Visual Inspection and Salvage Procedures for Aftercoolers in 3500 Engines {1063, 1063, 1379} Caterpillar

Caterpillar Products

All 3500 Engines

All G3500 Engines

Introduction

© 2019 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.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may 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

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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 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 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.

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.

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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, you must 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 contains information which helps to determine the reusability of aftercoolers. The guideline also contains suggestions to salvage aftercoolers that have minimal damage and also gives suggestions to help to prevent future failure.

Never install an aftercooler that this guideline shows should not be used again. When the parts are used in the same application, parts that meet the "Use Again" specifications in this guideline can be expected to give normal operations until the next overhaul of the engine. During reconditioning, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Nomenclature

Illustration 3	g02001123
Side View of Aftercooler (1) Inlet and Outlet Connectors (2) O-Ring Grooves (3) Drain Connector

Illustration 4	g02001235
Top View of Aftercooler (4) Flange (5) Fins

Visual Inspection

You should clean all inlet, outlet, and drain connectors thoroughly before inspection.

When the severity of pitting cannot be determined, perform a pressure test on the connectors. Install the seals and connect the aftercooler so that 345 kPa (50 psi) pressure can be applied. The aftercooler should not be used again if the seals leak.

Illustration 5	g02001276

Illustration 6	g02001277
Enlarged view of illustration 5 DO NOT USE AGAIN

The previous two illustrations show pitting that extends all the way across the top groove.

Illustration 7	g02001282

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Enlarged view of illustration 7 DO NOT USE AGAIN

The previous two illustrations show heavy pitting. This part should not be used again even though the pitting is not extended all the way across the groove.

Illustration 9	g02001280

Illustration 10	g02001281
Enlarged view of illustration 9 Although the pitting is shallow, the pitting is found in both grooves for the O-ring DO NOT USE AGAIN

Illustration 11	g02001278

Illustration 12	g03351800
Enlarged view of illustration 11 USE AGAIN

The previous two illustrations show pitting that is not heavy, the pitting does not extend across the groove, and the pitting is only in one of the grooves. This part can be used again.

Illustration 13	g02001286

Illustration 14	g02001287
Enlarged view of illustration 13 USE AGAIN

The previous two illustrations show pitting that is not heavy and the pitting is not all the way across the groove. This pitting is mainly in one groove only.

Illustration 15	g02001289

Illustration 16	g02002055
Enlarged view of illustration 15 USE AGAIN

The previous two illustrations show damage that is only cosmetic. Both grooves for the O-ring seals are acceptable.

Illustration 17	g02002056
Severe corrosion and several fins are broken out DO NOT USE AGAIN

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No fins are broken out and the mild corrosion was caused by a coolant leak USE AGAIN

The fins of the aftercooler should be straightened out carefully after the coolant leak has been repaired.

Illustration 19	g02002058
Weld all cracks and breaks before reusing USE AGAIN

Salvage Procedures

Grooves for O-ring Seals

When servicing aftercoolers, an emery cloth may be used. Silicone sealers are not recommended in the grooves for the O-rings.

Fins

A small flat head screwdriver can be used to straighten bent fins.

Flange

Depending on the severity of cracks or breaks and accessibility to welding equipment, it may be easier and faster to replace the flange. A cracked or broken flange must be fixed before reinstalling the aftercooler.

All welding and brazing on an aftercooler should be checked for cracks and leaks. Any cracks or leaks should be repaired before the aftercooler is used again.

Handling and Testing

Whenever you are servicing, transporting, or storing an aftercooler, make sure that all connectors are capped or plugged to prevent dirt and other contaminants from entering the system.

Also, copper fins are soft. Be sure to protect the fins during service, transport, and storage to prevent damage.

Testing Procedures

Plug one coolant inlet/outlet port with an expandable plug or blocking cover with O-rings. Seal the drain port with a suitable plug. Cap the other coolant port with an expandable plug or blocking cover equipped with an air pressure tap. Apply 413 kPa (60 psi) air pressure to the air pressure tap and immerse the core in room temperature water. If no air bubbles are seen, the core does not leak and the core can be put back into service.