IK1201211 - EPA 07 MaxxForce® DT/9/10 LT EGR Cooler Flushing Procedure

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IK1201211
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ENGINES

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9/19/2014

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Title : EPA 07 MaxxForce® DT/9/10 LT EGR Cooler Flushing Procedure
Applies To : EPA 07 MaxxForce® DT/9/10

CHANGE LOG
01/15/2019 - Changed acceptable temperature range for service tool.
01/09/2018 - New Article Owner
03/05/2015 - Initial Article Release

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Description

Symptoms

Diagnostics

Repair Procedure

Tools

Parts
Warranty

DESCRIPTION
This document provides the steps necessary to clean the Low Temperature (LT) Exhaust Gas Recirculation (EGR) Cooler.
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SYMPTOMS
EGR Cooler Plugging
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IK1201211 - EPA 07 MaxxForce® DT/9/10 LT EGR Cooler Flushing Procedure

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SPECIAL TOOLS
Tool Description

Tool Number

Cleaning Management System

Comments

Instructions

12-353-01A

LT EGR Cooler Flushing Adapters

12-856-07
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SERVICE PARTS INFORMATION
Kit Description
Fluid, EGR Cleaning

Part Number
3015979C1

Quantity Required

Notes

1

DIAGNOSTIC STEPS
All diagnostics should be completed before performing this procedure.
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REPAIR STEP(s)

Figure 1. LT EGR Cooler
Item 1: Inlet
Item 2: Outlet

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Figure 2. Internal Scale
Item 1: Internal scale

NOTE
There is an Internal Scale inside the Cleaning Management System (12-353-01A) that is pre-measured to 5, 10, and 20 Gallons for
ease of use.

To prevent property damage, personal injury, and / or death, park vehicle on hard flat
surface, turn engine off, set parking brake, and install wheel chocks to prevent vehicle
from moving in both directions.

To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.

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INSTALLATION
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission into Park or Neutral, set parking brake, and install wheel chocks.
3. Unlatch and open hood.
4. If necessary, clean and / or empty Cleaning Management System (12-353-01A) reservoir.
5. Inspect and clean filter sock (12-353-01-10); replace if needed.
CAUTION
To prevent property damage, do not activate HEATER switch with Cleaning Management System (12-353-01A) reservoir empty.
6. Add 2.5 gallons (9.5 L) of EGR cleaning fluid and 7.5 gallons (28.4 L) of clean tap water to Cleaning Management System (12-353-01A)
reservoir.
7. Plug-in the Cleaning Management System to a safe outlet.

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Figure 3. HEATER Switch
Item 1: Heater light
Item 2: HEATER
8. Activate PUMP / HEATER switch to HEATER (down position) (Figure 3, Item 2) before disassembling vehicle and allow temperature to
reach approximately 100-120°F (38-49°C) before cleaning the EGR Cooler. Ensure light (Figure 3, Item 1) below HEATER switch is
illuminated.
9. Remove Low-Temperature EGR Cooler from vehicle. Refer to Engine Service Manual, EGES-335-2.

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Figure 4. EGR Cooler Outlet Adapter (12-856-07-01) Installation
Item 1: Outlet EGR Cooler Adapter (12-856-07-01)
Item 2: LT EGR cooler outlet
10. Slide Outlet EGR Cooler Adapter (12-856-07-01) (Figure 4, Item 1) over LT EGR cooler outlet (Figure 4, Item 2).

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Figure 5. EGR Cooler Outlet Adapter (12-856-07-01) Installation
Item 1: Outlet EGR Cooler Adapter (12-856-07-01) collar
Item 2: Outlet EGR Cooler Adapter (12-856-07-01)
11. Hold Outlet EGR Cooler Adapter (12-856-07-01) collar (Figure 5, Item 1) while tightening Outlet EGR Cooler Adapter (Figure 5, Item
2) turning clockwise until adapter is secure.

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Figure 6. Inlet EGR Cooler Adapter (12-856-07-02) Installation
Item 1: Inlet EGR Cooler Adapter (12-856-07-02) recess
Item 2: LT EGR cooler inlet / flange tab
Item 3: Inlet EGR Cooler Adapter (12-856-07-02) collar
12. Install LT EGR cooler inlet (Figure 6, Item 3) into Inlet EGR Cooler Adapter (12-856-07-02) recess (Figure 6, Item 1), and turn Inlet EGR
Cooler Adapter collar (Figure 6, Item 1) clockwise until flange tabs (Figure 6, Item 3) are secure.

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Figure 7. Inlet EGR Cooler Adapter (12-856-07-02) Installation
Item 1: Inlet EGR Cooler Adapter (12-856-07-02)
Item 2: Inlet EGR Cooler Adapter (12-856-07-02) collar
13. Hold Inlet EGR Cooler Adapter (12-856-07-02) collar (Figure 7, Item 2) and turn Inlet EGR Cooler Adapter (Figure 7, Item 1) clockwise
until Inlet EGR Cooler Adapter is secure.

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Figure 8. Shop Air
Item 1: Push button valve
Item 2: Shop air source
Item 3: Air Injector Coupling (12-856-07-03)
14. Connect shop air source (Figure 8, Item 2) (approximately 100 PSI [690 kPa]) to Air Injector Coupling (12-856-07-03) (Figure 8, Item 1).

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Figure 9. Cleaning Management System (12-353-01A) Hook-Up
Item 1: FLOW RETURN hose (12-353-01-03)
Item 2: Inlet EGR Cooler Adapter (12-856-07-02)
Item 3: Outlet EGR Cooler Adapter (12-856-07-01)
Item 4: Air Injector Coupling (12-856-07-03)
Item 5: FLOW FROM PUMP hose (12-353-01-02)
Item 6: FLOW FROM PUMP connection on Cleaning Management System (12-353-01A)
Item 7: FLOW RETURN connection on Cleaning Management System (12-353-01A)

15. Connect Air Injector Coupling (12-856-07-03) (Figure 9, Item 4) to Outlet EGR Cooler Adapter (12-856-07-01) (Figure 9, Item 3).
16. Connect FLOW FROM PUMP hose (12-353-01-02) (Figure 9, Item 5) to FLOW FROM PUMP connection on Cleaning Management
System (12-353-01A) (Figure 9, Item 6).
17. Connect FLOW FROM PUMP hose (12-353-01-02) (Figure 9, Item 5) to Outlet EGR Cooler Adapter (12-856-07-01) (Figure 9, Item 3).
18. Connect FLOW RETURN hose (12-353-01-03) (Figure 9, Item 1) to FLOW RETURN connection on Cleaning Management System (12353-01A) (Figure 9, Item 7).
19. Connect FLOW RETURN hose (12-353-01-03) (Figure 9, Item 1) to Inlet EGR Cooler Adapter (12-856-07-02) (Figure 9, Item 2).

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Figure 10. Timer
Item 1: Timer
20. Set timer (Figure 10, Item 1) on Cleaning Management System (12-353-01A) to 10 minutes.

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CLEANING PROCEDURE

Figure 11. Activate PUMP / HEATER Switch
Item 1: Pump position
WARNING
To prevent damage, personal injury, and / or death, make sure all hose connections are secure before activating pump.
1. Activate PUMP / HEATER switch to PUMP (up position) (Figure 11, Item 1) and start timer (Figure 11, Item 1) .
CAUTION
To prevent property damage, make sure to introduce only specified amount of air bursts. Too much air introduced into system
could cause excessive foaming, which will overflow reservoir.
2. At 4- and 9-minute marks, introduce eight bursts of air at intervals of 1 second ON and 2 seconds OFF by pressing push button valve on the
Air Injector Coupling (12-856-07-03) (Figure 8, Item 1).

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Figure 12. Pump "OFF"
Item 1: Pump OFF position
3. After 10 minutes has expired, turn OFF PUMP (middle or neutral position) (Figure 12, Item 1), and using push button valve (Figure 8, Item
1), purge some of the cleaning solution from hoses back to reservoir to minimize spillage.
4. Disconnect FLOW FROM PUMP hose (12-353-01-02) (Figure 9, Item 5) from Outlet EGR Cooler Adapter (12-856-07-01) (Figure 9, Item
3).
5. Disconnect FLOW RETURN hose (12-353-01-03) (Figure 9, Item 1) from Inlet EGR Cooler Adapter (12-856-07-02) (Figure 9, Item 2).

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