C4.4 Marine Generator Set Caterpillar

Assembly Procedure

1. Ensure that all components of the air to air charge cooler are free from damage, wear, and restriction. Replace any component that is worn, damaged, or not free from restriction.
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   Illustration 1	g03725270

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   Illustration 2	g03725269

2. Apply Tooling (A) to new seal (13). Install the seal to bottom tank (12). Ensure that the seal is installed correctly into the bottom tank.

3. Apply Tooling (A) to spigot at both ends of core (14).

4. Install core (14) between side rails (15) and side rails (16). Ensure that the core and the seal are correctly located into bottom tank (12).

5. Apply Tooling (A) to new seal (17). Install the seal to top tank (11). Ensure that the seal is installed correctly to the end of the top tank.

6. Install air to air cooler core (14) into bottom tank (12), side rail (15), and side rail (16).

7. Install top tank (11) to side rail (15), and side rail (16).

8. Install the nuts and bolts (9) and the nuts and bolts (10) to top tank (11). Hand tighten the nuts and bolts.

9. Tighten the nuts and bolts (9), the nuts and bolts (10), nuts and bolts (8), and bolts (7) to a torque of 22 N·m (195 lb in).
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   Illustration 3	g03725271

10. Install the assembly of air to air cooler (6) onto radiator (3). Ensure that the assembly of the air to air cooler is correctly aligned onto the radiator.

11. Install the nuts and bolts (4) and the nuts and bolts (5) to the radiator (3). Hand tighten the nuts and bolts.

12. Tighten the nuts and bolts (4) and the nuts and bolts (5) to a torque of 22 N·m (195 lb in).
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    Illustration 4	g03725273

13. Position assembly of radiator (3) on a suitable surface as shown. Ensure that the coolant inlet and the coolant outlet tube assemblies are not damaged.

14. Install grill (2) onto radiator (3). Install bolts (1) to the grill. Tighten the bolts to a torque of 10 N·m (89 lb in).

End By:

1. Install the radiator. Refer to Disassembly and Assembly, "Radiator - Remove and Install" for the correct procedure.