PRODUCT SUPPORT PROGRAM FOR INSTALLING A JACKET WATER HEATER TO CERTAIN 3126B MARINE PROPULSION ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A JACKET WATER HEATER TO CERTAIN 3126B MARINE PROPULSION ENGINES

Usage:

SEBE7957

April 4, 2002
U-74
A-55
AU-48
S-48
H-48
O-62

Show/hide table

*After failure only*	PRODUCT SUPPORT PROGRAM FOR INSTALLING A JACKET WATER HEATER TO CERTAIN 3126B MARINE PROPULSION ENGINES
1383		PS50436

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50436" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

TERMINATION DATE

April 30, 2004

PROBLEM

Some 3126B Marine Propulsion Engines may have white smoke after start-up when operating in cooler climates with lower air or seawater temperatures. A jacket water heater can reduce the amount of white smoke after startup.

There are two jacket water heater options available for use on the 3126B Marine Propulsion Engines. Both options are available in 120 VAC or 240 VAC. Either option can be used at the dealer?s discretion.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3126B	3GS1-833
3126	9ZF1-332

PARTS NEEDED

NOTE: Either option in the 120 or 240 VAC may be used at the dealer?s discretion. Option 1 - 2145910 Tank Heater Group (120 VAC)

1 ? 1081478 Valve
1 ? 2145977 Heater ? JW Tank
1 ? 2149160 Tee
4 ? 1591503 Clamp
1 ? 3D2824 Seal O-Ring
1 ? 5L5502 Tee
1 ? 9M4814 Connector ? Hose
300cm 5P0767 Hose

Option 2 - 2154239 Tank Heater Group (240 VAC)

1 ? 1081478 Valve
1 ? 2154167 Heater - JW Tank
1 ? 2149160 Tee
4 ? 1591503 Clamp
1 - 3D2824 Seal 0-Ring
1 - 5L5502 Tee
1 - 9M4814 Connector ? Hose
300cm 5P0767 Hose

Option 3 - 2137329 Jacket Water Heater (120 VAC)

1 - 1240686 Jacket Water Heater Element
2 - 1013625 Clip
2 - 8T4200 Bolt
2 - 8T4224 Hard Washer
1 ? 2137328 Cord
2 - 3S2093 Cable Strap

Option 4 - 2137330 Jacket Water Heater (240 VAC)

1 ? 1240687 Jacket Water Heater Element
2 ? 1013625 Clip
2 - 8T4200 Bolt
2 - 8T4224 Hard Washer
1 ? 2137328 Cord
2 - 3S2093 Cable Strap

ACTION REQUIRED

See attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-2000 0-24 mos	100%	*see below	0	0	0	0
NOTE: Option 1 & 2 - This is a 4.0?hr job. Option 3 & 4 ? This is a 5.0-hr job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedures)

Rework Procedures

Options 1 & 2

Show/hide table

(1) 1591503 Hose Clamp	(6) 9M4814 Hose Connector
(2) 1081478 Valve	(7) 5P0767 Hose
(3) 3D2824 O-Ring Seal	(8) 2145977 Heater
(4) 2149160 Tee	(9) Elbow
(5) 5L5502 Fitting	(10) Plug or fitting

NOTE: Both Jacket Water Heater Gps must be supplied by a grounded power source. The 2145910 Jacket Water Heater Gp (120 VAC) comes with a 15 Amp 120 VAC plug. The 2154239 Jacket Water Heater Gp (240 VAC) comes with a 15 Amp 240 VAC plug.

Drain the coolant from the cooling system. Refer to Operation and Maintenance Manual, SEBU7242.
Remove the plug or fitting (10) that is on the engine.
Install fitting (5). Plug the fitting or install other existing coolant lines in order to reconnect to the engine?s cooling system.
Remove the hose from elbow (9). Remove elbow (9) from the Cylinder block.
Install valve (2) on tee (4). Install O-Ring seal (3) on tee (4).
Install tee (4) with valve (2) in the hole that was for elbow (9).
Install the hose that was connected to elbow (9) on tee (4).
Mount heater (8) in a suitable location. Heater (8) must be mounted below the level of the cooling system. Heater (8) must be positioned so that the hose from the water outlet of the heater that connects to valve (2) is as vertical as possible.
Install hose (7) from fitting (5) to heater (8). Connect the hose with hose clamps (1).
Install hose (7) from valve (2) to heater (8). Connect the hose with hose clamps (1).
Fill the engine with coolant. Refer to Operation and Maintenance Manual, SEBU7242.
Make the necessary electrical connections to the electrical system of the vessel.

Options 3 & 4

Illustration 1

Show/hide table

(A) 30±15 Degrees
(1) 1240686 Jacket Water Heater Element (120 VAC) or 1240687 Jacket Water Heater Element (240 VAC)
(2) 1013625 Clip	(6) 3S2093 Cable Strap
(3) 8T4200 Bolt	(7) Sensor
(4) 8T4224 Hard Washer	(8) Plug
(5) 2137328 Cord	(9) Plug

NOTE: Both Jacket Water Heater Gps must be supplied by a grounded power source.

Drain the coolant from the cooling system. Refer to the Operation and Maintenance Manual, SEBU7242.
Remove plug (9) from the cylinder block of the engine. Lubricate the hole in the cylinder block with glycerin or antifreeze.
Lubricate the seal on the jacket water heater element (1) with glycerin or antifreeze. Install jacket water heater element (1) in the position that is shown in Illustration 1. Remove the plastic cap and tap the jacket water heater element into the cylinder block with a driver that is 31.8 mm (1.25 inch) to 38 mm (1.50 inch) in diameter.
Remove plug (8) from the engine. Remove the sensor (7) from cord (5). Install the sensor (7) in the hold for pug (8). Tighten the sensor to a torque of 8 N·m (6 lb ft).
Route cord (5), as shown. Connect the cord to the Jacket Water Heater Element (1). Connect the cord to sensor (7). Install clips (2). Fasten the clips with bolts (3) and washers (4). Retain the cord to the clips with cable straps (6).
Fill the engine with coolant. Refer to Operation and Maintenance Manual, SEBU7242.
Make the necessary electrical connections to the electrical system of the vessel.