C15 GENERATOR SET
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Product: GENERATOR SET
Model: C15 GENERATOR SET C5E
Configuration: C15 Standby Generator Set (60Hz) C5E00001-UP
Disassembly and Assembly
C15 and C18 Generator Set Engines
Alternator - Remove and Install
SMCS - 1405-010
Removal Procedure
Personal injury can result from failure to disconnect the battery.
First, disconnect the negative battery cable. Then, disconnect the positive battery cable.
A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.
1. Disconnect the negative battery terminal. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
Illustration 1
2. Remove bolts (1). Remove guard (2).
Illustration 2
3. Put an identification mark on the harness assemblies that are connected to alternator (3) for installation purposes. Remove bolt (4) and nut (5). Disconnect harness assembly (6) from alternator (3).
3
4. Loosen nuts (12) on adjustment rod (13).
5. Loosen the nut on bolt (9). Push the bottom of alternator (3) toward the cylinder block. Remove the V-belt from the alternator pulley.
6. Remove bolt (9) and bolt (11). Remove alternator (3).
7. Remove nut (10) and the alternator pulley from alternator (3).
8. Remove nuts (7) and remove bracket (8).
Installation Procedure Table 1 Required Tools
Illustration 4 g01242411
1. Install the alternator pulley and nut (10). Tighten nut (10) to a torque of 102 ± 7 N·m (75 ± 5 lb ft).
2. Position bracket (8) in position on the studs. Apply Tooling (A) to the threads of the studs. Install nuts (7) and tighten nuts (7) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).
3. Put alternator (3) in position on bracket (8) and install bolt (9).
4. Put adjustment rod (13) in position on alternator (3). Install bolt (11) and tighten bolt (11) to a torque of 88.4 ± 6.8 N·m (65 ± 5 lb ft).
5. Install the V-belt. Tighten the V-belt. Refer to Testing and Adjusting, "Belt Tension Chart".
6. Tighten nuts (12) to a torque of 30 ± 15 N·m (22 ± 11 lb ft).
Illustration 5
7. Connect harness assembly (6) on alternator (3). Tighten nut (5) to a torque of 6.2 ± 0.6 N·m (55 ± 5 lb in). Tighten bolt (4) to a torque of 2.25 ± 0.25 N·m (20 ± 2 lb in).
Illustration 6 g01256155
8. Position guard (2) and install bolts (1).
9. Connect the negative battery terminal. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
Product: GENERATOR SET
Model: C15 GENERATOR SET C5E
Configuration: C15 Standby Generator Set (60Hz) C5E00001-UP
Disassembly and Assembly
C15 and C18 Generator Set Engines
Atmospheric Pressure Sensor - Remove and Install
SMCS - 1923-010
S/N - 1151-UP
S/N - 1881-UP
S/N - AN21-UP
S/N - AR21-UP
S/N - AR31-UP
S/N - BG41-UP
S/N - C2F1-UP
S/N - C2M1-UP
S/N - C5E1-UP
S/N - C5H1-UP
S/N - C5L1-UP
S/N - C6C1-UP
S/N - CYL1-UP
S/N - CYY1-UP
S/N - DKE1-UP
S/N - EKW1-UP
i02161234
S/N - G4C1-UP
S/N - GB31-UP
S/N - GM91-UP
S/N - H3J1-UP
S/N - L8B1-UP
S/N - L8D1-UP
S/N - LNA1-UP
S/N - LNB1-UP
S/N - LXJ1-UP
S/N - LXK1-UP
S/N - LZA1-UP
S/N - LZB1-UP
S/N - M1P1-UP
S/N - M1Y1-UP
S/N - M1Z1-UP
S/N - MBS1-UP
S/N - N1C1-UP
S/N - N1D1-UP
S/N - NAP1-UP
S/N - NAW1-UP
S/N - NKK1-UP
S/N - NKL1-UP
S/N - NR61-UP
S/N - NR71-UP
S/N - PEC1-UP
S/N - PEE1-UP
S/N - PEJ1-UP
S/N - PET1-UP
S/N - SNW1-UP
S/N - STD1-UP
S/N - STG1-UP
S/N - STM1-UP
S/N - X4R1-UP
S/N - X6X1-UP
S/N - XP51-UP
S/N - XP81-UP
S/N - ZKA1-UP
S/N - ZKB1-UP
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01095823
1. Disconnect harness assembly (1).
2. Remove atmospheric pressure sensor (2) from the adapter on the cylinder block.
3. Remove the O-ring seal from the atmospheric pressure sensor.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 2 g01095823
1. Install a new O-ring seal on the atmospheric pressure sensor.
2. Install atmospheric pressure sensor (2) and tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).
3. Connect harness assembly (1).
Copyright 1993 - 2024 Caterpillar Inc.
Rights Reserved.
Network For SIS Licensees. Wed Mar 6 22:51:12 UTC+0530 2024
Product: GENERATOR SET
Model: C15 GENERATOR SET C5E
Configuration: C15 Standby Generator Set (60Hz) C5E00001-UP
Disassembly and Assembly
C15 and C18 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 0.152 mm (0.002 to 0.006 inch)
Plastic Gauge (Blue)
to 0.229 mm (0.004 to 0.009 inch)
Plastic Gauge (Yellow)
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.
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.
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Wed Mar 6 22:51:00 UTC+0530 2024
Product: GENERATOR SET
Model: C15 GENERATOR SET C5E
Configuration: C15 Standby Generator Set (60Hz) C5E00001-UP
Disassembly and Assembly
C15 and C18 Generator Set Engines
Camshaft - Install
SMCS - 1210-012
Installation Procedure Table 1 Required Tools
H 9U-7243 Alignment Sleeve
J 486-1534 Camshaft Lubricant -
K 9S-3263 Thread Lock CompoundNOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
NOTICE
Care must be used when removing or installing the camshaft. Do not damage the finished surfaces of the camshaft or the camshaft bearings.
1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (J) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.
1
2. Install Tooling (A) on the cylinder head at Location (Y).
Illustration 2 g01056901
3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front housing (7) at this time.
4. Use Tooling (H) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold Tooling (B) to front housing (7). Remove Tooling (H).
Note: Tooling (H) should move freely from the bore of Tooling (B).
Illustration 3 g01047961
5. Install Tooling (C) on the rear of the camshaft.
6. Use two people to install the camshaft. Use Tooling (D) to assist in 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 while the camshaft is being installed in the cylinder head. The weight of camshaft (8) 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 completely installed in the cylinder head.
8. Remove Tooling (A) from the cylinder head.
9. Remove Tooling (B) from the front housing.
4 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 6 ± 1 N·m (53 ± 9 lb in).
Illustration 5 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 (J) and clean engine oil.
Illustration 6 g01056682
Illustration 7 g01056681
12. Install sealing plate (3) in front housing (7). Install adapter assembly (4) in the sealing plate. Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.
13. Install thrust plate (1). Apply Tooling (K) 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:
a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arms and Shaft - Install".
b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".
c. Install the terminal box. Refer to Disassembly and Assembly, "Terminal Box - Install".
Alternative Installation Procedure
(1) Part of 177-8003 Engine Tool Group
Note: This is an optional procedure to install the camshaft. The preceding tool list shows the required tooling for installing the camshaft from the front of the engine or the rear of the engine.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
NOTICE
Care must be used when removing or installing the camshaft. Do not damage the finished surfaces of the camshaft or the camshaft bearings.
1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (J) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.
2. To install the camshaft from the rear of the engine, go to Step 3 through Step 6. To install the camshaft from the front of the engine, go to Step 7 through Step 10.
Illustration 8 g01056714
Install the camshaft from the rear of the engine.
3. To install the camshaft from the rear of the engine, install Tooling (F) on the front of camshaft (8) with Tooling (G).
Note: Carefully align Tooling (F) with the end of camshaft (8). If the adapter and the camshaft are not aligned, the camshaft may not be removed. The adapter and camshaft bearing will interfere.
4. Install Tooling (E) on Tooling (F).
5. Use two people to install the camshaft. Carefully slide the camshaft into the cylinder head from the rear of the engine. Keep the camshaft level while the camshaft is being installed in the cylinder head. The weight of camshaft (8) is approximately 39 kg (86 lb).
Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.
6. Remove Tooling (E), Tooling (F), and Tooling (G) from the camshaft.
Illustration 9 g01056717
Install the camshaft from the front of the engine.
7. To install the camshaft from the front of the engine, install Tooling (F) on the rear of camshaft (8) with Tooling (G).
Note: Carefully align Tooling (F) with the end of camshaft (8). If the adapter and the camshaft are not aligned, the camshaft may not be removed. The adapter and camshaft bearing will interfere.
8. Install Tooling (E) on Tooling (F).
9. Use two people to install the camshaft. Carefully slide the camshaft into the cylinder head from the front of the engine. Keep the camshaft level while the camshaft is being installed in the cylinder head. The weight of camshaft (8) is approximately 39 kg (86 lb).
Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.
10. Remove Tooling (E), Tooling (F), and Tooling (G) from the camshaft.
Illustration 10 g01056675
11. 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 6 ± 1 N·m (53 ± 9 lb in).
Illustration 11 g01056684
12. 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 (J) and clean engine oil.
Illustration 12 g01056682
Illustration 13 g01056681
13. Install sealing plate (3) in front housing (7). Install adapter assembly (4) in the sealing plate. Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.
14. Install thrust plate (1). Apply Tooling (K) to bolts (2). Hold the assembly 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:
a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arms and Shaft - Install".
This is the sample of the manual click on the download link for complete manual
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