Hello from a new member

[J12345T]

Hello All,

...I've just moved this from general discussion to the diesel forum...

As the new owner of a 2003 Princess 45 I know I have a lot to learn. I'm hoping that this and similar online communities can assist me in the education process and along the way hopefully I can contribute my experiences in return.

To start the ball rolling I have two cracked aftercoolers on my CAT 3126's (450hrs and 9yrs old)... Oh yes welcome to boating I hear you say...

It's not the total disaster it may at first sound as the leaks are external only (I am assured and confirmed by oil samples) however, they both need either repairing (may be possible) or replacing (expensive ~NZD 9000 for the pair). I'm going to try to attach a couple of photos as explaining will take a small novel. Suffice it to say the leak is in the bronze header tanks on the fronts of each a'cooler. CAT are ducking for cover and not providing much help as to why this has happened but the radiator repair guys seem to think it looks like a corrosion issue (stands to reason given the bronze tanks contain the anodes and maybe at some point they weren't changed).

I should also say that the cracks were only found and the leak only started when I elected to remove, clean and check the entire raw water system...

Does anyone know of a similar issue or had success with similar fixes??

Thanks.

JT
Attached Images

 

[earthmover17]

I would have them repaired. Once repaired have them pressure checked. The check will at least put your mind at ease.

Jack

 

[J12345T]

Thanks,

I'm having a go at getting them repaired. Should be ready in a week or so. I just hope that if they pressurre check OK (I understand they heat them up during the check) that they will last a normal service life.

Cheers,

JT.

 

[Chris1960]

I've got one of my aftercoolers off at the moment for a general clean up and re-paint and while the aftercooler is off what can I use to clean out the inside ....Not the seawater side, I mean where the fins are as I notice there is some mastic/sealant in there I was going to use petrol but not sure if this will affect any internal seals. Regards Chris

 

[J12345T]

Hi,

From my experience if you have already removed the aftercoolers then I think it would be VERY worthwhile getting the job done professionally by a heat exchanger specialist who is also able to pressure test the units after cleaning. The guys who repaired my aftercoolers pressure tested the units to 30psi in hot (nearly boiling water) to simulate the heat stresses involved with normal operation.

Regarding your question I think you're talking about the air side? I'm not an expert but I don't think this is the cause of many problems; it's the sea water side you need to be concerned with and a clean and pressure check is worth it's weight in gold.

As an aside, if you feel the need to clean etc your aftercoolers then maybe you should consider doing the same to your heat exchangers and transmission oil coolers? 2 cents.:smt001

JT.

 

[earthmover17]

Air side gets oily and gummy and also needs to be cleaned. Cat 1000 hour service on my engine. I've cleaned mine with engine degreaser before. But I prefer to take it to qualified shop for testing and cleaning.

Jack

 

[BonBini]

I see a little corrosion, but the cracks are from thermal cycling. That’s what aftercoolers do.

As far as cleaning the air side: We have a dishwasher (hot water parts cleaner) at our shop that we throw square 3208 types in. What works best on those long skinny guys like yours is just a plain old hot water pressure washer. One has to be careful to stay back with the wand as not to fold the fins (wich can be straightened out fairly easily). The silicone seal will sometimes have to be re beaded but is no big deal.

When servicing the system as you are: the turbo compressor housing gets just as scanky as the air side of the aftercooler too. Power washing it also makes it like brand new again.

Cleaning the black gummy deposits of these two components usually provides a noticeable cleaner burn and a little better boost pressure.

 

[J12345T]

Thanks for the comments.

It would seem pretty poor that they have cracked from normal use after only 450hrs; although I tend to agree that they look like stress cracks as opposed to solely corrosion induced cracks.

I've had them repaired and they're being refitted today so I guess only time will tell if they're going to last a normal service life. I certainly hope so but any more info/experience would be appreciated.

Cheers,

JT