C6.6 Marine Generator Set Caterpillar

Removal Procedure

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

1. The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repairs is performed.

2. Turn the battery disconnect switch to the OFF position.

3. Turn the air supply at the air reservoir to the OFF position. Ensure that the air pressure is drained from the starting air system.

4. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.
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   Illustration 1	g01692375

5. Remove the nut and bolt (3) (not shown). Remove spacer (4) (not shown) from tube clips (5).

6. Loosen hose clamp (2) and hose clamp (7).

7. Remove tube assembly (6) from the turbocharger and air to air charge cooler (1).
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   Illustration 2	g01704233

8. Disconnect harness assembly (12) from coolant level switch (10).

9. Remove bolts (13) from tube clips (14). Disconnect plastic tube assembly (15) from radiator assembly (8).

10. Disconnect plastic tube assembly (9) from radiator assembly (8).

11. Remove nuts (11) and remove coolant level switch (10) from the radiator assembly.
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    Illustration 3	g01704374

12. Disconnect vent tube (16) from tube assembly (17).

13. Loosen hose clamp (18) (not shown) and hose clamp (19) (not shown). Remove tube assembly (17) from the water temperature regulator and the radiator assembly.
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    Illustration 4	g01704213

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    Illustration 5	g01693735

14. Disconnect vent tube (20) from exhaust manifold (21) (not shown).

15. Loosen hose clamp (22) and hose clamp (24). Remove tube assembly (23) from air to air charge cooler (1) to the elbow for the inlet manifold.

16. Loosen hose clamp (25) and disconnect tube assembly (26) from the bottom of the radiator assembly.
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    Illustration 6	g01692393

17. Remove bolts (33) from alternator guards (34) and remove the alternator guard.

18. Remove bolts (31) and remove panel (32).

19. Remove bolts (35) and remove guard (36).

20. Remove bolts from guard (30) and remove the guard from the air to air charge cooler.

21. Remove nuts and bolts (27) from guard (29). Remove bolts (28) from guard (29). Remove the guard from radiator assembly.
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    Illustration 7	g01693734

22. Remove bolts (39) from panel (40) and remove the panel.

23. Remove bolts (37) and remove guards (38) from radiator assembly (8).

24. Remove bolts (43) and remove guards (44).

25. Attach a suitable lifting device to radiator assembly (8). The weight of radiator assembly (8) is approximately 90 kg (198 lb).

26. Mark the position on base frame (45) for radiator assembly (8) for installation purposes.

27. Remove bolts (42). Move the radiator assembly forward to the front of the base frame.

28. Use the suitable lifting device in order to remove radiator assembly (8) from base frame (45).