Caterpillar C15 Generator Set

⚠ If new drive belts are installed, check the drive belt tension again after 30 minutes of engine operation at the rated rpm.

1. Remove the drive belt guard.
2. Loosen mounting bolt (1), adjusting nuts (2) and mounting bolt (3).
3. Turn adjusting nuts (2) in order to increase or decrease the drive belt tension.
4. Tighten adjusting nuts (2). Tighten mounting bolt (3). Tighten mounting bolt (1).
5. Reinstall the drive belt guard.

Tools: Marking pen

1. Operate engine until normal operating temperature is achieved; stop engine; remove a crankcase drain plug and drain oil pan completely.
2. Remove used engine oil filter; install new filter; install drain plug; tighten to 70 ± 14 N·m (50 ± 10 lb ft).
3. Add recommended oil: Standard Sump 45.4 L (48 qt); Deep Sump 64 L (68 qt).
4. Start engine; ensure lubrication system and new filter are filled; inspect for leaks.
5. Stop engine; allow oil to drain into crankcase approximately five minutes.
6. Check oil level; use a marking pen to engrave ADD mark (Y).
7. Add 3.8 L (4 qt) recommended oil; full volume now 49.2 L (52 qt) standard sump or 68.1 L (72 qt) deep sump; allow to drain five minutes.
8. Check oil level; use a marking pen to engrave FULL mark (X).

⚠ Ensure that the engine can not be started while this maintenance is being performed.

⚠ Hot engine components can cause burns; allow additional time for the engine to cool before measuring/adjusting valve lash clearance.

1. Initial valve lash adjustment on new, rebuilt, or remanufactured engines is recommended at the first scheduled oil change.
2. Adjust the electronic unit injector (preload) at the same interval as the valve lash adjustment.
3. Only qualified service personnel should perform this maintenance.

⚠ Only qualified service personnel should perform valve lash maintenance.

Tools: 9U-7227 Injector Height Gauge

1. Inspect the injector mechanism for signs of wear.
2. Put the No. 1 piston at the top center position on the compression stroke.
3. Use the 9U-7227 Injector Height Gauge to obtain 78.0 ± 0.2 mm (3.07 ± 0.01 inch) from top of unit injector to machined ledge of fuel injector body.
4. Turn unit injector adjustment screw clockwise until the correct height is obtained.
5. Hold adjustment screw and tighten locknut to 100 ± 10 N·m (75 ± 7 lb ft).
6. For cylinders 1, 2, 3, 7, 8, and 10 remove the timing bolt; turn flywheel 360 degrees counterclockwise (viewed from flywheel end) to put No. 11 piston at top center.
7. Repeat adjustment steps 3 through 4.
8. Remove timing bolt from flywheel; reinstall valve mechanism covers.

1. Remove the fuel filters.
2. Cut the fuel filters open.
3. Inspect the fuel filter before the filter warms. The inspection will show that the filter is filled with particles of either ice or wax.

⚠ The high voltage that is produced by an operating generator set can cause severe injury or death.

⚠ The megohmmeter is applying a high voltage to the circuit. Do not touch the instrument leads without first discharging them.

Tools: 142-5055 Insulation Testing Gp, 9U-6003 Insulation Testing Gp

1. Take the generator out of service.
2. Visually inspect the generator for moisture. If moisture exists, dry the unit first.
3. Discharge the capacitance of the windings.
4. Isolate the stator windings by disconnecting all other leads and cables from the generator terminals.
5. Connect the insulation tester's RED lead to ground.
6. Connect the insulation tester's BLACK lead to the wye point of the generator's windings.
7. Set the voltage to 500 Volts for units of 600 volts or less; 1000 Volts for units more than 600 volts.
8. Apply voltage and observe readings at 30 seconds and 60 seconds. Record the 60 second reading, temperature and humidity.

⚠ Batteries give off combustible gases which can explode.

⚠ The battery cover should be removed before any servicing is attempted.

1. Turn the key start switch to OFF. Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the charger.
3. Disconnect the NEGATIVE "-" cable from the NEGATIVE battery terminal.
4. Disconnect the POSITIVE "+" cable from the POSITIVE battery terminal.
5. Remove the used battery.
6. Install the new battery.
7. Connect the cable from the starting motor to the POSITIVE "+" battery terminal.
8. Connect the cable from the ground plane to the NEGATIVE "-" battery terminal.

⚠ Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated.

1. Ensure that the charger is turned OFF.
2. Adjust the voltage of the charger to match the voltage of the battery.
3. Connect the POSITIVE "+" charger lead to the POSITIVE "+" battery terminal and the NEGATIVE "-" lead to the NEGATIVE "-" terminal.
4. Turn ON the battery charger.

⚠ Do not leave an empty SCA maintenance element on a system that is filled with ELC. The element housing may corrode and leak causing an engine failure.

⚠ Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

⚠ The cooling system cleaner must be thoroughly flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system.

Tools: Caterpillar cleaner for cooling systems, 5P-3413 Pipe Sealant, Suitable containers to collect fluids

1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local regulations.
3. If equipped, remove the empty SCA maintenance element and the element base. Plug the coolant lines or bypass the coolant lines.
4. Flush the system with clean water in order to remove any debris.
5. Use Caterpillar cleaner for cooling systems in order to clean the system. Follow the instructions on the label.
6. Drain the cleaner into a suitable container. Flush the cooling system with clean water.
7. In systems with heavy deposits, disconnect the hoses. Clean deposits and debris from the hoses and fittings. Install the hoses and tighten the hose fittings.
8. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 C to 66 C (120 F to 151 F).
9. Drain the cooling system into a suitable container and flush the cooling system with clean water.
10. Repeat Steps 8 and 9 until the system is completely clean.
11. Fill the cooling system with the Cat ELC.
12. Operate the engine until the engine is warmed. While the engine is running, inspect the engine for leaks. Tighten hose clamps and connections in order to stop any leaks.
13. Attach the Special Publication, PEEP5027, "Label" to the cooling system filler for the engine in order to indicate the use of Cat ELC.

⚠ Check the cooling system only when the engine is stopped and cool.

⚠ Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC.

1. Loosen the cooling system filler cap slowly to relieve pressure. Remove the cap.
2. Drain enough coolant from the cooling system in order to add the Cat ELC Extender.
3. Add Cat ELC Extender according to the requirements for your engine's cooling system capacity.
4. Clean the filler cap. Inspect the gaskets. Replace the cap if the gaskets are damaged. Install the cap.

⚠ Never run the engine without an air cleaner element installed.

⚠ Never service the air cleaner element with the engine running.

1. Remove the cover. Remove the primary air cleaner element.
2. Remove and discard the secondary element for every three cleanings of the primary element.
3. Cover the air inlet with tape in order to keep dirt out.
4. Clean the inside of the air cleaner cover and body with a clean, dry cloth.
5. Remove the tape. Install the secondary element. Install a new or cleaned primary element.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.

⚠ Perform this maintenance with the engine stopped.

1. Remove the six bolts that attach the valve cover to the engine. Remove the valve cover.
2. Loosen the clamp that attaches the breather hose to the breather assembly. Remove the breather assembly.
3. Check the condition of the seal. Replace the seal if the seal is damaged.
4. Remove both breather elements. Wash the elements and the breather in clean nonflammable solvent.
5. Shake the breather elements until dry, or use pressurized air.
6. Install the elements into the breather and install the breather assembly onto the engine.
7. Install the hose onto the access for the breather and tighten the clamp. Install the valve cover and six bolts.