Jacket Water Heater Installation Procedures{1383} Caterpillar

Introduction

The jacket water heater keeps the engine water temperature warm when the ambient air temperature is below 13°C (55°F). The warm jacket water aids in preventing rough combustion after cold start-ups.

The jacket water heater can be installed on either side or both sides of the engine. However, it is recommended that a jacket water heater group be installed on both sides of the engine to insure even heating of the engine water.

NOTE: The 7E6249 Jacket Water Heater (120 volt) or the 7E6248 Jacket Water Heater (240/480 volt) may be used to provide 6 kilowatts of heat when the appropriate power source is available.

This instruction gives the procedures needed to install the jacket water heater mounting groups for the 3500 Engine Family, within the product serial number range given.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

NOTE: Attach a "DO NOT OPERATE" or similar warning tag to the start switch or controls before starting the jacket water heater installation procedure. These tags, Form SEHS7332, are available from your Caterpillar dealer.

Reference: Service Manual And Parts Book

Necessary Parts

NOTE: The jacket water heater mounting groups can not be ordered as a group. Refer to individual mounting groups for necessary parts needed for installation.

3508 Jacket Water Mounting Groups

3512 Jacket Water Mounting Groups

3516 Jacket Water Mounting Groups

Right Hand Mounting Installation Procedures

* This procedure applies to 3508, 3512 and 3516 Engines.

NOTE: Use a thread lubricant on all pipe threads before assembling.

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At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.

NOTE: The engine jacket water must be drained before starting this installation procedure.

1. Remove jacket water drain plug (1) and oil cooler water bonnet drain plug (2). Drain engine coolant into a clean 75.80 L (20 gal) storage container. The engine coolant will be reused later in this procedure.

Replace drain plug (1) and (2) when the engine coolant is completely drained from the water jackets.

Left Side View

Right Side View

2. Install 4P4774 Bracket Assembly (13) on right side of flywheel housing (20), using two 8V2636 Spacers (18), 2H3745 Bolts (16) and 5P8250 Washers (17) as shown.

3. Position appropriate jacket water heater (15) on bracket assembly (13), be sure that port (A) points to the front of the engine.

4. Install two 5P0598 Clamps (14) around jacket water heater (15) and bracket assembly (13) and tighten.

5. Install 6F0496 Tee (23) on port (B) and tighten. Be sure that the tee is in position as shown when tight.

Install 6H8297 Elbow (22) in the end of the tee (facing the front of engine) and tighten. Be sure the elbow is in position as shown when tight.

Install 3M7045 Plug (24) in the end of the tee (facing the rear of engine) and tighten.

6. Install 2R7712 Reducing Coupling (21) on port (A) and tighten.

7. Install two 6B9081 Pipe Reducing Bushings (11) into engine block and tighten.

8. Install 5N5988 Hose Assembly (12) into 6B9081 Pipe Reducing Bushing (11) and tighten. Install the other end of Hose Assembly (12) into 2R7712 Reducing Coupling (21) and tighten.

NOTE: Assemble 5N5988 Hose Assembly (12) to maintain a gradual rise from jacket water heater outlet port (A) to the engine block.

9. Install Hose Assembly 5N1649 (19), 3N7223 (5) or 3N4911 (3) into 6B9081 Pipe Reducing Bushing (11) and tighten. Slide 1S0724 Clips (4) over other end of the hose assembly and position on rail assembly (10).

NOTE: For proper clip quantity and location see appropriate engine side view. Drill two 10.4 mm (13/32in) holes in rail assembly if necessary to mount clips.

10. Install 1S0724 Clips (4) to rail assembly (10) using 0S1619 Bolts (6), 5M2894 Washers (7), 7K3377 Spacers (8) and 9S8752 Nuts (9) as shown. Do not tighten bolts (6).

11. Install the other end of Hose Assembly (3), (5) or (19) into 6H8297 Elbow (22) and tighten. Adjust the hose assembly and tighten bolts (6).

12. Fill the engine cooling system to the bottom of the fill tube. Use the engine coolant that was drained earlier. If necessary add new coolant of the proper mixture. Install the fill cap and tighten.

13. Start and operate the engine and allow to warm to operating temperature. Visually check the jacket water heater mounting group for leaks.

14. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to remove with your bare hand.

3516 RIGHT SIDE VIEW

3508-3512-3516 END VIEW

3512 RIGHT SIDE VIEW

3508 RIGHT SIDE VIEW

3512 LEFT SIDE VIEW

3508 LEFT SIDE VIEW

3516 LEFT SIDE VIEW

3508-3512-3516 END VIEW

Left Hand Mounting Installation Procedures

* This procedure applies to 3508, 3512 and 3516 Engines

NOTE: Use a thread lubricant on all pipe threads before assembling.

Show/hide table

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.

NOTE: The engine jacket water must be drained before starting this installation procedure.

1. Remove jacket water drain plug (1) and oil cooler water bonnet drain plug (2). Drain engine coolant into a clean 75.80 L (20 gal) storage container. The engine coolant will be reused later in this procedure.

Replace drain plug (1) and (2) when the engine coolant is completely drained from the water jackets.

Left Side View

Right Side View

2. Install 7C1707 Bracket Assembly (15) on left side of flywheel housing (11), using two 1S2303 Spacers (30), 9S1368 Bolts (28) and 5P8250 Washers (29) as shown.

3. Position appropriate jacket water heater (13) on bracket assembly (15), be sure that port (A) points to the front of the engine.

4. Install two 5P0598 Clamps (16) around jacket water heater (13) and bracket assembly (15) and tighten.

5. Install 6F0496 Tee (18) onto port (B) and tighten. Be sure that the tee is in position as shown when tight.

Install 6H8297 Elbow (19) into the end of the tee (facing the front of engine) and tighten. Be sure the elbow is in position as shown when tight.

Install 3M7045 Plug (17) into the end of the tee (facing the rear of engine) and tighten.

6. Install 2R7712 Reducing Coupling (20) on port (A) and tighten.

Install 5F6371 Connector (21) into end of 2R7712 Reducing Coupling (20) and tighten.

7. Install 8N8550 Elbow (8) and 7N4945 Gasket (9) with three 0S1594 Bolts (10) and one 0S1571 Bolt (12) as shown and tighten.

8. Install 043935 Elbow (7) into end of 8N8550 Elbow (8) and tighten. Be sure the elbow is in position as shown when tight.

9. Install 1L4031 Tee (27) into the engine block and tighten. Be sure the tee is in position as shown when tight.

Install 5B4855 Pipe Reducing Bushing (26) into end of the tee (facing away from engine) and tighten.

Install 2B0858 Plug (25) into end of pipe reducing bushing (26) and tighten.

Install 6B9081 Pipe Reducing Bushing (24) into side of the tee (facing the rear of engine) and tighten.

10. Install 8N0550 Hose Assembly (22) into 043935 Elbow (7) and tighten. Install the other end of hose assembly into 5F6371 Connector (21) and tighten.

NOTE: Assemble 8N0855 Hose Assembly to maintain a gradual rise from jacket water heater outlet port (A) to the engine block.

11. Install Hose Assembly 5N1649 (6), 3N7223 (3) or 3N4911 (5) into 6B9081 Pipe Reducing Bushing (24) and tighten. Slide 9F7716 Clips (4) over other end of the hose assembly and position on side of the engine.

NOTE: For proper clip quantity and location see appropriate engine side view. Remove existing side cover mounting bolts if necessary.

12. Install 9F7716 Clips (4) to side of engine using 0L1329 Bolts (31), 5P8245 Washers (32) and 8S5107 Spacers (14) as shown. Do not tighten bolts (31).

13. Install the other end of Hose Assembly (3), (5) or (6) into 6H8297 Elbow (19) and tighten. Adjust the hose assembly and tighten bolts (31).

14. Fill the engine cooling system to the bottom of the fill tube. Use the engine coolant that was drained earlier. If necessary add new coolant of the proper mixture. Install the fill cap and tighten.

15. Start and operate the engine and allow to warm to operating temperature. Visually check the jacket water heater mounting group for leaks.

16. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to remove with your bare hand.