HM ELECTRO-MOTIVE DIVISION M.1. 927 Rev. C * GENERAL MOTORS CORPORATION sence onrmoe MAINTENANCE INSTRUCTION ¢ LUBE OIL COOLERS INTRODUCTION Hot engine lubricating oil is cooled by passing water from the engine cooling system through a system of tubes (core) within the oil cooler. The tubes are surrounded by a tank through which the hot engine oil flows. Heat from the engine oil is transfered to the cooler water by using the tube material as the conductor. There are basically two types of oil coolers, the fin-tube core type, and the tube bundle type. Although construction is different, the method of cooling the lube oil remains the same. It should be noted that major servicing of the oil cooler should not be. undertaken until need for such maintenance is definitely established by un- satisfactory operation. FIN-TUBE CORE TYPE COOLER DESCRIPTION, Fig. 1 Cooling water enters the cooler through each side of the upper header, Fig. 2, and is discharged through outlets in the lower header. The engine lube oil enters the cooler through one side of the lower header, and is discharged through an outlet on the opposite side of the lower header. Fintube core type oil coolers are built with either a solder or mechanical type tube-to-header bond, CLEANING When it becomes necessary to clean the oil cooler, use the following procedure: 1. Perform the following steps to remove tank from oil cooler core. Pipe Nipple AL Mounting Bolts Lower Header aar22 Fig. 1 - Fin-Tube Core Type Oil Cooler Upper Header Lower Header: Clamp Plate: asa Fig. 2 - Cooler Core And Header Assembly *NOTE: Information contained herein is applicable to equipment being produced as of the date of publication.ML. 927 a, Remove water vent pipe nipple nut from top of oil cooler, Fig. 1. 'b. Loosen and remove tank to lower header mounting bolts, nuts, and washers. c. Remove clamping plate nuts and washers, Fig. 3. Remove clamping plate. 11617 Fig. 4 - Damaged Header Flanges, Fins, ‘And Rail Assembly should be sufficient to allow for complete submersion of the oil cooler. J.QuCoser Heder ee CAUTION: Use of caustic cleaners is not recom- [ier inetFinge Flaming Pate mended. The fin-to-tube bonding cee Cae solder will deteriorate with the use of caustic cleaners. Fig. 3 - Oil Cooler Disassembly d. Loosen and remove bolts and washers that 6. Soak core for three hours in a still tank, with secure the water inlet fitting to the oil tubes lying horizontally. If cleaning solution cooler header. Remove water inlet fitting. is agitated, cut soaking time in half. e. Remove tank from oil cooler. NOTE: Cleaning is more effective in an agitated NOTE: When reassembling renew “O" ring seal tank. and all gaskets. Apply a coat of gasket : sealing compound ‘> the gasket sealing 7. Rinse core using a steam-water mixture. : surfaces. Apply engine oil to “O" ring Suur'"te. prevent binding, thus easing NOTE: Rinse core as soon as possible to prevent assembly. residue from hardening. 2.Remove upper and lower header assemblies from core. CORE TESTING 3. If necessary, straighten header flanges, Fig. 4. Oil cooler core failures, other than damage, t® Come bert’ fins to ensure that flow is not be categorized under three headings: fin-to-tube reduced. bond failures, tube failures, or tube-to-header bond failures.’ Repair limits for fin-to-tube bond 4, Clean gasket surfaces. and tube failures can be found under Service ____ Data. If the failure is within the repair limits the 5. Fill a soak tank with an undiluted non toxic core can be repaired, if not, repair is not feasible Greanic cleaner. See Service Data, Level and the core should be scrapped.ad) Y FIN-TO-TUBE BOND CHECK Loose fins will hinder heat transfer. Use the following steps to check fin-to-tube bond. The oil cooler should be scrapped if loose fin area ex- ceeds limits under Service Data. 1. Using a suitable tool or probe, check the fin-to-tube bond by gently pressing against the fin collar, Fig. 5. If the fin moves and the tube is stationary, the fin is loose. 14018 Fig. 5 - Checking Fin-To-Tube Bond 2. Repeat Step 1 for each fin and measure loose fin area. NOTE: Repair of loose fin-to-tube bond is not possible. LEAK TEST Tube leaks or tube-to-header bond leaks can be accurately located using the following procedure: 1. Install a sealing plate or a tank on each header of the core. 2. Apply 345 kPa (50 psi) air pressure on the tube side with the core immersed in clean water at room temperature. CAUTION: Avoid exceeding 345 kPa (50 psi) air pressure; higher pressures will damage core tubes. 3.Mark tubes and areas of the tube-to-header bonds that are emitting bubbles. 4. Qualify the oil cooler by using the repair limit information given under Service Data. The oil cooler should be scrapped if tube failure exceeds repair limits. 5. For repair procedures, refer to either Tube Repair or Tube-To-Header Bond Repair sec- tions, depending on nature of leak. M.L. 927 TUBE REPAIR Tube leaks are repaired by sealing each end of the defective tube with solder, thus eliminating it from service. Experience has shown that up to 2% of the total tubes can be sealed by this method without adversely affecting efficiency. Use the information given under Service Data as a guideline in determining whether the core is scrapped or repaired. The recommended heating tip for melting out old solder and applying new solder is listed under Service Data. Use this procedure for both solder and mechanical tube- tovheader type bonds. Solder tubes closed using the following procedure: 1. Thoroughly dry inside of tubes repaired. to be 2. Pinch one end of each defective tube closed. NOTE: Use brass plugs to close tubes on mechan- ical tube-to-header type bonded cores. 3.Clean tube with zinc chloride flux. See Service Data. When applying flux, play a medium flame on the fluxed surfaces. The heating will boil the flux thus improving its cleaning ability. Use a soft wire brush to scrub and clean the areas which are being prepared for soldering. 4, When the tube is thoroughly cleaned, solder the pinched (plugged) end of the tube with a 50% tin, 50% lead, soft solder and a 243° C (470° F) flame. See Service Data. 5. Flush each soldered tube to avoid trapping unused flux inside. 6. Thoroughly dry inside of tube. 7. Tum core and solder opposite end of tube as described above. 8. Clean and flush both headers with water. 9. Repeat Leak Test to assure that all leaks have been eliminated. TUBE-TO-HEADER BOND REPAIR ‘The majority of tube-to-header bond leaks occur in the outer two tube rows along the long side of the header. Although less common, leaks at the middle tube rows are also possible.Mu.927 a 7 ro, Se Serie Dts. Us 327°C (620° ee ia te Deni Soe F) flame to sweat this solder into the tubetoreadr jt. will cause a load on the tubetorheader bond, ‘using premature failure. header bond are not repairable sng this When repaiting an outer tube row failure, the method. header is held square by the solder which as not ‘been removed from the middle tube rows, To Rida Medares ae sini for both outer and repair a middle tube row fates Canons ‘idle tube rows. The primary difernce being fixture, Fig. 6, shouldbe constructed fo ant nt the area from which the olf solder is melted out. header square while peas ons ee ‘OUTER TUBE ROW REPAIR ‘A leak detected within the first two outer tube rows may be repaired using the following rocedute! . When solder stops running, use a small Using 9.5 mm (3/8") TRIBAR puddle folder, see Service Dats, and a 260°C (500" F) fame, build up'a puddle with 2 inimum depth of 4 mm (6/32"). Blend with increasing depth up to 64 mm edge of the header dish Solder space between rows using a 3.2 ‘mim (1/8") wire puddle slder, se Service ‘While repairing tubetorheader bond fallres, it is rica that the eader‘be kept in a postion Melt the solder fram the fist two outer hich is square with the cubes A cocked header tube row Tr resoldering. 4 Repent Sty wing den Tis wi "ew Pudi oe wal bende Remove all traces of fx by immersing core several times in cold water. 2.With the core resting on one header and the tubes in the verti position: Run a length of No. 7, 3.2 mm Aiameter sver wie solder along each tube ‘3. Repeat Leak Test £0 assure that al leaks have been eliminated oe ar i x, | te Bre Fie 6~ Header Clamping Fixture ae Fig. 7~ Oi Coote SchematicMaL927 MIDDLE TUBE ROW REPAIR, Use the folowing middle tube cedure to repair leaks in the Construct a clamping fixture using the dlimenso 2. Bolt cach half of the clamping fixture tothe core header fangs. NOTE: When appiying tx, on the fuxed Repeat Step b using ean fx. This wil remove any retin ity fan mae, ted Fesform steps 2 and 3 under Oster Tube wm “Row Rena . Fis. 9 ~ Cuts View OF The Tube Bande Type Of Coot ‘TUBE BUNDLE TYPE COOLER j CLEANING DESCRIPTION, Figs 8 and 9 When it becomes necesiry to dean the oll eae ied for cooling the ube oll entry PPM the following procedure owe tog ie Tee eon, 1. Remove hae Gam ech nd of cone mics, @ = CAUTION: Uso eases not some flanged connection near one end of the cooler, ‘ended. Bonding solder vil dot ‘ flows anne” sound the a ‘Sie whe oof tue ces. Fig 5 -Fin-Tube SOLDERED MECHANICALLY ROLLED it Cooler Core Tube-Te-Header Bond CLEANING ‘© Remove clamping plate nuts and washers, Fig: 6. Remove di lamping plateML. 927 Water Passage Leak Test Ate Pe etamtiy Batfle/Relit Valve Assembly cauTion ig clamps may result in core SOLDERED MECHANICALLY ROLLED | pn water nd oesher (1) Cooter Core™ fo lower header Fig T8 Torguets Figs -Fn-Te oi re re Trento ns © icz Nim os wi LS CLEANING and spring lock When mes necessary to clean the oil cooker, bane, Fig. 14, i Procedure 4 1. Rerform the following steps to remove the oil cooler tan Nn EPS 8 18. Remove clamps. in Tube Type 19. Apply outlet ba following the same general ‘Cutaway View Shownng’ Procedure given above. Application of Tank Assembly | Avplletion of Tank Assembly alle orsnotonfom,revorkasreqred. 20, Ital th 3/4"ippleand gasket tothecemer ‘apped hole in the upper header can fully clamp lube oi inet bale to core, Fig ia, es ine.cetera" rig. 11 ~ Simpliies 01 cooler Coro Header esting Aptos eae (it Passage Leak Test 38. Apply blanking pats or test fitngs to the oil {alr and outlet openings inthe bottom header ‘sting and the ol outlet opening inthe ide of so eauipped). 5 plastic stand pipe, Fig. ‘threaded female ol vent iting onthe op ofthe cauTION smistake the canter ater ven fiting for ent Bing 40, Fill te oi coter with water containing a ras pine asembly bolts and tighten "inhibitor unl the water level 1 524 tan above the top ofthe tankNOTE Baffle relief valve must fit tightly against oil core side rail and gusset along its entire length prior to tightening bolt on clip support. Coil Inlet € Water Outlet U5 Side Of Baffle To Fit Tank Snugly Water Outlet € € oivoutter J, “O" Ring Seal 8. 1-1/4” Locknut 14. 174" Spring Lock Washer 2. Adapter 9. Gasket 15. Baffle Plate Assembly 3. Gasket 10. 1/2°-13 Hex Bolt, Spring 16. Baffle/Relief Valve Assembly @ Header Lock Washer, And Nut 17. Clip 5. 3/4"-2 Nipple 11. Stri 18. 1/2*.13 Hex Bolt, Spring & 3/4" Locknut 12° T Lock Washer, And Flat Washer 7. Nipple 13, 19. Oil Cooler Header 20. Gasker 14 - Baffle Application R2-