Installation of a Jacket Water Heater on 3412 Generator Sets{1383} Caterpillar

Engine:

3412 (S/N: 2WJ1-UP)

3412C (S/N: 9EP1-UP)

Introduction

This Special Instruction is intended for the installation of a jacket water heater on the 3412 Generator Sets. The new 236-4774 Jacket Water Heater Gp is now available to improve engine starting in cold weather. This jacket water heater should be used when the ambient air temperature is less than 20 °C (68 °F). When the ambient air temperature is less than 20 °C (68 °F) the generator set may produce some unwanted white smoke. Also, the engine may be hard starting. Installing the jacket water heater will help to eliminate the hard starting of the engine and white smoke in cold operating conditions.

This unit is electronically controlled. The heater heats the engine coolant. An electric pump circulates the engine coolant.

The heater is installed on the base of the generator set and the heater is fueled by diesel fuel from the fuel supply line of the generator.

The 236-4774 Jacket Water Heater Gp is available for field retrofits or the heater can be installed as a attachment on new generator sets.

Note: When the heater group is used as a field retrofit, the correct heater must be ordered for the correct Genset.

All of the required parts for installing the heater are included in the 236-4774 Jacket Water Heater Gp . The heater group includes the following parts:

• A microprocessor controller

• Enclosure for the controller

• Mounting brackets

• Fuel line

• Exhaust pipe

• Valves

• Hoses

• Cables

• Bolts

• Washers

• Screws

• Clamps

• Burner assembly

Note: Do not perform any procedure that is outlined in this publication until you have read the information and you understand the information. Do not order any parts until you have read the information and you understand the information.

Specifications

The system is designed to provide the engine with a water temperature of 68 °C (154 °F) to 85 °C (185 °F) for easy, warm starting. By keeping the coolant water warm, the coolant water warms the oil in the oil gallery and wear surfaces. Warm starting also reduces down time due to a cold start, and warm starting is intended for extended operation with only minimal routine maintenance.

The system uses a high temperature limit switch. The switch will shut down the heater in case of a failure.

Table 1

Specifications
Description	Specification
System Output	Boost 9.5 kW (13 hp) High 7.5 kW (10 hp) Med 3.2 kW (4 hp) Low 1.5 kW (2 hp)
Overall Dimensions
Length Width Height	425 mm (16.75 inch) 210 mm (8.25 inch) 288 mm (11.25 inch)
Weight	10 kg (22 lb)
Current Draw	Boost 10.4 amp High 6.3 amp Med 3.5 amp Low 2.9 amp
Length Outside Diameter	1500 mm (59 inch) 6.35 mm (0.25 inch)
Exhaust Tube
Length Inside Diameter Maximum Length Maximum Radius	1200 mm (47 inch) 30 mm (1.2 inch) 2000 mm (80 inch) 30 mm (1.2 inch)
Diameter of Hose Connection	19 mm (0.75 inch) ID of the hose
Fuel System
Maximum Flow Rate Lift Maximum length of the inlet hose	1.5 Liter per hour (0.4 Gph) 760 mm (30 inch) 1980 mm (78 inch)

Required Parts

Illustration 1	g01148167

Table 2

Chart B
Reference Number	Description	Part Number
----	Jacket Water Heater Gp	236-4850
1	Bolt	----------
2	Controller	236-4898
3	Cable	----------
3A	Seal	----------
4	Seal	----------
5	Glow Plug	236-4896
6	Screw	----------
7	Burner	236-4886
8	Seal	----------
9	Washer	----------
10	Screw	----------
11	Burner	----------
12	Seal	236-4889
13	Nut	----------
14	Temperature Sensor Gp	236-4895
15	Sleeve	----------
16	Cover	----------
17	Washer	----------
18	Screw	----------
19	Screw	----------
20	Blower	236-4881
21	Tie strap	----------
22	Screw	----------
23	Temperature Sensor Gp	236-4893
24	Seal	----------
25	Temperature Sensor Gp	236-4894
26	O-Ring Seal	----------
27	Screw	----------
28	O-Ring Seal	----------
29	Clip	----------
30	Heat Exchanger	----------
31	Outer Casting	----------
32	O-Ring Seal	----------
33	Clamp	----------
34	Water pump	236-4890

Table 3

Chart C
Reference Number	Description	Part Number
1	Plastic fuel line	----------
2	Clamp	----------
3	Hose	----------
4	Connector	----------
5	Harness	236-4775
6	Clamp	----------
7	Fuel Pump	236-4899
8	Cup	---------
9	Ring	----------
10	Connector	----------
11	Dust cap	----------
12	Connector	----------
13	Clamp	----------
14	Nut	----------
15	Washer	----------
16	Fuse holder	----------
17	Holder	----------
18	Bolt	----------
19	Washer	----------
20	Relay	236-4900
21	Fuse	139-5345
22	Grommet	----------
23	Hose	----------
24	Bolt	----------
25	Hose	----------
26	Block	----------
27	Fuse Holder	236-4901
28	Pigtail	----------
29	Cup	----------
30	Base of box	----------
31	Seal	----------
32	Grommet	----------
33	Hose	----------
34	Clamp	----------
35	Bolt	----------
36	Washer	---------
37	Shock mount	---------
38	Nut	----------
39	Washer	----------
40	Bolt	----------
41	Bolt	----------
42	Clamp	----------
43	Sleeve	----------
44	Shock mount kit	----------
45	Shock mount	----------
46	Washer	----------
47	Washer	----------
48	Nut	----------
49	Washer	----------
50	Flexible exhaust	----------
51	Bolt	----------
52	Mounting bracket	----------
53	Clamp	----------
54	Heater	----------
55	Pigtail	---------
56	Ring	----------
57	Cover	---------
57A	Base	---------
58	Fuse	207-1219
59	Hose	----------
60	Clamp	---------
61	Clamp	----------
62	Clamp	----------
63	Hose	----------
64	Clamp	----------
65	Cover	----------

Heater Kit

Illustration 2	g01139209

Table 4

Chart D
Reference Number	Quantity	Description	Part Number
1	4	Hose Clamp	2S-3440
2	2	Hose Connector	005-7898
3	2	Ball Valve	8C-1358
4	410 cm	Hose	5P-0765
5	1	Jacket Water Heater Gp	236-4850
6	1	Harness	254-6702
7	1	Adapter	236-5313
8	2	Connector	5P-4400
9	1	Harness	254-6701
10	1	Timer	236-4776
11	1	Elbow	213-3745
12	15 DM	Tube	205-6079

Table 5

Chart E
Reference Number	Quantity	Part Number and Part Name
1	1	236-4774
2	1	171-9947
3	1	236-5454
4	2	7X-0345
5	2	7X-0448
6	4	8T-4122
7	1	154-2949
8	1	005-8615
9	1	1L-0254
10	2	5S-2392
11	2	096-0061
12	1	171-9951
13	1	191-9952

Installation

Mounting the Heater Group and the Control Box to the Generator Set

1. Connect the flexible exhaust tube to the heater group by using the clamp that is provided with the kit.

2. Route the exhaust tube through the hole that is in the mounting bracket.

3. Mount the heater group onto the exhaust tube (3). Use the existing nuts and washers to mount the heater group. Tighten the nut to the standard torque.

4. Mount the heater group and the mounting bracket to the side beam by using the hex screws, nuts, and washers.

5. Route the exhaust tube forward toward the radiator. Also, route the exhaust tube down the hole in the side of the frame.

6. The exhaust must meet local codes and state codes.

7. Mount the timer (8) by using the bezel that is provided, into the rectangular hole in the bracket of the heater.

Electrical Connections, Fuel Connections, and Water Connections

1. Make all necessary water connections, fuel connections, and electrical connections by using the following procedures.

2. Check the water lines and the fuel lines for leaks.

3. Secure all of the lines and all of the hoses onto the generator by using tie straps. This will reduce the possibility of damage that is caused by abrasion.

Water Connections

1. Drain the coolant from the engine.

   Note: The coolant must be drained to a level below the water connections to the heater.

2. Cut a length of hose in order to connect the water inlet and the water outlet. Use 5P-0765 Hose .

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Illustration 3	g01140715

3. Remove the plug. Install pipe fitting (1), elbow (2), coolant valve (4), and hose fitting (5) into the water outlet port of the engine.

4. Apply 5P-3413 Pipe Sealant to the threads of the fittings.

   Note: The 6N-1782 Cover may not be installed on all engines. A 4N-1682 Cover is installed on certain engines. The 4N-1682 Cover does not have the threaded hole that is required to attach the water outlet hose. The cover can be reworked by either one of the following 2 procedures:

   • Replace 4N-1682 Cover with 6N-1782 Cover

   • Rework 4N-1682 Cover by drilling the cover and tapping the cover with a 3/4-14 NPTF hole

5. Connect hose (7) to hose fitting (5) by using clamp (6) .

6. Connect the other end of hose (2) to the inlet of the heater. Secure the hose to the inlet by using clamp (1) .

Illustration 4	g01143358

1. From 5P-0765 Hose , measure the hose and cut the hose to a length that is required to connect the water outlet of the heater to the water inlet of the engine on the oil cooler.

2. Remove the plug from the oil cooler and install pipe fitting (12), coolant valve (11), and hose fitting (5) into the water inlet port of the engine.

3. If the inlet and the outlet pressures are different, install a 126-4255 Check Valve .

4. Apply 5P-3413 Pipe Sealant to the threads of the fittings.

   Note: The 126-4255 Check Valve is not part of this kit. The check valve keeps the coolant from flowing backward through this system. The check valve does not need to be installed onto 3412 Generator Set Engines.

5. Connect hose (8) to hose fitting (10) by using clamp (9) .

6. Connect the other end of hose (8) to the outlet of the water pump of the heater. Secure the hose to the outlet by using clamp (9) .

Fuel Connections

Illustration 5	g01143417

1. Shut off fuel to the engine and drain the fuel from inlet line.

2. Remove inlet hose from the fuel block.

3. Install washer (6), adapter (4), and tee (1) into the inlet of the fuel block.

4. Connect fuel inlet line to one end of tee (1) .

5. Install fuel fitting (2) into the side of the tee (1) .

6. Install ferrule nut (3) onto the end of the fuel line. Connect the ferrule nut to the fuel fitting (10) .

7. Apply 5P-3413 Pipe Sealant to the threads of the fittings.

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Illustration 6	g01143424

8. The fuel line is routed to the heater. The routing is shown in figure 6.

9. Install a ferrule nut (8) onto the end of the fuel line (5). Connect the ferrule nut to the fuel fitting (7) .

10. Secure the fuel line in place by using tie straps.

Electrical Connections

1. Connect the main cable of the harness to the heater. Route the electrical cable to the battery and secure the electrical cable in place by using tie straps. Ensure that the cable is clear of the exhaust from the heater.

2. Connect two ring terminals and the red wires to the positive side of the battery. The connection can be made by using the bolt that clamps the battery terminal onto the post.

3. Connect two ring terminals and the black wires to the negative side of the battery.

7 Day Timer

The 7 day timer has been designed to control the operation of the heater. This timer connects to the diagnostic circuit of the heater. The timer displays any fault codes for the heater in a three digit number. The timer has preselection for the turn on time. The timer is set to the default by Espar to operate for two hours. Refer to the instructions that are provided with the timer for setting options.

1. Mount the bezel into the bracket and insert the timer.

2. Use the hardware that is supplied with the timer for the connections.

3. Connect the extension harness to the connector at the heater and run the harness to the location of the timer.

   Note: The harness should be clear of exhaust from the heater.

4. Connect the switch harness to the connector at the timer.

Checking Coolant Levels

Before starting the engine, fill the coolant system and purge all the air from the air system. Release the air at the outlet connection of the heater core. Check the coolant level again. As required, add coolant. Make sure that all coolant flow valves and heater controls are in the full open position before starting the system.

Fuel Pump Priming

The fuel pump is self-priming. The fuel pump may require more than one start cycle to be completely primed. If the pump does not completely prime on the first cycle, refer to the Operation Section for the reset and restart of the system. If the pump does not prime on the second attempt, check all fuel line connections. Restart the system again.

Operation Section

Heater Operation

Prestart Procedures

After completion of installation of the heater, prepare the heater for operation:

• Check all connections.

• Refill the engine coolant.

• Bleed the air from the cooling system by running the engine. As needed, refill the antifreeze.

• Secure the heater hose.

• Run the engine in order to further bleed the system.

Start-Up

Once the heater is switched on, the following sequence occurs:

• The control unit does a systems check.

• The water pump starts circulating coolant.

• The air blower for combustion starts.

• The glow pin begins to preheat at 20-50 seconds.

• After 20-50 seconds, the fuel metering pump starts delivering fuel. The air blower starts.

• Once ignition takes place the flame sensor alerts the control unit and the control unit shuts off the glow pin.

Note: If the heater fails to start the first time the heater will automatically attempt a second start. If the heater fails to start on the second attempt the heater will turn off.

Note: On the initial start-up, the heater may require several start attempts to prime the fuel system.

Running

Once ignition is successful the following operations take place:

• The heater runs in full heat mode and the temperature is monitored at the heat exchanger.

• Once the coolant reaches 72 °C (162 °F) the heater will start to cycle up and down between levels.

• If the coolant temperature continues to rise, the heater will shut off. This occurs when the temperature reaches 85 °C (185 °F).

• The water pump will continue to circulate coolant. This allows the heater to monitor the engine temperature.

• The heater will automatically restart once the coolant temperature reaches 68 °C (154 °F).

• The heater will continue to run until the heater is switched off. The heater will run until the heater is turned off by the timer.

Note: The heater will attempt one restart after a flameout. If the restart is successful the heater will continue to run. If the restart is not successful the heater will turn off.

Note: During operation, the heater continually senses the input voltage from the batteries. If the input voltage drops to 10 V or rises above 15 V the heater will automatically shut down.

Switching Off

• When the heater is switched off, the heater starts a controlled cool down cycle.

• The fuel metering pump stops delivering fuel and the flame is extinguished.

• The air blower and the water pump will continue running for 130 seconds. This is for the cooldown.

• The heater shuts off.

Safety Equipment

The following items monitor the functions of the heater:

• Control unit

• Overheating sensor

• Flame sensor

• The control unit ensures that the electrical circuits are complete prior to starting the heater.

• The starting procedure will be repeated if the heater does not ignite within 90 seconds of starting of the fuel pump. If the heater fails to ignite after 90 seconds of fuel delivery, a shutdown for safety will begin.

• If the heater fails to ignite within 10 seconds "flame out" shutdown follows. Without a flame, the heater will not run. After troubleshooting the problem, the heater can be restarted.

• A shutdown will occur if there is not enough water in the system. If the cooling system has been poorly bled, or there is a restriction in the cooling system, a shutdown can occur.

• If the voltage drops below 10 V or raises above 15 V a "high/low voltage" shutdown follows. The shutdown occurs after a 20 second delay.

Maintenance, Troubleshooting, and Repairs

Periodic Maintenance

• Check coolant hoses and clamps. Ensure that all of the valves are open. Ensure that the engine has the recommended coolant level in the engine. Ensure that the heater is properly bled after service that involves the cooling system.

• Check the fuel lines for leaks. Check fuel filter inserts. Check the fuel filter inserts. Replace the inserts.

• Check the electrical lines and electrical connections.

• Start the heater and run the heater. Every 30 days run the heater. Run the heater for 15 minutes.

• Maintain your batteries and all electrical connections in good condition. Without enough power, the heater will not start. The "high/low voltage" faults will stop the heater.

• Use fuel that is suitable for the climate. Blending used engine oil with diesel fuel is not permitted.

Troubleshooting

Basic Troubleshooting

In the event of a failure, there are several items which should be checked first before any major troubleshooting is done.

• Fuses

• Electrical lines and connections

• Interference in combustion air and exhaust pipes

• Fuel in the tank

• Battery voltage

• Coolant flow

Self-Diagnostics

The heater is equipped with self-diagnostic capability. You can retrieve the last 5 faults by using the Espar 7 day timer.

7 Day Timer

The 7 day timer has a device for retrieving fault codes. This function automatically activates if the heater is experiencing problems.

• Fault codes appear on the LCD display screen.

• The codes can be translated from the charts on the following pages.

• See the instruction sheet that comes with the device for retrieving the fault codes.

Fault Code Chart

Table 6

Fault Code Chart
Fault Code	Fault Description	Causes and Repair
000	Normal Operation
001	Overvoltage advanced warning	Check the voltage between pin 13 and pin 14 of the control unit.
002	Undervoltage advanced warning	Check the voltage between pin 13 and pin 14 of the control unit.
010	Overvoltage shutdown	Ensure that the voltage between pin 13 and pin 14 at the control unit is greater than 15 volts or 30 volts. Check the charging system for the vehicle.
011	Undervoltage shutdown	Ensure that the voltage between pins 13 and 14 at the control unit is less than 10 volts or 20 volts. Check batteries and connections.
012	Overheating	Check for possible causes of overheating. Check the water through flow. Also, check the sensor. Temperature at the temperature sensor is greater than 113 °C (235 °F). Impedance at the temperature sensor is less than 400 ohms. Check the difference at the control unit. Disassemble the control unit. Disconnect the internal plug from the control unit and measure the distance between pins 5 and 8.
013	Excessive temperature at flame sensor	The flame sensor signals a temperature that is greater than 700 °C (1292 °F). The difference at the flame sensor is greater than 3400 ohms. Check the impedance at the control unit. Disassemble the control unit. Disconnect the internal plug from the control unit. Measure the impedance between pins 10 and 12.
014	Overheating is detected.	The difference of measured values at temperature sensor is greater than 70 °C (158 °F). Check the temperature sensor and the overheating sensor. Open the slide valve for the heater and check water through flow. Check the impedance between 5 and 8 at the control unit.
015	Too much overheating	The control unit will go into interlock mode if the heater overheats 3 consecutive times. Cancel the interlock by clearing the memory with the diagnostic unit.
020	Glow pin open circuit	Check the glow pin. Replace the glow pin. Check pin 4 (white) on the control unit that leads to the glow plug to terminal 3 for a short circuit. If the display says "OKAY" replace the control unit.
021	Glow plug short circuit	Check the glow pin. Replace the glow pin. Check pin 4 (white) on the control unit that leads to the glow plug to terminal 3 for a short circuit. If the display screen reads "OKAY" replace the control unit.
033	Combustion air blower motor	A deviation from the normal speed for longer than 1 minute will result in a fault code. The nominal values are 5600 rpm (full load) and 1850 rpm (part load). Check burner motor. Apply supply voltage to the motor. Connect the positive cable to the 1.5 black cable and the negative cable to the 1.5 orange. If the motor does not turn replace the burner motor with the integrated sensor. Check sensor supply. Switch on the heater. Measure the voltage between output 13 and output 14 at the control unit. Check the sensor. Measure voltage between terminal 15 and terminal 14 with an analog voltmeter when the blower is running.
037	The water pump is not working.	Check the water pump.
042	Short circuit of water pump	Check the water pump and leads.
043	Short circuit at external components	Check terminal 2 of the control unit for a short circuit. Check connected components. If the components are worn, replace the components.
047	Short circuit of the fuel metering pump	Check terminal 1 of the control unit and the leads up to the metering pump for short circuit. Check the metering pump. If the pump is worn, replace the pump.
048	Open circuit of fuel metering pump	Check terminal 1 of the control unit and the leads up to the metering pump for short circuit. Check the metering pump. Replace the fuel metering pump if the pump is worn.
050	Too many attempts and no start.	The control unit is interlocked after the control unit has been switched on 10 times without detection of a flame. Check the fuel supply, the glow plug, exhaust piping, piping for the combustion air, and the flame sensor. Cancel the interlock by clearing the memory with the diagnostic unit.
051	Faulty flame recognition	The flame sensor signals a temperature that is greater than 80 °C (176 °F) despite 4 minutes of cooling with cold air. If no combustion takes place check the flame sensor. If it is necessary replace the sensor. [ 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
052	Exceeded no start time	No flame was detected during start-up. Check the fuel supply, the glow plug, exhaust piping, piping for the combustion air and the flame sensor. 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
053	Flame cutout in boost mode	The heater has started but there is a loss of flame. Check the fuel flow rate, speed of the blower, fuel supply, exhaust pipe, and piping for the combustion air. If combustion is OK check the flame sensor. Replace the flame sensor. 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
054	Flame cutout in high mode	The heater has started and the heater indicates loss of flame in a power setting. Check the fuel flow rate, speed of the blower, fuel supply, exhaust pipe, and piping for the combustion air. If combustion is OK check the flame sensor. Replace the flame sensor. 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
056	Flame cutout in medium mode	The heater has started and the heater indicates loss of flame in a power setting. Check the fuel flow rate, speed of the blower, fuel supply, exhaust pipe, and the piping for the combustion air. If combustion is OK check the flame sensor. Replace the flame sensor. 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
056	Flame cutout in low mode	The heater has started and the heater indicates loss of flame in a power setting. Check the fuel flow rate, speed of the blower, fuel supply, exhaust pipe, and piping for the combustion air. If combustion is OK check the flame sensor. Replace the flame sensor. 900 ohms at -25 °C (-13 °F) and 1100 ohms at 25 °C (77 °F)
059	Water temperature rises too quickly.	Check circulation of water and the temperature sensor.
060	Temperature control sensor interruption	The control sensor signals the temperature value that is outside of the measurement range. Check the connecting leads. 650 ohms at -25 °C (-13 °F) and 1000 ohms at 25 °C (77 °F)
061	Temperature control short circuit	The control sensor signals the temperature value that is outside of the measurement range. Check the connecting leads.
064	Flame sensor open circuit	The flame sensor signals the temperature value that is outside of the measurement range. Check the connecting leads.
065	Flame sensor short circuit	The flame sensor signals the temperature value that is outside of the measurement range. Check the connecting leads.
071	Open sensor short circuit	The temperature is outside of the measurement range. Check the connecting leads.
072	Overheat sensor short circuit	The temperature is outside the temperature range. Check the connecting leads.
090	Control unit (internal fault)	An error in the internal control unit has been detected.
093	Faulty control unit (RAM error)	An error in the internal control unit has been detected.
094	Faulty control unit (EPROM fault)	An error in the internal control unit has been detected.
097	Faulty control unit (power failure)	An error in the internal control unit has been detected.

Fuel Quantity Test

The quantity of fuel should be tested if the heater has difficulty of starting. The quantity of fuel should also be tested if the heater has difficulty in maintaining a flame.

Note: Measure the quantity of fuel when the battery is sufficiently charged.

Preparation

1. Remove the fuel line from the heater and insert the line into a graduated measuring cup.

2. Activate the heater. When the fuel delivery is uniform, the fuel line is full and the fuel line is bled.

3. Deactivate the heater.

4. Empty the measuring cup.

Measurement

1. Activate the heater.

   Note: The fuel delivery starts automatically after 63 seconds after activating the heater.

   Note: After 105 seconds of fuel delivery, the heater will shut off automatically.

2. Wait for the heater in order to perform the restart.

   Note: The fuel pump is automatically shut down after another 75 seconds.

3. Deactivate the heater.

4. Measure the fuel in the measuring cup.

Evaluation

1. If the quantity is less than the tolerance, replace the fuel metering pump. The value should be 19 mL ± 1.9 mL.