1996/04/15 Caterpillar

New Element Assemblies Available Within Jacket Water Heater Groups{1383}

Usage:

All Caterpillar Machines Powered By 3114, 3116, 3126, 3204, and 3208 Machine Engines

SUPPLEMENT: 04/15/96

Service Magazine; April 15, 1996; Page 6; "New Element Assemblies Available Within Jacket Water Heater Groups"for all Caterpillar Machines Powered By 3114, 3116, 3126, 3204, and 3208 Machines Engines.

The measurement for the core plug bore as mentioned in the third paragraph is incorrect. The correct value is 44.044 ± 0.050 mm (1.7340 ± .0020 in).

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New element assemblies are available with jacket water heater groups that are installed in machines powered by 3114, 3116, 3126, 3204, and 3208 Machine Engines.

The following table shows three new 124-0686, 124-0685, and 124-0687 Jacket Water Heater Element Assemblies to use with the five jacket water heater groups. The table also shows the appropriate cord assemblies to be used for each of the element assemblies.

The jacket water heaters are sized for use in a core plug bore of 0.050 ± 0.044 mm (.0020 ± .0017 in). The 132-1448 Jacket Water Heater Seal Kit is available for these three element assemblies.

Installation: The following procedure is recommended for installation of the jacket water heater assemblies as shown in Illustration 1.

1. Allow the engine to cool.

2. Drain the coolant.

3. Remove the freeze plug from the bore that the heater is to be installed in.

4. Clean the freeze plug bore in the block until it is smooth and free of any deposits or contamination.

NOTE: If the outside edge of the block bore is not chamfered, file down the sharp edges.

Illustration 1. Typical Jacket Water Heater Group: (1) Element Assembly. (2) Cord Assembly. (3) Cap Assembly.

5. Remove the yellow plastic dust cap assembly (3) from the heater.

6. Insert the element assembly (1) into the core plug hole with the orientation of the element assembly as shown in Illustration 2 for 3114, 3116, and 3126 Engines and Illustration 3 for 3204 and 3208 Engines.

NOTE: The element assembly should be inserted only deep enough so that the tanged washers do not engage the bore.

Rotate the element assembly so it does not touch the inner surface of the block. Mark the block and the heater so the heater may again be inserted in this position.

NOTE: Refer to Special Instruction "Installation of 7E-6310, 9X-3294, 6N-9125, 7E-5244 and 3T-8724 Jacket Water Heater Groups", SEHS9601, for specific engine installation instructions.

NOTE: For 3100 Family of Engines with rear-facing turbocharger turbine, 4P-1603 Turbocharger Shield Group must be installed.

7. Remove the heater. Apply a light coat of ethylene glycol to the heater O-ring and the block bore.

8. Place the heater into the block bore while indexing the element assembly with the mark from Step 6.

9. Place a 11/4 inch deep socket over the threaded end. Insert the heater by evenly and lightly tapping the socket until the heater adapter flange bottoms against the block.

NOTE: Attempting to wedge the heater into the bore will usually result in skewing of the heater and cutting of the O-ring. This procedure, however, may be attempted if space requirements demand this method. If this method is used, DO NOT preload one side.

Illustration 2. Typical Jacket Water Heater Element Assembly For Insertion Into Machines Powered By 3100 Family Of Machine Engines: (A) Orientation of 36 degrees for 3116 and 3126 Engines. (B) Orientation of 45 degrees for 3114 Engine. (4) Right-side Core Plug.

10. Install the cap assembly (3) onto the heater.

11. Fill the engine with coolant. Start the engine and check for leaks. Continue to operate the engine until the operating temperature is reached in order to assure that all air is purged from the cooling system.

12. When the operating temperature is reached, stop the engine. Allow the engine to cool.

Illustration 3. Typical Jacket Water Heater Element Assembly For Insertion Into Machines Powered By 3200 Family Of Machine Engines: 3204 Location-Right rear core plug orientation at twelve o'clock (12:00). 3208 Location-Left rear and right middle core plugs orientation at twelve o'clock (12:00). (5) Retaining Rings (two). (6) O-ring Seal. (7) Chamfer.