- Engine:
- C18 (S/N: ZKB1-UP)
- Generator Set:
- C15 GEN SET (S/N: T4A1-UP; ZKA1-UP; PEC1-UP; C5E1-UP; STG1-UP; C5H1-UP; C5L1-UP; NKL1-UP; CYY1-UP)
- C18 GEN SET (S/N: C6C1-UP; G4C1-UP; STD1-UP; DKE1-UP; PEE1-UP; PEJ1-UP; NKK1-UP; STM1-UP; EKW1-UP; M1Z1-UP)
- C18 MARINE GS (S/N: GBM1-UP; MGS1-UP)
- C18 GEN SET (S/N: C6C1-UP; G4C1-UP; STD1-UP; DKE1-UP; PEE1-UP; PEJ1-UP; NKK1-UP; STM1-UP; EKW1-UP; M1Z1-UP)
- Petroleum Engine:
- C15 PET GS ENG (S/N: PET1-UP)
Introduction
These instructions explain the field retrofit process for improving the jacket water heater system on existing C15 and C18 gensets that were shipped from factory with the previously installed jacket water heater option. The new retrofit has been designed to utilize most of the existing components from the original factory installed system you already have on the genset. The new retrofit adds the silicone hoses rated for 175° C (347° F) which will provide extra long life in high temperature environment. The new retrofit will also relocate the heater onto the genset base improving the coolant flow and more evenly distributing the heat into the engine. The new retrofit does not convert the existing legacy system into the current factory installed system with a remote thermostat and the new control system.
Important Safety Information
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed. 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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
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| NOTICE |
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Do not change the coolant until you read and understand the material in the Cooling System Specifications section. |
| NOTICE |
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Use only Caterpillar products or commercial products that have passed Caterpillar's EC-1 specification for pre-mixed or concentrated coolants. Use only Cat ELC Extender with Cat ELC. Mixing Cat ELC with other products reduces the Cat ELC service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Required Parts
| C15 Narrow Base | C15 Wide Base | ||||
| Quantity | Part Number | Description | Quantity | Part Number | Description |
| 1 | 9R-3253 | Plate | 1 | 9R-3253 | Plate |
| 1 | 163-7451 | Bracket | 1 | 163-7451 | Bracket |
| 1 | 336-8586 | Bracket | 1 | 336-8586 | Bracket |
| 1 | 357-4579 | Connector | 1 | 357-4579 | Connector |
| 2 | 5P-7854 | Clip | 3 | 5P-7854 | Clip |
| 1 | 6V-2492 | Connector | 1 | 6V-2492 | Connector |
| 1 | 6V-8801 | Nut | 1 | 6V-8801 | Nut |
| 4 | 7X-7958 | Hose Clamp | 4 | 7X-7958 | Hose Clamp |
| 1 | 8T-4896 | Hard Washer | 1 | 8T-4896 | Hard Washer |
| 10 | 8T-4121 | Hard Washer | 16 | 8T-4121 | Hard Washer |
| 5 | 8T-4133 | Nut | 8 | 8T-4133 | Nut |
| 5 | 8T-4195 | Bolt | 8 | 8T-4195 | Bolt |
| 2m | 302-7411 | Hose | 2.5m | 302-7411 | Hose |
| 1 | 6V-6609 | O-Ring Seal | 1 | 362-6539 | Bracket |
| 2 | 347-4444 | Connector | 1 | 6V-6609 | O-Ring Seal |
| 1 | 3B-6491 | Pipe Coupling | 2 | 347-4444 | Connector |
| 1 | 3B-6491 | Pipe Coupling | |||
| If Ball Valves Retained | If Ball Valves Retained | ||||
| 2 | 6V-2492 | Connector | 2 | 6V-2492 | Connector |
| C18 Narrow Base | C18 Wide Base | ||||
| Quantity | Part Number | Description | Quantity | Part Number | Description |
| 1 | 9R-3253 | Plate | 2 | 9R-3253 | Plate |
| 1 | 163-7451 | Bracket | 1 | 362-1639 | Bracket |
| 1 | 336-8586 | Bracket | 1 | 357-4579 | Connector |
| 1 | 357-4579 | Connector | 2 | 5P-7854 | Clip |
| 2 | 5P-7854 | Clip | 3 | 347-4444 | Connector |
| 3 | 347-4444 | Connector | 4 | 7X-7958 | Hose Clamp |
| 4 | 7X-7958 | Hose Clamp | 10 | 8T-4121 | Hard Washer |
| 10 | 8T-4121 | Hard Washer | 5 | 8T-4133 | Nut |
| 5 | 8T-4133 | Nut | 5 | 8T-4195 | Bolt |
| 5 | 8T-4195 | Bolt | 2m | 302-7411 | Hose |
| 2m | 302-7411 | Hose | 1 | 0T-0055 | Bolt |
| 1 | 0T-0055 | Bolt | 1 | 6V-6609 | O-Ring Seal |
| 1 | 6V-6609 | O-Ring Seal | 1 | 3B-6491 | Pipe Coupling |
| 1 | 3B-6491 | Pipe Coupling | |||
| If Ball Valves Retained | If Ball Valves Retained | ||||
| 2 | 6V-2492 | Connector | 2 | 6V-2492 | Connector |
Installation Procedure
Note: In order to apply the new retrofit, the genset must already have a factory installed jacket water heater system.
Preparation for the Retrofit
Note: The existing legacy jacket water system has ball valves. The ball valves have NPT threads and are connected to the engine utilizing NPT Connectors. The NPT threads may be the source of leaks, especially if disturbed during this installation. The ball valves should be removed when the long life silicone hose is installed.
- Drain engine coolant, remove the ball valves and go to Step3
Note: If the ball valves are kept in place, skip this step, shut off the ball valves, and go to Step 2.
- Remove all fittings from the valves, while leaving the valves attached to the engine. Be careful not to turn the existing fittings and break the seals.
- Remove from the engine block the existing jacket water system fittings, hoses, and the jacket water heater, including the bracket.
- Loosen the jacket water heater wiring harness so that the harness can reach the new location of the relocated jacket water heater. Leave the electrical harness connected to the heater. The existing heater will be reused after the following modification.
- Remove the heater from the bracket. Remove the hoses and existing fittings from the heater. Inspect the heater element and the fitting ports. Do not reuse the heater if there are any cracks on the ports.
- Install the new 347-4444 Connector on the outlet of the heater using Loctite sealant. Torque the connector to 37 N·m (27 lb ft).
- Install a new 3B-6491 Pipe Coupling (2) on the heater (1) inlet and a 347-4444 Connector (3) on the heater inlet using Loctite sealant. Torque the fitting to 37 N·m (27 lb ft). Refer to Illustration 1.
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| Illustration 1 | g02555896 |
C15 Engine Fitting Installation (without Ball Valves)
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| Illustration 2 | g02554316 |
- Install the new 6V-2492 Connector (4) into the rear of the oil cooler bonnet. Refer to illustration 2. Apply Loctite sealant on the connector threads and torque the connector to 60 N·m (44 lb ft).
- Install the new 357-4579 Connector (5) and 6V-6609 O-Ring Seal into the front engine port. Refer to Illustration 3. Torque the connector to 60 N·m (44 lb ft).
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| Illustration 3 | g02556141 |
- Install 9R-3253 Plate (6) on the stud on the oil cooler using 6V-8801 Nut (7) and 8T-4896 Hard Washer (8). Refer to Illustration 4.
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| Illustration 4 | g02556183 |
- On C15 gensets with a wide base install the return hose support 362-6539 Bracket (9) by removing the flywheel barring tool access cover bolt. Use this bolt to attach the bracket. Make sure that the bracket is in a horizontal position. Refer to Illustration 5.
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| Illustration 5 | g02556276 |
C15 Engine Fitting Installation (with Ball Valves)
- Install the new 6V-2492 Connectors into the existing valves. Apply Loctite sealant on the connector threads and torque the fitting to 60 N·m (44 lb ft). Be careful not to turn the existing connectors and break the seals.
- Proceed to "Heater Installation".
C18 Engine Fitting Installation (without Ball Valves)
- Install the new 347-4444 Adapter (10) into the rear of the oil cooler bonnet. Refer to Illustration 6. Apply Loctite sealant on the connector threads and torque the connector to 75 N·m (55 lb ft).
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| Illustration 6 | g02556316 |
- Install the new 357-4579 Connector and 6V-6609 O-Ring Seal into the front engine port. Refer to Illustration 3. Torque the connector to 60 N·m (44 lb ft).
- Install 9R-3253 bracket (11) on the oil cooler. Remove the existing bolt and replace the bolt with the longer 0T-0055 Bolt (12) to hold the bracket in place. Refer to Illustration 7.
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| Illustration 7 | g02556521 |
- Proceed to "Heater Installation".
C18 Engine Fitting Installation (with Ball Valves)
- Install the new 6V-2492 Connectors into the existing valves. Apply Loctite sealant on the connector threads and torque the connector to 60 N·m (44 lb ft). Be careful not to turn the existing fittings and break the seals.
- Proceed to "Heater Installation".
Heater Installation
- Cut a 1.3 m (4.3 ft) piece of the silicone 302-7411 Hose .
Note: For C15 on a wide base cut the hose 1.6 m (5.2 ft) long. Slide two 5P-7854 Clips into middle of the longer supply hose, and two 7X-7958 Hose Clamps , one on each end of the hose.
- Push the hose on the front engine block connector. Do not torque the hose clamp yet.
- Cut a 0.7 m (2.3 ft) long piece of the silicone 302-7411 Hose . Slide two 7X-7958 Hose Clamps , one on each end of the hose.
Note: For C15 on a wide base cut the hose 0.8 m (2.6 ft) long and slide one hose clip 5P-7854 Clip into the middle of this hose.
- Slide the hose on the rear engine connector. Do not torque the hose clamp yet.
- Mount the heater to the new bracket 336-8586 Bracket reusing the heater mounting U-bolt clamps and hardware.
Note: For C18 wide base gensets use 362-1639 Bracket . Make sure that the heater outlet connector is tilted 6 degrees from vertical and toward the engine.
- Determine the best location for the new heater with the new bracket. The bracket will mount to the top of the genset base rail. Place the new heater in a location on the base rail that does not obstruct any installed equipment. Also ensure that the hoses can be routed to the heater inlet and outlet.
- Mark the holes for the bracket in the base rail (13). Drill four 12 mm (0.47 inch) holes in the base rail. Refer to Illustration 8.
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| Illustration 8 | g02556996 |
- Install the new heater bracket on the genset base rail using 8T-4195 Bolts , 8T-4133 Nuts , and 8T-4121 Hard Washers .
- Slide the 4D-7388 Clip (14) already on the hose to match the hole in the oil cooler 9R-3253 Plate (6), and attach this plate using 8T-4195 Bolts (15), 8T-4133 Nuts (17), and 8T-4121 Hard Washers (16). Refer to Illustration 9.
Note: Omit this step if retaining the existing ball valves.
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| Illustration 9 | g02557057 |
- Route the supply hose to the heater inlet. Allow enough slack in the hose to clear the oil cooler. Prevent excessive sagging. Trim the supply hose to the desired length. Push the hose end on the heater inlet connector. Fit the hose clamps over the connectors and torque the clamps to 7.5 N·m (66 lb in).
- Install hose 127-9323 Bracket As (18) on the base rail (13) with M10 hardware. Locate the optimal place of the support bracket and drill one 12 mm (0.47244 inch) hole in the top of the base. Place the bracket in a location that provides the best support for the hose and prevents sagging or kinking of the hose. Refer to Illustration 10.
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| Illustration 10 | g02557717 |
- Route the return hose to the heater outlet connector. Allow enough slack in the hose to avoid kinking or collapsing, but prevent the hose from excessive sagging. Ensure that the hose has a continuous rise toward the engine.
Note: On C15 with a wide base attach the 5P-7854 Clip to the support bracket 362-6539 Bracket . Trim the return hose to the desired length, and install the hose on the heater outlet. Fit the hose clamps over the connectors and torque the clamps to 7.5 N·m (66 lb in).
- Secure the heater wiring harness using cable ties.
- Refill the cooling system with coolant and inspect for leaks.