screw until the camshaft drive gear is free of the camshaft
taper. Remove the tooling and the camshaft drive gear from the camshaft.
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Illustration 7 g00662447
Camshaft timing
(13) Timing pin
9. Remove timing pins (13) from the storage positions which are located under the rear
camshaft covers on each side of the engine.
10. Turn the camshafts until timing pins (13) can be installed through timing holes and into the
grooves (slots) in the camshaft.
11. Use the following procedure to install camshaft gears (5) and (8) :
a. For correct timing, the timing bolt must be installed in the flywheel and all gear
clearance (backlash) must be removed. Turn the camshaft drive gears in the same
direction as crankshaft rotation and hold in this position.
b. Pin both camshafts and put the camshaft drive gears in position in line with idler
gears (6) on each camshaft taper.
Note: Make sure that the gear tapers and the shaft tapers are clean, dry, and free of
lubricants.
c. Install speed/timing ring (7), bolt (10) and washer (9) on the left side. Install bolt (11)
and plate (12) on the right side in order to hold the camshaft drive gears to each
camshaft.
d. Remove camshaft timing pins (13). Tighten bolts (10) and (11) to a torque of 360 ±
40 N·m (26 ± 30 lb ft).
e. Strike plate (12) or the center of speed/timing ring (7). This will seat the gear on the
taper. Then tighten the bolt to a torque of 360 ± 40 N·m (266 ± 30 lb ft).
Note: If necessary, repeat Step 11.e until the torque does not change. Make sure that
the drive gears are in full contact with the taper on the camshafts.
f. Verify the crankshaft in relation to the camshaft by installing camshaft timing pins
(13). Loosen bolt (11) and the camshaft drive gear if the timing pins cannot be
installed. Repeat the installation procedure of the camshaft drive gear.
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12. Install the gasket and the camshaft gear cover on the rear housing. Use two 3/8 inch by 6
inch long guide bolts.
13. Remove timing pins (13) from the camshafts. Install timing pins (13) in the storage
positions. Install the covers over the camshafts and timing pins.
14. Remove the timing bolt from the flywheel housing.
15. Install the 5M-6213 Pipe Plug in the flywheel housing timing hole. Remove the engine
turning pinion, and install the cover and the gasket.
16. Correctly engage the rocker arms with the pushrods. Tighten the bolts for the rocker shafts
to a torque of 120 ± 20 N·m (89 ± 15 lb ft).
17. Adjust the valve lash. Refer to Testing And Adjusting, "Valve Lash and Valve Bridge
Adjustment".
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