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Caterpillar c15 manual free download. Download Caterpillar C-15 TRUCK ENGINE Service Repair Manual 6NZ
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Caterpillar E/C15 2ws1/up Shop - Free Download PDF - Caterpillar marine diesel engines
Position engine support 2 against the cylinder block. Install Tooling A on the flywheel. Use a suitable lifting device. The weight of the flywheel is approximately 40 kg 88 lb. Remove two bolts 1. Install Tooling B. Remove remaining bolts 1 that hold the flywheel to the crankshaft. Remove flywheel 2. Note: Ring gear 3 must be installed with the chamfered side of the teeth upward. The chamfered side of the gear teeth will be facing toward the starting motor when the flywheel is installed.
This will ensure that the starting motor will engage correctly. Raise the temperature of ring gear 3 and install the ring gear on flywheel 2. Install Tooling A on flywheel 2. Position flywheel 2 on the crankshaft. Apply clean engine oil to the threads of bolts 1. Remove Tooling B. Install bolts 1 in place of Tooling B. Remove Tooling A from the flywheel. Check the flywheel runout. Remove the flywheel. Note: The crankshaft rear seal and the wear sleeve must be replaced at the same time.
Once the crankshaft rear seal and the wear sleeve are separated, these components can not be used again. Note: Wear sleeve 2 is removed at the same time as crankshaft rear seal 1. Use a small drill in order to puncture three or more holes in crankshaft rear seal 1. Use Tooling A to remove crankshaft rear seal 1 and wear sleeve 2.
Once the crankshaft rear seal and the wear sleeve are separated, these components cannot be used again. Note: Do not use any type of lubricant during the installation of the crankshaft seal and wear sleeve. Before installation of the crankshaft seal and the wear sleeve, inspect the crankshaft for scratches. Also, inspect the crankshaft for any distortion on the surface that may lead to an out of round condition. Use a polishing cloth in order to remove any imperfections on the crankshaft.
Clean the outside diameter of the crankshaft and the inside diameter of the wear sleeve. Fasten Tooling B to the crankshaft with Tooling C. Note: Install the crankshaft rear seal with the arrow that shows the direction of crankshaft rotation toward the rear of the engine.
Position wear sleeve 2 and crankshaft rear seal 1 on Tooling B. Install Tooling E on Tooling B. Lubricate the face of the washer on Tooling D. Install Tooling D on Tooling B.
Remove Tooling C and Tooling B from the crankshaft. Check the crankshaft rear seal and the wear sleeve for the correct installation. End By: Install the flywheel. Remove the crankshaft rear seal. Remove the electric starter motor. Install Tooling A and a suitable lifting device on flywheel housing 2. Remove flywheel housing 2 from the cylinder block. The weight of the flywheel housing is approximately 27 kg 60 lb. Install Tooling A and a suitable lifting device on the flywheel housing.
Apply Tooling B on seal 4 and seal 5. Install the seals in the flywheel housing. Note: Apply Tooling B to the bottom of seal 5 in order to fill the space at the cylinder block, the flywheel housing, and the engine oil pan. Position flywheel housing 2 on the cylinder block.
Install bolts 3 and remove Tooling A. Tighten the bolts, as follows: a. Install the electric starting motor. Install the crankshaft rear seal.
Install Tooling A. Remove remaining bolts 1. Remove plate 3. Remove vibration damper 4 from adapter 5 and pulley 2. Remove pulley 2 and adapter 5 from the crankshaft. Remove Tooling A from the crankshaft. Either of these conditions can cause the weight to make contact with the case. Install Tooling A in the crankshaft. Install adapter 5 and pulley 2 on Tooling A. Install vibration damper 4 on Tooling A. Install plate 3 on Tooling A. Apply Tooling B to bolts 1.
Remove Tooling A and install remaining bolts 1. Remove the vibration damper and the pulley. Note: The crankshaft front seal and the wear sleeve must be replaced at the same time. Once the crankshaft front seal and the wear sleeve are separated, these components can not be used again. Note: Wear sleeve 2 is removed at the same time as crankshaft front seal 1. Use a small drill in order to puncture three or more holes in crankshaft front seal 1.
Use Tooling A to remove crankshaft front seal 1 and wear sleeve 2. Once the crankshaft front seal and the wear sleeve are separated, these components cannot be used again. Note: Do not use any type of lubricant during the installation of the crankshaft front seal and the wear sleeve. Before installation of the crankshaft front seal and the wear sleeve, inspect the crankshaft for scratches.
Note: Install the crankshaft front seal with the arrow that shows the direction of crankshaft rotation toward the front of the engine. Position wear sleeve 2 and crankshaft front seal 1 on Tooling B. End By: Install the vibration damper and the pulley.
Use Tooling A to remove button head screws 1. Remove nuts 5 and spacers 4 from studs 3. Remove front cover 2 from the front housing. Install front cover 2 on studs 3. Use Tooling A to install button head screws 1. 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. If studs 24 are loose or the threads are damaged, install new studs 24 in the front plate. Apply Tooling D to the serrations of studs Install studs 24 in the front plate.
Install integral seal 25 on the dowel pins on the cylinder block. Note: Apply Tooling C to the bottom of integral seal 25 in order to fill the space at the cylinder block, the front housing, and the engine oil pan. Install plate 22 on the dowel pins on the cylinder block.
Note: Clean the old sealant from the bolts and apply Tooling D to the bolts. Install stub shaft Apply Tooling D to the studs and the bolt for stub shaft Install stub shaft assembly Apply Tooling D to the studs and the bolt for stub shaft assembly Do not tighten nuts 17 and the bolt for stub shaft assembly 16 at this time. Nuts 17 and the bolt for stub shaft assembly 16 will need to be tightened when the backlash is adjusted. Adjust the backlash between the camshaft gear and the adjustable idler gear assembly.
The backlash should be 0. Apply Tooling D to bolts Use Tooling A to install the sleeve bearing in cluster gear assembly Put cluster gear assembly 13 on the stub shaft.
Ensure that Timing Marks V are aligned on the cluster gear assembly and the crankshaft gear. Position plate 15 with the oil groove toward the face of the gear. Use Tooling A to install the sleeve in idler gear assembly Put idler gear assembly 10 on the stub shaft. Install plate 12 with the oil groove toward the gear face.
Use Tooling A to install the sleeve bearing in adjustable idler gear assembly 7. Note: Align the oil hole in the bearing with the oil hole in the adjustable idler gear assembly. Put adjustable idler gear assembly 7 on the stub shaft assembly. Position plate 9 with the oil groove toward the face of the gear. Apply Tooling D to bolts 8. Install bolts 8. Note: Check the backlash for the camshaft gear and the adjustable idler gear assembly. The camshaft gear must be installed and the adjustable idler gear assembly must be removed in order to perform the backlash adjustment procedure.
Install O-ring seal 5 and O-ring seal 6 in sealing plate 3. Install adapter 4. Ensure that the dowel in the adapter engages the hole in the camshaft. Install sealing plate 3 and thrust plate 1.
Ensure that the dowel in the adapter engages the hole in the thrust plate. Apply Tooling D to bolts 2. Install bolts 2. Evenly tighten bolts 2 in order to ensure that sealing plate 3 and O-ring seal 5 are seated against the cylinder head. Adjust the backlash for the camshaft gear and the adjustable idler gear, if necessary. Note: The camshaft gear must be installed and the adjustable idler gear must be removed in order to perform the backlash adjustment procedure.
Install the fuel transfer pump, if necessary. Install the auxiliary water pump, if necessary. Install the water pump, if necessary. Install the air compressor, if necessary.
Install the front housing. Remove the camshaft position sensor. Remove the crankshaft position sensor. Remove the engine support. Remove the accessory drive. Remove the air compressor. Remove the camshaft gear. Remove the crankshaft front seal. Remove the bolts and clips 1. Remove bracket 2 from plate 4 and the cylinder head.
Remove cable strap 5 from the cylinder head and front housing Remove bolt 7 and nut 6 from the front housing. Remove bolts 8 and nuts 9 from the front housing. Remove bolts 11 from the front housing. Loosen bolts 15 from the engine oil pan. Note: It is not necessary to remove the engine oil pan from the engine.
Remove front housing If necessary, remove studs 14 and the O-ring seals from the front housing. Remove gasket 12 from plate 13 and the front housing. If studs 14 are loose or the threads are damaged, install new studs in front housing Apply Tooling A to the threads of studs Install the O-ring seals on the studs and install the studs in the front housing. Thoroughly clean the mating surfaces of plate 13 and front housing Install gasket 12 on plate Note: Trim the gasket even with the bottom of the front housing after assembly.
Apply Tooling B to the bottom of gasket 12 in order to fill the space at the front housing and the engine oil pan. Install front housing 10 on the dowel pins on the cylinder block.
Install bolts 11 in front housing Tighten bolts Install bolt 7 and nuts 6. Install bolts 8 and nuts 9. Install cable strap 5 on the front housing and on the cylinder head. Install bracket 2 on plate 4 and the front housing. Install the crankshaft front seal and the wear sleeve. Install the camshaft gear. Install the air compressor. Install the accessory drive. Install the engine support. Install the camshaft position sensor. Install the crankshaft position sensor.
Position valve mechanism cover 2 on the valve cover base. Remove the valve mechanism cover. Disconnect the harness assembly from variable valve actuator oil pressure sensor 8. Disconnect the harness assembly from the oil pressure solenoid for variable valve actuator 9.
Disconnect harness assemblies 7 from the electronic unit injectors. Remove tube assembly 4. Disconnect harness assembly 1 from valve mechanism cover base 2. Remove bolt 3. Remove valve mechanism cover base 2. Remove seal 10 from valve mechanism cover base 2. Remove bolts 12 , harness assembly 11 , and the connector seal from the valve mechanism cover base. Remove bolts 13 and the clips for harness assembly Remove the harness assembly from the valve mechanism cover base.
Apply Tooling B to the threads of bolts Install bolts 13 and the clips for harness assembly Install the harness assembly on the valve cover base. Note: Align the white mark on the harness assembly with the connecting points. Tie the strap to the connecting points. Ensure that no moving parts contact the harness assembly. Install the connector seal and harness assembly 11 to the valve cover base. Note: Install the connector seal with the curved part of the seal against the valve cover base.
Install seal 10 in valve mechanism cover base 2. Apply Tooling A to the seal joint. Put valve mechanism cover base 2 in position on the cylinder head. Install bolt 3. Install tube assembly 4. Connect tube assembly 6. Position harness assembly 7 in position on the electronic unit injector. Tighten the cap nuts to a torque of 2. Connect the harness assembly to variable valve actuator oil pressure sensor 8. Connect the harness assembly to the oil pressure solenoid for variable valve actuator 9.
End By: Install the valve mechanism cover. Any attempt to disassemble the variable valve actuator will void the warranty of the component.
Disconnect harness assembly 1. Remove engine oil connector 7. Remove the O-ring seals from the engine oil connector. Remove nuts 4. Remove variable valve actuator 5.
Refer to Specifications for more information. Install variable valve actuator 5. Install nuts 4. Tighten the bolt and tighten the nuts in the sequence that is shown.
Perform the following flush procedure prior to installing engine oil connector 7. Remove the valve from the oil rail for the variable valve actuator.
Install Tooling B in the opening. Disconnect the harness assemblies for the electronic unit injectors. Crank the engine for at least 5 seconds in order to flush the oil rail for the variable valve actuator.
Reinstall the valve in the oil rail for the variable valve actuator. Connect the harness assemblies for the electronic unit injectors. Install the O-ring seals in engine oil connector 7. Apply Tooling A on the mounting surface of the variable valve actuator and the engine oil connector. Position engine oil connector 7 on the valve cover base and install bolts 6. Adjust the lash for the variable valve actuators. Adjust the lash for the compression brake.
Valve rocker arms and unit injector rocker arms can move on the shaft after the bolts have been removed. The shaft should be kept level when removed from the cylinder head. To avoid possible personal injury, keep fingers clear of the valve rocker arms and the unit injector rocker arms when lifting the assembly from the cylinder head.
Remove studs 2. Use Tooling A to remove rocker arm shaft assembly 4 , valve rocker arms 3 , and electronic unit injector rocker arms 1 as a unit. Remove the rocker arms and the rocker shaft. Remove valve rocker arms 11 and electronic unit injector rocker arm 3 from rocker shaft assembly 4. Remove jam nut 7 from adjustment screw 8. Remove adjustment screw 8 from valve rocker arms Remove button 10 from adjustment screw 8. Remove O-ring seal 9 from the adjustment screw. Remove jam nut 2 from unit injector adjustment screw 1.
Remove unit injector adjustment screw 1 from electronic unit injector rocker arm 3. Remove button 6 from unit injector adjustment screw 1. Remove O-ring seal 5 from the unit injector adjustment screw. Note: Do not reuse the O-ring seal on the adjustment screw if the button is removed from the adjustment screw.
Install O-ring seal 9 in button Use a soft hammer to seat button 10 on adjustment screw 8. Install adjustment screw 8 in valve rocker arms Install jam nut 7 on the adjustment screw.
Install O-ring seal 5 in button 6. Use a soft hammer to seat button 6 on unit injector adjustment screw 1. Install unit injector adjustment screw 1 in electronic unit injector rocker arm 3. Install jam nut 2 on the unit injector adjustment screw. Lubricate rocker shaft assembly 4 with clean engine oil. Install valve rocker arms 11 and electronic unit injector rocker arm 3 on rocker shaft assembly 4. End By: Install the rocker arms and the rocker shaft.
Position shaft 3 , valve rocker arms 1 , and unit injector rocker arms 2 as a unit with Tooling A on the engine. Repeat Step 1 for the remainder of the rocker arm assemblies. Install the compression brake. Install the valve actuator. Remove the valve mechanism cover base. Remove the turbocharger. Remove the aftercooler. Remove the water temperature regulator. Disconnect hose assembly 7 at the cylinder head. Remove the bolt and the clip that secures the hose assembly to the front housing.
Remove the bolt and the clip that secures the hose assembly to the cylinder head. Disconnect tube assembly 8 at the cylinder head. Disconnect tube assembly 10 at the cylinder head.
Disconnect hose assembly 9 at the cylinder head. Disconnect hose 13 at the cylinder head. Remove bracket Disconnect boost pressure sensor Disconnect inlet air temperature sensor Remove the air inlet elbow and the gasket from the cylinder head. Remove the breather tube from the cylinder head. Attach a suitable lifting device to cylinder head The weight of the cylinder head is approximately kg lb. Ensure that all of the following items are clear from the cylinder head: harness assemblies, tube assemblies and hose assemblies.
Remove cylinder head bolts Carefully remove the cylinder head. Remove cylinder head gasket Remove spacer plate Remove seals 22 and seal Remove spacer plate gasket Remove O-ring seal 19 from the dowel in the cylinder block. Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head and the top of the cylinder block.
A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed. Install O-ring seal 19 on the dowel in the cylinder block. Install spacer plate gasket 21 on the cylinder block. Install spacer plate Install seals 22 and seal Install cylinder head gasket 17 on the spacer plate. Carefully install the cylinder head on the dowel pins on the cylinder block.
Apply Tooling A to the threads of the cylinder head bolts 15 and both sides of the washers. Install cylinder head bolts The rest of the bolts are mm 7. Tighten the cylinder head bolts according to the following procedure. Connect tube assembly 8. Connect tube assembly Connect hose assembly 9.
Connect hose Connect hose assembly 7 at the cylinder head. Install the bolt and the clip that secures the hose assembly to the front housing. Install the bolt and the clip that secures the hose assembly to the cylinder head. Install bracket Connect inlet air temperature sensor Connect boost pressure sensor Install the gasket and the air inlet elbow on the cylinder head.
Install O-ring seal 5 and O-ring seal 6 on sealing plate 3. Install adapter assembly 4 and sealing plate 3. Ensure that the dowel in adapter assembly 4 engages the hole in the camshaft. Note: Ensure that the O-ring seal stays in the groove in sealing plate 3. Install thrust plate 1. Apply Tooling C 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. Install the water temperature regulator.
Install the aftercooler. Install the turbocharger. Install the valve mechanism cover base. Install the electronic unit injectors. Remove the rocker arms and the rocker shafts. Do not turn the crankshaft or the camshaft while the camshaft gear is removed.
Remove sealing plate 3 from the front housing. Remove adapter assembly 4 from the crankshaft. Do not damage the finshed surfaces of the camshaft or the camshaft bearings. Install Tooling B on front housing 7. Tooling B is used to support camshaft 8. Do not tighten the bolts for Tooling B at this time. 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. 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.
Caterpillar C2 Repair Manual. Caterpillar Electrical circuit. C15 Cat Engine Wiring Schematics. Cat EWD. Caterpillar B and E Wiring. Caterpillar b, c, c Engine Wiring, Caterpillar. David McDonald Sunday, 29 January Searching for a service and maientance manual for a cr mini excavator; also price. Mechanic BK Wednesday, 21 September Ricky Elliott Wednesday, 17 August User Settings.
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