POWER 5378169 - Caterpillar

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Holder for soldering the module
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Locations for holding folded core during soldering (T) Support on stiffener (U) Clamp (V) Work benchSolder the tank to the tubes. Apply solder from both sides of the module.
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Soldering the tank to the tubesSteam 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.
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Attach compressed air for testing for leaks.
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Leak test under waterCore 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.
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Rounder toolOnly 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
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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