C4.4 Marine Generator Set Caterpillar

Assembly Procedure

1. Ensure that all parts of the aftercooler are clean and free from damage.

   If the tube stack is still contaminated with limescale or with sludge after cleaning, then the tube stack must be replaced. Do not use a contaminated tube stack. The use of a contaminated tube stack could lead to engine failure.

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   Illustration 1	g03619516

2. Install a new O-ring seal (4) to tube stack (3).

3. Install tube stack (3) into housing (5). Ensure that the tube stack is correctly orientated and is seated correctly into the housing.

4. Position a new O-ring seal (2) onto tube stack (3).

5. Position inlet cap (1) onto tube stack (3). Ensure that the inlet cap is correctly orientated.

6. Install allen head bolts (10) to inlet cap (1) hand tight.

7. Position a new O-ring seal (6) onto tube stack (3).

8. Position spacer (7) onto tube stack (3). Ensure that the spacer plate is correctly orientated.

9. Position a new O-ring seal (8) onto tube stack (3).

10. Position outlet cap (9) onto tube stack (3). Ensure that the outlet cap is correctly orientated.

11. Install allen head bolts (11) to outlet cap (9) hand tight.

12. Tighten allen head bolts (10) and allen head bolts (11) to a torque of 22 N·m (195 lb in).

13. If necessary, follow Step 13.a through Step 13.b in order to install drain valve (13).

    1. Install a new O-ring seal (12) to drain valve (13).

    2. Install drain valve (13) to housing (5). Tighten the drain valve to a torque of 22 N·m (195 lb in).

End By:

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