C18 Generator set and C18 Marine Engines Caterpillar

Assembly Procedure

Note: Check the O-ring seals and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g02718244

1. Install hose connector (14) on filler neck (15). Install O-ring seal (16) on the filler neck.

2. Position filler neck (15) on the frame assembly. Install bolts (13).

3. Install pressure cap (12).
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   Illustration 2	g02718243

4. Use Tooling (F) to install lip seal (11) in the frame assembly.
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   Illustration 3	g02718239

5. Install inserts (10).

6. Install elbows (8) and zinc plugs (9). Ensure that elbows (8) are in the proper orientation.

7. Install seals (7) in elbows (8).

8. Install Tooling (B) and Tooling (A) in the frame assembly. Ensure that Tooling (B) and Tooling (A) are securely installed. Apply Tooling (C) to the threads of the nut and the threads of the guide stud prior to installation.
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   Illustration 4	g02146574

9. Position the new seals on the heat exchanger plate. Install tabs (T) of the seals into the slots of heat exchanger plate (6).
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   Illustration 5	g06014758

   Note: Type 1 heat exchanger

   Note: Do not use the old gasket.

   Note: Heat Exchanger Plate (Y) and Heat Exchanger Plate (Z) are identical. The orientation of the dimple (one dimple) on the heat exchanger plate is critical during the assembly of the heat exchanger plates. Heat Exchanger Plate (Y) and Heat Exchanger Plate (Z) are for the jacket water in the heat exchanger.

   Note: Heat Exchanger Plate (X) has notches that are stamped in the heat exchanger plate. The notches identify the ports that are blocked to prevent coolant flow. Heat Exchanger Plate (X) is installed against the front frame.Position the flat side of the seal against the frame assembly.

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   Illustration 6	g06015789
   (a) 125-5595 Seal (a1) 377-3077 End Plate (e1) 374-5493 End Plate (e) 125-5600 Seal (b) 125-5600 Seal (b1) 266-9515 Plate (c) 125-5594 Seal (c1) 266-9516 Plate (d) assembly

   Note: Type 2 heat exchanger

   Note: Plates shown will come with adjoining seal.

   Note: Ensure the proper order and orientation of the heat exchanger plates and the seals. Refer to illustration 6

   Note: The seals on the heat exchanger plates should face the front frame during installation.

   Note: Use Tooling (A) to ensure that the heat exchanger plates are properly aligned.

   Note: Ensure that the edges of the heat exchanger plates are properly aligned and the seals are in the proper grooves in the heat exchanger plates.

   Note: If the heat exchanger plates appear stuck together, or do not align during installation, the heat exchanger plates edges can be lightly lifted and adjusted.

10. Orient plates.
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    Illustration 7	g02138403
    Typical Example

11. Install heat exchanger plates (6), the seals, and front frame (2).

12. Place top spacers (5) in position. After heat exchanger plates (6) are compressed, access to top spacers (5) will be limited.

13. Tighten the nuts on Tooling (B) evenly until the front frame is approximately 13 mm (0.5 inch) from the top spacers.

    Note: As the front frame lowers, the heat exchanger plates will slide along Tooling (A).

    Note: Check the heat exchanger plates, the seals, and the seal tabs frequently during compression to ensure proper alignment. Ensure that the seals are not pinched during compression. A pinched seal will be observed by the edges of the adjacent heat exchanger plates separating slightly.

    Note: If the heat exchanger plates are improperly aligned during compression, the front frame can be loosened and the heat exchanger plates lightly adjusted.

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    Illustration 8	g02139225

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    Illustration 9	g01059447

14. Install bolts (4) for the top spacers. Install bottom spacers (5) and bolts (4). Remove Tooling (A) and install the spacers and bolts (3). Remove Tooling (B) and install the spacers and bolts (1).

15. Tighten all the bolts evenly for one full turn until the front frame contacts the spacers. Tighten the bolts in a numerical sequence to a torque of 115 ± 6 N·m (85 ± 4 lb ft).

Leak Checking the Heat Exchanger

Note: Leak checking of the heat exchanger should be completed before installation on the engine.

1. Install Tooling (G) on the ports of the heat exchanger.

   1. Attach an air hose to one end of Tooling (G) on the sea water (SW) circuit.

   2. Verify that flow through is achieved on (SW).

   3. Pressurize (SW) at 138 kPa (20 psi) and close off the circuit.

   4. Close one end of jacket water (JW) circuit.

   5. Attach a hose to the other end of (JW). Place the end of the hose under water and check for bubbles with (SW) pressurized. A continuous stream of bubbles from the hose would indicate an internal leakage in the heat exchanger. An internal leakage indicates that the heat exchanger was improperly assembled.

   6. Leave (SW) pressurized. Repeat Step 1.a through Step 1.c with the (JW).

2. With all circuits pressurized and closed off, submerge the entire heat exchanger and check for a continuous stream of bubbles from the heat exchanger. Bubbles may be present initially when the heat exchanger is submerged, but the bubbles should stop after a few minutes.
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   Illustration 10	g02183700
   Cross-section of Plate Assembly

3. The seals on the heat exchanger plates contain weep holes at Locations (H). As a result, bubbles may be present near Locations (H). The bubbles should stop after a few minutes. Leave the entire heat exchanger submerged until bubbles stop coming from the weep holes.

   Note: Once the heat exchanger is installed on the engine and started, water may leak out of the weep holes. After a short time, the water leak will stop. The leak is not an indication of a faulty heat exchanger.

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1. Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".