The Configuration of the Jacket Water Heater System for C9 Generator Sets Has Been Improved{1383} Caterpillar

Generator Set:

C9 GEN SET (S/N: C9E1-UP)

Introduction

This Special Instruction provides the procedure for the reconfiguration of the existing jacket water heater system for the C9 generator sets in order to improve heating efficiency. This reconfiguration will also prevent coolant leaks.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Show/hide table

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

Required Parts

Procedure

ReferenceRefer to Operation and Maintenance Manual, SEBU7878, "C9 Generator Set" for more information.

ReferenceRefer to Specifications, SENR3130, "Torque Specifications" for more information.

1. Isolate the generator set before starting any work on the unit. Open the breaker of the generator set and activate the emergency stop. Disconnect the battery cables.

2. Drain the coolant from the engine. Refer to Operation and Maintenance Manual, SEBU7878, "C9 Generator Set" for the proper procedure.

3. Remove all of the existing components of the assembly of the jacket water heater from the generator set. Detach the cable ties that secure the wiring harness of the jacket water heater to the generator set.

4. Detach the hose assemblies and the mounting bracket from the jacket water heater. The wiring harness for the jacket water heater does not need to be disconnected from the control panel. Retain the hardware that secures the jacket water heater to the bracket. This hardware will be reused.

5. Examine the jacket water heater for signs of damage that would prohibit the jacket water heater from being reused. Do not reuse the jacket water heater if the ports show signs of cracking. Do not reuse the jacket water heater if the plastic body of the interior shows signs of blistering.

Show/hide table



Illustration 1	g02139790
Narrow base frame

Show/hide table



Illustration 2	g02139791
Wide base frame

6. Determine if the base frame assembly is wide or narrow. Refer to Illustration 1 and Illustration 2. Measure the location and mark the location for new holes (1) for the new bracket.

7. Drill two 12 mm (0.5 inch) holes (1) in the base frame.

Show/hide table



Illustration 3	g02139792
(2) 355-0413 Bracket (3) 8T-4121 Hard Washer (4) 8T-4133 Nut (5) 8T-4195 Bolt

8. Use the following hardware to secure the new bracket (2) to the base frame:
   • 4 8T-4121 Hard Washers (3)

   • 2 8T-4133 Nuts (4)

   • 2 8T-4195 Bolts (5)

   Refer to Illustration 3.

Show/hide table



Illustration 4	g02139793
(6) 258-6844 Coolant Heater (7) Original mounting hardware

9. Reuse the original hardware (7) in order to install the jacket water heater (6) to the bracket. Refer to Step 4.

   Note: The integral wiring harness of the jacket water heater may be of insufficient length in order to follow the original routing on certain C9 generator sets that are equipped with oversized generators. Reroute the wiring harness in order to accommodate the oversized generators. If rerouting is unsuccessful, a service replacement 258-6844 Coolant Heater may need to be utilized. These coolant heaters have a longer integral wiring harness.

10. Remove the existing belt guard for the charging alternator. Install the new 356-5932 Alternator Guard Gp .

Show/hide table



Illustration 5	g02139838
(8) 353-5123 Adapter

11. Install a new adapter fitting (8) in the rear engine block. Apply thread sealant and tighten the fitting to a torque of 75 + 8 N·m (55 + 6 lb ft). Refer to Illustration 5.

Show/hide table



Illustration 6	g02139794
(9) 260-9144 Connector As

12. Install a new adapter fitting (9) in the front engine block. Secure the fitting with an O-ring and tighten the fitting to a torque of 60 + 6 N·m (44 + 4 lb ft). Refer to Illustration 6.

Show/hide table



Illustration 7	g02139795
(10) 260-9144 Connector As (11) 4I-0472 Clip (12) 6V-8843 Hose (13) Fitting of the thermostat

13. Measure a section of the hose and cut a section of the hose (12) to 1400 mm (55 inch). Place one 159-1503 Hose Clamp and one clip (11) on each end of the hose.

    Connect one end of the hose assembly to the adapter fitting (10). Connect the other end of the hose to the fitting of the thermostat (13) on the bottom of the jacket water heater. Do not tighten the clamps.

    Use one 8T-4195 Bolt and one 8T-4121 Hard Washer to secure the clips (11) to the alternator guard assembly. The hose must not have any bends. The hose must not make contact with the alternator guard or the bracket. Refer to Illustration 7.

Show/hide table



Illustration 8	g02139796
(11) 4I-0472 Clip (14) 353-5123 Adapter (15) Outlet fitting

14. Measure a section of the hose and cut a section of the hose to 1090 mm (42.3 inch). Place one 159-1503 Hose Clamp on each end of the hose. Place one clip (11) on the hose.

    Connect one end of the hose assembly to the adapter fitting (14). Connect the opposite end of the hose to the outlet fitting (15) that is on the top of the jacket water heater. Do not tighten the clamps. Refer to Illustration 8.

Show/hide table



Illustration 9	g02139797
(16) 356-5787 Bracket (17) 5C-6266 Bolt (18) 8T-4122 Hard Washer (3) 8T-4121 Hard Washer (4) 8T-4133 Nut (5) 8T-4195 Bolt (11) 4I-0472 Clip

15. Install the bracket (16) on the engine flywheel with a bolt (17) and a washer (18). Attach the clip (11) to the bracket with a bolt (5), a washer (3), and a nut (4). Orient the clip at a 25 degree angle. The hose must have a constant rise. The hose must not have any bends. The hose must not make contact with the flywheel housing. Refer to Illustration 9.

16. Tighten the clamps to a torque of 7 N·m (5 lb ft).

17. Reconnect the wiring harness of the jacket water heater. Use tie straps to secure the wiring harness.

18. Replenish the engine coolant with the appropriate coolant mixture. Inspect the system for any coolant leaks and repair the system if any leaks are found. Refer to Operation and Maintenance Manual, SEBU7878, "C9 Generator Set" for the proper procedure.

19. Energize the jacket water heater system in order to confirm proper operation. Measure the coolant temperature at the outlet side of the jacket water heater. The temperature of the coolant should be between 70° C (158° F) and 90° C (194° F).

20. Restore the generator set to the proper operational condition.