TIP GP-EXTRA-DUTY 2545077 - Caterpillar

Clean the Aftercooler Core
Illustration 1 g03455796
(1) Sealing rings (2) Zinc rods (3) Cover (4) Body (5) Heat exchanger (6) Spacer (7) Front coverRemove the core. Refer to the Disassembly and Assembly Manual, "Aftercooler - Remove" for the procedure.
To remove debris, lay the aftercooler core on one side. Remove the debris that is accessible.
Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.
Back flush the core with cleaner.Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 1 lists Hydrosolv liquid cleaners that are available from your Cat dealer.
Table 1
Hydrosolv Liquid Cleaners (1)    
Part Number     Description     Size    
1U-5490     Hydrosolv 4165    
19 L (5 US gallon)    
174-6854     Hydrosolv 100    
19 L (5 US gallon)    
( 1 ) Use a 2 to 5 percent concentration of the cleaner at temperatures up to 93°C (200°F). Consult your Cat dealer for more information.
Steam-clean the core in order to remove any residue. Flush the fins of the aftercooler core. Remove any other trapped debris from the inside and from the outside of the core.Note: Do not use high pressure when the fins are cleaned. High pressure can damage the fins.
Wash the core with hot, soapy water.
Flush the core thoroughly in order to remove residue and remaining debris. Flush the core with clean, fresh water until the water that is exiting the core is clear and free of debris.
Personal injury can result from air pressure.Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.
Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.Test the Aftercooler Core
Inspect the core for trapped debris and cleanliness. If necessary, remove the debris and repeat the cleaning procedure.
Inspect the core for damage and perform a pressure test in order to detect leaks. Many shops that service radiators are equipped to perform pressure tests.
Plug both ends of the aftercooler core and pressurize the core to 205 kPa (30 psi). Submerge the core in water. Look for bubbles which are being emitted from the core. The bubbles are evidence of leaks.
If any leaks are found, do not attempt to repair the core. Install a core that is clean and a core that passes the pressure test in step 3. Refer to the Disassembly and Assembly Manual, "Aftercooler - Install" for the procedure.For more information on cleaning the core, consult your Cat dealer.