C4.4 Marine Generator Set Engines Caterpillar

Removal Procedure

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.

2. Loosen the hose clamps and remove the hose from the water pump inlet.

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Illustration 1	g01263054
Typical example

3. Remove bolts (4) . The bolts are different lengths. Note the positions of the different bolts.

   Note: Do not remove bolts (7) at this time.

4. Remove water pump (3) from front cover (1) .

   Note: If necessary, tap the water pump with a soft hammer in order to loosen the water pump.

5. Remove gasket (2) .

6. If necessary, remove cover (6) from the water pump. Follow Steps 6.a through 6.c in order to remove the cover.

   1. Remove bolts (7) .

   2. Remove cover (6) .

   3. Remove gasket (5) .

Disassembly Procedure

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Illustration 2	g03367454
Typical example

1. Remove bolts (2) from cover (3) of the assembly of water pump (1) . Remove gasket (4) (not shown) and cover (3) .

   Note: All of the other bolts are removed during the removal of the water pump.

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Illustration 3	g03367455
Typical example

2. Use Tooling (B) in order to drill 12 holes between the existing holes in the impeller (5) . Break pieces from the impeller (5) .

3. Install a suitable two legs puller (6) onto the remaining boss of impeller (5) .

4. Use the suitable two legs puller (6) in order to remove the remaining boss of impeller (5) .

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Illustration 4	g03367456

5. Breaking coolant seal (10) will be necessary in order to remove the coolant seal from water pump (1) .

6. Use Tooling (B) in order to drill three holes that are equally spaced into coolant seal (10) . The holes should be drilled into the face of coolant seal (10) that would have faced impeller (5) .

7. Use Tooling (A) in order to remove coolant seal (10) off the shaft (11) . Alternate the position of Tooling (A) from one hole to another. Alternating the position of Tooling (A) will allow the coolant seal to be easily removed from water pump (1) .

8. If necessary, remove the center sleeve of the coolant seal from the shaft with a suitable extractor.

9. Remove outer circlip (14) .

10. Remove inner circlip (13) .

11. Support machined Face (X) of water pump (1) on a suitable support. Press on the shaft (11) until the gear (12) and the bearing (9) are free from the shaft.

12. Discard shaft (11) , bearing (9) . Remove the gear (12) through the side of water pump (1) .

13. Insert a suitable mandrel onto oil seal (8) and press the oil seal out of water pump (1) .

14. The oil seal (8) can be removed through the side of water pump (1) after the seal has been released from the water pump.

15. Support the machined Face (Y) of water pump (1) on a suitable support.

16. Use a suitable mandrel to press needle bearing (7) out of water pump (1) .

Assembly Procedure

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Illustration 5	g03367456

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Illustration 6	g03367477

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Illustration 7	g03367457
(A) 54.0 mm (2.126 inch) (B) 6.0 mm (0.236 inch) (C) 10.0 mm (0.394 inch) (D) 48.0 mm (1.890 inch) (E) 44.0 mm (1.732 inch) (F) 18.0 mm (0.709 inch) (G) 54.0 mm (2.126 inch)

1. Thoroughly clean the inside of the housing of water pump (1) . Ensure that the bores for needle bearing (7) , bearing (9) and coolant seal (10) are clean and free from corrosion.

2. Inspect gear (12) for wear and damage. If necessary, replace gear (12) .

3. Support machined Face (Y) of water pump (1) on a suitable support.

4. Use a suitable mandrel to press a new oil seal (8) into water pump (1) . Ensure that the new oil seal is correctly orientated before pressing the oil seal into the water pump.

5. Stop pressing oil seal (8) into water pump (1) when the lower face of the oil seal is level with the lower Face (Z) of the recess for the oil seal.

6. Install the gear (12) through the side of water pump (1) . Use a suitable adapter to press shaft (11) through oil seal (8) and into gear (12) . Continue to press the shaft (11) into gear (12) until there is a gap of 1.5 mm (0.060 inch) between the gear and the top of the housing for the gear within water pump (1) .

7. Use a suitable adapter in order to press bearing (9) against the shoulder of the recess for the bearing.

8. Install a new circlip (13) into the recess water pump (1) . Install a new circlip (14) into the recess in shaft (11) . Ensure that circlip (13) and circlip (14) are installed into the recess correctly.

9. Support machined Face (X) of water pump (1) on a suitable support. Press needle bearing (7) into the housing for the bearing. Continue to press needle bearing (7) into the housing until the needle bearing is either level with the top face of the housing or the needle bearing is no more than a maximum of 0.5 mm (0.020 inch) below the top face of the housing.

10. Support machined Face (Y) of water pump (1) on a suitable support.

Note: Avoid hand contact with the coolant seal (10) . The coolant seal (10) must not be contaminated by oil or grease. The coolant seal (10) must only be touched and/or held at the edge of the outer flange.

Note: Do not lubricate the coolant seal (10) .

11. Manufacture a suitable tool in order to press the coolant seal (10) into position. The tool should be made to the dimensions shown in the illustration 7.

12. Position a new coolant seal (10) onto shaft (11) with the largest diameter of the coolant seal toward bearing (9) .

13. Use the manufactured tooling in order to push coolant seal (10) onto the shaft (11) until the coolant seal is in contact with the counterbore for the coolant seal. Ensure that coolant seal (10) is square with the counterbore. Use a suitable adapter in order to press the coolant seal (10) into the counterbore until the outer flange of the coolant seal is in contact with the body of water pump (1) . Maintain the pressure on coolant seal (10) for about 10 seconds in order to ensure that the coolant seal remains in position.

14. Press the impeller (5) onto the shaft (11) until the top of the impeller is level with the top of the shaft.

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Illustration 8	g03367454
Typical example

15. Install a new gasket (4) (not shown) onto water pump (1) . Ensure that the gasket is correctly orientated.

16. Position cover (3) to the water pump (1) .

17. Install bolts (2) and tighten the bolts finger tight.

    Note: The bolts will be fully tightened after the water pump has been installed.

Installation Procedure

1. Ensure that the water pump is clean and free from wear or damage. If necessary, replace the water pump.

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Illustration 9	g01269391
Typical example

2. If necessary, install cover (6) to water pump (3) . Follow Steps 2.a through 2.d in order to install the cover.

   1. Clean the gasket surface of cover (6) .

   2. Position a new gasket (5) onto water pump (3) .

   3. Install cover (6) to water pump (3) .

   4. Install bolts (7) to cover (6) . Tighten the bolts finger tight.

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Illustration 10	g03367020

3. Clean the gasket surface of front cover (1) .

4. Install Tooling (C) in position (X) .

5. Use Tooling (C) in order to align a new gasket (2) to front cover (1) . Install the gasket to the front cover.

6. Align water pump (3) with Tooling (A) . Install the water pump to front cover (1) .

   Note: Ensure that the gear of the water pump and the gear of the fuel injection pump mesh.

7. Install bolts (4) . Refer to Illustration 9. Tighten the bolts finger tight.

   Note: Ensure that bolts of different lengths are installed in the correct positions.

8. Remove Tooling (C) and install remaining bolts (4) finger tight.

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Illustration 11	g01269393
Tightening sequence for the water pump

9. Tighten bolts (4) and bolts (7) to a torque of 22 N·m (16 lb ft). Refer to Illustration 9. Tighten the bolts in the sequence that is shown in Illustration 11.

10. Install the hose to the water pump inlet. Securely tighten the hose clamps.

11. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.