Best Practice submission form

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DATE: Feb. 05/09

BEST PRACTICE TITLE Improved 3500 Engine Exhaust Manifold Salvage

SUBMITTER NAME Ricardo Chegwin H

PHONE NUMBER 5753437408 - 573135321940

EMAIL ADDRESS ricardo_chegwin@gecolsa.com.co

COMPANY Gecolsa

DEALERSHIP Gecolsa

MINE SITE Mine/site name

REGION LACD

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authorization to publish/ share this Best Practice? No
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Please submit to:

Caterpillar Global Mining Best Practices Process Owner: Dale Brehm

Email: brehm_dale_e@cat.com
Phone 309.494.4447, Fax 309.675.4616

CGM BEST PRACTICE STAFF ONLY

BP Number: 2006-1.1-1001

Category (main): Component Rebuild

Category (secondary): Salvage

Site Assessment items:

 BEST PRACTICE SERIES

Improved 3500 Engine

Exhaust Manifold Salvage
Component
Maintenance Component Component MARC
Application Life
and Repair Renewal (CRC) Rebuild Management
Management

3500 Engine Exhaust Manifold Salvage ............Error!

Bookmark not defined.
1.0 Introduction........................................................1
2.0 Best Practice Description ..................................1
3.0 Implementation Steps........................................1
4.0 Benefits .............................................................2
5.0 Resources Required..........................................2
6.0 Supporting Attachments / References ...............2
7.0 Related Best Practices ......................................3
8.0 Acknowledgements ...........................................3

April 09
0906-4.5-1013
300 Hamilton Blvd., Ste. 300, Peoria, IL 61629-3810, U.S.A. catminer.com
CAT GLOBAL MINING BEST PRACTICE SERIES

1.0 Introduction

Significant cost savings can be achieved by salvaging the ends (seals area) of certain 3500
engine exhaust manifolds.

2.0 Best Practice Description

The ends of the manifolds are machined down, a fabricated repair sleeve is installed, and the
manifold can return to service.

3.0 Implementation Steps

CAUTION: SAFETY PROCEDURES FOR THE SHOP EQUIPMENT INVOLVED MUST BE

FOLLOWED.
Clean the exhaust manifold using a shot-peen or sandblast method.
Inspect the manifold for cracks. If a crack is found, salvage of the manifold is not
recommended, as the cracks may continue to propagate.
Machine the end of the manifold to 4.374 .001 inches, 1.750 inches long.

4,370 0,001

1,750

THE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Improved 3500 Engine Exhaust Manifold Salvage 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

Fabricate a sleeve from SAE 1040 grade mechanical tubing, DOM, 4.370 ID by 4.563 OD
by 1.750 length with an inside chamfer of 45 degrees by .06 long. The inside diameter
should be about 4.370 as delivered.

Heat the fabricated sleeve to approximately 250 degrees F.

Before dropping the sleeve onto the manifold some High Temperature Manifold Sealer
2P-2333 is applied to it by means of a brush.
Drop the heated sleeve onto the machined exhaust manifold using heat resistant gloves.
The sleeve material should provide .003 to .004 inches interference fit.

4.0 Benefits

The finished manifolds can be mixed along with new manifolds on the same engine bank,
because the centerlines have not changed.
To reduce turnaround time for an engine rebuild, sufficient quantities of spare manifolds can be
inventoried.
The manifold can be sleeved additional times, if inspection criteria about cracking are met.

5.0 Resources Required

22-inch swing lathe with cutting tools.

Oven.

6.0 Supporting Attachments / References

See publication SEPD0611, page 36, A new exhaust seal and a new exhaust manifold sleeve
are used in the exhaust manifold groups.

THE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Improved 3500 Engine Exhaust Manifold Salvage 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

7.0 Related Best Practices

See Best Practice number 0907-4.5-1091

8.0 Acknowledgements

The idea of improvement of this Best Practice, belongs to:

Luis Meneses
Machine Shop Chief
Gecolsa CAT
luis_meneses@gecolsa.com.co
57 5 3741022

This Best Practice was revised and re-written by:

Edgar Castaez N
Machine Shop Development Engineer
Gecolsa CAT
edgar_castanez@gecolsa.com.co
57 5 3741022

THE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Improved 3500 Engine Exhaust Manifold Salvage 4/3/2009 0000-1.1-1001
00