C4.4 Marine Generator Set Caterpillar

Removal Procedure

1. The engine start automatically. 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. If the engine is equipped with an air starting motor. 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. Turn the valve for the sea water circuit to the OFF position.

5. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.
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   Illustration 1	g03612276

6. Loosen the hose clamps and remove the hoses assembly from connection (10) on aftercooler (9).

7. Loosen hose clamp (11) from hoes assembly (12).

8. Loosen clamps (2) for hose assembly (1).

9. Remove bolt (6) from tube assembly (8).

10. Remove tube assembly (8) from aftercooler (9) and the auxiliary water pump.

11. Remove O-ring seal (7) (not shown).

12. Disconnect the hose assembly from connection (3).

13. Disconnect harness assembly (4) from the inlet air temperature.

14. Disconnect harness assembly (5) from the boost pressure sensor.
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    Illustration 2	g03612278

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    Illustration 3	g03612280

15. Remove bolts (14). Remove bracket (15) from aftercooler (9) and the inlet duct.

16. Remove bolts (13) and bolt (16) (not shown) from aftercooler (9). Support the weight of the aftercooler as the bolts are removed.

17. Remove aftercooler (9) from adapter (17) and mounting bracket (21).

18. Remove adapter (17) from inlet duct (19). Remove O-ring seal (20) and O-ring seal (18) (not shown) from adapter (17).

19. If necessary, disassemble aftercooler (9) refer to Disassembly and Assembly, "Aftercooler - Disassemble" for the correct procedure.
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    Illustration 4	g03614337

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    Illustration 5	g03614707

20. If necessary, follow Step 2.k through Step 3 in order to remove mounting bracket (21).

    1. Remove the nut covers and nuts (23) and remove cover (24).

    2. Make temporary marks on harness assemblies to show position of cable straps. Cut cable straps (27) from the harness assemblies.

    3. Disconnect harness assembly (22) and harness assembly (26). Position the harness assemblies away from the mounting bracket (21).

    4. Remove bolt (30) from the clip. Disconnect tube assembly (31) from the connection and relief valve (25) (not shown).

    5. Remove fuel manifold (29) (not shown) refer to Disassembly and Assembly, "Fuel Manifold (Rail) (None M.C.S Arrangement) - Remove and Install" and Disassembly and Assembly, "Fuel Manifold (Rail) (M.C.S. Regulated Engines) - Remove and Install" for the correct procedure.

    6. Disconnect tube assembly (28).

    7. Remove allen head bolts (32) (not shown) and bolts (33) from mounting bracket (21). Support the mounting bracket as the bolts are removed.

    8. Remove mounting bracket (21) from the cylinder head (34).

Installation Procedure

1. Ensure that all components of the aftercooler, mounting bracket, and tube assembly are free from damage and restriction.
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   Illustration 6	g03614337

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   Illustration 7	g03614707

2. If necessary, follow Step 2.a through Step 2.k in order to install mounting bracket (21).

   1. Position mounting bracket (21) onto the cylinder head (34).

   2. Install allen head bolts (32) (not shown) and bolts (33) to mounting bracket (21). Support the mounting bracket as the bolts are installed.

   3. Tighten allen head bolts (32) (not shown) and bolts (33) to a torque of 22 N·m (195 lb in).

   4. Connect tube assembly (28).

   5. Install fuel manifold (29) (not shown) refer to Disassembly and Assembly, "Fuel Manifold (Rail) (None M.C.S Arrangement) - Remove and Install" and Disassembly and Assembly, "Fuel Manifold (Rail) (M.C.S. Regulated Engines) - Remove and Install" for the correct procedure.

   6. Securely tighten the tube nuts for tube assembly (28).

   7. Connect tube assembly (31) to the connection and relief valve (25) (not shown). Securely tighten the tube nuts on tube assemble (31).

   8. Install bolt (30) to the clip. Tighten the bolt to a torque of 44 N·m (32 lb ft). Ensure that the clip is not strained as the bolt is tightened.

   9. Position harness assembly (22) and harness assembly (26) onto the mounting bracket (21).

   10. Connect harness assembly (22) and harness assembly (26). Install new cable straps (27) to the harness assemblies.

   11. Install cover (24) and install nuts (23). Tighten the nuts to a torque of 9 N·m (80 lb in). Install the nut covers to nuts (23).
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   Illustration 8	g03612280

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   Illustration 9	g03612278

3. Apply tooling (A) to new O-ring seal (20) and new O-ring seal (18) (not shown). Install the O-ring seals to adapter (17). Ensure that the O-ring seals are correctly installed into the recesses of the adapter.

4. Install adapter (17) into inlet duct (19). Ensure that adapter is installed fully into the inlet duct.

5. If necessary, assemble aftercooler (9) refer to Disassembly and Assembly, "Aftercooler - Assemble" for the correct procedure.

6. Position aftercooler (9) onto adapter (17) and mounting bracket (21). Ensure that the aftercooler is correctly installed into the hose assemblies.

7. Install bolts (14) and bolt (16) (not shown) to aftercooler (9) hand tight. Support the weight of the aftercooler as the bolts are installed. Tighten the bolts to a torque of 44 N·m (32 lb ft).

8. Position bracket (15) onto aftercooler (9) and the inlet duct. Install bolts (14) hand tight. Tighten the bolts to a torque of 22 N·m (195 lb in).
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   Illustration 10	g03612276

9. Tighten hose clamp (11) for hose assembly (12) to a torque of . 11 N·m (97 lb in).

10. Position a new O-ring seal (7) (not shown) onto tube assembly (8). Ensure that the O-ring seal is correctly positioned into the recesses of the tube assembly.

11. Install tube assembly (8) to aftercooler (9) and the auxiliary water pump.

12. Install bolt (6) to tube assembly (8) hand tight.

13. Tighten bolts (6) to a torque of 22 N·m (195 lb in).

14. Tighten clamps (2) for hose assembly (1) to a torque of 7 N·m (62 lb in).

15. Connect the hose assembly to connection (3). Tighten the hose clamp securely.

16. Connect the hose assembly to connection (10) on aftercooler (9). Tighten the hose clamps securely.

17. Connect harness assembly (4) to the inlet air temperature.

18. Connect harness assembly (5) to the boost pressure sensor.

19. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct filling procedure.

20. Restore the isolated power supply.

21. Turn the battery disconnect switch to the ON position.

22. Turn the valve for the sea water circuit to the ON position.

23. If the engine is equipped with an air starting motor. Turn the air supply at the air reservoir to the ON position.