MBE 900 and MBE 4000 EGR Cooler Leak Tester

TO: FROM: SUBJECT: Service Locations Technical Support Development MBE 900 and MBE 4000 EGR Cooler Leak Tester No.: 06 TL 03rev September 20, 2006 ISSUE Detroit Diesel has released an EGR cooler test kit (J-47192) for improved diagnostics of the MBE 900 and MBE 4000 EGR coolers (see figure 1). One kit (J-47192) will be shipped out to all MBE 900 EGR and MBE 4000 EGR certified locations. This will be an automatic shipment. Please DO NOT place an order. REQUIRED ACTION Use EGR cooler test kit J-47192 to pressure test the EGR cooler on either the MBE 900 or MBE 4000 EGR engines. Note: Prior to using the kit, ensure all fittings used are clean of dirt and antifreeze. This allows for the best sealing properties for the fittings. Use the following test procedures: 1. Seal Washers 3. Safety Straps 2. Hose Clamps Figure 1 - EGR Cooler Leak Test Kit (J-47192) for MBE 900 and MBE 4000 Engines DA 1 Detroit Diesel Corporation 13400 Outer Drive, West / Detroit, Michigan 48239-4001

06 TL-03rev - 2 - September 20, 2006 TEST PROCEDURE MBE 4000 1. Attach air supply fitting (J-47192-1) and seal washer (item 1 in figure 1, item 4 in figure 2) from kit J-47192, to the EGR cooler vent line (see figure 2). 2. Attach the two plugs (J-47313-3) to the coolant inlet and outlet pipes on the EGR cooler. Secure the plugs to the EGR cooler using the supplied clamps (see figure 2). 3. Connect pressure hose (J-47313-2) to regulator (J-45982-7) (see figure 2). The pressure regulator and gauge (J-45982-7) are not included in the EGR cooler leak test kit. This gauge and regulator can be found in the cylinder head and block leak tester kit (J-45982). If test kit J-45982 was not shipped essential to your facility, you may order the gauge and regulator under part number J-45982-7. 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 40 psi (276 kpa) air pressure. 4. Check and ensure the shutoff valve is in the OFF position. 5. Set the regulator to zero pressure by pulling up on the adjusting knob and turning counter clockwise until its stops. 6. Connect shop air hose to the pressure regulator and turn shutoff valve to the ON position. 7. Adjust system pressure by pulling up on the adjusting knob and turn clockwise until pressure reading on gauge is 90 kpa (13 psi). NOTE: Do not connect pressure hose (J-47313-2) to air supply fitting (J-47192-1) on the EGR cooler until the pressure regulator has been adjusted to 90 kpa (13 psi). 8. Once pressure regulator has been adjusted to 90 kpa (13 psi), connect the pressure hose to fitting on the vent line. 1. Hose Clamps (supplied in kit) 2. EGR Cooler 3. Regulator and Gauge J-45982-7 (not part of kit) 4. Seal Washers (supplied in kit) 5. Shutoff Valve 6. Regulator Valve Figure 2 Testing the MBE 4000 EGR Cooler with EGR Cooler Leak Test Kit J-47192

06 TL-03rev - 3 - September 20, 2006 BURNS To avoid injury from burning, use lifting tools and heat-resistant gloves when handling heated components. 9. Submerge the EGR cooler completely in a hot water tank. Tip one end of the cooler up so that air bubbles will quickly escape. 10. Leave the EGR cooler submerged for five minutes. 11. In the event of a failed EGR cooler, a steady stream of small air bubbles will come out of the highest end of the EGR cooler. Replace the EGR cooler. 12. Turn OFF the regulator valve, remove the shop air supply, and slowly turn ON the regulator valve to relieve residual pressure from EGR cooler. 13. Remove the EGR cooler test kit components from the EGR cooler. TEST PROCEDURE MBE 900 NOTE: When removing EGR rotary valve from EGR cooler ONLY remove the five nuts attaching the housing to the cooler. Remove EGR rotary valve as an assembly. Ensure the air supply fittings and EGR cooler are clean and free of antifreeze. Antifreeze left on the air supply fitting will allow the rubber seal to slip and not provide proper sealing. 1. Install the air supply fitting (J-47313-1) to the upper EGR coolant passage and secure the safety strap to the EGR cooler (see figure 3). 2. Install plug (J-47192-2) to the opposite end of the upper EGR coolant passage and secure the safety strap to the EGR cooler (see figure 3). NOTE: The MBE900 requires two tests to determine if the cooler is faulty. Make sure the air fitting and plug are located on the same shell (see figure 3). 3. Connect pressure hose (J-47313-2) to pressure regulator (J-45982-7). The pressure regulator and gauge (J-45982-7) are not included in the EGR cooler leak test kit. This gauge and regulator can be found in the cylinder head and block leak tester kit (J-45987). If test kit J-45987 was not shipped essential to your facility, you may order the gauge and regulator under part number J-45982-7. 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 40 psi (276 kpa) air pressure.

06 TL-03rev - 4 - September 20, 2006 4. Check and ensure that the shutoff valve is in the OFF position. Connect the shop air hose to the pressure regulator. 5. Set the regulator to zero pressure by pulling up on the adjusting knob and turning counter clockwise until its stops. 6. Connect shop air hose to the pressure regulator and turn shutoff valve to the ON position. 7. Adjust system pressure by pulling up on the adjusting knob and turn clockwise until pressure reading on gauge is 90 kpa (13 psi). NOTE: DO NOT connect pressure hose (J-47313-2) to air supply fitting (J-47313-1) on the EGR cooler until the pressure regulator has been adjusted to 90 kpa (13 psi). 8. Once the pressure regulator has been adjusted, connect the pressure hose to fitting (J-47313-1). 1. EGR Cooler 4. Shutoff Valve 2. Regulator and Gauge J-45982-7 (not part of kit) 5. Regulator Valve 3. Safety Straps Figure 3 - Testing the MBE 900 EGR Cooler with EGR Cooler Leak Test Kit J-47192 BURNS To avoid injury from burning, use lifting tools and heat-resistant gloves when handling heated components.

06 TL-03rev - 5 - September 20, 2006 9. Submerge the EGR cooler completely in a hot water tank. Tip one end of the cooler up so that air bubbles will quickly escape. 10. Leave the EGR cooler submerged for five minutes. 11. In the event of a failed EGR cooler, a steady stream of small air bubbles will come out of the highest end of the EGR cooler. Replace the EGR cooler. 12. If no leaks are found, the second tube and shell must be checked. 13. Turn OFF air valve on regulator, remove shop air, and now slowly turn ON air valve on regulator to relieve residual pressure from EGR cooler. 14. Move fitting to opposite tube and shell and repeat the above procedure. 15. After the second tube has been checked, remove the EGR cooler test kit components from the EGR cooler. CONTACT INFORMATION Please contact the DDC Customer Support Center at 313-592-5800 if you have any questions.