Transcript
NUMBER: 10–03–11 2011
S.M. REF.: Listed in Table
ENGINE: EPA04 Series 60
DATE: October
SUBJECT: INSTALLATION OF THE TUBE AND SHELL BOLTED FLANGE EGR COOLER ADDITIONS, REVISIONS, OR UPDATES Publication Number
Platform
Section Title
Change
DDC-SVC-MAN-0004
EPA04 Series 60
Installation of the Tube and Shell Bolted Flange EGR Cooler
Installation procedure revised
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
INSTALLATION OF THE TUBE AND SHELL BOLTED FLANGE EGR COOLER
Installation steps are as follows: 1. Install the EGR water outlet hose and clamps onto the oil cooler inlet. See Figure 1.
1. Bolt
3. Clamp
2. EGR Water Inlet Hose
4. Tube and Shell Bolted Flange EGR Cooler
Figure 1
EGR Cooler and Related Parts
2. Insert the oil cooler inlet hose over the cooler water outlet. Secure the hose with clamps.
PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling.
3. Align the cooler back plate holes with the four bosses on the cylinder block. 4. Thread four M10 bolts through the back plate and into the cylinder block. Torque bolts to 46-52 N·m (34-38 lb·ft). 5. Install the hose and clamps onto the cooler water inlet. See Figure 1. 6. Insert the water pump outlet elbow into the EGR cooler water inlet hose. Secure the hose with clamps. 7. Install a new seal ring on the water pump elbow and secure the elbow with two M10 bolts. Torque bolts to 58-73 N·m (43-54 lb·ft).
8. Secure the delivery pipe clamp to the cooler outlet. Torque the clamp nut to 12 N·m (106 lb·in.). See Figure 2.
1. Clamp
3. EGR Cooler
2. Venturi-Section
4. Air Lines
Figure 2
Tube and Shell Bolted Flange EGR Cooler and Delivery Pipe
9. Attach the Delta P tube fittings to the venturi tube. See Figure 2. 10. Torque the tube fittings to 24-30 N·m (18-22 lb·ft). 11. If the Tube and Shell Bolted Flange (TSBF) EGR cooler studs have not been installed, use the following procedure: [a]
Install three M8 studs into the threaded holes on the cooler.
[b]
Torque the studs to 28-32 N·m (21-24 lb·ft).
12. If the upper hot pipe and gasket have not been installed, use the following procedure: [a]
Install gasket and upper hot pipe onto the exhaust manifold center section studs.
[b]
Install two nuts on the studs to secure the upper hot pipe.
[c]
Torque the nuts to 22-26 N·m (16-19 lb·ft).
13. Loosely install the bellow to the EGR valve assembly and secure using the bellow clamps. 14. Slip the remaining bellow clamp over the flange of the upper hot pipe. 15. Install a new EGR cooler gasket. 16. Align the bellow with the upper hot pipe and while pressing against the upper hot pipe, lower the EGR valve assembly onto the TSBF EGR cooler studs. 17. Install the three nuts to secure the EGR valve to the TSBF EGR cooler.
18. Torque the nuts to 22-26 N·m (16-19 lb·ft). NOTE: Bellow clamps must be positioned correctly for exhaust manifold mid-setback and high-mount center sections. See Figure 3 for correct clamp orientation.
1. Exhaust Manifold Mid-Setback Center Section
7. Bellow
2. Stud
8. EGR Valve-to-Bellow Clamp Orientation for all Engines
3. Gasket
9. Exhaust Manifold High-Mount Center Section
4. Upper Hot Pipe
10. Clamp Orientation for a High-Mount Center Section
5. Nut
11. TSBF EGR Cooler
6. Bellow Clamp Orientation Mid-Setback Center Section
Figure 3 Bellow Clamp Orientation for High-Mount or Mid-Setback Center Section Exhaust Manifolds
19. Torque nut on bellow clamps to 12 N·m (106 lb·in.). NOTICE: Particle debris in the lubrication inlet and outlet ports of the actuator assembly can cause performance problems. Use care to keep any debris out of the actuator and oil lines when servicing. See Figure 4.
1. Oil Inlet
Figure 4
2. Oil Outlet
EGR Valve and Hydraulic Actuator Oil Inlet and Outlet Locations
20. Install the oil inlet and outlet fittings to the hydraulic actuator assembly. Torque the fittings to 24-28 N·m (18-21 lb·ft). See Figure 5.
1. EGR Valve and Hydraulic Actuator Assembly
3. Oil Inlet Line and Fitting
2. Oil Outlet Line and Fitting
Figure 5
EGR Valve and Hydraulic Actuator Assembly
21. Install air line fitting to the pneumatic actuator assembly. Torque to 19-22 N·m (14-16 lb·ft). See Figure 6.
1. EGR Valve and Pneumatic Actuator Assembly
Figure 6
2. Air line Tube
EGR Valve and Pneumatic Actuator Assembly
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.
Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2011 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
