3412E, C30 and C32 Marine Engines Caterpillar

Assembly Procedure

Note: The following story is for 373-2564 Sea Water Heat Exchanger Gp.

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Illustration 1	g02720226

1. Install hose connector (12) on filler neck (16). Install O-ring seal (17) on the filler neck.

2. Position filler neck (16) on rear frame (8). Install bolts (14).

3. Install pressure cap (11).

4. Use Tooling (F) to install lip seals (18) in rear frame (8).

5. Install O-ring seal (13) on cover (10). Install water temperature regulators (15). Position cover (10) on rear frame (8) and install bolts (9).

   Note: Align the marks on the elbows and the rear frame to ensure proper orientation.

6. Install elbow (20) and elbow (19). Ensure that the elbows are in the proper orientation. Install the zinc rods in elbow (20) and elbow (19).
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   Illustration 2	g02149033

7. Install seals (7) in the elbows and rear frame (8).
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   Illustration 3	g02149052

8. Position the new seal on the heat exchanger plate. Install tabs (X) of the seal into the slots of heat exchanger plate (6).
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   Illustration 4	g02720317
   Alternate Plates (k) and Plates (l), and Plates (l) and Plates (d), with the associated seal. (a) 125-5595 Seal (b) 374-5494 Transition Plate (c) 125-5594 Seal (d) 266-9518 Plate (e) 125-5600 Seal (f) 266-9514 Plate (g) 374-5517 Turn Plate (h) 294-8676 Turn Plate (k) 266-9516 Plate (l) 266-9515 Plate (m) 374-5493 End Plate (n) 151-5257 Ring Seal

   Note: Use a new seal on the heat exchanger plates for the fuel.

   Note: Ensure the proper order and orientation of the heat exchanger plates and the seals.

   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.

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   Illustration 5	g02149027

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

10. Install Tooling (B) in the rear frame. Ensure that Tooling (B) is 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 6	g02149028

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

12. Install spacers (5) and bolts (4).
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    Illustration 7	g02149025

13. Remove Tooling (A) and install the spacers and bolts (3) in front frame (2).
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    Illustration 8	g02149026

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    Illustration 9	g01059447

14. 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 140 kPa (20 psi) and close off the circuit.

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

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

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

   7. Leave (SW) and (JW) pressurized. Repeat Step 1.a through Step 1.c with the (FC).

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.

End By:

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