Installation Procedure for the New Floating Aftercooler Core for Certain C30 and C32 Marine Engines{1063, 1380, 3319} Caterpillar

Marine Engine:

C30 MARINE (S/N: CLX1-UP)

C32 MARINE (S/N: RXB1-UP; SLT1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Effectivity

Table 1 shows the effectivity for the new floating aftercooler core.

Parts

Refer to Table 2 for the correct parts that are used to convert the 195-5220 Raw Water Aftercooler Gp to the new 286-7913 Raw Water Aftercooler Gp .

Refer to Table 3 for the correct parts that are used to convert the 203-2230 to the new 290-2305 . The 290-2305 Auxiliary Sea Water Lines Gp is used with the new 286-7913 Raw Water Aftercooler Gp .

Refer to Table 4 for the correct parts that are used to convert the 264-7813 Auxiliary Sea Water Lines Gp to the new 318-0719 Auxiliary Sea Water Lines Gp . The 318-0719 Auxiliary Sea Water Lines Gp is used with the new 286-7913 Raw Water Aftercooler Gp .

Installation Procedure

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Illustration 1	g01445910

1. Install the gasket between the new base assembly and the engine. Install the new base assembly (3) on the engine. Install bolts (2). Install the two locating dowels (1) into the base assembly. Make sure that the dowels are deep enough to allow the cover and the seat to sit on the base. Leave about 6 mm (0.24 inch) from the base.

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Illustration 2	g01434880

2. Install the temperature sensor and the pressure sensor into the base assembly. Also connect the harness assemblies (4) to the base assembly.

Note: Illustration 1 shows the new base assembly. Illustration 2 shows the old base assembly.

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Illustration 3	g01434882

3. Install the new seal (5) on the core assembly. Install the O-rings (6) on the ports. Use lubrication on the O-rings.

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Illustration 4	g01434883
(7) Lines group for air (8) Mounting bolts for the core assembly (9) Cover Assembly for the aftercooler (10) Mounting bolts for the cover assembly (11) Adapter (12) Lines group for water

4. Position the cover (9) on the core assembly. The weight of the cover (9) is approximately 23 kg (50 lb).

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Illustration 5	g02096185

5. Install the bolts (8) with the washers, the seals, and the spacers that attach the core assembly to the cover. Illustration 5 shows the bolts, washers, and spacers.

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Illustration 6	g01434885

6. Torque the bolts (8) to 25 ± 6 N·m (19 ± 5 lb ft).

7. Install tooling (A) and a suitable lifting device on the cover (9). The weight of the cover (9) and the core assembly is approximately 79 kg (175 lb).

8. Secure the housing to the base with the bolts, the seals, and the washers. The dowels must be installed deeper into the base if the housing does not sit flush on the base.

9. Connect the air tube assemblies. The air tube assemblies do not have any changes.

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Illustration 7	g01434887
An adapter

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Illustration 8	g01434889
The adapters are installed.

10. Install the adapters (11) for the tubes for the salt water. This includes the new adapter and the new isolation seal. When the adapters (11) are installed, ensure that the ports from the core assembly are in a centered position in the opening of the housing. Do not force the adapters onto the ports if the ports are not centered in the opening in the housing. This may cause a port failure, and salt water to leak into the engine.

11. Install the new flange, the insert, and the O-rings on the tubes.

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Illustration 9	g01434891

12. Install the tube assemblies (12) .

13. Refill the raw water coolant system. Open the sea cock and check for leaks.