-
Disassembly and Assembly C15 On-highway Engines
Fuel Priming Pump - Remove and Install SMCS - 1258-010
Removal Procedure
1. Turn the fuel supply to the "OFF" position.
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02112573
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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A-PDF Merger DEMO : Purchase from www.A-PDF.com to remove the
watermark
-
2. Remove bolts (1). Remove fuel priming pump assembly (2) from
fuel filter base (4) .
3. Remove gasket (3) from the fuel priming pump assembly and the
fuel filter base.
Installation Procedure
Illustration 1 g01075873
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Position gasket (3) on fuel filter base (4) .
2. Position fuel priming pump assembly (2) on the fuel filter
base and install bolts (1). Tighten the bolts to a torque of 15 3
Nm (11 2 lb ft).
3. Turn the fuel supply to the "ON" position.
4. Remove the air from the system. Refer to Testing and
Adjusting, "Fuel System - Prime".
Illustration 2 g01075873
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Disassembly and Assembly C15 On-highway Engines
Fuel Filter Base - Remove SMCS - 1262-011
Removal Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02121646
Table 1
Required Tools
Tool Part Number Part Description Qty A 185-3630 Strap Wrench
1
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Turn the fuel supply to the "OFF" position.
2. Disconnect hose assembly (3) from fuel filter base (4) .
3. Disconnect hose assembly (5) .
4. Disconnect tube assembly (6) .
5. Disconnect the harness assembly from fuel pressure sensor
(3). Remove the fuel pressure sensor from the fuel filter base.
6. Use Tooling (A) to remove fuel filter (7) from fuel filter
base (4) .
7. Remove bolts (1) and remove the fuel filter base.
Illustration 1 g01080654
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Disassembly and Assembly C15 On-highway Engines
Fuel Filter Base - Disassemble SMCS - 1262-015
Disassembly Procedure Start By:
A. Remove the fuel filter base. Refer to Disassembly and
Assembly, "Fuel Filter Base - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02086029
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Remove fuel bypass valve (2) from fuel filter base assembly
(1). Remove the O-ring seals from the fuel bypass valve.
2. Remove fuel check valve (5) from fuel filter base assembly
(1). Remove the O-ring seals from the fuel check valve.
3. Remove fitting (3) from fuel filter base assembly (1). Remove
the O-ring seals from the fitting.
4. If necessary, remove hollow stud (4) from fuel filter base
assembly (1) .
Illustration 1 g01063845
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Disassembly and Assembly C15 On-highway Engines
Fuel Filter Base - Assemble SMCS - 1262-016
Assembly Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02086033
Table 1
Required Tools
Tool Part Number Part Description Qty A 155-0695 Thread Lock
Compound -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Install the O-ring seals on fuel bypass valve (2). Install
the fuel bypass valve in fuel filter base assembly (1) .
2. Install the O-ring seals on fuel check valve (5). Install the
fuel check valve in fuel filter base assembly (1). Tighten the fuel
check valve to a torque of 35 3 Nm (26 2 lb ft).
3. Install the O-ring seals on fitting (3). Install the fitting
in fuel filter base assembly (1) .
4. If necessary, install hollow stud (4) to fuel filter base
assembly (1). Tighten the hollow stud to a torque of 70 15 Nm (52
11 lb ft).
Note: Apply Tooling (A) to the first 7.6 0.8 mm (0.30 0.03 inch)
of threads at the base end of the taperlock stud.
End By: Install the fuel filter base. Refer to Disassembly and
Assembly, "Fuel Filter Base - Install".
Illustration 1 g01063845
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Fuel Filter Base - Install SMCS - 1262-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02121648
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01080654
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1. Position fuel filter base (4) on the cylinder block. Install
bolts (1) .
2. Install fuel filter (7) on the fuel filter base. Follow the
directions on the fuel filter for the correct installation
procedure. Do not overtighten the fuel filter.
3. Connect hose assembly (3) to the fuel filter base.
4. Connect hose assembly (5) to the fuel filter base.
5. Connect tube assembly (6) to the fuel filter base.
6. Install fuel pressure sensor (3). Connect the harness
assembly to the fuel pressure sensor.
7. Turn the fuel supply to the "ON" position.
8. Remove the air from the system. Refer to Testing and
Adjusting, "Fuel System - Prime".
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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Disassembly and Assembly C15 On-highway Engines
Fuel Transfer Pump - Remove SMCS - 1256-011
Removal Procedure
1. Turn the fuel shutoff valve to the "OFF" position.
2. Disconnect the fuel supply line at the fuel transfer
pump.
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02112624
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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3. Disconnect tube assembly (4) .
4. Remove bolts (3) .
5. Remove fuel transfer pump (1) from front housing (5) .
6. Remove O-ring seal (2) from the fuel transfer pump.
Illustration 1 g01075935
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Fuel Transfer Pump - Install SMCS - 1256-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02112625
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01075935
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1. Install O-ring seal (2) on fuel transfer pump (1). Lubricate
the O-ring seal with clean engine oil.
2. Position the fuel transfer pump on front housing (5). Install
bolts (3) .
3. Connect tube assembly (4) .
4. Connect the fuel supply line to the fuel transfer pump.
5. Turn the fuel supply valve to the "ON" position.
6. Remove the air from the fuel system. Refer to Testing and
Adjusting, "Fuel System - Prime".
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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-
Disassembly and Assembly C15 On-highway Engines
Electronic Unit Injector - Remove SMCS - 1290-011
Removal Procedure
Start By:
A. Remove the variable valve actuator. Refer to Disassembly and
Assembly, "Valve Actuator (Variable) - Remove".
B. Remove the rocker arms and the rocker arm shaft. Refer to
Disassembly and Assembly, "Rocker Arm and Shaft - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02112720
Table 1
Required Tools
Tool Part Number Part Description Qty A 5F-4764 Pry Bar 1
NOTICECare 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.
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1. Disconnect harness assembly (1) .
2. Remove bridge assemblies (3) .
3. Remove bolt (4), spacer (5), and clamp (6) .
4. Place an identification mark on electronic unit injector (2)
for installation purposes. Each electronic unit injector must be
reinstalled in the original location in the cylinder head.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01076052
NOTICEIf the injector hold down bolt is loose during the removal
procedure, inspect the injector bore for wear and debris. Replace
the clamp and spacer.
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5. Use Tooling (A) to pry beneath the base and free electronic
unit injector (2) .
6. Remove the electronic unit injector from the cylinder
head.
Illustration 2 g01076047
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Electronic Unit Injector - Install SMCS - 1290-012
Installation Procedure
1. Use Tooling (C) to remove the fuel and oil from the cylinder.
Evacuate as much fuel and oil as possible from the cylinder before
installing the electronic unit injector. Several evacuations may be
necessary.
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02877472
Table 1
Required Tools
Tool Part Number Part Description Qty B 8T-2998 Lubricant -
C
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle -
4C-4057 Tube 7.9 mm (0.31 inch) OD -
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765 Surface Reconditioning Pad -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Use Tooling (D) to clean the carbon deposit from the inside
of the electronic unit injector sleeve. Tooling (E) is available to
clean loose material from the bore of the electronic unit injector
sleeve and the cylinder.
3. Use Tooling (F) to clean the carbon from the seat area that
is inside of the electronic unit injector sleeve.
4. Install the O-ring seals on the electronic unit injector.
Lubricate the top two O-ring seals with a 50/50 mixture of clean
engine oil and Tooling (B) .
5. Install electronic unit injector (2) into the original
location in the cylinder head.
6. Install spacer (5) , clamp (6) , and bolt (4) . Tighten the
bolt to a torque of 55 10 Nm (41 7 lb ft).
Illustration 1 g01076052
NOTICEWhen an electronic unit injector is replaced, the new
electronic injector code must be programmed into the engine's
personality module software by using the calibration menu on the
Electronic Service Tool. If the new electronic injector code is not
entered, the characteristics of the previous electronic unit
injector is assumed.
If it is not possible to immediately reprogram the electronic
injector code into the personality module software, the engine will
not be severely harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to optimize engine
performance.
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7. Install bridge assemblies (3) .
Note: Make sure that the slotted end of the bridge assemblies
are positioned toward the rocker arm shaft.
8. Connect harness assembly (1) . Tighten the nuts to a torque
of 2.5 0.25 Nm (22 2 lb in).
9. Remove the air from the fuel system. Refer to Testing and
Adjusting, "Fuel System - Prime".
End By:
a. Install the rocker arms and the rocker arm shaft. Refer to
Disassembly and Assembly, "Rocker Arm and Shaft - Install".
b. Install the variable valve actuator. Refer to Disassembly and
Assembly, "Valve Actuator (Variable) - Install".
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:42:57 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Electronic Unit Injector Sleeve - Remove SMCS - 1713-011
Removal Procedure
Start By:
A. Remove the electronic unit injectors. Refer to Disassembly
and Assembly, "Electronic Unit Injector - Remove".
1. Drain the coolant from the engine. Refer to Operation and
Maintenance Manual, "Cooling System Coolant - Change".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02169626
Table 1
Required Tools
Tool Part Number Part Description Qty A 9U-6891 Injector Tool
Group 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Install Tooling (A) in electronic unit injector sleeve (1)
.
3. Tighten the nut on Tooling (A) until the electronic unit
injector sleeve is pulled free of the cylinder head.
4. Remove O-ring seals (2) and O-ring seal (3) from electronic
unit injector sleeve (1) .
Illustration 1 g01076133
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Electronic Unit Injector Sleeve - Install SMCS - 1713-012
Installation Procedure
1. Use Tooling (B) to clean the bore in the cylinder head for
the electronic unit injector sleeve.
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02536688
Table 1
Required Tools
Tool Part Number Part Description Qty
B
9U-6862 Tapered Brush 1
9U-6863 Small Bore Brush 1
9U-7244 End Brush 1
9U-7237 Brush Extension 1
4C-5552 Large Bore Brush 1
C (1) 221-9778 Puller Stud 1
D (1) 9U-7258 Driver Cap 1
E 4C-9507 Retaining Compound - ( 1 ) Part of the 9U-6891
Injector Tool Group
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Install new O-ring seals (2) and O-ring seal (3) on
electronic unit injector sleeve (1) .
Note: Do not apply Tooling (E) to the cylinder head surfaces.
Apply Tooling (E) on the electronic unit injector sleeve only.
3. Apply Tooling (E) to the contact surface of electronic unit
injector sleeve (1) on the surface that is Marked "X".
4. Lubricate O-ring seals (2) with clean engine oil.
NOTICEEnsure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and sealant
debris.
Illustration 1 g01043165
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5. Install Tooling (C) into the threads of electronic unit
injector sleeve (1) .
6. Position Tooling (C) and the electronic unit injector sleeve
in the cylinder head. Use care not to damage the O-ring seals on
the electronic unit injector sleeve.
7. Use Tooling (D) and a hammer to install electronic unit
injector sleeve (1) in the cylinder head.
8. Remove Tooling (D) and Tooling (C) . Use a clean towel and
remove excess Tooling (E) .
9. Fill the cooling system with coolant. Refer to Operation and
Maintenance, "Refill Capacities" for the cooling system
capacity.
End By: Install the electronic unit injectors. Refer to
Disassembly and Assembly, "Electronic Unit Injector - Install".
Illustration 2 g01076119
NOTICEEnsure that the electronic unit injector sleeve is
properly seated in the cylinder head. The Tooling will "RING" when
the electronic unit injector sleeve is fully seated in the bore of
the cylinder head.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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Disassembly and Assembly C15 On-highway Engines
Turbocharger - Remove - High Pressure SMCS - 1052-011
Removal Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02113340
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
NOTICEFailure to follow established procedures can lead to
damage of the parts.
To avoid damage to the parts, always identify and mark the parts
so that the parts can be installed in the same location.
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1. Put identification marks on the bellows for alignment and
orientation during installation of the bellows.
2. Loosen clamp assembly (7). Loosen clamp assembly (2) .
Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
3. Remove duct (1) and bellows (6) from the turbochargers.
4. Loosen clamp assembly (4). Loosen clamp assembly (9).
Illustration 1 g01076580
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
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Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
5. Remove duct (5) and bellows (10) from the turbochargers.
6. Disconnect hose (8) .
7. Disconnect hose assembly (3) .
8. Disconnect hose assembly (11) (not shown).
9. Loosen clamp assembly (15) .
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
Illustration 2 g01076587
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Note: Do not remove bellows (18) from the precooler.
10. Loosen clamp assembly (13) .
Note: It may be necessary to rotate the turbocharger housing in
order to remove the turbocharger from the studs on the exhaust
manifold.
11. Remove locknuts (12) .
12. Use a suitable lifting device in order to remove
turbocharger (14). The weight of the turbocharger is approximately
25 kg (55 lb).
Note: It may be necessary to rotate the turbocharger housing in
order to remove the turbocharger from the studs on the exhaust
manifold.
13. Do not remove bellows (18) from the precooler. Remove backup
ring (16) and seal (17) from bellows (18) .
Note: Do not reuse seal (17) .
14. Remove turbocharger gasket (19) from the exhaust
manifold.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:44:27 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Turbocharger - Remove - Low Pressure SMCS - 1052-011
Removal Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02113328
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
NOTICEFailure to follow established procedures can lead to
damage of the parts.
To avoid damage to the parts, always identify and mark the parts
so that the parts can be installed in the same location.
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1. Put identification marks on the bellows for alignment and
orientation during installation of the bellows.
2. Loosen clamp assembly (8). Loosen clamp assembly (11) .
Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
3. Remove air inlet elbow (9) and bellows (10) from the
turbochargers.
4. Loosen clamp assembly (5). Loosen clamp assembly (2) .
Illustration 1 g01076551
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
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Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
5. Remove duct (4) and bellows (3) from the turbochargers.
6. Disconnect hose (7) .
7. Disconnect hose assembly (6) .
8. Disconnect hose assembly (15) .
9. Loosen clamp assembly (17). Remove inlet elbow (13) and the
O-ring seal from the turbocharger.
10. Remove locknuts (14). Remove exhaust elbow (12) and the
gasket from the turbocharger.
11. Remove locknuts (1) .
12. Use a suitable lifting device in order to remove
turbocharger (16). The weight of the turbocharger is approximately
29 kg (65 lb).
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:44:55 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Turbocharger - Install - High Pressure SMCS - 1052-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02113344
Table 1
Required Tools
Tool Part Number Part Description Qty A 5P-3931 Anti-Seize
Compound -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
NOTICEThe alignment of the bellows is important. Improper
alignment may lead to premature failure of the bellows.
Misalignment can be identified by visually inspecting the
convolutions for uniformity of compression.
Inspect the bellows for damage prior to installation. If there
is any damage to the convolutions, discard the bellows. Minor
damage to the ends of the bellows may be repaired. However, if
there is any difficulty in installation after the repair, discard
the bellows.
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Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
1. Install a new seal (17) and backup ring (16) in bellows (18)
.
2. Install turbocharger gasket (19) on the exhaust manifold.
3. Use a suitable lifting device in order to install
turbocharger (14) on the exhaust manifold and in the bellows on the
precooler. The weight of the turbocharger is approximately 25 kg
(55 lb).
Note: If necessary, loosen clamp (13) and rotate the
turbocharger housing in order to align the bellows for
assembly.
4. Apply Tooling (A) to the threads of the studs. Install
locknuts (12). Tighten the locknuts to a torque of
Illustration 1 g01076587
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
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55 5 Nm (41 4 lb ft).
5. Install clamp assembly (15). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 9 2 Nm (80 18 lb
in).
6. If clamp assembly (13) was loosened, apply Tooling (A) to the
threads of the clamp assembly and tighten to torque of 16 1 Nm (142
9 lb in).
7. Connect hose assembly (11) (not shown).
8. Connect hose assembly (3) .
9. Connect hose (8) .
Illustration 2 g01076580
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
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Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
10. Install bellows (6) and duct (1) to the turbochargers.
11. Install clamp assembly (7). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
12. Install clamp assembly (2). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
13. Install bellows (10) and duct (5) on the turbochargers.
14. Install clamp assembly (9). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
15. Install clamp assembly (4). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:45:21 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Turbocharger - Install - Low Pressure SMCS - 1052-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02113338
Table 1
Required Tools
Tool Part Number Part Description Qty A 5P-3931 Anti-Seize
Compound -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
NOTICEThe alignment of the bellows is important. Improper
alignment may lead to premature failure of the bellows.
Misalignment can be identified by visually inspecting the
convolutions for uniformity of compression.
Inspect the bellows for damage prior to installation. If there
is any damage to the convolutions, discard the bellows. Minor
damage to the ends of the bellows may be repaired. However, if
there is any difficulty in installation after the repair, discard
the bellows.
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1. Use a suitable lifting device in order to install
turbocharger (16) on the exhaust manifold. The weight of the
turbocharger is approximately 29 kg (65 lb).
2. Apply Tooling (A) to the threads of the studs. Install
locknuts (1). Tighten the nuts to a torque of 55 5 Nm (41 4 lb
ft).
3. Connect hose (7) .
4. Connect hose assembly (6) .
5. Connect hose assembly (15) .
6. Position the gasket and exhaust elbow (12) on the
turbocharger. Apply Tooling (A) to the threads of the studs.
Install locknuts (14) .
7. Position the O-ring seal and inlet elbow (13) on the
turbocharger. Install clamp assembly (17). Apply Tooling (A) to the
threads of the clamp assembly and tighten to a torque of 12 4 Nm
(106 35 lb in).
Illustration 1 g01076551
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Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
8. Install bellows (3) and duct (4) on the turbochargers.
9. Install clamp assembly (2). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
10. Install clamp assembly (5). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
Note: Refer to Special Instruction, REHS1728, "Application
Guideline for the Bellows" for additional information on handling
the bellows.
11. Install bellows (10) and duct (9) on the turbochargers.
12. Install clamp assembly (11). Apply Tooling (A) to the
threads of the clamp assembly and tighten to a torque of 12 4 Nm
(106 35 lb in).
13. Install clamp assembly (8). Apply Tooling (A) to the threads
of the clamp assembly and tighten to a torque of 12 4 Nm (106 35 lb
in).
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
The ends of the bellows are very sharp. Injury could occur if
the bellows are not handled properly. Handle the bellows by the
convolutions.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:45:49 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Exhaust Manifold - Remove and Install SMCS - 1059-010
Removal Procedure Start By:
A. Remove the precooler. Refer to Disassembly and Assembly,
"Precooler - Remove". B. Remove the water temperature regulator
housing. Refer to Disassembly and Assembly, "Water
Temperature Regulator Housing - Remove and Install".
1. Remove bracket (5) .
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02113672
Illustration 1 g01076838
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2. Remove exhaust manifolds (2) .
3. Remove exhaust sleeves (3) from the cylinder head.
4. Loosen hose clamp (1) and slide the heat shields onto the
exhaust manifold. Disassemble the exhaust manifolds.
5. If necessary, remove taperlock studs (6) from the exhaust
manifold.
6. If necessary, remove the taperlock studs from the cylinder
head.
Installation Procedure
1. If necessary, apply Tooling (A) to the taperlock studs.
Install exhaust manifold studs in the cylinder head. Tighten the
studs to a torque of 35 5 Nm (26 4 lb ft).
2. Apply clean engine oil to the female ends of the exhaust
manifolds before assembly. Apply Tooling (B) to the male ends of
the exhaust manifolds before assembly. Remove excess sealer from
the assembled joint.
Table 1
Required Tools
Tool Part Number Part Description Qty A 5P-3931 Anti-Seize
Compound -
B 2P-2333 High Temperature Sealer -
C 165-4638 Guide 3
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3. Install Tooling (C) in the cylinder head at location "X".
4. Install exhaust sleeves (3) in the cylinder head.
5. Assemble exhaust manifolds (2) on Tooling (C) in order to
align the exhaust manifolds. Install the spacers on the exhaust
manifold studs. Install locknuts (4) finger tight.
6. Remove Tooling (C) and install the remaining spacers and
locknuts.
7. Tighten the locknuts in a numerical sequence that is shown in
Illustration 2. Tighten the locknuts to a torque of 38 5 Nm (28 4
lb ft).
8. If necessary, apply Tooling (A) to taperlock studs (6).
Install taperlock studs in the exhaust manifold and tighten to a
torque of 35 5 Nm (26 4 lb ft).
9. Install bracket (5) .
10. Position the heat shields on the exhaust manifolds. Tighten
hose clamp (1) to a torque of 5 1 Nm (44 9 lb in). Tighten hose
clamp (1) again to a torque of 16 1 Nm (142 9 lb in).
End By:
a. Install the water temperature regulator housing. Refer to
Disassembly and Assembly, "Water Temperature Regulator Housing -
Remove and Install".
b. Install the precooler. Refer to Disassembly and Assembly,
"Precooler - Install".
Illustration 2 g01076954
Illustration 3 g01076970
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Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:46:19 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Inlet and Exhaust Valve Springs - Remove and Install SMCS -
1108-010
Removal Procedure
Start By:
A. Remove the electronic unit injectors. Refer to Disassembly
and Assembly, "Electronic Unit Injector - Remove".
Note: Place the piston at the top of the compression stroke
(TC). Remove the valve springs for that cylinder. If the valves
fall into the cylinder liner, then the cylinder head must be
removed.
1. Position the No. 1 piston at the top center of the
compression stroke. Refer to Testing and Adjusting, "Finding Top
Center Position for No. 1 Piston".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02300073
Table 1
Required Tools
Tool Part Number Part Description Qty A 9U-7241 Valve Spring
Compressor 1
B 8S-2263 Spring Tester 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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Illustration 1 g01073852
Illustration 2 g01043625
Personal injury can result from being struck by parts propelled
by a released spring force.
Make sure to wear all necessary protective equipment.
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2. Install Tooling (A) in the electronic unit injector sleeve.
Secure Tooling (A) with unit injector clamp (1) .
3. Tighten the full nut until valve spring keepers (3) are loose
on valve (2) .
4. Remove valve spring keepers (3) from the valve.
5. Carefully remove Tooling (A) .
6. Remove valve rotator (4) .
7. Remove outer valve spring (6) and inner valve spring (5) from
the valve.
8. Remove washer (7) from the valve guide.
9. Use Tooling (B) to check the valve springs (spring force).
Refer to Specifications, "Cylinder Head Valves" for additional
information on the valve springs.
Installation Procedure
1. Lubricate the valve stems with clean engine oil.
Follow the recommended procedure and use all recommended tooling
to release the spring force.
Table 2
Required Tools
Tool Part Number Part Description Qty A 9U-7241 Valve Spring
Compressor 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Ensure that washer (7) is installed on the valve guide.
3. Install inner valve spring (5) and outer valve spring (6) on
valve (2) .
4. Install valve rotator (4) on valve (2) .
5. Use Tooling (A) to compress inner valve spring (5) and outer
valve spring (6) . Install valve spring keepers (3) on valve (2) .
Remove unit injector clamp (1) and Tooling (A) .
End By: Install the electronic unit injectors. Refer to
Disassembly and Assembly, "Electronic Unit Injector - Install".
Illustration 3 g01043625
Improper assembly of parts that are spring loaded can cause
bodily injury.
To prevent possible injury, follow the established assembly
procedure and wear protective equipment.
The valve spring keepers can be thrown from the valve when the
valve spring compressor is released. Ensure that the valve spring
keepers are properly installed on the valve stem. To help prevent
personal injury, keep away from the front of the valve spring
keepers and valve springs during the installation of the
valves.
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Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:46:47 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Inlet and Exhaust Valves - Remove and Install SMCS -
1105-010
Removal Procedure
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly,
"Cylinder Head - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02642655
Table 1
Required Tools
Tool Part Number Part Description Qty A 5S-1330 Valve Spring
Compressor 1
B 8S-2263 Spring Tester 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Install Tooling (A) and compress the valve springs. Remove
valve spring keepers (2) from valve (1) .
Illustration 1 g01015263
Personal injury can result from being struck by parts propelled
by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling
to release the spring force.
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2. Carefully remove Tooling (A) from valve (1) .
3. Remove valve rotator (3) .
4. Remove outer valve spring (5) and inner valve spring (4) from
valve (1) .
5. Remove washer (6) and valve (1) from the valve guide.
6. Use Tooling (B) to check the valve springs (spring force).
Refer to Specifications, "Cylinder Head Valves" for additional
information on the valve springs.
7. Inspect the valves. Refer to Specifications, "Cylinder Head
Valves" for additional information on the inlet and exhaust
valves.
Installation Procedure
Note: A small amount of grease can be used to hold the retainer
locks in position during installation.
1. Lubricate the valves with clean engine oil. Install the
valves in the cylinder head.
Table 2
Required Tools
Tool Part Number Part Description Qty A 5S-1330 Valve Spring
Compressor 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Install washer (6) on the valve guide.
3. Install inner valve spring (4) and outer valve spring (5) on
valve (1) .
Illustration 2 g01015263
Improper assembly of parts that are spring loaded can cause
bodily injury.
To prevent possible injury, follow the established assembly
procedure and wear protective equipment.
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4. Install valve rotator (3) on valve (1) .
5. Use Tooling (A) to compress inner valve spring (4) and outer
valve spring (5) . Install valve spring keepers (2) on valve (1)
.
6. Carefully remove Tooling (A) .
End By: Install the cylinder head. Refer to Disassembly and
Assembly, "Cylinder Head - Install".
The valve spring keepers can be thrown from the valve when the
valve spring compressor is released. Ensure that the valve spring
keepers are properly installed on the valve stem. To help prevent
personal injury, keep away from the front of the valve spring
keepers and valve springs during the installation of the
valves.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:47:36 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Inlet and Exhaust Valves - Remove and Install SMCS -
1105-010
Removal Procedure
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly,
"Cylinder Head - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02642655
Table 1
Required Tools
Tool Part Number Part Description Qty A 5S-1330 Valve Spring
Compressor 1
B 8S-2263 Spring Tester 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Install Tooling (A) and compress the valve springs. Remove
valve spring keepers (2) from valve (1) .
Illustration 1 g01015263
Personal injury can result from being struck by parts propelled
by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling
to release the spring force.
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2. Carefully remove Tooling (A) from valve (1) .
3. Remove valve rotator (3) .
4. Remove outer valve spring (5) and inner valve spring (4) from
valve (1) .
5. Remove washer (6) and valve (1) from the valve guide.
6. Use Tooling (B) to check the valve springs (spring force).
Refer to Specifications, "Cylinder Head Valves" for additional
information on the valve springs.
7. Inspect the valves. Refer to Specifications, "Cylinder Head
Valves" for additional information on the inlet and exhaust
valves.
Installation Procedure
Note: A small amount of grease can be used to hold the retainer
locks in position during installation.
1. Lubricate the valves with clean engine oil. Install the
valves in the cylinder head.
Table 2
Required Tools
Tool Part Number Part Description Qty A 5S-1330 Valve Spring
Compressor 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Install washer (6) on the valve guide.
3. Install inner valve spring (4) and outer valve spring (5) on
valve (1) .
Illustration 2 g01015263
Improper assembly of parts that are spring loaded can cause
bodily injury.
To prevent possible injury, follow the established assembly
procedure and wear protective equipment.
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4. Install valve rotator (3) on valve (1) .
5. Use Tooling (A) to compress inner valve spring (4) and outer
valve spring (5) . Install valve spring keepers (2) on valve (1)
.
6. Carefully remove Tooling (A) .
End By: Install the cylinder head. Refer to Disassembly and
Assembly, "Cylinder Head - Install".
The valve spring keepers can be thrown from the valve when the
valve spring compressor is released. Ensure that the valve spring
keepers are properly installed on the valve stem. To help prevent
personal injury, keep away from the front of the valve spring
keepers and valve springs during the installation of the
valves.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:47:36 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Inlet and Exhaust Valve Guides - Remove and Install SMCS -
1104-010
Removal Procedure
Start By:
A. Remove the inlet and exhaust valves. Refer to Disassembly and
Assembly, "Inlet and Exhaust Valves - Remove and Install".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02109151
Table 1
Required Tools
Tool Part Number Part Description Qty A (1) 9U-6895 Valve Guide
Driver 1
( 1 ) Part of 9U-7530 Engine Tool Group
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Remove valve stem seal (1) from valve guide (2) .
2. Use Tooling (A) and a hammer to remove the valve guide from
the cylinder head.
Installation Procedure
Illustration 1 g01073841
Table 2
Required Tools
Tool Part Number Part Description Qty A (1) 9U-6895 Valve Guide
Driver 1
B (1) 9U-6894 Guide Collar 1 ( 1 ) Part of 9U-7530 Engine Tool
Group
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Lubricate the bores for the valve guides with clean engine
oil.
2. Install valve guide (2) in the cylinder head with Tooling (A)
and Tooling (B) .
Note: Tooling (B) must be used in order to install the valve
guide to the correct height.
Height to top of valve guide from cylinder head surface ...
35.00 0.50 mm (1.378 0.020 inch)
Note: For more information, refer to Specifications, "Cylinder
Head Valves".
3. Install valve stem seal (1) on the valve guide.
End By: Install the inlet and exhaust valves. Refer to
Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and
Install".
Illustration 2 g01073842
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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Disassembly and Assembly C15 On-highway Engines
Inlet and Exhaust Valve Seat Inserts - Remove and Install SMCS -
1103-010
Removal Procedure
Start By:
A. Remove the inlet and exhaust valves. Refer to Disassembly and
Assembly, "Inlet and Exhaust Valves - Remove and Install".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02118491
Table 1
Required Tools
Tool Part Number Part Description Qty A 166-7441 Valve Seat
Extractor Tool Group 1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Use Tooling (A) to remove valve seat insert (1) from the
cylinder head.
2. Clean the bores in the cylinder head for the valve seat
inserts. Remove any rough areas from the bores.
Installation Procedure
Illustration 1 g01082582
Table 2
Required Tools
Tool Part Number Part Description Qty
B (1) 9U-6898 Valve Seat Driver (Exhaust) 1
9U-6897 Valve Seat Driver (Inlet) 1 ( 1 ) Part of 9U-7530 Engine
Tool Group
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Lower the temperature of new valve seat insert (1) .
2. Use Tooling (B) to install the new valve seat insert in the
cylinder head.
Note: Do not machine the prefinished valve seat inserts in order
to correct the valve projection. Excessive valve projection
indicates that the valve seat insert is not seated or material was
not cleaned from the bottom of the counterbore.
End By: Install the inlet and exhaust valves. Refer to
Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and
Install".
Illustration 2 g01079028
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Filter Base - Remove SMCS - 1306-011
Removal Procedure
Start By:
A. Remove the oil cooler. Refer to Disassembly and Assembly,
"Engine Oil Cooler - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02118579
Table 1
Required Tools
Tool Part Number Part Description Qty A 185-3630 Strap Wrench As
1
NOTICECare 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.
NOTICE
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1. Remove engine oil filter (6) with Tooling (A) .
2. Disconnect hose assembly (2) .
3. Remove bolts (1) and bolts (5) .
4. Remove engine oil filter base (3). Remove O-ring seals (4)
from the engine oil filter base.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01079095
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Filter Base - Disassemble SMCS - 1306-015
Disassembly Procedure Start By:
A. Remove the engine oil filter base. Refer to Disassembly and
Assembly, "Engine Oil Filter Base - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02528158
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Remove bolts (2) . Remove elbow (1) from engine oil filter
base (7) . Remove O-ring seals (3) from the elbow.
2. Remove plug (6) .
3. Remove spring (5) .
4. Remove plunger (4) .
5. If necessary, remove taperlock stud (8) from the engine oil
filter base.
Illustration 1 g01079267
Personal injury can result from being struck by parts propelled
by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling
to release the spring force.
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:50:03 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Filter Base - Assemble SMCS - 1306-016
Assembly Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02528165
Table 1
Required Tools
Tool Part Number Part Description Qty A 155-0695 Thread Lock
Compound -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Lubricate plunger (4) and spring (5) with clean engine oil.
Install the plunger and the spring in engine oil filter base (7)
.
2. Install plug (6) in engine oil filter base (7) . Tighten plug
(6) to a torque of 100 15 Nm (74 11 lb ft).
3. Install O-ring seals (3) on elbow (1) . Position elbow (1) on
the engine oil filter base and install bolts (2) .
4. If necessary, install taperlock stud (8) to engine oil filter
base (7) . Tighten the taperlock stud to a torque of 68 7 Nm (50 5
lb ft).
Note: Apply Tooling (A) to the first 10.5 1.5 mm (0.41 0.06
inch) of threads at the base end of the taperlock stud.
End By: Install the engine oil filter base. Refer to Disassembly
and Assembly, "Engine Oil Filter Base - Install".
Illustration 1 g01079267
Improper assembly of parts that are spring loaded can cause
bodily injury.
To prevent possible injury, follow the established assembly
procedure and wear protective equipment.
Copyright 1993 - 2012 Caterpillar Inc. Wed Jan 18 07:50:32
UTC-0400 2012
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All Rights Reserved.
Private Network For SIS Licensees.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Filter Base - Install SMCS - 1306-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02118580
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01079095
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1. Install O-ring seals (4) on engine oil filter base (3) .
2. Position engine oil filter base (3) on the engine oil cooler
and install bolts (1) and bolts (5) .
3. Connect hose assembly (2) .
4. Install engine oil filter (6). Follow the directions on the
engine oil filter for the correct installation procedure. Do not
overtighten the engine oil filter.
5. Fill the lubrication system with engine oil. Refer to
Operation and Maintenance Manual, "Refill Capacities" for the
lubrication system capacity of the engine.
End By: Install the oil cooler. Refer to Disassembly and
Assembly, "Engine Oil Cooler - Install".
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Cooler - Remove SMCS - 1378-011
Removal Procedure
1. Drain the cooling system. Refer to Operation and Maintenance
Manual, "Cooling System Coolant - Change".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02119148
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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2. Disconnect hose assembly (1) from the cylinder block.
3. Disconnect hose (2) from the outlet bonnet.
4. Disconnect hose assembly (5) from the cylinder block.
5. Remove bolts (4). Remove outlet bonnet (6) from the cylinder
block and the engine oil cooler.
Illustration 1 g01079420
Illustration 2 g01079434
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Remove integral seal (3) and O-ring seal (7) from the outlet
bonnet.
6. Remove bolts (13). Rotate core assembly (8) and slide the
core assembly toward the rear of the engine in order to remove the
core assembly from the engine oil filter base. Remove O-ring seals
(12) from the engine oil filter base.
7. Remove bolts (10). Remove oil cooler bonnet (9) from the
water pump. Remove integral seal (11) and O-ring seal (14) from the
oil cooler bonnet.
Illustration 3 g01079448
Copyright 1993 - 2012 Caterpillar Inc.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Cooler - Install SMCS - 1378-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02119144
Table 1
Required Tools
Tool Part Number Part Description Qty A 1U-6396 O-Ring Assembly
Compound -
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Install O-ring seal (14) on oil cooler bonnet (9). Apply
Tooling (A) to the O-ring seal. Install the oil cooler bonnet in
the engine oil cooler.
2. Install integral seal (11) on oil cooler bonnet (9). Position
the oil cooler bonnet on the water pump and install bolts (10)
.
3. Install O-ring seals (12) on the engine oil filter base.
4. Slide core assembly (8) toward the front of the engine.
Rotate the core assembly into position. Install bolts (13) .
Illustration 1 g01079448
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5. Install integral seal (3) and O-ring seal (7) on outlet
bonnet (6). Apply Tooling (A) to the O-ring seal. Position outlet
bonnet (6) and install bolts (4).
6. Connect hose assembly (5) .
7. Connect hose (2) .
8. Connect hose assembly (1) .
9. Fill the cooling system. Refer to Operation and Maintenance
Manual, "Cooling System Coolant - Change".
Illustration 2 g01079434
Illustration 3 g01079420
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Pump - Remove SMCS - 1304-011
Removal Procedure Start By:
A. Remove the engine oil pan. Refer to Disassembly and Assembly,
"Engine Oil Pan - Remove and Install".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02115856
NOTICECare 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.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Remove tube assembly (6). Remove the O-ring seal from the
tube assembly.
2. Remove the suction bell assembly and tube assembly (2).
Remove the O-ring seal from the tube assembly.
3. Remove bolts (5) and remove engine oil pump (1) from the
cylinder block.
4. If necessary, remove bolts (4) and remove underframe assembly
(3) .
Illustration 1 g01077736
Copyright 1993 - 2012 Caterpillar Inc.
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Wed Jan 18 07:52:34 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Pump - Disassemble SMCS - 1304-015
Disassembly Procedure
Start By:
A. Remove the engine oil pump. Refer to Disassembly and
Assembly, "Engine Oil Pump - Remove".
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02020477
Table 1
Required Tools
Tool Part Number Part Description Qty A 1P-2321 Combination
Puller 1
B 1P-0510 Driver Group 1
NOTICECare 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.
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1. Remove the bolt that holds drive gear (1) to the shaft of
engine oil pump (2) .
2. Use Tooling (A) to remove drive gear (1) from the shaft.
Remove the key from the shaft.
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01001918
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3. Remove bolts (6) that hold retainer (9) to pump body (3)
.
4. Remove retainer (9), spring (8), and relief plunger (7) from
the pump body.
5. Remove bolts (12) and cover (10) from the pump body.
Note: Inspect the bores in the cover. The aluminum cover does
not have bearings. If the bores in the cover are damaged, replace
the cover with a new part.
6. Remove idler gear (5) and drive gear (4) from the pump
body.
7. Use Tooling (B) to remove sleeve bearings (11) from pump body
(3) .
Illustration 2 g01043546
Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are
loosened.
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Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:53:05 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Pump - Assemble SMCS - 1304-016
Assembly Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02020480
Table 1
Required Tools
Tool Part Number Part Description Qty B 1P-0510 Driver Group
1
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
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1. Install sleeve bearings (11) in the pump body with Tooling
(B). The bearing joint should be 30 15 degrees from the center line
of the two bearing bores. Install the sleeve bearings so the sleeve
bearings are even with the outside of the pump body.
2. Before final assembly, check the condition and specifications
of all of the parts of the engine oil pump. Refer to Specification,
"Engine Oil Pump".
Illustration 1 g01053962
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3. Lubricate the idler gear and the drive gear with clean engine
oil. Lubricate sleeve bearings (11) with clean engine oil. Install
idler gear (5) and drive gear (4) in pump body (3) .
4. Install cover (10). Install bolts (12) in order to secure the
cover to the pump body.
Note: The engine oil pump must turn freely after assembly. Turn
the engine oil pump by hand. Reposition cover (10) if the engine
oil pump does not turn freely.
5. Install relief plunger (7), spring (8), retainer (9), and
bolts (6) .
6. Install the key on the shaft.
Illustration 2 g01043546
Improper assembly of parts that are spring loaded can cause
bodily injury.
To prevent possible injury, follow the established assembly
procedure and wear protective equipment.
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7. Install drive gear (1) on the shaft of engine oil pump (2).
Install bolt (13) . Tighten the bolt to a torque of 55 10 Nm (41 7
lb ft).
End By: Install the engine oil pump. Refer to Disassembly and
Assembly, "Engine Oil Pump - Install".
Illustration 3 g01043619
Copyright 1993 - 2012 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 18 07:53:43 UTC-0400 2012
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Disassembly and Assembly C15 On-highway Engines
Engine Oil Pump - Install SMCS - 1304-012
Installation Procedure
Shutdown SIS
Previous Screen
Product: TRUCK ENGINE
Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP
Media Number -RENR9403-09 Publication Date -01/02/2008 Date
Updated -20/02/2008
i02183426
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
Illustration 1 g01077736
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1. Position underframe assembly (3) and install bolts (4) .
2. Position engine oil pump (1) on the dowels in the cylinder
block. Install bolts (5) .
Note: Ensure that the engine oil pump is seated on the dowels
before the bolts are tightened.
3. Install the O-ring seal on tube assembly (6). Lubricate the
bore in the engine oil pump with clean engine oil. Install tube
assembly (6) .
4. Install the O-ring seal on tube assembly (2). Lubricate the
bore in the engine oil pump with clean engine oil. Install the
suction bell assembly and tube assembly (2) .
End By: Install the engine oil pan. Refer to Disassembly and
Assembly, "Engine Oil Pan - Re