CAT Caterpillar C1.5 Service Repair Manual PDF Download

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Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Alternator - Remove and Install

SMCS - 1405-010

Removal Procedure

Start By:

A. Remove the V-belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

1. Disconnect the battery.

Illustration 1 g00830949

2. Disconnect all harness assemblies from alternator (3) before proceeding. Mark the connections or identify the connections for later installation.

i02406729

3. Remove bolt (1) and washer (2) from alternator (3) .

4. Remove bolts (5) , washers (4) , and nuts (6) that fasten alternator (3) to the engine.

5. Remove alternator (3) from the engine.

Installation Procedure

Illustration 2

1. Position alternator (3) on the engine.

2. Install bolts (5) , washers (4) , and nuts (6) .

3. Install bolt (1) and washer (2) on alternator (3) .

4. Hand tighten bolts (5) and bolt (1) on alternator (3) .

g00830949

Note: When you install the alternator, ensure that the alternator pulley is in alignment with the crankshaft pulley within 2.40 mm (0.095 inch).

5. Reconnect all harness assemblies to alternator (3) .

6. Connect the battery.

End By: Install the V-belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

1993 - 2024 Caterpillar Inc.

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media Number -RENR2447-01

Auxiliary Water Pump - Assemble

SMCS - 1371-016

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

-08/01/2004

i02014182

Illustration 1

1. Install bearing (21) and seal (20) on shaft (22) .

2. Install seal (19), washer (18), and retaining clip (17) on shaft (22) .

3. Install shaft (22) into housing (3) .

4. Install wear plate (2) onto shaft (22). Install pin (9) in wear plate (2) .

5. Install cam (1) and screw (12). Install impeller (4), seal (6), O-ring seal (7), cover (8), and bolts (15) .

6. Install bearing (16) and retaining clip (14) on shaft (22). Install key (11), gear (13), washer (10), and nut (5) on shaft (22) .

End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Install".

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media Number -RENR2447-01

Auxiliary Water Pump - Disassemble

SMCS - 1371-015

Disassembly Procedure

Start By:

A. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

i02014176

Illustration 1 g00995065

1. Remove nut (5), washer (10), gear (13), retaining ring (14), and bearing (16) from shaft (22) .

2. Remove key (11) from shaft (22) .

3. Remove bolts (15), cover (8), O-ring seal (7), and seal (6). Remove impeller (4) .

4. Remove screw (12), cam (1), and pin (9). Remove wear plate (2) from shaft (22) .

5. Remove shaft (22) from housing (3) .

6. Remove retaining ring (17), washer (18), and seal (19) from shaft (22) .

7. Remove seal (20) and bearing (21) from shaft (22) .

Wed Jun 19 13:50:25 UTC+0530 2024

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media Number -RENR2447-01

Auxiliary Water Pump - Install

SMCS - 1371-012

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

i02005504

Illustration 1

1. Position auxiliary water pump (3) on the front housing. Install the washers, bolts (1), and nuts (2) .

2. Install elbow assembly (5) (if applicable).

3. Connect hose (4) to auxiliary water pump (3) .

Wed Jun 19 13:51:21 UTC+0530 2024

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media Number -RENR2447-01

Auxiliary Water Pump - Remove

SMCS - 1371-011

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Close the drain valve for the sea water circuit.

i02005481

2. Disconnect hose (4) from auxiliary water pump (3). Remove elbow assembly (5) (if applicable).

3. Plug and cap all openings. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

4. Remove bolts (1), nuts (2), and the washers. Remove auxiliary water pump (3) from the front housing.

Network For SIS Licensees. Wed Jun 19 13:49:52 UTC+0530 2024

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement Procedure Table 1

Required Tools

198-9142

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

Plastic Gauge (Red)

to

to 0.006 inch)

Plastic Gauge (Blue)

to 0.229 mm (0.004 to 0.009 inch)

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

i05977048

Note: Cat does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE

Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the bores are clean and dry.

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

• The crankshaft must be free of oil at the contact points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1 g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media Number -RENR2447-01 Publication Date -01/01/2004 Date Updated -08/01/2004

Camshaft - Install

SMCS - 1210-012

Installation Procedure NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft is clean. Lubricate the camshaft with clean engine oil.

i02005467

Illustration 1 g01003212

2. Carefully install camshaft (10) and camshaft gear (4) in cylinder block (11). Be careful not to damage the lobes of the camshaft or the camshaft bearings.

Illustration 2 g00828468

3. Align the bolt holes in camshaft retainer (9) with the bolt holes in cylinder block (11). Rotate camshaft gear (4) in order to align access hole (8) in the camshaft gear with the hole for bolt (6). Install bolt (6) and bolt (7) that secures camshaft retainer (9) in position on cylinder block (11). Tighten bolt (6) and bolt (7) to a torque of 11 N·m (95 lb in).

Illustration 3 g00828467

4. Install idler gear (5). Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

Note: When you install the idler gear, ensure that timing marks (2) are aligned on the following components.

Camshaft gear (4)

Idler gear (5)

Crankshaft gear (3)

5. Install slider (1) to camshaft gear (4) .

End By:

a. Install the engine front housing. Refer to Disassembly and Assembly, "Housing (Front)Install".

b. Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer PumpInstall".

c. Install the fuel injection pump. Refer to Disassembly and assembly, "Fuel Injection PumpInstall".

d. Install the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Camshaft - Remove

SMCS - 1210-011

Removal Procedure

Start By:

A. Remove the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

B. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove".

C. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer PumpRemove".

D. Remove the engine front housing. Refer to Disassembly and Assembly, "Housing (Front)Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

i01908247

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1 g00828467

1. Remove slider (1) from camshaft gear (4) .

2. Rotate the crankshaft until timing marks (2) on the following components are aligned.

Note: The No. 1 cylinder is at the top center position when these marks are in alignment. Refer to Illustration 1.

Camshaft gear (4)

Idler gear (5)

Crankshaft gear (3)

3. Remove idler gear (5). Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

2 g00828468

4. Rotate camshaft gear (4) in order to align access hole (8) in the camshaft gear with bolt (6). Remove bolt (6) and remove bolt (7) from camshaft retainer (9) .

Illustration 3 g01003180

Illustration

5. Carefully remove camshaft gear (4) and camshaft (10) from cylinder block (11). Be careful not to damage the lobes of the camshaft or the camshaft bearings.

6. Inspect the components for wear or damage. Replace the components that are worn or damaged.

Wed Jun 19 13:52:11 UTC+0530 2024

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Media

-RENR2447-01

Connecting Rod Bearings - Install

SMCS - 1219-012

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

When the connecting rod caps are installed, ensure that the identification marks are aligned.

i02007213

Illustration 1 g01047932

1. Check the clearance between the connecting rod bearing and the connecting rod bearing journal of the crankshaft. Install the connecting rod bearings dry when the clearance checks are made. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for information on bearing clearance checks.

2. Clean the bearing surface of connecting rod (1) and connecting rod cap (4). Ensure that the number on connecting rod cap (4) matches the number on connecting rod (1) .

3. Clean upper connecting rod bearing (3) and lubricate the bearing face with clean engine oil.

4. Clean lower connecting rod bearing (3) and lubricate the bearing face with clean engine oil.

Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in connecting rod (1) .

5. Install upper connecting rod bearing (3) to connecting rod (1) .

6. Pull connecting rod (1) into position against the crankshaft.

7. Install lower connecting rod bearing (3) in connecting rod cap (4) .

8. Install connecting rod cap (4) in position on connecting rod (1) and install connecting rod nuts (5) to connecting rod bolts (2). Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install" for the correct torque of connecting rod nuts (5) .

Note: Ensure that identification mark (X) on the connecting rod matches the identification mark on the connecting rod cap. The identification marks must face the right side of the engine for correct installation.

9. Repeat Steps 2 through 8 for the installation of the remaining connecting rod bearings.

End By:

a. Install the oil supply tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".

b. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Wed Jun 19 13:49:45 UTC+0530 2024

Product: GENERATOR SET

Model: C1.5 GENERATOR SET TAF

Configuration: C1.5 Marine-Generator Engine TAF00001-UP

Disassembly and Assembly

C1.5 and C2.2 Marine Generator Set Engines

Connecting Rod Bearings - Remove

SMCS - 1219-011

Removal Procedure

Start By:

A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

B. Remove the oil supply tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.