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

   Show/hide table

   Illustration 1	g03623237

   Show/hide table

   Illustration 2	g03623236

2. Position a new O-ring seal (12) onto tube stack (11). Install the tube stack into housing (13). Ensure that the tube stack is correctly orientated.

3. Install a new O-ring seal (14), spacer (15), and a new O-ring seal (14) onto tube stack (11).

   Note: Ensure that the spacer is correctly orientated.

4. Position housing (17) onto the assembly of housing (13). Ensure that the housing is correctly orientated.

5. Install allen head bolts (20) hand tight.

6. Position anew O-ring seal (19) onto tube stack (18). Install the tube stack into housing (5). Ensure that the tube stack is correctly orientated.

7. Position a new O-ring seal (6), spacer (7), and a new O-ring seal (8) onto tube stack (18).

8. Position a new O-ring seal (10) onto tube stack (11). Position inlet housing (9) onto the assembly housing (13).

   Note: Ensure that the inlet housing is correctly orientated.

9. Position the assembly of housing (5) onto inlet housing (9). Ensure that the assembly of housing is correctly orientated.

10. Install allen head bolts (4) hand tight.

11. Position a new O-ring seal (3) onto tube stack (18).

12. Position cover (2) onto the assembly of housing (5). Ensure that the cover is correctly orientated.

13. Install allen head bolts (1) hand tight.

14. Tighten allen head bolts (4) to a torque of 22 N·m (195 lb in).

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

    Tighten allen head bolts (20) to a torque of 22 N·m (195 lb in).

15. If necessary, follow Step 15.a through Step 15.b in order to install drain valve (22).

    1. Install a new O-ring seal (21) to drain valve (22).

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

End By:

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