Replacing the Convection Jacket Water Heaters with the 325-6250 Jacket Water Heater Gp on 3500 Generator Set Engines{1361, 1383, 1408} Caterpillar

Engine:

3508 (S/N: ZAB1-UP)

3508B (S/N: ZAD1-UP)

3512 (S/N: ZAF1-UP; YAK1-UP)

3512B (S/N: ZAH1-UP; YAM1-UP)

3512C (S/N: SBG1-UP)

3516 (S/N: ZAL1-UP; YAS1-UP)

3516B (S/N: ZAP1-UP; PBR1-UP; YAT1-UP)

3516C (S/N: SBJ1-UP; SBK1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction describes the retrofitting from jacket water heaters that circulate the jacket water by the convection of heat to a jacket water heater that utilizes a pump in order to circulate the jacket water.

Theory of Operation

Illustration 1	g01624957
Schematic of the coolant flow (1) Pump (2) Heater (3) Control box

The new jacket water heater is mounted to the rail on the left side of the engine. The new heater consists of a pump, a heater, and a control box. The heater contains three heating elements and a thermostat.

The heater is activated and deactivated by the controller on the generator set. When the controller for the generator set activates the contactor for the space heater, electrical power is supplied to the space heater (if equipped), to the pump, and to the thermostat.

The pump continuously draws coolant from the rear of the engine block into the heater. The contacts of the thermostat will close when the temperature of the coolant is below the set point. The closed contacts of the thermostat complete an electrical circuit that supplies power to the coil of the contactor for the water heater. The contactor for the water heater supplies electrical power to the heating elements. The heating elements heat the coolant and the coolant is returned to the engine block by the pump.

When the engine is running, the controller for the generator set deactivates the contactor for the space heater. This disables the pump, the thermostat, and the heating elements.

Electrical Requirements

The customer must provide a source of three-phase 480 VAC at 60 Hz. This electrical source must be protected by a 20 amp circuit breaker. A transformer is provided inside the control box which provides single-phase 240 VAC at 60 Hz to the pump.

Parts Lists

Order the jacket water heater that is appropriate for the application. Refer to Table 1.

Table 1

Jacket Water Heater Gp

60 Hz Generator Sets

325-6250 Jacket Water Heater Gp

For single-phase 220 VAC and 240 VAC heaters, refer to Special Instruction, REHS1658-01, "Replacing the Convection Jacket Water Heaters with a Recirculating Jacket Water Heater on 3500 Engines".

Order the additional parts that are appropriate for your engine. Refer to Tables 2 and 3. Look up the pricing arrangement for the engine and for the frame in Table 3. Find the required parts from Table 2.

Table 2

List of Required Parts for Installation
Part Number	Description	Feature Code JWHWP
		37	38	39	40	41	42	43	44	45	46	47
325-6250	Heater Gp	1	1	1	1	1	1	1	1	1	1	1
307-8457	Mounting Gp	0	1	0	1	0	0	1	0	1	0	0
307-8458	Mounting Gp	1	0	0	0	1	0	0	1	0	1	1
307-8459	Mounting Gp	0	0	1	0	0	1	0	0	0	0	0
328-3418	Wiring Gp	0	0	0	0	1	0	0	0	1	0	0
328-3423	Wiring Gp	1	1	0	0	0	0	0	0	0	0	0
328-3426	Wiring Gp	0	0	0	0	0	0	0	0	0	0	1
328-3429	Wiring Gp	0	0	1	0	0	0	0	0	0	0	0
328-3432	Wiring Gp	0	0	0	1	0	0	0	0	0	1	0
313-5252	Connection Gp	1	1	1	1	1	1	1	1	1	1	1

Table 3

Feature Codes for Various Frames
3508		3512		3516
Frame	Feature Code	Frame	Feature Code	Frame	Feature Code
691	JWHWP39	146X-1B	JWHWP38	825-2B	JWHWP37
692		148X-1B		826-2B
693		162X-1B		827-2B
695-B		164X-1B		828-2B
High Voltage	JWHWP42	166X-1B		162X-1B
		160X-2B		164X-1B
		162X-2B		166X-1B
		164X-2B		182X-2B
		182X-2B		160X-1B	JWHWP41
		824-2B		824-1B	JWHWP46
		827-2B		825-1B
		692-1B	JWHWP40	184X-2B	JWHWP47
		696-1B		186X-2B
		822-1B		High Voltage	JWHWP44
		825-1B
		140X	JWHWP45
		142X
		144X
		160X
		697-1B
		High Voltage	JWHWP43

Note: Ensure that all parts are available before the jacket water heater is installed.

Mechanical Installation

Remove the Existing Jacket Water Heaters

Note: Some engines have convection heaters on the left side and on the right side. Both of the convection heaters must be removed from the engine.

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To avoid electric shock, disconnect all electrical power to the jacket water heaters and to the generator space heater prior to performing any maintenance.

1. Disconnect the wiring from the existing jacket water heaters.

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Personal injury can result from hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

2. If the existing heaters are equipped with shutoff valves, ensure that all of the shutoff valves are completely closed. This will reduce the loss of coolant.

3. Disconnect the coolant lines for the existing jacket water heaters. Drain the coolant from the lines into an appropriate container.

4. Remove the coolant lines, the heaters, and the mounting brackets for each heater. If the engine is equipped with shutoff valves, remove the shutoff valves from the engine.

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Illustration 2	g01625187
Left side view

5. Install one plug on the left side of the engine. Refer to Illustration 2.

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Illustration 3	g01625190
Right side view

6. Install one plug on the right side of the engine. Refer to Illustration 3.

Install the New Jacket Water Heater

Modify the Rail

Note: The new jacket water heater is attached to a bracket. The bracket is attached to the rail on the left side of the engine. The rail must be modified by drilling two holes in the rail. Refer to Table 4 and Illustration 4 for the correct assembly dimension for the bracket.

Table 4

Dimensions for the Location of the Mounting Bracket
3508 Generator	3512 Generator	3516 Generator
Dimension X	Dimension X	Dimension X
1374 mm (54.1 inch)	1320 mm (52 inch)	1834 mm (72.2 inch)

Illustration 4	g01625211
Top view of left side rail

1. Drill two 14 mm (0.5625 inch) holes through the rail at the location that is specified by Illustration 4.

Prepare the Pump

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Illustration 5	g01625292
Jacket water heater (1) Bolt (2) Washer (3) Flange (4) Seal (5) Nut (6) Pump (7) Hose assembly (8) Connector

Note: Flange (3) must be removed from pump (6) in order to install connector (8) onto the flange. The pump body may break if the flange is attached to the pump during installation of the connector.

1. Remove two nuts (5) and two washers (2) from pump (6). Remove two bolts (1), two washers (2), flange (3), and seal (4). Retain all of the parts for the reinstallation of the flange.

2. Apply 5P-3413 Pipe Sealant to the pipe threads of connector (8). Tighten the connector to flange (3) .

3. Thread the elbow of hose assembly (7) onto connector (8) and tighten the elbow securely.

4. Reassemble the flange to the pump by using the original hardware. Be sure to install the gasket between the flange and the pump body.

5. Tighten nuts (5) in an alternate pattern in order to keep an equal distance between the flanges.

   Torque ... 40 ± 8 N·m (30 ± 5 lb ft)

Install the Heater

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Illustration 6	g01625323
Rear view of engine Typical installation for the mounting bracket (9) 8T-4194 Bolt (10) 5P-1076 Hard Washer (11) Bracket for the jacket water heater (12) Rail (13) 8T-4244 Nut

1. Install the bracket to the rail with the hardware that is listed in Illustration 6.

Hardware for 3508 Installation

Illustration 7	g01625385
Left side view of engine (1) 8C-6875 Connector (2) 5K-9090 O-Ring Seal (3) 307-9377 Hose As (4) 5P-1076 Hard Washer (5) 8T-4194 Bolt (6) 8T-4244 Nut (7) 6V-9854 Elbow

Illustration 8	g01625386
Rear view of engine (8) 7X-0326 Bolt (9) 8T-4223 Hard Washer (10) 7D-4092 Clip (11) 8S-5107 Spacer (12) 131-4863 Elbow (13) 8T-6912 Bolt (14) 5C-7261 Nut (15) 8T-4224 Hard Washer (16) 2B-0941 Spacer (17) 184-7211 Clip (18) 307-9376 Hose As

Illustration 9	g01625387
Right side view of engine

Hardware for 3512 Installation

Illustration 10	g01625593
Left side view of engine (1) 8C-6875 Connector (2) 5K-9090 O-Ring Seal (3) 7D-4092 Clip (4) 8T-4223 Hard Washer (5) 307-8765 Hose As (6) 5P-1076 Hard Washer (7) 8T-4244 Nut (8) 8T-4194 Bolt (9) 307-8764 Hose As

Illustration 11	g01625595
Rear view of engine (10) 7X-0326 Bolt (11) 8S-5107 Spacer (12) 8T-4224 Hard Washer (13) 5C-7261 Nut (14) 8T-6912 Bolt (15) 2B-0941 Spacer (16) 184-7211 Clip

Illustration 12	g01625596
Right side view of engine

Hardware for 3516 Installation

Illustration 13	g01625651
Left side view of engine (1) 5K-9090 O-Ring Seal (2) 8C-6875 Connector (3) 7D-4092 Clip (4) 8T-4223 Hard Washer (5) 307-9372 Hose As (6) 307-8764 Hose As

Illustration 14	g01625652
Rear view of engine (7) 8T-4244 Nut (8) 5P-1076 Hard Washer (9) 8T-4194 Bolt (10) 5C-7261 Nut (11) 8T-4224 Hard Washer (12) 8T-6912 Bolt (13) 2B-0941 Spacer (14) 184-7211 Clip (15) 7X-0326 Bolt (16) 8S-5107 Spacer

Illustration 15	g01625654
Right side view of engine

1. Refer to Illustrations 7 through 15. Install the hoses and the associated hardware according to the appropriate illustration. Apply 5P-3413 Pipe Sealant to the ends of any tapered pipe threads.

2. Open the shutoff valves that were installed with the new heater. Fill the system with coolant.

3. Check for any coolant leaks and correct any coolant leaks.

Electrical Installation

Note: Two sets of connections must be made. The jacket water heater must be supplied with 480 VAC three-phase electricity. A heater contactor must be wired to the generator control module in order to turn the heater and the pump off when the engine is running. Refer to Illustration 16.

Illustration 16	g01974073
Jacket water heater wiring

Note: Two wires are used for the pump and two wires are used for the thermostat.

Install the Harness

Note: High voltage packages do not come with wiring harnesses. High voltage packages must have terminal 11 and terminal 12 in the control box of the jacket water heater connected to a normally closed contactor. This contactor must open when the generator is running.

Install the Wiring Group

Refer to Table 2 for the wiring group for your application.

The following wiring groups are available for installing the 325-6250 Jacket Water Heater Gp :

• 328-3418 Jacket Water Heater Wiring Gp

• 328-3423 Jacket Water Heater Wiring Gp

• 328-3425 Jacket Water Heater Wiring Gp

• 328-3429 Jacket Water Heater Wiring Gp

• 328-3432 Jacket Water Heater Wiring Gp

The parts list for each wiring group is identical except for the electrical conduit that is needed. Refer to Table 5.

Installation of the 328-3418 Jacket Water Heater Wiring Gp

Refer to Table 5 and Illustration 17 for installation of the 328-3418 Jacket Water Heater Wiring Gp .

Table 5

Wiring Groups
Item Number	Part Number	Description	Quantity
1	5P-4116	Hard Washer	6
2	9X-6772	Cable Strap	6
3	156-6175	Clip	3
4	328-3414	Wiring Harness	1
5	328-3418 Jacket Water Heater Wiring Gp	328-3417 Electrical Conduit Gp	1
	328-3423 Jacket Water Heater Wiring Gp	328-3420 Electrical Conduit Gp
	328-3426 Jacket Water Heater Wiring Gp	328-3425 Electrical Conduit Gp
	328-3429 Jacket Water Heater Wiring Gp	328-3428 Electrical Conduit Gp
	328-3432 Jacket Water Heater Wiring Gp	328-3431 Electrical Conduit Gp
6	5C-2890	Nut	3
7	8T-4139	Bolt	1
8	8T-4223	Hard Washer	2
9	8T-4244	Nut	1
10	8T-4971	Bolt	3

Illustration 17	g01625926
328-3418 Jacket Water Heater Wiring Gp

Installation of the 328-3423 Jacket Water Heater Wiring Gp

Refer to Table 5 and Illustration 18 for installation of the 328-3423 Jacket Water Heater Wiring Gp .

Illustration 18	g01626085
328-3423 Jacket Water Heater Wiring Gp

Installation of the 328-3426 Jacket Water Heater Wiring Gp

Refer to Table 5 and Illustration 19 for installation of the 328-3426 Jacket Water Heater Wiring Gp .

Illustration 19	g01626085
328-3426 Jacket Water Heater Wiring Gp

Installation of the 328-3429 Jacket Water Heater Wiring Gp

Refer to Table 5 and Illustration 20 for installation of the 328-3429 Jacket Water Heater Wiring Gp .

Illustration 20	g01626190
328-3429 Jacket Water Heater Wiring Gp

Installation of the 328-3432 Jacket Water Heater Wiring Gp

Refer to Table 5 and Illustration 21 for installation of the 328-3432 Jacket Water Heater Wiring Gp .

Illustration 21	g01626378
328-3432 Jacket Water Heater Wiring Gp

Detail for the Bulkhead

Illustration 22	g01626387
Bulkhead fitting for conduit

1. Tighten conduit locknut (1) until the nut fits securely to the elbow. Hand tighten locknut (2). Tighten again by another 90 degrees.

Jacket Water Heater Wiring

Illustration 23	g01626392
Wiring for the Jacket water heater control box

1. Tighten conduit locknut (1) until the nut fits securely to the elbow. Hand tighten locknut (2). Tighten again by another 90 degrees.

Connections at Generator Panel

Illustration 24	g01626402
Wiring for the generator control module

Note: The same connections are made at the generator panel for all engines and for all generator frame sizes. Refer to Illustration 24 for the connections that must be made.

Wiring to Utility Power

Illustration 25	g01626404
Wiring for utility power

Three-phase 480 VAC must be wired to the jacket water heater control box using terminals "L1", "L2", and "L3". These wires must be routed through a customer supplied 20 amp breaker. Refer to Illustration 25.

Note: Do not energize the system yet. Prior to energizing the jacket water heater for the first time, the engine must be started and the engine must be brought to operating temperature.

Adjustment of the Thermostat

Illustration 26	g01626414
Dial for adjusting the set point of the thermostat

1. In order to adjust the set point for the thermostat, remove the cover for the jacket water heater.

2. Turn the dial for the thermostat to the desired temperature.

   Note: The recommended temperature for engine starting is 49 °C (120 °F). Refer to Illustration 26.

3. Replace the cover for the jacket water heater.

Engine Start-up

1. Prior to starting the engine for the first time, verify that the jacket water heater is not energized. Check that all electrical connections and all fluid connections are tight.

2. Ensure that the shutoff valves are open before starting the unit. Failure of the jacket water heater and personal injury may result from operating the heater with the shutoff valves closed.

3. After the unit is filled with coolant, loosen the flange of the pump outlet on the jacket water heater. Purge all of the air out of the system. Tighten the flange of the pump outlet again.

4. Start the engine and allow the engine to reach normal operating temperature. This will ensure that no air is trapped in the jacket water heater system.

5. Shut down the engine. Energize the jacket water heater. Verify that the heater functions properly.