A New Heated Insulation Kit Is Now Available for Open Crankcase Ventilation Systems on Certain C15 and C18 Generator Set Engines {1317} Caterpillar

Generator Set

C15 GEN SET (S/N: LNA1-UP; T4A1-UP; X5M1-UP)

C18 GEN SET (S/N: X5F1-UP)

The 508-8247 is combination of heated and non-heated insulation wraps are intended to prevent the open crankcase ventilation (OCV) from freezing in cold-weather climates that experience temperatures down to −33° C (−27.4° F) ambient.

The kit includes a combination of AC and DC powered heaters. The AC heaters only run when the generator set is running. The DC heaters run when the battery switch is turned.

Note: The heaters run when the battery switch is turned on. Therefore, a battery charger must be operational when the engine is not running.

The new insulation assemblies are adaptable to the above engines back to first production.

Required Parts

Illustration 1	g06156767
(1) 507-9004 Insulation (2) 445-7995 Insulation As (3) 445-8008 Insulation As (4) 445-8004 Insulation As (5) 508-8248 Insulation As (6) 508-8250 Insulation (7) 505-7936 Heater As (8) 505-7934 Insulation As

Installing the Heater and Insulation

Illustration 2	g06156777

1. Drill an 11/64 inch hole approximately 3/8 inch deep at the location shown in Illustration 2.
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   Illustration 3	g06156782
   (1) 030-9612 Screw (2) 109-3038 Wire End (3) 8T-7875 Electrical Wire

2. Cut wire (3) to approximately 3.5 m (11.5 ft).

3. Install wire end (2) onto one end of wire (3).

4. Secure wire end (2) to wire (3) with 3 cm (1.2 inch) of 125-7874 Heat Shrink Tube.

5. Attach ring terminal (2) to the valve cover with one screw (1).
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   Illustration 4	g06156789
   (4) 505-7936 Heater As

   Note: The minimum application temperature is 25° C (77° F). Any attempt to apply the heaters to a part at a temperature below 25° C (77° F) will result in a compromise of the bonding.

6. Use methyl alcohol to clean the part surface so that the surface is free of oil, grease, dirt, rust, or oxides and have a smooth bonding surface.

   Note: Do not use any cleaner which leaves an oily film (for example, kerosene, gasoline, Naphtha).

7. Attach heater pad (4) to the breather.

   • Support the power leads so that the power leads will not pull the heater from the part.

   • Peel off the release liner.

   • Position edge of heater on the part surface.

   • Roll into place to make sure that there are no air pockets between the heater and part surface.

   • Route and secure the wires to prevent rubbing and heat exposure.

8. Install approximately 305 mm (12 inch) of 109-0887 Sleeve over each lead and secure with cable straps.

9. Install the 271-5600 Connector Receptacle As, two 271-5604 Connector Pins, and the 271-5602 Wedge on the end of the heater pad wires.
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   Illustration 5	g06156797
   (5) 505-7934 Insulation As

10. Install insulation assembly (5) around the breather. Secure insulation clips to the four valve cover bolts at the corners of the valve cover.
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    Illustration 6	g06156823
    (6) 445-7995 Insulation As (7) 445-8008 Insulation As (8) 445-8004 Insulation As (9) 507-9004 Insulation

11. Install insulation (9) around the hose. Close the Velcro seam.

12. Install insulation assemblies (6), (7), and (8) around the canister. Secure insulation assemblies with the springs and clips.
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    Illustration 7	g06156831
    (10) 508-8248 Insulation As (11) 508-8250 Insulation

13. Install insulation assembly (10) around the OCV horizontal fumes hose. Close the Velcro seam.

    Note: Before installing the insulation on the OCV horizontal fumes hose, make sure that the hose has a continuous downhill slope to promote drainage and eliminate low spots.

14. Install insulation assembly (11) around the OCV drain line. Close the Velcro seam.

Electrical Schematic

Illustration 8	g06159680
(A) T1 (Top of breaker) (B) T2 (Bottom of breaker) (C) 200 mm (7.874 inch) (D) 3000 mm (118.11 inch) (E) 500 mm (19.685 inch) (F) Shore Power Line terminal (SP1L) (G) Shore Power Neutral terminal (SP1N) (H) Ground terminal (Ground wire to breather/valve cover) (1) 271-5590 Connector Plug As (2) 271-5599 Wedge (3) 374-8372 Connector Socket (4) 9X-1813 Sleeve

Illustration 9	g06156844
(F) Shore Power Line terminal (SP1L) (G) Shore Power Neutral terminal (SP1N) (H) Ground terminal (Ground wire to breather/valve cover)

Note: Callouts (A), (B), (F), (G), and (H) use the 109-3038 Wire Ends.

The heated breather pad has the following specifications:

• 120 V AC

• 150 W maximum

• 6.5 A maximum current draw

Illustration 10	g06159684
(A) T1 (Top of breaker) (B) T2 (Bottom of breaker) (C) 200 mm (7.874 inch) (D) 3000 mm (118.11 inch) (E) 500 mm (19.685 inch) (J) +VE (DC terminal) (K) -VE (DC terminal) (4) 9X-1813 Sleeve (5) 9X-3402 Connector Socket (6) 155-2270 Connecting Plug Kit

Illustration 11	g06157102
(J) +VE (DC terminal) (K) -VE (DC terminal)

Note: Callouts (A) and (B) use the 109-3038 Wire Ends.

Note: Callouts (J) and (K) use the 2L-8079 Ring Terminals secured with 3 cm (1.181 inch) of 125-7874 Heat Shrink Tube.

The heated insulation has a maximum 7.54 Amps at 28 V.