VENTILATOR A. 3K7861 - Caterpillar

PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure
Thoroughly review these instructionsprior to beginning the rework effort.Step 1: Remove aftercooler core in accordancewith D&A Manual.Step 2: Core Repair
Remove the end covers.
If the aftercooler core was previously weldedto eliminate intake air leaks between the core sideplates and tube endplates, cut through the weld using a hand grinder.
Prior to removing the side plates from the core,mark the side plate and tube plate so that the parts can be reassembledto the same location.
Reinstalling the sideplates in thesame location is important in order to properly match the gasket surfacesof the sideplates and tubeplates. Prior to unbolting the sideplates fromthe stiffening cross-bars and core assembly tubeplates, properly securethe sideplates with lifting eyebolts. Illustration 1
After properly marking sideplates and tubeplates,remove all 10mm and 12mm bolts that secure sideplates to core assemblyand to the cross-bars.
Remove sideplates and top and bottom clampingbars.
Inspect central cross-bars:
If bars are rotated or can be moved with slighthand pressure, drive the bars out using a piece of wood and hammer.
Do not remove central cross-bars ifthey are secured firmly in place and have not rotated.
Removal of all brass sidesheets from core assembly.
Using a propane torch, heat the solder jointswhile applying a slight pulling pressure to sidesheet until it breaks freefrom solder joint. Continue this process on all solder joints that appearto be holding the sidesheet in place.
Do not attempt to remove solder fromcore assembly air-fins. The solder material is not detrimental to coreperformance. Attempting to remove solder material may create loose soldermaterial that can become trapped in air fins and may eventually come looseand enter engine.
Thoroughly clean core assembly to remove loosedebris on air fins and any material on gasket surfaces.
Inspection and plugging of worn core assemblywater tubes:
If the brass sidesheets have worn through to thetube, inspect the tube for damage. If there appears to be tube contactwith the brass side sheet, plug the tube using a tapered brass plug. Drivethe 2322361 plug into the tube until it is flush with the tube end.
Plug only those tube that appear tohave made contact with the brass sidesheets. If more than 14 tube requiring plugging,the aftercore will have to be replaced to maintain cooling system performance. Any new 2-stage core assembly, 1308130(change level 08 and greater), ordered from the parts system will not requirerework per this program. Parts system core assemblies have already beenupdated to the improved design configuration.
Welding 20x20x20 mm bars to inside of sideplates:
Clean inside face of one sideplate prior to weldingbars in place.
Temporarily install all cross-bars to allow properpositioning of the (6) turnstop blocks.
If the central bars were not removed,use the one of the upper or lower cross-bars to positions the turnstopblocks.Refer to the following graphic for more specificdetails. Illustration 2 The purpose of the bars is to helpkeep the cross-bars from rotating. After welding turnstop blocks in-place,the cross-bars can be removed. Clean all weld slag from sideplate surfaces.
Reworking cross-bars:
Remove the silicon pads on all cross-bars removedfrom the core assembly
Clean the silicon pads surfaces