7
2. Line the tool up with the proper holes in the cooler as shown. Hand tighten the
appropriate knurled screw for the cooler down into the threaded hole until the tool
contacts the surface.
3. Hand tighten the knurled knobs on the tool in order to compress the o-rings and seal
against the inside of the pipes. Do not over tighten the knobs as damage to the o-rings
could result.
KL20030-4:
1. Thread the plugs into the ports and hand tighten until the o-rings contact the sealing
surface. Do not over tighten the plugs as damage to the o-rings could result.
KL20020-13 (P
RESSURE
R
EGULATOR
):
1. Connect a pressurized air line to the regulator assembly, and verify that the air pressure
is being properly regulated to 55 psi. If it is not, use the regulator’s adjustment knob to
adjust the pressure to 55 psi.
P
RESSURIZE
THE
S
YSTEM
AND
C
ONDUCT
T
EST
#2
IMPORTANT:
Begin by turning the 3-way valve on tool KL20030-1 to Test 2 (Hose). This is
necessary for this part of the test to be completed properly. Not completing this
would result in an invalid test and would provide false results.
NOTE:
The air poppet in KL20030-2 is set to 60 PSI to prevent damage to the coolers
and for safety in the case of over pressurization.
The compressed air line that is
connected to this system must be regulated to 55 PSI.
1. Connect the KL20020-13 Pressure Regulator to the KL20030-2.
DO NOT INSTALL ONTO
THE KL20030-1.
2. Check for leaks by placing the end of the hose from the KL20030-1 into a container of
water to a depth of .375” which is marked with red dye on the hose. The system must
remain pressurized and the operator should look for air bubbles to come from the end
of the hose. The bubbles indicate a leak, and a very small leak may take up to
5 minutes
to appear. This is the maximum time that would be required of the operator to watch
for air bubbles to be sure there are no leaks in the cooler.
NOTE:
Be sure to record if the EGR coolers passed or failed the leak test.
D
ISASSEMBLY
1. Disconnect the compressed air line from the system.
2. Remove all tools from coolers and clean any oil and dirt from them. Refer to installation
instructions and reverse them for removal.
3. Replace the tools in the storage case for protection.
