- Engine:
- 3508B (S/N: S2A1-UP; S2B1-UP; S2D1-UP; S2E1-UP; S2F1-UP; BAG1-UP; 2BM1-UP; 3DM1-UP; 7SM1-UP; 1TW1-UP; 3DW1-UP; CTC1-UP; 1FZ1-UP)
- 3512B (S/N: NSC1-UP; S2K1-UP; S2N1-UP; S2J1-UP; MRG1-UP; S2G1-UP; MKH1-UP; S2H1-UP; S2L1-UP; S2M1-UP; 7HM1-UP; 8EM1-UP; BRN1-UP; 4TN1-UP; 1PW1-UP; 2GW1-UP; 2EZ1-UP; CTB1-UP; 1GZ1-UP)
- 3516B (S/N: S2P1-UP; S2R1-UP; S2S1-UP; S2T1-UP; S2W1-UP; 2TD1-UP; CDE1-UP; B5G1-UP; PAG1-UP; CBN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; 2FW1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP; S2Y1-UP; CTA1-UP; 1HZ1-UP)
- 3512B (S/N: NSC1-UP; S2K1-UP; S2N1-UP; S2J1-UP; MRG1-UP; S2G1-UP; MKH1-UP; S2H1-UP; S2L1-UP; S2M1-UP; 7HM1-UP; 8EM1-UP; BRN1-UP; 4TN1-UP; 1PW1-UP; 2GW1-UP; 2EZ1-UP; CTB1-UP; 1GZ1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
This Special Instruction contains procedures for cleaning the heat exchangers that are listed in Table 1. This instruction also covers the usage of the 248-6745 Bars (service tool) and 162-7120 Pins that are listed in Table 2.
| Heat Exchangers for the 3500B Marine Engines | ||
| Part Number | Engine Model | |
| 249-1021 | 3508B 3512B |
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| 245-9841 | 3516B | |
| Required Service Tools | ||
| Part Number | Description | Qty |
| (248-6745) | Bars | 2 |
| (162-7120) | Pin | 2 |
Unless the water system for the heat exchanger is sealed, debris may enter the water. Examples of debris are seaweeds, wood chips, mussels, barnacles, etc. Debris in the water will reduce the efficiency of the heat exchanger. This can result in excessive water temperatures that may require an engine shutdown. Preventing debris from entering the water and/or filtering the water will reduce the need for cleaning.
The quality of the water can also affect the performance of the heat exchanger. Buildup such as sediment and scale reduces the heat transfer characteristics of the plates. The pressure differential of fluids that flow through the heat exchanger is increased. Corrosion can occur beneath the buildup. The buildup can result from sources that are organic or inorganic.
The combination of these two factors indicate that the heat exchanger requires cleaning:
- Inability of the heat exchanger to maintain the desired temperatures
- Increased pressure differential of the fluids that flow through the heat exchanger
Frequently record these parameters during operation if a concern is present:
- Aftercooler inlet water temperature
- Inlet manifold air temperature
- Jacket water coolant temperature
- Pressure differential of the fluids that flow through the heat exchanger
Compare the data to previously recorded data. Clean the heat exchanger, if necessary.
Ensure that the engine will not operate when this maintenance is performed. Attach a "DO NOT OPERATE" tag or similar warning tag to the controls before performing maintenance or repairs.
Draining the Cooling System
Note: Refer to Operation and Maintenance Manual for information on the interval for changing the coolant.
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Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. |
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| 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. |
- Prepare a suitable container for the coolant.
Note: If the heat exchanger is hot, wait until the temperature of the heat exchanger is reduced to approximately 40 °C (104 °F) before proceeding.
- Drain the heat exchanger.
Note: For complete draining, all of the circuits of the heat exchanger must be ventilated. If the installation does not have vent valves, remove the filler caps from the expansion tanks.
Removal and Installation of the Heat Exchanger (If Required)
It is not necessary to remove the heat exchanger in order to clean the plates.
Do not remove the heat exchanger unless a complete disassembly of the heat exchanger is desired. Breaking the seals on the rear of the heat exchanger will require a complete disassembly in order to remove collar (6). A complete disassembly is also required in order to replace liner (8). Refer to Illustration 1.
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| Illustration 1 | g01153325 |
Heat exchanger (1) Tightening bolts (2) Washer (3) Spacer (4) Front frame (5) Spacer (6) Collar (7) Rear plate (8) Liner (9) Washer (10) Bolt | |
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| Illustration 2 | g01162242 |
The heat exchanger will require removal if there is a leak at location (A) or at location (B).
Removal Procedure
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. |
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- Before removing the heat exchanger, stop the engine. Ensure that the engine will not start during this procedure.
- Shut off the fuel supply valve to the engine.
- Open the purge valve for the fuel.
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| Illustration 3 | g01161740 |
Purge valve for the fuel | |
- Disconnect fuel lines from connections (11) and (12) on the front frame.
| NOTICE |
|---|
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. |
| NOTICE |
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Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately. |
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| Illustration 4 | g01159199 |
Connections for the fuel lines | |
- The heat exchanger weighs approximately 36 kg (80 lb). Use a suitable lifting device before attempting to begin the removal of the heat exchanger.
- Loosen and remove bolts (13) on elbows (15) at all four connections.
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| Illustration 5 | g01159200 |
(13) Bolts (14) Liners (15) Elbows (16) O-rings | |
- In order to remove the heat exchanger from the engine, there are six mounting bolts that need to be removed. Remove three bolts (17) that are on each side of the expansion tank.
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| Illustration 6 | g01162264 |
- Remove the heat exchanger. Place the heat exchanger on the work bench or in an appropriate place in order to perform the work.
- Discard liners (14) and O-rings (16) .
- Open the heat exchanger in order to clean the plates. Refer to ""Opening the Heat Exchanger" ".
Installation Procedure
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During operation, the fluid in the lines of the cooling system is hot and pressurized. A rupture of the coupling could cause parts and hot fluid to be expelled. Improper selection, installation, or use of the coupling could result in property damage, personal injury, or death. Install couplings that are proper for the application according to the instructions. |
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- Close the heat exchanger. Refer to ""Closing the Heat Exchanger" ".
- Install the heat exchanger on the engine and secure the three mounting bolts (17) that are on each side of the expansion tank.
| | |
| Illustration 7 | g01162264 |
(17) Mounting bolts | |
- Replace O-rings (16) and replace liners (14) at all four connections.
| | |
| Illustration 8 | g01159200 |
(13) Bolts (14) Liners (15) Elbow (16) O-ring | |
- Place bolts (13) in elbows (15) at all four connections.
- Ensure that O-rings (16) are in the groove before securing bolts (13) .
- Tighten the bolts.
Opening the Heat Exchanger
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| Illustration 9 | g01153325 |
Heat exchanger (1) Tightening bolts (2) Washer (3) Spacer (4) Front frame (5) Spacer (6) Collar (7) Rear plate (8) Liner (9) Washer (10) Bolt | |
- Before opening the heat exchanger, stop the engine. Ensure that the engine will not start during this procedure.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. |
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- Shut off the fuel supply valve to the engine.
- Open the purge valve for the fuel.
| | |
| Illustration 10 | g01161740 |
- Disconnect the fuel lines from connections (11) and (12) on the front frame.
| NOTICE |
|---|
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. |
| NOTICE |
|---|
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately. |
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| Illustration 11 | g01154750 |
Connections for the fuel lines | |
- Remove bolts, washers, and spacers from the locations for the bars.
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| Illustration 12 | g01161355 |
Locations for the 248-6745 Bars | |
- Install the 248-6745 Bars .
Note: The 248-6745 Bars require the use of 162-7120 Pins . The pins have a diameter of 8.9 mm (0.3504 inch). Insert the pins in the drilled holes at the ends of the bars in order to prevent the heat exchanger from falling.
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| Illustration 13 | g01156143 |
248-6745 Bars (service tool) | |
- Remove the remaining bolts (1) and washers (2) from the front frame (4) .
Removal and Installation of the Plates
- Mark the outside of the plates diagonally and/or number the plates in sequence. If the plates are removed, this is useful for reassembly.
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| Illustration 14 | g01156102 |
Diagonally marked plates | |
- Slide the front frame on the 248-6745 Bars .
- Only remove the plates if the material that is fouling the heat exchanger cannot be easily removed. Remove the plates, if necessary. Clean the plates. Refer to the ""Cleaning the Plates" " topic.
Note: When possible, clean debris from the plates without removing the plates. Refer to the ""Cleaning the Plates" " topic.
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Bare hands can be injured by the plates of the heat exchanger. To help prevent hand injuries, always wear protective gloves when handling the plates. |
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Note: Handle the plates carefully. Do not damage the gaskets.
- After the plates are clean, hang the plates.
Hang the number one plate against the front frame. Orient the plates so that the plates have the side without the gasket toward the rear plate.
- Inspect the sealing surfaces for cleanliness.
Inspect the gaskets for proper installation and for good condition. Ensure that the two tabs for each gasket are seated correctly. For instructions on installing the gaskets, refer to the literature that is supplied by the OEM of the heat exchanger.
Ensure that the plates are hanging in the correct order.
When the plates are assembled correctly, the edges form a honeycomb pattern. Inspect the edge of the plate assembly for this condition. To ensure that the plates are hanging in the correct order, check the plates with the data that is provided by the OEM of the plates.
Cleaning the Plates
| NOTICE |
|---|
Improper methods of cleaning will damage the plates. Do not scrape or scratch the plates. Do not use a wire brush for cleaning the plates. Use a brush with soft bristles. Be careful not to damage the gaskets. |
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| Illustration 15 | g01159218 |
Locations of the gaskets | |
- Use a brush with soft bristles for cleaning.
Be careful not to damage the gaskets.
Cleaning Buildup From the Plates
Note: Do not use hydrofluoric acid to clean titanium plates. Do not use water with more than 300 ppm chlorine for the preparation of the cleaning solutions. Do not allow paraffinic or naphtha based solvents (kerosene) to remain in contact with the gaskets for more than 30 minutes. Contact with this cleaning solvent must be limited to 30 minutes or less in order to prevent swelling of the rubber gasket..
Different types of buildup may require different cleaning solutions. To determine the cause of the buildup, obtain an analysis of the material and of the water. The following list contains the types of buildup that may be encountered.
- Incrustation and/or scaling
- Sediment
- Biological growth and/or slime
- Fouling
- Oils
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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
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Personal injury can result from acid. Wear all necessary protective equipment, such as rubber gloves and goggles when working with acid. The bottle containing the etchant should be properly marked ACID and should be stored in a protective place. |
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Add acid to the water at normal room temperature. Do not add water to the acid. Add neutralizing agents to the water. Do not add water to the neutralizing agents. There are many safety precautions when handling acid. Therefore, this should only be done by qualified personnel. |
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| 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. |
Use the following procedure to clean incrustation, scaling, and sediment.
Clean the gaskets by using one of the following solvents:
- Nitric acid
- Sulfamic acid
- Citric acid
- Phosphoric acid
- Complexing agents EDTA and/or NTA
- Sodium polyphosphates
- Mix the solvent with water. Use a maximum concentration of 0.15 Liters (5 ounces) for every 3.8 Liters (1 gallon) of water.
- Heat the cleaning solution to a maximum temperature of 60 °C (140 °F).
- Use running water and a brush with soft bristles for cleaning debris. Pressurized water at a maximum of 275 kPa (40 psi) may be used.
Avoid damaging the gasket.
Use the following procedure to clean biological growth (slime).
Clean the gaskets by using one of the following solvents:
- Sodium hydroxide
- Sodium carbonate
- Mix the solvent with water. Use a maximum concentration of 0.15 Liters (5 ounces) for every 3.8 Liters (1 gallon).
- Heat the cleaning solution to a maximum temperature of 80 °C (176 °F).
- Use running water and a brush with soft bristles for cleaning debris. Pressurized water at a maximum of 275 kPa (40 psi) may be used.
Avoid damaging the gasket.
Use the following procedure to clean deposits of oil from the plates.
Clean the gaskets by using one of the following solvents:
- Paraffinic based solvent
- Naphtha based solvent
- Use a brush with soft bristles and paraffinic or naphtha based solvents (kerosene) in order to clean deposits of oil. Use the solvent at full strength.
Avoid damaging the gasket.
Note: Do not allow paraffinic or naphtha based solvents (kerosene) to remain in contact with the gaskets for more than 30 minutes. Contact with this cleaning solvent must be limited to 30 minutes or less in order to prevent swelling of the rubber gasket.
Do not use solvents that contain the following:
- Ketones (acetone, methylketone, or methylisobutyketone)
- Esters (ethylacetate or butylacetate)
- Halogenated hydrocarbons (chlorothene, carbon tetrachloride, or freons)
- Aromatics (benzens, or toluene)
- Ketones (acetone, methylketone, or methylisobutyketone)
Dry the plates with a clean cloth.
Closing the Heat Exchanger
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| Illustration 16 | g01153183 |
Bolt tightening sequence | |
- Press the plate assembly together.
- Install bolt (1) through bolt (8) and hand tighten the bolts.
- Remove the 248-6745 Bars and install the remaining bolts (9) and (10) with washers and spacers.
- Torque the bolts in sequence. Refer to Illustration 16 for the bolt tightening sequence.
- Connect fuel line connections (11) and (12) on the front frame.
| | |
| Illustration 17 | g01154750 |
- Close the purge valve.
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| Illustration 18 | g01161740 |
- Turn the fuel supply valve to the ON position.
Note: Make sure that the fuel system is primed before attempting to start the engine.
Filling the Cooling System
| NOTICE |
|---|
Only use coolant/antifreeze mixtures that are recommended by the Operation and Maintenance Manual for the engine. Failure to do so can cause damage to the engine and the equipment. |
| NOTICE |
|---|
Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures. Water alone does not provide adequate protection against boiling or freezing. |
- Remove the filler caps for the expansion tanks.
- Vent the aftercooler circuit. Open the vent valve or remove the vent plug. See Illustration 19.
| NOTICE |
|---|
The vent valve or vent plug for the aftercooler must be opened in order to allow the aftercooler system to fill properly. Failure to do this will cause an air lock which will result in damage to the engine. Open the vent for the aftercooler in order to allow the system to fill properly. |
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| Illustration 19 | g01153171 |
Typical example Location for the vent plug for the aftercooler on 3500B Engines | |
- Add the proper coolant mixture into the jacket water and aftercooler cooling systems.
When the coolant flows from the vent for the aftercooler, close the vent. Shut the vent valve or install the vent plug.
| NOTICE |
|---|
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. |
- Do not install the filler caps for the expansion tanks. Start the engine.
Operate the engine in order to purge air from the cavities of the engine block. Allow the coolant to warm and allow the coolant level to stabilize. Inspect the cooling system for leaks and for proper operating temperature.
- Stop the engine. Top off the expansion tanks. Install the filler caps.