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Product: GAS ENGINE

Model: G3516 GAS ENGINE 3RC
Configuration: G3516 Engine 3RC00001-UP

Reuse And Salvage Guidelines

Visual Inspection and Salvage Procedures for Aftercoolers in Series 3500 Series
Engines{1063, 1063, 1379}
Media Number -SEBF8422-04 Publication Date -17/12/2010 Date Updated -17/12/2010

i04170229

Visual Inspection and Salvage Procedures for Aftercoolers in

Series 3500 Series Engines{1063, 1063, 1379}
SMCS - 1063-040; 1379-040

Engine: All 3500 Engines

Introduction
Table 1
Revision Summary of Changes in SEBF8422
04 Updated Effectivity
03 Updated Effectivity

© 2010 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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, please use the following resources in
order to communicate your request to Caterpillar Repair Process Engineering:

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• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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.

Nomenclature

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Illustration 1 g02001123

Side View of Aftercooler

(1) Inlet and Outlet Connectors

(2) O-Ring Grooves

(3) Drain Connector

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Illustration 2 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.

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Illustration 3 g02001276

Illustration 4 g02001277

Enlarged view of illustration 3

DO NOT USE AGAIN

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

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Illustration 5 g02001278

Illustration 6 g02001279

Enlarged view of illustration 5

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.

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Illustration 7 g02001280

Illustration 8 g02001281

Enlarged view of illustration 7

Although the pitting is shallow, the pitting is found in both grooves for the O-ring

DO NOT USE AGAIN

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Illustration 9 g02001282

Illustration 10 g02001284

Enlarged view of illustration 9

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.

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Illustration 11 g02001286

Illustration 12 g02001287

Enlarged view of illustration 11

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.

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Illustration 13 g02001289

Illustration 14 g02002055

Enlarged view of illustration 13

USE AGAIN

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

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Illustration 15 g02002056

Severe corrosion and several fins are broken out

DO NOT USE AGAIN

Illustration 16 g02002057

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

USE AGAIN

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

Illustration 17 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.

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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.

Copyright 1993 - 2014 Caterpillar Inc. Thu Jan 16 20:43:20 UTC+0700 2014
All Rights Reserved.
Private Network For SIS Licensees.

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