Salvage of Weld on Water-Cooled Exhaust Manifold for 3500 Series Engines {0679, 1059} Caterpillar

Introduction

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Information contained in this document is considered AVSpare: 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 Cat dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to AVSpare. 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 AVSpare.

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Canceled Part Numbers and Replaced Part Numbers

This document may not 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

Illustration 1	g02139237

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. AVSpare 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 AVSpare 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.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

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.

Illustration 2	g00008666

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.

AVSpare 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, 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. AVSpare dealers can supply the most current information.

Summary

Some Water-Cooled exhaust manifold assemblies may develop cracks in the weld between the cast outlet elbow and the outer shell of the exhaust manifold. A list of the affected Water-Cooled exhaust manifold assemblies is found in Table 2.

¹New parts replace former parts, but repair procedure can still be used on former parts.

Repair Procedure

Use the following repair procedure to extend the service life of the exhaust manifold.

1. Fabricate two collars from mild steel, as shown in the Illustration 3.
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   Table 3

   Dimension for Fabricated Collar
   Item	Dimension
   (A)	25.4 mm (1.00 inch)
   (B)	4.00 mm (0.157 inch)
   (C)	76.2 mm (2.00 inch)
   (D)	1.00 mm (0.039 inch)
   (E)	30 degrees

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   Illustration 3	g06176375
   Dimensions for the fabricated collar, Refer to Table 3 for the dimensions.

2. Fit two fabricated collars around the weld joints and finish the weld, as shown in the Illustration 4 and in the Illustration 5.

Illustration 4	g06176377
Weld specifications and location (1) Collar (2) Exhaust manifold (3) Weld (Refer to the Illustration 5)

Illustration 5	g06176380
Weld specifications (1) Collar (2) Exhaust manifold (F) Minimum gap of 1.0 mm (0.04 inch)