Procedure to Replace the Current Alternator Mounting Groups with Improved Alternator Mounting Groups on Certain C15 and C18 Engines{1154, 1405} Caterpillar

Industrial Engine:

C-15 (S/N: BEM1-UP)

C15 (S/N: JRE1-UP; MCW1-UP)

C18 (S/N: WJH1-UP; WRH1-UP)

Petroleum Engine:

C15 (S/N: JDK1-UP; JDY1-UP)

C18 (S/N: WJW1-UP; WJY1-UP)

Introduction

This Special Instruction contains the procedures to replace the old engine alternator mounting groups with new engine alternator mounting groups. This change will help prevent vibration damage present in the old alternator mounting group design.

Note: If the engine in question has a support assembly that is not cast iron, the following additional parts will have to be ordered, 6L-7283 Bolt , 7X-0339 Bolt and 9S-8752 Full Nut

Safety Section

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Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts. When working on an engine that is running, avoid contact with hot parts and rotating parts.

Change from the Old 118-3419 Alternator Mounting Gp to the New 449-4904 Alternator Mounting Gp

Disassembly of the 118-3419 Alternator Mounting Gp (Old)

Illustration 1	g03478246

1. Remove the V-belt

2. Remove the alternator mounting hardware and adjusting rod indicated in Illustration 1.

   Note: Retain specified hardware for reassembly.

Assembly of the 449-4904 Alternator Mounting Gp (New)

Illustration 2	g03479597

Illustration 3	g03485322
Alternator support group (Typical example for all new group mountings) (7) 1F-7958 Full Nut (1/2"-13) (8) 4Y-3046 Washer (Hard) 3 mm (0.12 inch) (9) 437-7746 Mount (Rubber Isolator) (10) 5P-8245 Hard Washer 3 mm (0.12 inch) thick (11) 9H-8260 Bolt .

1. Mount support assembly (6) and secure with bolt (3), two washers (2), and nut (1). Also secure with bolt (5), and washer (4). Refer to Illustration 2.

   Note: Assemble in mounting location "A".

2. . Assemble the alternator to the support assembly (6) with bolt (11), washers (8) (10), mounts (9) and nut (7) .

   Note: Place washer (8) on the inside next to the mount (9) on the nut side. Refer to Illustration 3 for locations and specifications.

   Note: Torque bolt (11) to 105 ± 20 N·m (77 ± 15 lb ft).

3. Assemble adjusting rod (17), one jam nut (16), and rod end (18) to the engine mount, with bolt (21), washers (20), and nut (19). Tighten the assembly to the proper torque.

   Note: Use a backup wrench to secure the rod end (18) when tightening the jam nut against the rod end. Torque the jam nut (16) to 40 N·m (30 lb ft)

Note: Assemblies in Step 4 are to be assembled hand tight, so that the alternator V belt can be adjusted prior to final torque of the components.

4. Assemble adjusting rod (17) to the alternator using block (15), two jam nuts (16), bolt (14) and washers (12) (13) .

5. Install the V-belt (22) and adjust belt tension according to the following procedure.

   1. With both rod adjustment jam nuts (16) loose, release rod block bolt by ? turn.

   2. Drape belt around the pulleys.

   3. Check that the belt fits in the pulley grooves.

   4. Set belt tension (180 +/- 10 lbs).

   5. Torque rod block bolt (14).

   6. Torque outside jam nut (16) while holding the inside jam nut (16) to maintain correct positioning. Torque to 40 N·m (30 lb ft).

Change from the Old 270-8444 Alternator Mounting Gp to the New 444-6556 Alternator Mounting Gp

Disassembly of the 270-8444 Alternator Mounting Gp (Old

Illustration 4	g03481345

1. Remove the V-belt

2. Remove the alternator mounting hardware and adjusting rod indicated in Illustration 4.

   Note: Retain specified hardware for reassembly.

Assembly of the 444-6556 Alternator Mounting Gp (New)

Illustration 5	g03481484

1. Mount support assembly (6) and secure with bolt (3), two washers (2), and nut (1). Also secure with bolt (5), and washer (4). Refer to Illustration 5.

   Note: Assemble in mounting location "B".

2. . Assemble the alternator to the support as (6) with bolt (11), washers (8) (10), mounts (9) and nut (7) .

   Note: Place washer (8) on the inside next to the mount (9) on the nut side. Refer to Illustration 3 for locations and specifications.

   Note: Torque bolt (11) to 105 ± 20 N·m (77 ± 15 lb ft).

3. Assemble adjusting rod (17), one jam nut (16), and rod end (18) to the engine mount, with bolt (21), washers (20), and nut (19). Tighten the assembly to the proper torque.

   Note: Use a backup wrench to secure the rod end (18) when tightening the jam nut against the rod end. Torque the jam nut (16) to 40 N·m (30 lb ft)

Note: Assemblies in Step 4 are to be assembled hand tight, so that the alternator V belt can be adjusted prior to final torque of the components.

4. Assemble adjusting rod (17) to the alternator using block (15), two jam nuts (16), bolt (14) and washers (12) (13) .

5. Install the V-belt (22) and adjust belt tension according to the specifications.

   1. With both rod adjustment jam nuts (16) loose, release rod block bolt by ? turn.

   2. Drape the belt around the pulleys.

   3. Check that the belt fits in the pulley grooves.

   4. Set belt tension (180 +/- 10 lbs).

   5. Torque rod block bolt (14) .

   6. Torque outside jam nut (16) while holding the inside jam nut (16) to maintain correct positioning. Torque to 40 N·m (30 lb ft).

Change from the Old 135-5077 Alternator Mounting Gp to the New 449-4905 Alternator Mounting Gp

Disassembly of the 135-5077 Alternator Mounting Gp (Old)

Illustration 6	g03483416

1. Disconnect the V-belt. (Retain for reassembly)

2. Remove the alternator mounting hardware and adjusting rod indicated in Illustration 6.

   Note: Retain specified hardware for reassembly.

Assembly of the 449-4905 Alternator Mounting Gp (New)

Illustration 7	g03483519

1. Mount support assembly (6) and secure with bolt (3), two washers (2), and nut (1). Also secure with bolt (5), and washer (4). Refer to Illustration 7.

   Note: Assemble in mounting location "A".

2. Assemble the alternator to the support assembly (6) with bolt (11), washers (8) (10), mounts (9) and nut (7) .

   Note: Place washer (8) on the inside next to the mount (9) on the nut side. Refer to Illustration 3. for locations and specifications.

   Note: Torque bolt (11) to 105 ± 20 N·m (77 ± 15 lb ft).

3. Assemble adjusting rod (17), one jam nut (16), and rod end (18) to the engine mount by fastening with bolts (20) (23), washers (19) (22) and block (21) .

   Note: Use a backup wrench to secure the rod end (18) when tightening the jam nut (16) against the rod end. Torque the jam nut (16) to 40 N·m (30 lb ft)

Note: Assemblies in Step 4 are to be assembled hand tight, so that the alternator V belt can be adjusted prior to final torque of the components.

4. Assemble adjusting rod (17) to the alternator using block (15) and by fastening with two jam nuts (16), bolt (14), and washers (12) (13) .

5. Install V-belt (24) and adjust the belt tension according to the following procedure.

   1. With both rod adjustment jam nuts (16) loose, release rod block bolt (14) by ? turn.

   2. Drape the belt around the pulleys.

   3. Check that the belt fits in the pulley grooves.

   4. Set belt tension (180 +/- 10 lbs).

   5. Torque rod block bolt (14) .

   6. Torque outside jam nut (16) while holding the inside jam nut (16) to maintain correct positioning. Torque to 40 N·m (30 lb ft).

Change from the Old 9E-6169 Alternator Mounting Gp to the New 451-7227 Alternator Mounting Gp

Disassembly of the 9E-6169 Alternator Mounting Gp (Old)

Illustration 8	g03519116

1. Disconnect the V-belt. (Retain for reassembly)

2. Remove the alternator mounting hardware and adjusting rod indicated in Illustration 8

   Note: Retain specified hardware for reassembly.

Assembly of the 451-7227 Alternator Mounting Gp (New)

Illustration 9	g03519757

1. Mount support assembly (6) and secure with bolt (3), two washers (2), and nut (1). Also secure with bolt (5), and washer (4). Refer to Illustration 9.

   Note: : Assemble in mounting location "A".

2. Assemble the alternator to the support assembly (6) with bolt (11), two washers (10), two mounts (9), washer (8), and nut (7) .

   Note: Place washer (8) on the inside next to mount (9) on the nut side. Refer to Illustration 3 for locations and specifications.

   Note: Torque bolt (11) to 105 ± 20 N·m (77 ± 15 lb ft).

3. Assemble the adjusting rod (17), one jam nut (15), and the rod end (18) to the engine mount fastening the adjusting rod with bolt (21), two washers (20) and nut (19) .

   Note: Use a backup wrench to secure the rod end (18) when tightening the jam nut (15) against the rod end. Torque the jam nut (15) to 40 N·m (30 lb ft)

Note: Assemblies in Step 4 are to be assembled hand tight, so that the alternator V belt can be adjusted prior to final torque of the components.

4. Assemble the adjusting rod (17) to the alternator with the block (16) and fastening with two jam nuts (15), bolt (14), washer (13) and washer (12) .

5. Assemble the V-belt (22) and adjust belt tension according to specification.

   1. With both rod adjustment jam nuts (15) loose, release rod block bolt (14) by ? turn.

   2. Drape the belt around the pulleys.

   3. Check that the belt fits in the pulley grooves.

   4. Set belt tension (180 +/- 10 lbs).

   5. Torque rod block bolt (14) .

   6. Torque outside jam nut (15) while holding the inside jam nut (15) to maintain correct positioning. Torque to 40 N·m (30 lb ft).