Installation Instructions for Jacket Water Heaters with Seal Kits{1383} Caterpillar

Engines:

3054 (S/N: 7BJ1-UP; 5HK1-UP; 9RM1-UP)

3054B (S/N: 7SG1-UP)

3056 (S/N: 8XJ1-UP)

3114 (S/N: 2ZF1-UP; 5EF1-UP; 1ZG1-UP; 2FG1-UP; 4RR1-UP; 97Z1-UP)

3116 (S/N: 4TF1-UP; 2WG1-UP; 4PG1-UP; 1CK1-UP; 1SK1-UP; 9GK1-UP; 5EN1-UP; 2MR1-UP; 6RR1-UP; 98Z1-UP)

3126 (S/N: 55K1-UP; 6JK1-UP; 1WM1-UP)

3126B (S/N: BMA1-UP; 5GG1-UP)

3176C (S/N: 3PD1-UP)

3196 (S/N: 5ED1-UP)

3204 (S/N: 7YJ1-UP; 45V1-UP; 10X1-UP)

3208 (S/N: 90N1-UP; 01Z1-UP; 02Z1-UP; 03Z1-UP)

Introduction

This Special Instruction contains the necessary instructions in order to install the following Jacket Water Heaters: 3T-8724, 6N-9125, 7E-5244, 7E-6310, 9X-3294, 9Y-5316, 9Y-5318, 127-8603, 127-8605, 166-0658 and 194-7258.

Installation Instructions for Seal Kit

The following procedure is recommended for installation of the following Seal Kits: 132-1448, 133-3413 and 161-8200. Refer to Table 1.

Illustration 1	g00804700
Typical Installation Of Seal Kit (1) Snap Ring. (2) Retainer Rings. (3) Spacer Ring. (4) Seal. (5) Heater Adapter. (6) Cap Assembly. (7) Cord Assembly.

1. If necessary, remove old snap ring (1), retainer rings (2), spacer ring (3), and seal (4). Discard old parts.

2. Clean heater adapter (5). Make sure that the heater adapter is free from dirt, grease, and any other debris.

3. Install seal (4) onto heater adapter (5) .

4. Install retainer rings (2) and spacer ring (3) .

   Note: Assemble retainer rings (2) on each side of spacer ring (3). Offset the teeth from each other and orient the teeth toward seal (4). Refer to Illustration 1.

5. Install snap ring (1) .

Installation Instructions for Jacket Water Heaters

The following procedure is recommended for installation of the Jacket Water Heaters.

Illustration 2	g00803515
Typical Installation Of Jacket Water Heaters

1. Allow the engine to cool and drain the coolant.

2. Remove the existing jacket water heater. If new installation is required, remove the appropriate cup plug from the bore in the block.

3. Clean the bore in the block until the bore is free of any deposits.

   Note: If the outside edge of the bore is not chamfered, file any sharp edges.

4. Remove cap assembly (6) from the heater.

5. Apply a light coat of grease to seal (4) and to the bore.

6. Place the heater SQUARELY into the bore. Ensure that the heater element is oriented correctly.

   Note: Do not wedge the heater into the bore because damage to the retaining rings and the seal may result. The heater element should not touch any walls.

7. Once the heater has started into the bore, place a 1 1/4 inch deep socket over the threaded end of the heater. Insert the heater by lightly tapping the socket until the heater adapter seals against the block.

8. Install cap assembly (6) onto the heater.

   Note: The cap assembly is used to protect the terminals when the cord assembly is disconnected from the heater.

9. Fill the engine with coolant. Start the engine and check the engine for leaks. Continue to operate the engine until the operating temperature is reached in order to ensure that all of the air is purged from the cooling system.

10. When the operating temperature is reached, stop the engine. Allow the engine to cool.

11. Check the coolant level in the radiator or in the expansion tank. If necessary, top off the coolant.

12. Remove cap assembly (6) from the heater.

13. Install cord assembly (7). Hand tighten the final installation of the cord assembly. Energize the heater.

    Note: Always unplug the heater before starting the engine.