Caterpillar C175-16 Generator Set Engine Manual [, ENG, 62 MB]

RENR7466 May 2007 Disassembly and Assembly Preliminary Information C175-16 Generator Set Engine WYB1-Up (Generator Set)

i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

RENR7466 3 Table of Contents Table of Contents Disassembly and Assembly Section Prelubrication Oil Pump - Remove and Install ....... 4 Electronic Control Module (Engine) - Remove and Install ..................................................................... 5 Fuel Filter Housing - Remove ................................. 6 Fuel Filter Housing - Install ..................................... 7 Fuel Priming Pump - Remove and Install .............. 7 Fuel Transfer Pump - Remove ................................ 8 Fuel Transfer Pump - Install .................................... 9 High Pressure Fuel Rails - Remove and Install ...... 9 Flow Limiter - Remove and Install ........................ 12 Fuel Control Valve - Remove and Install .............. 14 Fuel Pump (High Pressure) - Remove and Install .. 16 Air Cleaner - Remove and Install .......................... 19 Turbocharger - Remove ........................................ 20 Turbocharger - Install ............................................ 21 Aftercooler - Remove and Install ......................... 22 Air Inlet Manifold - Remove and Install ................ 25 Exhaust Elbow - Remove and Install ................... 27 Exhaust Manifold - Remove and Install ............... 28 Water Temperature Control Valve - Remove ........ 29 Water Temperature Control Valve - Install ............ 31 Water Pump - Remove ......................................... 32 Water Pump - Disassemble ................................. 33 Water Pump - Assemble ...................................... 35 Water Pump - Install ............................................. 38 Fuel and Auxiliary Water Pump Drive - Remove and Install ................................................................... 38 Auxiliary Water Pump - Remove .......................... 41 Auxiliary Water Pump - Disassemble ................... 42 Auxiliary Water Pump - Assemble ....................... 43 Auxiliary Water Pump - Install .............................. 45 Engine Oil Cooler - Remove ................................. 46 Engine Oil Cooler - Disassemble ......................... 47 Engine Oil Cooler - Assemble .............................. 48 Engine Oil Cooler - Install ..................................... 48 Engine Oil Pump - Remove .................................. 49 Engine Oil Pump - Disassemble ........................... 52 Engine Oil Pump - Assemble ................................ 53 Engine Oil Pump - Install ...................................... 54 Engine Oil Filter Housing - Remove ..................... 56 Engine Oil Filter Housing - Install ......................... 57 Engine Oil and Water Pump Drive - Remove ....... 57 Engine Oil and Water Pump Drive - Disassemble .. 58 Engine Oil and Water Pump Drive - Assemble ..... 59 Engine Oil and Water Pump Drive - Install ........... 59 Engine Oil Screen - Remove and Install .............. 60 Engine Oil Pan - Remove .................................... 61 Engine Oil Pan - Disassemble .............................. 63 Engine Oil Pan - Assemble ................................... 64 Engine Oil Pan - Install ........................................ 64 Crankcase Breather - Remove and Install ........... 66 Valve Cover - Remove and Install ........................ 67 Rocker Shaft and Push Rods - Remove .............. 68 Rocker Shaft - Disassemble ................................ 68 Rocker Shaft - Assemble ..................................... 69 Rocker Shaft and Push Rods - Install .................. 70 Valve Lifter - Remove ........................................... 70 Valve Lifter - Disassemble .................................... 71 Valve Lifter - Assemble ......................................... 71 Valve Lifter - Install ............................................... 72 Electronic Unit Injector - Remove ......................... 73 Electronic Unit Injector - Install ............................. 74 Electronic Unit Injector Sleeve - Remove ............. 75 Electronic Unit Injector Sleeve - Install ................. 76 Cylinder Head - Remove ...................................... 77 Cylinder Head - Install .......................................... 79 Inlet and Exhaust Valve Springs - Remove and Install ................................................................... 80 Inlet and Exhaust Valves - Remove and Install .... 82 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 84 Inlet and Exhaust Valve Seat Inserts - Remove and Install ................................................................... 85 Inlet Valve Seals - Remove and Install ................. 85 Front Drive Housing - Remove and Install ........... 88 Vibration Damper - Remove and Install ............... 90 Crankshaft Front Seal - Remove .......................... 91 Crankshaft Front Seal - Install .............................. 92 Flywheel - Remove and Install ............................. 92 Crankshaft Rear Seal - Remove ........................... 94 Crankshaft Rear Seal - Install ............................... 95 Flywheel Housing - Remove ................................. 95 Flywheel Housing - Install ..................................... 97 Idler Gears (Front) - Remove and Install ............ 100 Gear Group (Rear) - Remove ............................. 101 Gear Group (Rear) - Install ................................. 102 Piston Cooling Jets - Remove and Install ........... 103 Bearing Clearance - Check ................................. 104 Connecting Rod Bearings - Remove and Install ........................................................................... 105 Crankshaft Main Bearings - Remove .................. 107 Crankshaft Main Bearings - Install ...................... 109 Pistons, Liners, and Connecting Rods - Remove .............................................................. 111 Pistons and Connecting Rods - Disassemble ...... 112 Pistons and Connecting Rods - Assemble .......... 113 Pistons, Liners, and Connecting Rods - Install .... 115 Camshaft - Remove ............................................. 117 Camshaft Bearings - Remove .............................. 119 Camshaft Bearings - Install ................................. 120 Camshaft - Install ................................................ 122 Crankshaft - Remove .......................................... 124 Crankshaft - Install .............................................. 126 Index Section Index ................................................................... 129

4 RENR7466 Disassembly and Assembly Section Disassembly and Assembly Section i02462807 Prelubrication Oil Pump - Remove and Install SMCS Code: 1319-010 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, 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. g01228833 Illustration 1 1. Disconnect harness assemblies (1). Disconnect harness assembly (2). Remove the bolts and disconnect clips (3). Disconnect tube assembly (4). g01228834 Illustration 2 2. Attach a suitable lifting device onto prelubrication pump (10). The weight of prelubrication pump (10) is approximately 41 kg (90 lb). Remove bolts (5). Disconnect tube assembly (6). Remove the bolts and disconnect clip (7). Remove the bolts and disconnect clip (8). Remove bolts (9). Remove prelubrication pump (10). Installation Procedure g01228834 Illustration 3 1. Attach a suitable lifting device onto prelubrication pump (10). The weight of prelubrication pump (10) is approximately 41 kg (90 lb). Install prelubrication pump (10). Install bolts (9). Connect clip (7) and the bolt. Connect tube assembly (6). Install bolts (5). Connect clip (8) and the bolt.

RENR7466 5 Disassembly and Assembly Section g01228833 Illustration 4 2. Connect tube assembly (4). Connect clips (3) and install the bolts. Connect harness assembly (2). Connect harness assemblies (1). i02422161 Electronic Control Module (Engine) - Remove and Install SMCS Code: 1900-010 Removal Procedure g01210403 Illustration 5 1. Remove bolts (1) from both sides of box (3). Remove cover (2). g01210407 Illustration 6 2. Disconnect harness assemblies (6) and (7). Remove bolts (5). Remove electronic control module (4). Installation Procedure g01210407 Illustration 7 1. Position electronic control module (4). Install bolts (5). Connect harness assemblies (6) and (7). Tighten the connectors for harness assemblies (6) and (7) to a torque of 6 ± 1 N·m (53 ± 9 lb in). g01210403 Illustration 8 2. Install cover (2) onto box (3). Install bolts (1) on both sides of box (3).

6 RENR7466 Disassembly and Assembly Section i02438952 Fuel Filter Housing - Remove SMCS Code: 1262-011 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Turn the fuel supply to the OFF position. g01218837 Illustration 9 2. Remove bolts (1). Disconnect clamps (2) and (3). Remove bolts (4). Disconnect clamps (5). g01218838 Illustration 10 3. Disconnect harness assembly (6). Disconnect fitting (7). Disconnect fitting (9). Remove tube assembly (8). g01218840 Illustration 11 4. Disconnect harness assembly (10). Remove tube assembly (11). g01218841 Illustration 12 5. Remove bolts (13). Remove fuel filter housing (12). The weight of fuel filter housing (12) is approximately 23 kg (50 lb).

RENR7466 7 Disassembly and Assembly Section i02439510 Fuel Filter Housing - Install SMCS Code: 1262-012 Installation Procedure g01218841 Illustration 13 1. Install fuel filter housing (12). The weight of fuel filter housing (12) is approximately 23 kg (50 lb). Install bolts (13). g01218840 Illustration 14 2. Install tube assembly (11). Connect harness assembly (10). g01218838 Illustration 15 3. Position tube assembly (8). Connect fitting (9). Connect fitting (7). Connect harness assembly (6). g01218837 Illustration 16 4. Connect clamps (5). Install bolts (4). Connect clamps (2) and (3). Install bolts (1). 5. Turn the fuel supply to the ON position. i02434239 Fuel Priming Pump - Remove and Install SMCS Code: 1258-010 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the fuel supply to the OFF position.

8 RENR7466 Disassembly and Assembly Section g01216054 Illustration 17 2. Disconnect hose assemblies (1) and (3). Disconnect harness assembly (4). Remove bolts (2). Remove fuel priming pump (5). Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g01216054 Illustration 18 1. Install fuel priming pump (5). Install bolts (2). Connect harness assembly (4). Connect hose assemblies (1) and (3). 2. Turn the fuel supply to the ON position. i02433497 Fuel Transfer Pump - Remove SMCS Code: 1256-011 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Turn the fuel supply to the OFF position. g01215984 Illustration 19 2. Disconnect fitting (3) at the bottom of tube assembly (2). Loosen fitting (1) at the top of tube assembly (2). Position tube assembly (2) out of the way. Disconnect hose assemblies (4) and (5). Disconnect harness assembly (6).

RENR7466 9 Disassembly and Assembly Section g01215654 Illustration 20 3. Remove bolts (7). Remove fuel transfer pump (8). i02434219 Fuel Transfer Pump - Install SMCS Code: 1256-012 Installation Procedure g01215654 Illustration 21 1. Install fuel transfer pump (8). Install bolts (7). g01215984 Illustration 22 2. Connect harness assembly (6). Connect hose assemblies (4) and (5). Position tube assembly (2). Connect fitting (3) at the bottom of tube assembly (2). Tighten fitting (1) at the top of tube assembly (2). 3. Turn the fuel supply to the ON position. i02683811 High Pressure Fuel Rails - Remove and Install SMCS Code: 1274 Removal Procedure Start By: a. Remove the air inlet manifold. Refer to Disassembly and Assembly, “Air Inlet Manifold - Remove and Install”. b. Remove the flow limiters. Refer to Disassembly and Assembly, “Flow Limiters - Remove and Install”. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, 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 Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury. Note: If necessary, cap tube assemblies, fittings, ports, and any opening in the fuel system in order to prevent contamination.

10 RENR7466 Disassembly and Assembly Section g01285837 Illustration 23 1. Remove bolt (1) and the clamp from tube assembly (2). g01285006 Illustration 24 g01285319 Illustration 25 2. Remove bolts (5). Remove bolts (3). Remove bolts (4). Disconnect tube assembly (6). Remove tube assembly (2) and the O-ring seals. g01285008 Illustration 26 g01285323 Illustration 27 3. Remove bolts (9). Remove bolts (10) and bolts (11). Repeat for the opposite side. 4. Remove tube assembly (7). Remove tube assembly (8) and the O-ring seal. g01285012 Illustration 28 5. Attach a suitable lifting device onto fuel rail (13). The weight of fuel rail (13) is approximately (). Remove bolts (12). Remove fuel rail (13). 6. Repeat Step 5 for the opposite side.

Caterpillar C175-16 Generator Set Engine Manual [, ENG, 62 MB]

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