C4.4 Marine Generator Set Caterpillar

Removal Procedure

1. The engine can 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.
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   Illustration 1	g03650190

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   Illustration 2	g03650192

4. Remove bolts (1) from guard (2). Remove the guard from the engine.

5. If necessary, follow Step 9.a through Step 9.b in order to remove the brackets for guard (2).

   1. Make temporary marks on all brackets for installation purposes.

   2. Remove bolts (3) from bracket (4). Remove the bracket from the cylinder block.

   3. Remove allen head bolts (7) and allen head bolts (8) from bracket (9) and bracket (10). Remove the brackets from the cylinder block.

   4. Remove pillar (6) from the alternator bracket.

6. Remove alternator belt (5). Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.
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   Illustration 3	g03650193

7. Place identification marks on the harness assemblies that are connected to the alternator.

8. Disconnect harness assembly (13) and harness assembly (14) from the alternator (19).

9. Slide boot (11) and boot (16) away from the alternator harness assemblies.

10. Remove nut (12) (not shown) and nut (17) (not shown). Remove harness assemblies from alternator (19). Position harness assemblies away from the alternator.

11. Remove bolt (15) (not shown) and bolt (15) (not shown) from alternator (19).

12. Remove alternator (19) from the bracket.
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    Illustration 4	g03650198

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    Illustration 5	g03650219

13. If necessary, follow Step 2.a through Step 3 in order to remove brackets (22).

    1. Remove bolts (20) and allen head bolt (21) from bracket (22).

    2. Remove bracket (22) from the cylinder block.

    3. If necessary, remove belt tensioner (23). Refer to Disassembly and Assembly, "Belt Tensioner - Remove and Install" for the correct procedure.

    4. If necessary, remove dowels (24) from the cylinder block. Only remove the dowels if the dowels are damaged.

Installation Procedure

1. Ensure that al components of the alternator and the bracket are free from wear or damage. If any component that is worn or damaged.
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   Illustration 6	g03650198

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   Illustration 7	g03650219

2. If necessary, follow Step 2.a through Step 2.e in order to install brackets (22).

   1. If necessary, install new dowels (24) to the cylinder block.

   2. Position bracket (22) onto the cylinder block. Ensure that the bracket is correctly located onto dowels (24).

   3. Install bolts (20) and allen head bolt (21) to bracket (22).

   4. Tighten bolts (20) and allen head bolt (21) to a torque of 44 N·m (32 lb ft).

   5. If necessary, install belt tensioner (23). Refer to Disassembly and Assembly, "Belt Tensioner - Remove and Install" for the correct procedure.
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   Illustration 8	g03650193

3. Install alternator (19) to the bracket.

4. Install bolt (15) (not shown) and bolt (15) (not shown) to alternator (19). Tighten the bolts to a torque of 44 N·m (32 lb ft).

5. Install harness assemblies onto alternator (19). Install nut (12) (not shown) and nut (17) (not shown). Ensure that the harness assemblies are correctly installed onto the harness assemblies original position.

6. Tighten nut (12) (not shown) and nut (17) (not shown) to a torque of 8 N·m (71 lb in).

7. Slide boot (11) and boot (16) onto the alternator harness assemblies.

8. Connect harness assembly (13) and harness assembly (14) to alternator (19).
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   Illustration 9	g03650190

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   Illustration 10	g03650192

9. If necessary, follow Step 9.a through Step 9.e in order to remove the brackets for guard (2).

   1. Install pillar (6) to the alternator bracket. Tighten the pillar to a torque of 22 N·m (195 lb in).

   2. Position bracket (4) onto the cylinder block. Install bolts (3) to the bracket. Ensure that the bracket is correctly position.

   3. Tighten bolts (3) to a torque of 44 N·m (32 lb ft).

   4. Position bracket (9) and bracket (10) onto the cylinder block. Ensure that the brackets are correctly position.

   5. Install allen head bolts (7) and allen head bolts (8) to the brackets. Tighten allen head bolts to a torque of 190 N·m (140 lb ft).

10. Install alternator belt (5). Refer to Disassembly and Assembly, "Alternator Belt - Remove and Install" for the correct procedure.

11. Position guard (2) onto the brackets. Install bolts (1) to the guard hand tight. Ensure that the guard is correctly positioned onto the brackets.

12. Tighten bolts (1) to a torque of 22 N·m (195 lb in).

13. Reinstate the isolated power supply.

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

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