3054 and 3056 Marine Generator Set Engines Caterpillar

Clean the Heat Exchanger Core and Inspect the Heat Exchanger Core

Inspect the following parts at each oil change:

• Hoses

• Hose clamps

• Gasket joints

1. Remove the heat exchanger core. Refer to Disassembly and Assembly Manual, "Heat Exchanger - Remove" for the complete procedure.
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   Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

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   NOTICE
   Do not use caustic cleaners to clean the core. Caustic cleaners can attack the internal metals of the core and cause leakage.

2. Use hot, soapy water to clean the heat exchanger core. Use a rod with a diameter of 4 mm (0.16 inch). Push the rod carefully into the tubes in the opposite direction of flow. Ensure that all of the tubes are clean.

3. Flush the inside of the core in the reverse direction of flow. Use hot, soapy water. Thoroughly rinse the core with clean water. Blow dry the core with compressed air.

4. Thoroughly clean the external surfaces of the heat exchanger.

5. Inspect the heat exchanger core for signs of leakage, cracks, and damage.

6. Pressure test the heat exchanger core. Refer to "Clean the Heat Exchanger Core and Inspect the Heat Exchanger Core".

Test the Heat Exchanger Core

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Dust plug chains must be installed to the aftercooler core or to the radiator brackets to prevent possible injury while you are testing. Do not stand in front of the dust plugs while you are testing.

1. Install a dust plug on the outlet of the core. Secure the plug with hose clamps and install safety chains. This will prevent the release of the plug if the hose clamps fail to hold the plug under pressure.

2. Install a plug to the inlet of the core. The plug should have an air valve. Tighten the plug with hose clamps and install safety chains. This will prevent the release of the plug if the hose clamps fail to hold the plug under pressure.

3. Install a regulated air supply to the air valve.
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   Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

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   NOTICE
   Do not use more than 240 kPa (35 psi) of air pressure or damage to the core can be the result.

4. Apply 220 kPa (32 psi) of pressurized air to the core.

5. While the core is still under pressure, completely submerge the core in a tank of water for at least one minute. Check for signs of leakage.
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   To help prevent personal injury when the tooling is removed, relieve all pressure in the system slowly by using an air regulator and a valve assembly.

6. Remove the core from the tank of water. Slowly relieve the air pressure until the air pressure is zero.

7. If the core leaked, replace the O-ring seals. Check the core for signs of corrosion. Retest the core after the O-ring seals have been replaced. If the core still leaks, the core will need to be replaced.

8. Install the heat exchanger core. Refer to Disassembly and Assembly Manual, "Heat Exchanger - Install" for the correct procedure.