Salvage of Folded Core Radiators{1353} Caterpillar


Salvage of Folded Core Radiators{1353}

Usage:

769C 01X
Agricultural Tractor:
65 (S/N: 7YC1-UP)
65B (S/N: 7YC1-UP)
65C (S/N: 2ZJ1-UP)
65D (S/N: 2ZJ1-UP)
65E (S/N: 6GS1-UP)
75 (S/N: 4CJ1-UP)
75C (S/N: 4KK1-UP)
75D (S/N: 5AR1-UP)
75E (S/N: 1HM1-UP; 6HS1-UP)
85C (S/N: 9TK1-UP)
Landfill Compactor:
826B (S/N: 58U1-UP; 90K1-UP)
826C (S/N: 87X1-UP)
826G Series II (S/N: AYH1-UP)
826G (S/N: 7LN1-UP)
826H (S/N: AWF1-UP)
Excavator:
375L (S/N: 1JM1-UP)
Integrated Toolcarrier:
IT18 (S/N: 7ZB1-UP; 9NB1-UP)
IT18B (S/N: 4ZD1-UP; 1DF1-UP; 2NJ1-UP)
IT28 (S/N: 8JB1-UP; 2KC1-UP)
IT28B (S/N: 5SD1-UP; 1HF1-UP; 1JK1-UP)
Motor Grader:
16H (S/N: 6ZJ1-UP; ATS1-UP)
Off-Highway Truck/Tractor:
69D (S/N: 9SS1-UP; 9XS1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
777 (S/N: 84A1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
784C (S/N: 2PZ1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: MSY1-UP)
789C (S/N: 2BW1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
797B (S/N: JSM1-UP)
Quarry Truck:
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
Pipelayer:
572G (S/N: 8PC1-UP; 40U1-UP)
Track-Type Skidder:
D4 TSKH Series II (S/N: 8ZF1-UP)
D4 TSKH Series III (S/N: 7PK1-UP)
Track-Type Tractor:
D10N (S/N: 2YD1-UP; 3SK1-UP)
D11N (S/N: 4HK1-UP; 74Z1-UP)
D3B (S/N: 2PC1-UP; 3YC1-UP; 5MC1-UP; 23Y1-UP; 24Y1-UP; 27Y1-UP; 28Y1-UP)
D4H Series II (S/N: 8PB1-UP; 9DB1-UP; 2AC1-UP; 3AC1-UP)
D4H Series III (S/N: 4NK1-UP)
D5H Series II (S/N: 8RC1-UP; 9HC1-UP; 1DD1-UP)
D5H (S/N: 7NC1-UP; 8SC1-UP; 1YD1-UP; 2SD1-UP; 3MD1-UP; 4KD1-UP)
D6 (S/N: 19B1-UP; 5HF1-UP; 4LG1-UP)
D6D (S/N: 19B1-UP; 5YB1-UP; 36C1-UP; 37C1-UP; 38C1-UP; 6HC1-UP; 7XF1-UP; 7YK1-UP; 9FK1-UP; 74W1-UP; 75W1-UP; 03X1-UP; 04X1-UP; 05X1-UP; 06X1-UP; 19X1-UP; 20X1-UP; 30X1-UP; 31X1-UP; 32X1-UP; 33X1-UP; 01Y1-UP)
D6H Series II (S/N: 4RC1-UP; 6FC1-UP; 8FC1-UP; 1KD1-UP; 2KD1-UP; 3ED1-UP; 3ZF1-UP; 4YF1-UP; 5HF1-UP; 6CF1-UP; 2TG1-UP; 3YG1-UP; 4GG1-UP; 4LG1-UP; 1FJ1-UP; 8ZJ1-UP; 9KJ1-UP; 2DK1-UP; 5KK1-UP; 6CK1-UP; 8KK1-UP; 8SK1-UP; 9LK1-UP; 9RK1-UP; 1YL1-UP; 2BL1-UP; 2TL1-UP)
D6H (S/N: 8KB1-UP; 7PC1-UP; 8YC1-UP; 3YJ1-UP; 7ZK1-UP)
D7G Series 2 (S/N: 7MB1-UP; 3ZD1-UP; 3GF1-UP; C7G1-UP; 35N1-UP; 64V1-UP; 65V1-UP; 91V1-UP; 92V1-UP; 44W1-UP; 45W1-UP; 72W1-UP)
D7H Series II (S/N: 2SB1-UP; 4AB1-UP; 5WB1-UP; 5BF1-UP; 2RG1-UP; 3XG1-UP; 4FG1-UP; 79Z1-UP; 80Z1-UP; 82Z1-UP)
D7H (S/N: 77Z1-UP)
D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)
D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)
D9N (S/N: 1JD1-UP; 6XJ1-UP)
Wheel Dozer:
824 (S/N: 29G1-UP)
824B (S/N: 36H1-UP)
824C (S/N: 85X1-UP)
824G Series II (S/N: AWW1-UP)
824G (S/N: 4SN1-UP)
824H (S/N: ASX1-UP)
Wheel Loader:
916 (S/N: 2XB1-UP; 9WB1-UP; 5KC1-UP)
926 (S/N: 94Z1-2208,2209-UP)
926E (S/N: 4NB1-2075,2076-UP; 8NB1-1541,1542-UP; 94Z1-2208,2209-UP)
936 (S/N: 4SB1-1622,1623-UP; 33Z1-3090,3091-UP; 45Z1-3056,3057-UP)
936E (S/N: 4SB1-1622,1623-UP; 33Z1-3090,3091-UP; 45Z1-3056,3057-UP)
936F (S/N: 8AJ1-UP; 4TK1-UP; 9MK1-UP)
950B (S/N: 63R1-6053,6054-UP; 65R1-3087,3088-UP; 22Z1-3189,3190-UP)
950E (S/N: 63R1-6053,6054-UP; 65R1-3087,3088-UP; 22Z1-3189,3190-UP)
966D (S/N: 35S1-2522,2523-UP; 94X1-6488,6489-UP; 99Y1-5314,5315-UP)
966E (S/N: 35S1-2522,2523-UP; 94X1-6488,6489-UP; 99Y1-5314,5315-UP)
980C (S/N: 13B1-UP; 2EB1-UP; 2XD1-UP; 63X1-UP)
988B (S/N: 50W1-UP)
G916 (S/N: 5GD1-UP)
G926 (S/N: 1SD1-UP; 3TD1-UP)
G936 (S/N: 3HD1-UP; 4ND1-UP; 8ED1-UP)
Wheel Tractor-Scraper:
621B (S/N: 6XB1-UP; 7KC1-UP; 8HC1-UP; 9AC1-UP; 45P1-UP; 31V1-UP; 35V1-UP; 36V1-UP; 73V1-UP)
621E (S/N: 6AB1-UP; 6BB1-UP; 2PD1-UP; 2TF1-UP)
621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)
621G (S/N: DBB1-UP; ANG1-UP; CEN1-UP; ALP1-UP; CEP1-UP; DBX1-UP)
623B (S/N: 61E1-UP; 46P1-UP)
623E (S/N: 6CB1-UP; 6DB1-UP; 6YF1-UP; 5SG1-UP)
623F (S/N: 5SG1-UP; 6BK1-UP; 3XW1-UP; 5EW1-UP)
623G (S/N: AWB1-UP; DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)
627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 7CG1-UP; 3WJ1-UP)
627F (S/N: 4YK1-UP; 1DL1-UP)
627G (S/N: DBD1-UP; AXF1-UP; AYK1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)
631E Series II (S/N: 1AB1-UP; 1BB1-UP; 1NB1-UP; 6PC1-UP; 3ND1-UP)
631E (S/N: 4LD1-UP)
631G (S/N: DFA1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; AXZ1-UP)
633E Series II (S/N: 1EB1-UP; 2PS1-UP)
637E Series II (S/N: 7CB1-UP)
637E (S/N: 1FB1-UP; 1HB1-UP; 1JB1-UP; 1LB1-UP)
637G (S/N: AWE1-UP; CEH1-UP; CEJ1-UP; DFJ1-UP; CEM1-UP; AYN1-UP; AXT1-UP; DEX1-UP; DEY1-UP)
651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)
657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

Introduction

Table 1
Revision     Summary of Changes in SEBF8130    
06     Updated Effectivity

Added ""Canceled Part Numbers and Replaced Part Numbers" " section.

Added ""Important Safety Information" " section.

Added information for purchasing the rounder tool mentioned within the ""Salvage of the Tank" " section.    

© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

  • Caterpillar Dealer Technical Communicator

  • Dealer Solution Network

  • Caterpillar Technical Representative

  • Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

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 specifically recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

----------------------

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The "WARNING" Safety Alert Symbol is shown below.




Illustration 1g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline gives the procedures and the materials that are needed in order to salvage folded core radiators. This guideline addresses the cleaning of the cores, complete tank disassembly and assembly, the procedures to rod, pressure testing, and repainting the module.

Modules that have been repainted and subject to corrosive environments may not resist corrosion as well as new modules. The special paint process during the manufacturing process cannot be duplicated at a dealership. This factor should be considered before reconditioning or replacing the module. Replace cores with new cores when the cores have rusted after operating in a corrosive environment, or when a caustic cleaning solution has removed the original paint.

Nomenclature

See Illustration 2 for a list of the components of the radiator that are referenced in this guideline.




Illustration 2g01626611

(A) Tank

(B) Seal

(C) Center stiffener

(D) Fins

(E) Top tank

(F) Bottom tank

Cleaning Without Removing Protective Paint

Steam clean the module to remove dirt and material that is trapped between the fins.




Illustration 3g01626894

External cleaning with clean water

Before putting the core back into service, the core must pass the flow test and the pressure test. These two tests will ensure that the module will function properly.

Flow Test

Run a flow test on the module by connecting a device for performing the flow test to the module. Refer to Illustration 4.




Illustration 4g01626652

The connection for the flow test to the module

The module must have a flow rate of 38 L/min to 57 L/min (10.0 US gpm to 15.0 US gpm). If the module does not have a flow rate of 38 L/min to 57 L/min (10.0 US gpm to 15.0 US gpm), the tubes must be cleaned out.

Construct a test stand for the flow test on the modules. Refer to Illustrations 5, 6, and 7.




Illustration 5g01631415

Sketch of machine for flow test

(G) Rubber hose

(H) Indicator for flow test on the tank

(J) Grate

(K) Drain

(L) Pump

(M) Valve for controlling flow

(N) Rubber hose for connecting the module




Illustration 6g01626664

Machine for the flow test




Illustration 7g01626665

Connection with hole for indicating test failures

The attachment to the module is a rubber hose. The rubber hose is connected to two tanks. The tanks are welded with a hole that is drilled in the top of the tank. If the module does not flow at the specified rate, the excess water will flow out of the drilled hole. Flow out of the hole in the top tank indicates a failed test.

The flow for the flow test is adjusted with a valve on the rear of the machine. To check the flow, measure the length of time that is needed to fill a specified volume, such as a 5 gallon container.

Set the flow on the test stand at a rate of 38 L/min (10.0 US gpm) to perform the flow test on the module.

Note: Be sure to recalibrate the test stand before each use.

The core has passed the flow test when the core flows at a rate of 38 L/min (10.0 US gpm). The core is now ready to be pressure tested. Refer to the ""Pressure Test" " section of this guideline.

If the core does not flow at a rate of 38 L/min (10.0 US gpm), water will flow out of the hole in the tank. Refer to Illustration 4. This result indicates a failed test. The tubes in the module must be cleaned out in order to allow the proper flow. When all the water flows through the core and no water flows out of the hole in the test device, the module has passed the flow test.

Cleaning the Tubes

There are two methods for cleaning the tubes.

The first method involves removing the tank from the module and cleaning the tubes with steam. The procedure to rod can also be used to clean the tubes. Refer to the ""Procedures to Rod" " section of this guideline.

For the second method, use an ultrasonic clean tank. The use of an ultrasonic cleaner does not require removing the tank. However, the ultrasonic cleaner may not clean out the tubes. Ultrasonic cleaners can also remove the paint when a caustic cleaning agent is used.

Procedures to Rod

If the module fails the flow test, use the following procedure to rod.

The tank must be removed to steam and rod. Before removing the tank, measure the distance and record the distance from the tank to the center stiffener or another specified mark. The tank must be reinstalled to this distance in order to prevent leakage when separate modules are assembled into a radiator.

There are two methods that can be used to measure the tank for proper installation. The methods are described below.

For the first option, create a template to use as a spacer between the center stiffener and the tank. Refer to the ""Installation of the Tank" " section of this guideline.

For the second option, insert a small wire between the fins of the core. Use this wire as a reference for installing the tank. Refer to Illustration 8.




Illustration 8g01631475

Example of a core with tool

(P) Holder

(R) Piece of wire

(S) Reference length

Remove the tank. Refer to the ""Removal of the Tank" " section of this guideline in order to remove the tank.

Unplugging Folded Cores

Steam clean each tube individually after the tank has been removed. The pressure from the steam cleaner may be sufficient to clean the tubes. Previous operating conditions may cause steam cleaning to be ineffective.




Illustration 9g01626720

Steam cleaning each tube

Perform another flow test on the module in order to determine if the tubes are clean.

Note: Only one tank must be installed in order to perform the flow test on the module.

If the module fails the flow test after steam cleaning the tubes, it is necessary to perform the procedures to rod. Refer to the ""Procedures to Rod" " section of this guideline. There are several available rod sizes from suppliers of radiators. Begin with the larger rod, and then use a smaller rod, if necessary.

Insert the rod and push the rod through the entire tube. Refer to Illustration 10. Both tanks need not be removed to rod. Continue to rod until the rod passes through each tube. The rod will clean out any built up debris or contamination in the tube.

Note: Excess rod may cause grit to build up in the tubes. The excess grit will grind the wall of the tube thin.




Illustration 10g01626726

Insert rod into the tube.

Steam clean each tube to remove all the material from the tubes after the procedures for rod have been completed. Perform a flow test on the module in order to ensure that the module flows at a rate of 38 L/min to 57 L/min (10.0 US gpm to 15.0 US gpm).

Repeat the procedure until the module passes the flow test.

After the module passes the flow test, install the tank and pressure test the module. Refer to the ""Installation of the Tank" " and ""Pressure Test" " sections of this guideline.

Ultrasonic Cleaning

A second method of cleaning the module is ultrasonic cleaners. Refer to the ""Suppliers" " section of this guideline for organizations that manufacture ultrasonic cleaners.

Note: The paint may be removed and all of the tubes may not be cleaned out when ultrasonic cleaning is used.

Internal corrosion and external plugging can be cleaned successfully with the use of a mild detergent and ultrasonic cleaning. Do not remove the tanks in order to clean the cores.




Illustration 11g01626878

Example of moderate corrosion




Illustration 12g01626914

Example of external plugging




Illustration 13g01626918

An example of a core after moderate corrosion has been removed.




Illustration 14g01626930

An example of a core after external plugging has been removed.

In order to prevent the removal of paint during the cleaning, use a mild detergent. An example of a mild detergent is Caterpillar Hydrosolv 2237. A five percent solution of Hydrosolv 2237 is good for this application.




Illustration 15g01626937

Typical ultrasonic tank

After the soap solution has been mixed well in the ultrasonic tank, allow the solution to heat to approximately 82 °C (180.0 °F). Elevated temperatures are required in order to clean off external grease and any external corrosive plugging. Place the cores that need to be cleaned on the end over the transducers in the tank. The modules must stand upright in the tank in order to achieve internal cleaning of the tube ends and internal passages of the tubes.

Most internal plugging of the tubes occurs at the end of the tube, or within 6 inches from the end of the tube. Placing the cores upright in the tank allows the ultrasonic action to reach these areas. In this position, external plugging of the fins is normally removed at the same time. Leave the cores in the cleaner with the transducers that are running for approximately 30 to 45 minutes based on the severity of the corrosion. Next, turn over the core with the opposite end in the solution and repeat this procedure for the same amount of time.

During this process of cleaning, all external plugging should be removed as well. If external plugging remains, lay the cores on the sides in the tank in order to concentrate the ultrasonic action on the surfaces of the fins for an additional 15 to 20 minutes.

Remove the cores from the tank and thoroughly flush the inside and the outside of the cores with clean water. Inspect the ends of each core in order to ensure that all corrosion has been removed.




Illustration 16g01626963

Internal flushing with clean water

Perform a flow test on the module at a rate of 38 L/min (10.0 US gpm). If the module does not pass the flow test, perform the procedures to rod on the module. Refer to the ""Procedures to Rod" " section of this guideline.

The module must be pressure tested in order to check for leaks after the module passes the flow test. Refer to the ""Pressure Test" " section of this guideline.

Removal of the Tank

Remove the tank by heating the tank with an oxyacetylene torch. Use a small hammer to tap the tank. This tapping will determine the location that the solder begins to loosen. As the tank begins to separate from the tubes, hold the tank with a pair of pliers and remove the tank.


NOTICE

Do not concentrate the flame in one area too long or damage to the tube may occur.





Illustration 17g01627025

Heating of the tank and the joint with an oxyacetylene torch

Remove the remaining solder from the tube ends and the tank.

Remove four to six fins from the end of the module. This opening will create enough room to solder the tank to the tubes again when the tank is reinstalled. Separate and remove the fins. Refer to Illustration 18. Remove the fins that are perpendicular to the tubes in order to prevent bending the tubes on the ends.




Illustration 18g01627043

Removing fins from the module

Installation of the Tank

Straighten the tubes with pliers and a screwdriver. This process will make installation and soldering of the tank to the tubes easier. Straightening the tubes will also help prevent leaks.




Illustration 19g01627242

Straightening the tubes

The tanks must be cleaned before reinstallation. Place the tanks in the ultrasonic cleaner for 30 minutes. Then, blast the tanks with glass beads of 150 grit.

After the tubes have been thoroughly cleaned, the area of the joint should be tinned in order to ensure correct adhesion of the solder. The cleaned tank should also be tinned at this time. Tinning applies a thin layer of solder to the surfaces. The thin layer of solder allows the two surfaces to bond during the soldering.

Various tinning compounds are available. In order to tin the surface, heat the surface and apply the compound with a fiberglass or steel brush. Once the tinning is complete, the module is ready for assembly.




Illustration 20g01627247

Tinning tubes on the end




Illustration 21g01627261

Tinning the tank

Steam clean the tubes on the end and the tank in order to remove any burnt flux that was created during tinning. If necessary, straighten the tubes on the end again.

Insert the tank onto the tubes. Use a mark or a template to ensure that the tank is the same distance from the center stiffener. Check the distance on both sides of the module. This will provide a square connection for the tank.

One example of a template is the wooden template in Illustration 22. Ensure that the ends are square when the template for referencing the distance from the center stiffener is constructed. The template should also be wide enough to cover the entire width of the module. Check the proper distance on both sides of the module in order to provide a square connection.




Illustration 22g01627264

Template for installing the tank




Illustration 23g01627269

Installation of the tank

After the tank is positioned on the tubes, the tank must be soldered again. This process is easiest if the module is vertically supported. Illustrations 24 and 25 show two ways to brace the core. The module can be supported vertically by inserting the module between two forks from a lift truck that are mounted on the wall. The center stiffener supports the module. This method works well because both sides of the module can be easily accessed without rotating the module.

Note: The tank should not support any weight in order to keep the components square. The module will also be held at the correct length if the tank is not supporting any weight. The weight of the module may cause the tubes to move the tank when the joint is heated.




Illustration 24g01627338

Holder for soldering the module




Illustration 25g01631774

Locations for holding folded core during soldering

(T) Support on stiffener

(U) Clamp

(V) Work bench

Solder the tank to the tubes. Apply solder from both sides of the module.




Illustration 26g01627788

Soldering the tank to the tubes

Steam clean the soldered connection at the first 6 inches of the module in order to remove any remaining flux. This cleaning will prevent the flux from causing corrosion.

After completing the assembly process, pressure test the module in order to check for leaks.

Pressure Test

After the core has been cleaned and inspected, the core must pass the pressure test in order to check for leaks. Use expansion plugs to plug the core so air pressure can be applied. Expansion plugs are available from most suppliers of radiators. Test the core under water with approximately 105 kPa (15.0 psi) to 125 kPa (18.0 psi) of air pressure. Any air bubbles from leakage will require the core to be replaced or repaired. Refer to the following section for repair procedures.

Cores that pass the pressure test and the flow test are ready to be put back into service.




Illustration 27g01627438

Attach compressed air for testing for leaks.




Illustration 28g01627451

Leak test under water

Core Leakage in the Tube to Tank Joint

If the core leaks after removing and installing the tank, add solder to the leaking area. Test the module again in order to determine if the leaking area was fixed.

If the core leaks after ultrasonic testing, the tank must be removed in order to reseal the module. Refer to ""Removal of the Tank" " and ""Installation of the Tank" " in order to remove the tank and seal the connection. Pressure test the module in order to determine if the leak was fixed.

Core Leakage in Other Areas

Tube leakage can occur anywhere along the length of the core. Tube leakage is usually caused by some type of external damage. Do not block any tubes in order to fix a leak since each core has a limited number of tubes. Cores with this type of damage should be replaced.

Salvage of the Tank

It is important not to damage the inlet and outlet fitting at each end of the core. Damaged fittings will not seal correctly when the module is reassembled. If the fitting is slightly bent, the fitting may be corrected with a rounder. The tool with a diameter of 22.00 mm (0.866 inch) to 41.00 mm (1.614 inch) will work on the fitting.




Illustration 29g01627487

Rounder tool

Only use the rounder tool to salvage fittings. Damaged tanks cannot be salvaged. Refer to Illustration 30 for an example of a damaged tank. The core must be replaced or the tanks may be removed and replaced with another good tank.

Note: The rounder tools, part numbers: 188-0 and 188-1188-2 can be purchased through The Barbee Company, Inc.

The Barbee Company, Inc
418 East Breckinrige Street
Louisville, KY 40203
http://www.barbeecompany.com/
1-800-626-5302



Illustration 30g01627493

This tank cannot be salvaged. Do not use the tank again.

Note: Do not reuse fittings that have been straightened on the inward end after being rounded. Straight fitting ends may damage the seals during assembly. Refer to the ""Removal of the Tank" " and ""Installation of the Tank" " sections of this guideline in order to replace the tank.

Painting Folded Core Modules

Folded core modules should be repainted when the salvage procedure is complete. Remember that repainted cores may not have the same corrosion resistance as new cores since a special paint process is used at the factory.

------ WARNING! ------

Paint and products used in painting may be flammable and hazardous. Read, understand, and follow instructions for use on the container. Wear NIOSH/MSHA certified respiratory protection.

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To paint the cores, use standard black paint for radiators. Use the manufacturer's instructions in order to make the paint thinner. The paint should be thin enough to allow good penetration of the high density fins without plugging or bridging any of the fins with excessive paint. To assist with this process, the air pressure to the sprayer should be set at 690.0 kPa (100.00 psi) to 930.0 kPa (135.00 psi). The higher pressures will aid in obtaining the desired coverage through the core. Apply the paint from both sides of the core and allow the paint to dry. The core is then ready to be put back into service.

Suppliers

There are several sources of supply for equipment for repairing radiators. One manufacturer is the Barbee Company Inc. Barbee manufactures ultrasonic tanks, tanks for pressure tests, and other equipment. Barbee may be contacted at one of the following addresses.

418 East Breckinrige Street
Louisville, KY 40203
502-584-21551-800-626-5302

1703 Mattawa Avenue
Mississauga, Ontario
Canada L4X1K5
1-800-268-2839

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