NUMBER: 506–10 S.M. REF.: Listed in Table ENGINE: EPA07/10 DD Platform DATE: May2010

SUBJECT: OIL COOLER REMOVAL, TESTING, AND INSTALLATION

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)

DDC-SVC-MAN-0081 EPA07/10 DD Platform 27 Oil Cooler New section outliningremoval, testing andinstallation of the oilcooler.

NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

REMOVAL OF THE OIL COOLER

Remove oil cooler as follows:

1. Remove the oil coolant module. Refer to section .

2. Remove eight bolts securing the oil cooler to the oil coolant module. Discard O-rings.

INSPECTION AND PRESSURE TESTING OF THE OIL COOLER

Test the oil cooler as follows:

1. Inspect the oil cooler sealing surfaces and old gaskets for imperfections.

NOTE:Damaged gaskets or sealing imperfections may produce symptoms similar to a leaking oil cooler. DoNOT replace the oil cooler unless it has been confirmed as leaking with this test.

2. Install the pressure test adaptors (W060589009100) over each of the oil passages of the oilcooler, as the DD13, DD15, and DD16 oil cooler leak test setup illustrates, using the suppliedfasteners. Evenly torque fasteners to 10 N·m (8 lb·ft).

1. Regulator Valve 3. Regulator and Gauge J-45982–7 5. DD13/15/16 Oil Cooler

2. Shutoff Valve 4. J-47313-2 Pressure Hose

EYE INJURY

To avoid injury from flying debris when using compressed air,wear adequate eye protection (face shield or safety goggles)and do not exceed 276 kPa (40 psi) air pressure.

3. Connect the pressure hose to the pressure regulator (J-45982-7 or equivalent).□ The pressure regulator and gauge (J-45982-7) are not included in the oil cooler leak test

adaptor kit. This gauge and regulator can be found in the cylinder head and block leaktester kit (J-45987).

□ If test kit J-45987 was not shipped to your facility as an essential tool, a suitable air pressureregulator and gauge capable of 275 kPa (40 PSI) is adequate.

4. Check and ensure that the shutoff valve is in the OFF position. Connect shop air to the pressureregulator.

EYE INJURY

To avoid injury from flying debris when using compressed air,wear adequate eye protection (face shield or safety goggles)and do not exceed 276 kPa (40 psi) air pressure.

5. Set the regulator to zero pressure by pulling up on the adjusting knob and turning counterclockwise until it stops.

6. Turn shutoff valve to the ON position.

7. Adjust system pressure by pulling up on the adjusting knob and turn clockwise until pressurereading on gauge is 275 kPa (40 PSI).

NOTICE:

DO NOT connect pressure hose (J-47313-2) to air supply fitting onthe oil cooler until the pressure regulator has been adjusted to 275kPa (40 PSI) in order to avoid exceeding the required pressure.

8. Once the pressure regulator has been adjusted, connect the pressure hose to the air supplyfitting on the adaptor plate.

BURNS

To avoid injury from burning, use lifting tools andheat-resistant gloves when handling heated components.

9. Submerge the oil cooler completely in a hot water tank for five minutes.

10. In the event of a failed oil cooler, a steady stream of air bubbles will appear from the oil cooler.

NOTE:Some leakage may occur from the adaptor fittings. Do NOT mistake this for a leaking oil cooler.

11. Reduce the air pressure and remove the oil cooler test kit components from the oil cooler.

INSTALLATION OF THE OIL COOLER

Install the oil cooler as follows:

1. Using new O-rings, install the oil cooler to the oil coolant module.

2. Torque the eight securing bolts to 25-30 N·m (18-22 lb·ft).

3. Install the oil coolant module. Refer to section .

ADDITIONAL SERVICE INFORMATION

Additional service information is available in Power Service Literature.

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