Installation Procedure for Improved Jacket Water Heater on Certain C27 Generator Sets{1383} Caterpillar

Generator Set:

C27 GEN SET (S/N: DWB1-UP)

Introduction

This Special Instruction provides information to install the new and improved jacket water heater for Narrow-Base/Wide-Base C27 Generator Sets.

Important Safety Information

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. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for others. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. Bodily contact with electrical potential will cause personal injury or death.

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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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Only persons with training in electrical installations must carry connections to the generator. The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect. The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these two steps in order to prevent accidental starting: Isolate the DC breaker. Disconnect the DC supply battery.

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from any utility and/or other generators that can provide power service), and either lock out or tag as "DO NOT OPERATE". Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.

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Failure to connect the unit to a suitable grounding electrode will result in electrical shock and will cause injury or death.

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Working with electrical circuits is hazardous. Bodily contact with electrical potential will cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

Preparing the Machine

1. Move the machine to a smooth, level surface that will support the weight of the machine.

2. Turn off the machine with the engine switch to the OFF position.

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Illustration 1	g03055081

3. Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar Dealer.

Required Parts

C27 Narrow-Base

C27 Wide-Base

Wide Base used only with Caterpillar-packaged enclosures.

Suggested Parts

Installation Procedure for Narrow-Base C27 Generator Sets

Mechanical Installation

Illustration 2	g02718770
Overview of complete frame rail overview

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, active Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger.

   Ensure that all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.

   Only qualified repair personnel should service this equipment. For all on-package welding, refer to the Operation and Maintenance Manual, SEBU8088 before commencing work.

2. Reference the Maintenance section of Operation and Maintenance Manual, SEBU8088 to drain the coolant from the generator set.

3. Remove the existing jacket water heater system. Disconnect the line routing from both sides of the engine block, remove the jacket water heater complete with line routing from the generator set, disconnect the conduit group from the existing JWH connection box and customer connection box, and remove all related tie straps and clips.

   Note: Use an adequate container to capture any spilled coolant from the disconnection of the line routing.

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Illustration 3	g02719456
JWH mounting and modification details

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Illustration 4	g02719459
Fuel and oil sump line frame modification details

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Illustration 5	g02719462
Forward rail cross member modification details

4. In order to install the new jacket water heater and line routing, perform the following frame modifications (Refer to Illustration 2):

   1. Drill two new 16.75 mm (0.66 inch) diameter holes on top of the right-hand frame rail as shown in Illustration 3.

   2. Drill a 28.5 mm (1.12 inch) hole on the side of the right-hand frame rail and then weld a 277-3717 Coupling into the hole as shown in Illustration 4.

   3. Drill a 41.5 mm (1.63 inch) hole in the right-hand frame rail, and weld a 277-3716 Coupling into the hole as shown in illustration 4.

   4. Weld two 8T-3851 Weld Boss (M10 × 1.5) on top of the cross member surface in the specified locations as shown in Illustration 5.

   5. Touch up all newly welded surfaces with black touch-up paint and allow time for the paint to dry before continuing.

5. Detach the fuel-in hose line on the inside of the rail frame and attach the fuel line to the coupling added in Step 4.b.

6. Detach the oil sump line on the inside of the rail frame and attach this oil line to the coupling added in step 4.c.

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Illustration 6	g02719516
JWH mounting on frame rail

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Illustration 7	g03211838
Complete JWH assembly and routing detail

7. Attach the 369-1719 Jacket Water Heater Gp to the right-hand side frame rail using the holes created in Step 4.a, two 8T-4183 Bolts , four 8T-4223 Hard Washers , and two 9X-2066 Nuts . Refer to Illustration 6. The heater group should be positioned such that it fixed inside the frame rail and the control box faces up.

8. Perform the following to attach the line routing between the jacket water heater outlet and the engine block:

   ReferenceIllustration 7

   1. Attach the elbow end of the 369-3817 Hose As to the fitting on the jacket water pump outlet.

   2. Insert 5K-9090 O-Ring Seal and 7M-8485 O-Ring Seal into and on the 6V-9008 Elbow , respectively.

   3. Attach the elbow to the female end of 172-8024 Flow Control Valve As and insert another 7M-8485 O-Ring Seal onto the male end of the ball valve.
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   Illustration 8	g03211758
   Right-side engine block JWH connections

   4. Remove the 1-5/16" pipe plug fitting from the right side engine block and attach the ball valve, with elbow connected, to the block. (Remember to ensure full range of valve handle motion upon assembly). Refer to Illustration 8.

   5. Attach the other end of 369-3817 Hose As to the 6V-9008 Elbow .

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Illustration 9	g03319148
Left-side engine block JWH connections

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Illustration 10	g03211838
Complete JWH assembly and routing detail

9. Perform the following to attach the remaining line routing between the jacket water heater inlet and the engine block:

   ReferenceIllustration 10

   1. Remove the 25.4 mm (1 inch) pipe plug fitting from the left-side engine block and attach the 8C-5053 Adapter to the block. Refer to Illustration 9.

   2. Insert 7M-8485 O-Ring Seal onto 172-8024 Flow Control Valve As and attach the valve to the 8C-5053 Adapter .

   3. Insert 7M-8485 O-Ring Seal onto 173-0064 Elbow . Attach the 173-0064 Elbow to the 172-8024 Flow Control Valve As (Final orientation will depend on steps 9.e and 9.f below).

   4. Insert 7M-8485 O-Ring Seal onto the male end of 368-4955 Hose As and attach the end to the 173-0064 Elbow .

   5. Attach the female end of 368-4955 Hose As to the fitting on the jacket water heater inlet.

   6. Fasten the 368-4955 Hose As to the forward rail cross member, and engine using the bosses added in Step 4.d, three 242-6099 Clips , two 8T-4195 Bolts , three 3E-4353 Hard Washers , two 8T-4121 Hard Washers , and one 8T-4137 Bolt on the engine. Orient the clips to position the hose assembly on the flywheel side of the bosses.

10. Refer to the Maintenance Section of Operation and Maintenance Manual, SEBU8088 to refill the generator set with coolant.

Electrical Installation

Illustration 11	g03212076
Removal of old breaker and contactor block from customer connection box (2) 363-1877 Circuit Breaker (3) 225-0547 Terminal Blocks (140 and 142)

1. Remove 363-1877 Circuit Breaker (2) from the upper din rail and both "140" and "142" 225-0547 Terminal Blocks (3) from the lower din rail in the customer connection box. Refer to Illustration 11.

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Illustration 12	g03218217
Removal of old breaker and contactor block from customer connection box (4) 393-0405 Circuit Breaker (5) 301-8313 Terminal Blocks (140 and 142) (6) 301-8316 End Covers

2. Install 393-0405 Circuit Breaker (4) on the upper din rail and two 301-8313 Terminal Blocks (5) with 301-8316 End Covers (6) in place of the removed "140", and "142" labeled 225-0547 Terminal Block on the lower din rail in the customer connection box. Relabel the new terminal blocks as "140", and "142", respectively.

   Refer to Illustration 12.

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Illustration 13	g03212117
Customer connection box wiring terminations for new JWH (7) 371-2891 Wiring Harness (8) 131-9134 Circuit Breaker As

3. Assemble 131-9134 Circuit Breaker As (8) to the upper din rail in the customer connection box, as shown in Illustration 13.

4. Connect the 371-2891 Wiring Harness (7) as follows:

   ReferenceIllustration 13

   1. Connect the "136-JW32" to the top "L2" side of the newly installed 131-9134 Circuit Breaker As (8) and to "L2" on the lower din rail.

   2. Connect the "133-JW24" to the top "L1" side of the newly installed 131-9134 Circuit Breaker As (8) and to "L1" on the lower din rail.

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Illustration 14	g03215436
JWH connection box wiring terminations and conduit connection

5. Using the 372-0880 Electrical Conduit Gp , connect the straight end into the JWH connection box and make the following wire connections as shown in Illustration 14:
   • Connect the "L1-JH6" to "L1"

   • Connect the "L2-JH5" to "L2"

   • Connect the "JWH-JH3" to "21"

   • Connect the "JWH-JH7" to "A1"

   • Connect the "200-JH4" to "GND"

   Note:

   • Tightening Procedure - Hand tighten until spanner nut contacts box surface. Then further tighten 1/4 turn or 90 degrees.

   • Tighten the nut by hand or wrench to bottom out nut on elbow shoulder.

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Illustration 15	g03215457
Right-side view of JWH conduit routing

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Illustration 16	g03215458
Customer connection box routing for JWH conduit wiring

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Illustration 17	g03215459
Customer connection box section C1-C1

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Illustration 18	g03215460
Ground wire termination section A-A

6. Connect the opposite end of the 372-0880 Electrical Conduit Gp to the customer connection box, and route the conduit wiring through the customer connection box. Refer to the Illustration 15 to Illustration 17.

   Note:

   • Tightening Procedure - Hand tighten until spanner nut contacts box surface. Then further tighten 1/4 turn or 90 degrees.

   • Tighten the nut by hand or wrench to bottom out nut on elbow shoulder.

7. Secure the 372-0880 Electrical Conduit Gp wiring in the customer connection box as follows:

   ReferenceIllustrations 13, 16, and 18

   1. Connect the "L1-JH6" to 131-9134 Circuit Breaker As on the upper din rail.

   2. Connect the "L2-JH5" to 131-9134 Circuit Breaker As on the upper din rail.

   3. Connect the "JWH-JH7" to newly installed 301-8313 Terminal Block labeled "140" on the upper din rail.

   4. Connect the "JWH-JH3" to newly installed 301-8313 Terminal Block labeled "142" on the upper din rail.

   5. Connect the "200-JH4" to ground termination bar at location "F" using one 8T-4186 Bolt , two 8T-4121 Hard Washers , and one 8T-4133 Nut .

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Illustration 19	g03215476
Mounting points for conduit wiring on base rail

8. Using the following steps, secure the 372-0880 Electrical Conduit Gp in the customer connection box and on the base rail:

   ReferenceIllustration 16 through Illustration 19

   1. Install a 280-1799 Clip inside the customer connection box at location "A" using one 8T-0337 Screw , one 4B-4274 Washer , and existing nutsert. Refer to Illustration 17.

   2. Inside the customer connection box, use five 7K-1181 Cable Straps to secure the conduit wiring to an existing harness or clip at points A-E. Refer to Illustration 16.

   3. On the base rail, attach the conduit wiring at rail locations G-I using three 339-6169 Clips , three 8T-4195 Bolts , six 8T-4896 Hard Washers , and three 8T-4133 Nuts . Orient all clips on top of the base rail facing outward. Refer to Illustration 19.

9. Reconnect all power sources and verify correct operation of the JWH.

Installation Procedure for Wide-Base C27 Generator Sets

Mechanical Installation

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Illustration 20	g02720953
Complete frame rail overview

1. Isolate the Generator Set before commencing any work on the unit, open generator set breaker, active Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger.

   Ensure that all health and safety requirements are adhered to at all times. Also, ensure that proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.

   Only qualified repair personnel should service this equipment. For all on-package welding, refer to Operation and Maintenance Manual, SEBU8088 before commencing work.

2. Refer to the Maintenance Section of Operation and Maintenance Manual, SEBU8088 to drain the coolant from the Generator Set.

3. Remove the existing jacket water heater system. Disconnect the line routing from both sides of the engine block, remove the jacket water heater complete with line routing from the Generator Set, disconnect the conduit group from the existing JWH connection box and customer connection box, and remove all related tie straps and clips.

   Note: Please remember to use an adequate container to capture any spilled coolant from the disconnection of the line routing.

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Illustration 21	g02720954
JWH mounting and modification details

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Illustration 22	g02720955
Forward rail cross member modification details

4. In order to install the new jacket water heater and line routing, perform the following frame modifications (Refer to Illustration 20):

   1. Drill two new 16.75 mm (0.66 inch) diameter holes on top of the right-hand frame rail as shown in Illustration 21.

   2. Weld one 8T-3851 Weld Bosses (M10 × 1.5) on top of the cross member surface in the specified locations as shown in Illustration 22.

   3. Touch up all newly welded surfaces with black touch-up paint and allow time for the paint to dry before continuing.

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Illustration 23	g02720959
JWH mounting on frame rail

5. Attach the 369-1719 Jacket Water Heater Gp to the right-hand side frame rail using the holes created in Step 4.a, the 369-3840 Tube , two 8T-4910 Bolts , four 8T-4223 Hard Washers , and two 9X-2066 Nuts . Refer to Illustration 23. The heater group should be positioned such that the heater group fixed inside the frame rail and the control box faces up.

6. Perform the following steps to attach the line routing between the jacket water heater outlet and the engine block:

   ReferenceIllustration 26

   1. Attach the non-straight end of the 369-3817 Hose As to the fitting on the jacket water pump outlet.

   2. Insert 5K-9090 O-Ring Seal and 7M-8485 O-Ring Seal into and on the 6V-9008 Elbow , respectively.

   3. Attach the adaptor to the female end of the 172-8024 Flow Control Valve As and insert another 7M-8485 O-Ring Seal onto the male end of the ball valve.
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   Illustration 24	g03319149
   Right-side engine block JWH connections

   4. Remove the 1-5/16" pipe plug fitting from the right side engine block and attach the ball valve, with elbow connected, to the block. (Remember to ensure full range of valve handle motion upon assembly). Refer to Illustration 24.

   5. Attach the other end of 369-3817 Hose As to the 6V-9008 Elbow .

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Illustration 25	g03319150
Left-side engine block JWH connections

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Illustration 26	g03319151
Complete JWH assembly and routing detail

7. Perform the following to attach the remaining line routing between the jacket water heater inlet and the engine block:

   ReferenceIllustration 26

   1. Remove the 25.4 mm (1 inch) pipe plug fitting from the left side engine block and attach the 8C-5053 Adapter to the block. Refer to Illustration 25.

   2. Insert 7M-8485 O-Ring Seal onto 173-0064 Elbow , and attach the 173-0064 Elbow to the 8C-5053 Adapter . (Final orientation will depend on Steps 7.e and 7.fbelow).

   3. Insert 7M-8485 O-Ring Seal onto 172-8024 Flow Control Valve As , and attach the valve to the 173-0064 Elbow .

   4. Insert 7M-8485 O-Ring Seal onto the male end of 369-3818 Hose As , and attach the end to the 172-8024 Flow Control Valve As .

   5. Attach the female end of 369-3818 Hose As to the fitting on the jacket water heater inlet.

   6. Fasten the 369-3818 Hose As to the forward rail cross member by using the boss added in Step 4.b, one 242-6099 Clip , one 8T-4136 Bolt , and one 8T-4121 Hard Washer . Orient the clip to position the hose assembly on the flywheel side of the boss.

8. Refer to the Maintenance Section of Operation and Maintenance Manual, SEBU8088 to refill the Generator Set with coolant.

Electrical Installation

Illustration 27	g03212076
Removal of old breaker and contactor block from customer connection box (2) 363-1877 Circuit Breaker (3) 225-0547 Terminal Blocks (140 and 142)

1. Remove 363-1877 Circuit Breaker (2) from the upper din rail and both "140" and "142" 225-0547 Terminal Blocks (3) from the lower din rail in the customer connection box. Refer to Illustration 27.

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Illustration 28	g03218217
Removal of old breaker and contactor block from customer connection box (4) 393-0405 Circuit Breaker (5) 301-8313 Terminal Blocks (140 and 142) (6) 301-8316 End Covers

2. Install 393-0405 Circuit Breaker (4) on the upper din rail and two 301-8313 Terminal Blocks (5) with 301-8316 End Covers (6) in place of the removed "140", and "142" labeled 225-0547 Terminal Block on the lower din rail in the customer connection box. Relabel the new terminal blocks as "140", and "142", respectively. Refer to Illustration 28.

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Illustration 29	g03212117
Customer connection box wiring terminations for new JWH (7) 371-2891 Wiring Harness (8) 131-9134 Circuit Breaker As

3. Assemble 131-9134 Circuit Breaker As (8) to the upper din rail in the customer connection box, as shown in Illustration 29.

4. Connect the 371-2891 Wiring Harness (7) as follows:

   ReferenceIllustration 29

   1. Connect the "136-JW32" to the top "L2" side of the newly installed 131-9134 Circuit Breaker As (8) and to "L2" on the lower din rail.

   2. Connect the "133-JW24" to the top "L1" side of the newly installed 131-9134 Circuit Breaker As (8) and to "L1" on the lower din rail.

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Illustration 30	g03215436
JWH connection box wiring terminations and conduit connection

5. Using the 372-0880 Electrical Conduit Gp , connect the straight end into the JWH connection box and make the following wire connections as shown in Illustration 30:
   • Connect the "L1-JH6" to "L1"

   • Connect the "L2-JH5" to "L2"

   • Connect the "JWH-JH3" to "21"

   • Connect the "JWH-JH7" to "A1"

   • Connect the "200-JH4" to "GND"

   Note:

   • Tightening Procedure - Hand tighten until spanner nut contacts box surface. Then further tighten 1/4 turn or 90 degrees.

   • Tighten the nut by hand or wrench to bottom out nut on elbow shoulder.

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Illustration 31	g03215457
Right-side view of JWH conduit routing

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Illustration 32	g03215458
Customer connection box routing for JWH conduit wiring

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Illustration 33	g03215459
Customer connection box section C1-C1

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Illustration 34	g03215460
Ground wire termination section A-A

6. Connect the opposite end of the 372-0880 Electrical Conduit Gp to the customer connection box, and route the conduit wiring through the customer connection box. Refer to the Illustration 31 to Illustration 33.

   Note:

   • Tightening Procedure - Hand tighten until spanner nut contacts box surface. Then further tighten 1/4 turn or 90 degrees.

   • Tighten the nut by hand or wrench to bottom out nut on elbow shoulder.

7. Secure the 372-0880 Electrical Conduit Gp wiring in the customer connection box as follows:

   ReferenceIllustrations 29, 32, and 34

   1. Connect the "L1-JH6" to 131-9134 Circuit Breaker As on the upper din rail.

   2. Connect the "L2-JH5" to 131-9134 Circuit Breaker As on the upper din rail.

   3. Connect the "JWH-JH7" to newly installed 301-8313 Terminal Block labeled "140" on the upper din rail.

   4. Connect the "JWH-JH3" to newly installed 301-8313 Terminal Block labeled "142" on the upper din rail.

   5. Connect the "200-JH4" to ground termination bar at location "F" using one 8T-4186 Bolt , two 8T-4121 Hard Washers , and one 8T-4133 Nut .

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Illustration 35	g03215476
Mounting points for conduit wiring on base rail

8. Using the following steps, secure the 372-0880 Electrical Conduit Gp in the customer connection box and on the base rail:

   ReferenceIllustration 32 to Illustration 35

   1. Install two 280-1799 Clip inside the customer connection box at location "A" and "B" using one 8T-0337 Screw , one 4B-4274 Washer , and existing nutsert. Refer to Illustration 33.

   2. Inside the customer connection box, use five 7K-1181 Cable Straps to secure the conduit wiring to an existing harness or clip at points A-E. Refer to Illustration 32.

   3. On the base rail, attach the conduit wiring at rail locations G-I using three 339-6169 Clips , three 8T-4195 Bolts , six 8T-4896 Hard Washers , and three 8T-4133 Nuts . Orient all clips on top of the base rail facing outward. Refer to Illustration 35.

9. Reconnect all power sources and verify correct operation of the JWH.