Lubricating Oil Cooler O-Ring Replacement

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Technical Service Bulletin Number
TSB160018

Technical Service Bulletin

Subject
Lubricating Oil Cooler O-Ring Replacement

Warranty Statement
The information in this document authorizes specific changes to the repair practice for failures
covered under product warranty coverages.

Contents
Product Affected



ISX15 (All Versions)
QSX15 (All Versions)

Issue
Symptom:


Lubricating oil leak or coolant leak form the threaded plugs and fitting on the lubricating
oil cooler.

Root Cause:


Material malfunction of the o-rings.

Verification


Verify coolant or lubricating oil is leaking from at least one of the six threaded plugs or

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fittings shown in Figure 3 below.
A unit equipped with suspect o-rings can be identified by a groove on the threaded plug
for the lubricating oil thermostat. See Figures 1 and 2 below. With the threaded plug still
installed, inspect for a groove.
Proceed to the Resolution section below only if a groove is present on the threaded plug.

Figure 1, Example of Oil Cooler Thermostat Plug with No Groove and Good O-ring.

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Figure 2, Example of Oil Cooler Thermostat Plug with Groove and Suspect O-ring.
Resolution


If any of the seven threaded plugs or fittings shown in Figure 3 below are leaking

And


If the threaded plug for the lubricating oil thermostat (Figure 3, Item 1) has a groove
present

Resolution:




All o-rings listed below should be replaced if installed on the lubricating oil cooler
housing.
See Service Parts Availability section and Service Instructions section below.

Service Parts Availability
Service tool, Part Number 5394435, is being made available free of charge to all dealers and
Cummins® distributors to assist in the replacement of the suspect o-ring seal for the lubricating
oil thermostat threaded plug. These tools have been shipped to your local distributor branch
headquarters and will be distributed to all certified repair locations in that territory. All tools
should be distributed by mid-April 2016. Contact your local Cummins® distributor parts
manager with questions.

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Seal kit, Part Number 4376561, contains seven revised o-rings, and is available for purchase.
If the lubricating oil cooler housing has plug number 7 (Figure 3, Item 7) an additional o ring
seal, Part Number 3678912, will be needed and must be ordered separately.
Table 1, Seal Kit and Service Tool Part Number
Part Description

Part Number

WRENCH,HEXAGON

5394435

KIT,SEAL

4376561

Table 2, Parts Needed if Seal Kit, Part Number 4376561, is not Available
Part Description

Part Number

Quantity

Location in Figure 3

SEAL,O RING

3089025

1

1

SEAL,O RING

3678606

1

2

SEAL,O RING

3678912

3

3, 4, and 5

SEAL,O RING

3679139

1

6

SEAL,O RING

3922794

1

6

Service Tools and Training Available
Instructional video available. See link below.
NOTE: If you are not able to see the video link please reference the link below and
navigate to the heading, "Computer/Browser/Video Settings That Affect QuickServe
Online"and select, "What do I need to check when a document I am viewing indicates a
video is available but I am unable to see the video?".
NOTE: https://qsol.cummins.com/qs3/qsol/faqs/summary.html
Service Instructions
Select Service Tools
Recommended Cummins® Service Tools


Hexagon Wrench, Part Number 5394435.

Additional Service Items






½ inch ratchet
White paint marker
Pry bar or large screwdriver
Safety glasses
Gloves

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Scraper

Component Location

Figure 3, Plug and Fitting Locations on Lubricating Oil Cooler Housing.
Reference numbers for plugs and fittings to be removed and o-ring locations for this
procedure. (See Figure 3 above for component location):
1.
2.
3.
4.
5.
6.
7.

Lubricating Oil Thermostat Threaded Plug - Oil
Lubricating Oil Filter Bypass Valve Threaded Plug- Oil
Threaded Plug Near Lubricating Oil Filter Bypass Valve- Oil
Thread Plug Near Lubricating Oil Thermostat- Oil
Threaded Plug - Coolant
Turbocharger Oil Supply Line Fitting- Oil
Optional Threaded Plug - Coolant (This plug will only be installed on some units and
only needs to be replaced if it exists on the housing and a different fitting was not
installed into this location)

Label each plug or fitting as they are removed. This will help identify the plugs or fitting through
the replacement procedure.
Preparatory Steps

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WARNING
Wear appropriate eye and face protection when using compressed air. Flying debris and dirt
can cause personal injury.

WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of
personal injury.

WARNING
Some state and federal agencies have determined that used engine oil can be carcinogenic
and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil. If not reused, dispose of in accordance with local environmental
regulations.

WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance
with local environmental regulations.

WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can
cause personal injury.

WARNING
Batteries can emit explosive gases. To reduce the possibility of personal injury, always
ventilate the compartment before servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the negative (-) battery cable last.




Disconnect the batteries. See equipment manufacturer service information.
Clean area with solvent and dry with shop air.
If needed, remove the charging system alternator to access lubricating oil thermostat
threaded plug. See the corresponding Service Manual. Reference Procedure 013-001 in
Section 13.

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Remove the two capscrews from the water pump housing that extend into the charging
system alternator/refrigerant compressor mounting bracket.

Replace
1.) O-ring for Lubricating Oil Thermostat Threaded Plug (Figure 3, Item 1):


Insert tool, Part Number 5394435, into hex feature of lubricating oil thermostat threaded
plug and while using a pry bar or large screwdriver to maintain engagement into hex
feature of threaded plug. See Figure 4, Item 1 below.

NOTE: If the tool, Part Number 5394435, does not fit or is not able to loosen the plug,
removal of the charging system alternator/refrigerant compressor mounting bracket
may be necessary. See the corresponding Service Manual. Reference Procedure 009056 in Section 9.
















Insert ½ inch ratchet into tool and loosen threaded plug. Remove tool from threaded
plug.
Rotate threaded plug counterclockwise by hand until sufficient room exists for removal
of suspect o-ring.
Remove and discard suspect o-ring. See Figure 4, Item 2 below.
Rotate threaded plug counterclockwise by hand until sufficient room exists to install
new o-ring.
Roll new o-ring, Part number 3089025, onto threaded plug until new o-ring slips into oring groove. See Figure 4, Item 3 below.
Verify new o-ring is properly installed and rotate threaded plug clockwise back into plug
bore by hand.
Insert tool into hex feature of threaded plug and use a pry bar or large screwdriver to
maintain engagement into hex feature.
Tighten threaded plug until plug makes full contact with lubricating oil cooler housing.
Use ½ inch torque wrench to tighten threaded plug while using a pry bar or large
screwdriver to maintain engagement.

Torque Value: 99 N•m [ 66 ft-lb ]


Place a small ‘x’ to the left of the plug with white paint marker.

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Figure 4, Removal and Installation of O-ring:
1. Tool, Part Number 5394435, Inserted Into Hex Feature of Lubricating Oil Thermostat
Plug.
2. Removal of Suspect O-ring.
3. Installation of New O-ring.
2.) O-ring for Lubricating Oil Filter Bypass Valve Threaded Plug (Figure 3, Item 2):





Remove lubricating oil filter bypass valve threaded plug.
Remove and discard suspect o-ring.
Install new o-ring, Part Number 3678606, onto threaded plug.
Install threaded plug.

Torque Value: 45 N•m [ 33 ft-lb ]


Place a small ‘x’ to the left of the plug with white paint marker.

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Figure 5, 1.) Lubricating Oil Filter Bypass Valve Threaded Plug. 2.) O-ring.
3.) O-ring for Threaded Plug Near Lubricating Oil Filter Bypass Valve (Figure 3, Item 3):





Remove threaded plug near lubricating oil filter bypass valve.
Remove and discard suspect o-ring.
Install new o-ring, Part Number 3678912, onto threaded plug.
Install threaded plug.

Torque Value: 12 N•m [ 9 ft-lb ]


Place a small ‘x’ to the left of the plug with white paint marker.

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Figure 6, 1.) Threaded Plug Near Lubricating Oil Filter Bypass Valve. 2.) O-ring.
4.) O-ring for Threaded Plug Near Lubricating Oil Thermostat (Figure 3, Item 4):
NOTE: If a coolant dam or coolant vacuum tool is not available, the threaded plug
removed from location number 4 will be used to quickly replace the threaded plug
removed from location number 5 to prevent coolant loss.




Remove threaded plug by lubricating oil thermostat.
Remove and discard suspect o-ring.
Install new o-ring, Part Number 3678912, onto threaded plug.

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Figure 7, 1.) Threaded Plug Near Lubricating Oil Thermostat. 2.) O-ring.
5.) O-ring for Threaded Plug (Figure 3, Item 5)


Remove threaded plug number 5 and insert threaded plug number 4 into location
threaded plug number 5 was removed from.

Torque Value: 12 N•m [ 9 ft-lb ]




Remove and discard suspect o-ring from threaded plug number 5.
Install new o-ring, Part Number 3678912, onto threaded plug.
Install threaded plug into location threaded plug number 4 was removed from.

Torque Value: 12 N•m [ 9 ft-lb ]


Place a small ‘x’ to the left of the plug with white paint marker.

6.) O-rings for Turbocharger Oil Supply Line Fitting (Figure 3, Item 6):






Remove turbocharger oil supply line from the oil supply line fitting (Figure 9, Item 1).
Remove the turbocharger oil supply line fitting (Figure 9, Item 2).
Remove and discard both suspect o-rings.
Install new o-rings, Part Number 3679139 and 3922794, onto fitting.
Install the fitting.

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Torque Value: 36 N•m [ 26.5 ft-lb ]


Install turbocharger oil supply line to fitting

Torque Value: 30 N•m [22 in-lb]


Place a small ‘x’ to the left of the fitting with white paint marker.

NOTE: Step 7 below will only be performed on select chassis.
7.) O-ring for Optional Threaded Plug Near Lubricating Oil Filter Bypass Valve (Figure 3, Item
7):
If the Lubricating Oil Cooler Housing has a threaded plug in this location:





Remove threaded plug near lubricating oil filter bypass valve.
Remove and discard suspect o-ring.
Install new o-ring, Part Number 3678912, onto threaded plug.
Install threaded plug.

NOTE: If a coolant dam or coolant vacuum tool is not available, the threaded plug
removed from location number 3 will be used to quickly replace the threaded plug
removed from location number 7 to prevent coolant loss.
Torque Value 12 N•m [ 9 ft-lb ]


Place a small ‘x’ to the left of the plug with white paint marker.

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Figure 8, 1.). O-ring. 2.) Turbocharger Oil Supply Line Fitting 3.) O-ring.

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Figure 9, 1.) Turbocharger Oil Supply Line. 2.) Turbocharger Oil Supply Line Fitting.
Finishing Steps


Install capscrews removed from the water pump housing.

Torque Value: 30 N•m [22 ft-lb]









Install charging system alternator if removed. See the corresponding Service Manual.
Reference Procedure 013-001 in Section 13.
Install the charging system alternator drive belt. See the corresponding Service Manual.
Reference Procedure 013-005 in Section 13.
Connect the batteries. See equipment manufacturer service information.
Add coolant to full cold line if necessary. See the corresponding Service Manual.
Reference Procedure 008-018 in Section 8.
Operate the engine to normal operating temperature and check for leaks.

Production Status
Implemented for production. See Table 3.
Table 3, Production Information
Product

Engine Serial Number (ESN) First Build Date* Engine Plant

QSX15 CM570 79825116

25-Mar-15

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Jamestown Engine Plant

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*Engine build date can be found on the engine dataplate.

Document History
Date
2016-2-19
2016-4-6

Details
Module Created
Added mention of seventh o-ring, message about service tool, Part Number
5394435, availability, video link, and Step 7.

Last Modified: 07-Apr-2016
Copyright © 2000-2010 Cummins Inc. All rights reserved.

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