Installation of 7E-6310, 9X-3294, 6N-9125, 7E-5244 and 3T-8724 Jacket Water Heater Groups{1383} Caterpillar

Installation of 7E-6310, 9X-3294, 6N-9125, 7E-5244 and 3T-8724 Jacket Water Heater Groups{1383}

Usage:

3114 (2ZF, 5EF, 1ZG, 2FG, 97Z);
3116 (4TF, 2WG, 4PG, 9GK, 98Z);
3126 (1WM);
3204 (7YJ, 45V, 10X);
3208 (90N, 01Z, 02Z, 03Z Engines

Introduction

This Special Instruction contains procedures, information and parts required to install 7E-6310, 9X-3294, 6N-9125, 7E-5244 and 3T-8724 Jacket Water Heater Groups in 3114, 3116, 3126, 3204 and 3208 engines.

Jacket Water Heater Groups

7E-6310 Jacket Water Heater Group

3114 ... 5EF, 1ZG

3116 ... 2WG, 4PG, 9GK, 98Z

3126 ... 1WM

NOTE: A 3114, 3116 or 3126 engine with a rearward facing turbocharger turbine MUST have a shield group installed to protect the jacket water heater group from excessive heat. Refer to 4P-1603 Shield Group in this instruction for the installation procedures.

NOTE: Refer to "Installation (Inline Engines ONLY)" in this instruction, for general installation procedures.

9X-3294 Jacket Water Heater Group

3114 ... 2FG, 97Z

3116 ... 4TF, 98Z

3126 ... 1WM

NOTE: Refer to "Installation (Inline Engines ONLY)" in this instruction, for general installation procedures.

6N-9125 Jacket Water Heater Group

3204 ... 45V, 10X, 7YJ

NOTE: Refer to "Installation (Inline Engines ONLY)" in this instruction, for general installation procedures.

7E-5244 Jacket Water Heater Group

3208 ... 90N, 01Z, 02Z, 03Z

3T-8724 Jacket Water Heater Group

3114 ... 2ZF, 2FG, 97Z

3116 ... 98Z, 4TF

3126 ... 1WM

3204 ... 45V, 7YJ

3208 ... 03Z

NOTE: A 3114, 3116, or 3126 engine with a rearward facing turbocharger turbine MUST have a shield group installed to protect the jacket water heater group from excessive heat. Refer to 4P-1603 Shield Group in this instruction for the installation procedures.

A 240V/1000 Watt jacket water heater is available for all the engines listed.

NOTE: For 3114, 3116 and 3204 engines, refer to "Installation (Inline Engines ONLY)" in this instruction, for general installation procedures.

Installation (Inline Engines ONLY)

Typical view of jacket water heater group.

Drain Engine Cooland and Remove Cylinder Block Core Plug(s)

NOTE: All reference to LEFT side or RIGHT side is made as viewed from the flywheel end of the engine.

1. Remove the cylinder block core plug from the appropriate side(s) of the block depending on the engine model to drain coolant.

NOTE: Take care to NOT damage the core plug bore when removing the core plug. The installation of the element assembly requires a water and pressure tight seal for the correct operation of the jacket water heater group.

2. Remove any rust and scale deposits from the core plug bore.

NOTE: The installation of the heater's element requires a compression fit of an O-ring at the core plug bore. The core plug bore must have a thirty degree inward sloping chamfer to allow the O-ring to properly seal. Inspect the core plug bore to determine if any machining is required. Remove any sharp edges from the bore to prevent damage to the O-ring.

Position Element Assembly

3. The position of the element assembly for installation is dependent on the engine model.

3114, 3116:

Position the element assembly slightly off vertical.

Refer to 3114 (Right Side), and 3116 (Right Side), in this instruction, for jacket water heater location and element orientation.

3204:

Position the element assembly vertically.

Refer to 3204 (Right Side), 3208 (Right Side), and 3208 (Left Side), in this instruction for jacket water heater location and element orientation.

4. Apply Ethylene Glycol antifreeze on the rubber O-ring on the heater body.

NOTE: Use Ethylene Glycol antifreeze ONLY as an installation lubricant.

Do NOT use Propylene Glycol antifreeze, silicone, grease, oil, liquid soap or any other type of lubricant.

5. Orientate the heater as defined in Step 3 and insert into the block.

Install a 11/4 inch socket (1/2 inch drive) over the head of the heater.

NOTE: The socket is used as a driver.

Tap or wedge the heater into the block until the outer edge is firmly seated against the block.

NOTE: Be sure that the heater is started squarely, or the O-ring could be cut.

6. Install cap as shown for element assembly.

NOTE: The cap is used as a dust cover when cord assembly is removed.

7. Install cord assembly.

Align the terminals in cord assembly with the terminals of element assembly.

Tighten nut to a torque of 8 ± 2 N·m (72 ± 18 lb in)

8. Refill with engine coolant.

NOTE: Do NOT reuse heater if it is removed from block unless the 132-1448 Rebuild Kit is being installed.

Turbocharged Engines With Rear Facing Exhaust

Example of 3114, 3116 engine shield location. 1. 8T4200 Bolt. 2. 8T4224 Washer. 3. Shield.

Some 3114, 3116, and 3126 engines may have a turbocharger with a rear facing exhaust design. An engine with a turbocharger rear facing exhaust MUST have a shield to protect the heater from excessive temperature.

The 4P-1603 Shield Group can be installed for engines not originally equipped with a shield.

NOTE: The 4P-1603 Shield Group is part of the 7E-6310 Jacket Water Heater Group but can be ordered separately if required.

4P-1603 Shield Group

Heater Location and Element Orientation

3114 (Right Side)

Typical view of jacket water heater group installation location and element orientation. 1. Heater location. 2. Element orientation.

3116 and 3126 (Right Side)

Typical view of jacket water heater group installation location and element orientation. 1. Heater location. 2. Element orientation.

3204 (Right Side)

Typical view of jacket water heater group installation location and element orientation. 1. Heater location. 2. Element orientation-vertical.

3208 Engines

Typical view of jacket water heater group installation location and element orientation.

Drain Engine Coolant and Remove Cylinder Block Core Plug(s)

NOTE: All reference to LEFT side or RIGHT side is made as viewed from the flywheel end of the engine.

1. Remove a cylinder block core plug from the left and the right side of the block at the locations shown above.

NOTE: The installation of the heater's element requires a compression fit of an O-ring at the core plug bore. The core plug bore must have a thirty degree inward sloping chamfer to allow the O-ring to properly seal. Inspect the core plug bore and machine if required. Remove any sharp edges from the bore to prevent damage to the O-ring.

2. Remove any rust and scale deposits from the core plug bore.

Position Element Assembly

3. Position each element assembly (1) as shown above (vertical orientation).

4. Apply Ethylene Glycol antifreeze on the rubber O-ring on the heater body.

NOTE: Use Ethylene Glycol antifreeze ONLY as an installation lubricant. Do NOT Use Propylene Glycol antifreeze, silicone, grease, oil, liquid soap or any other type of lubricant.

5. Orientate the heater as defined in Step 3 and insert into the block.

Install a 1 1/4 inch (1/2 inch drive) over the head of the heater.

NOTE: The socket is used as a driver.

Tap or wedge the heater into the block until the outer edge is firmly seated against the block.

NOTE: Be sure the heater is started squarely or the O-ring may be cut.

6. Install thermostat housing (2) in left cylinder head after removing the 2B-0858 Pipe Plug.

7. Strap heater cord to engine wiring harness and water pipe at approximately 200 mm (8.0 in) intervals (3) as shown.

Align the terminals in cord assembly with the terminals of element assembly.

Tighten nut to a torque of 8 ± 2 N·m (72 ± 18 lb in)

8. Refill with engine coolant.

NOTE: Do NOT reuse the heater if it is removed from block unless the 132-1448 Rebuild Kit is being installed.

Extension Cords

The jacket water heater groups do NOT include the extension cord for connecting to an external 120V or 240V power source.

The extension cords must be ordered separately. The desired cord length must be matched to the jacket water heater group element assembly part number as shown in the following chart.