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adding oil cooler to D2 stationary engine

adding oil cooler to D2 stationary engine

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Jack
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I decided the generator engine oil was getting pretty warm after about seven hours of sustained run at rated HP, so am puting on an oil cooler. I couldn't find an air-cooled unit, so made one out of copper pipe. It is tankless and involves three 1/2" pipes teed from the inlet hose on each end, standing vertical.

Question: Should I put the oil (1) into the top and let it run downward through the cooling tubes and back to the engine, or (2) feed it into the bottom and take the cooled oil off the top and back to the engine. Would one way or the other be prone to air locking? Would it make any difference in some other way? 😕😕😕

Please, HELP!!!

Generator system ran without so much as a hicup all last winter, except for the oil getting hot and thinning out. It does produce enough power to heat my big house and have some extra, IF I chose to run it hour/hour of heating. As was, it knocked off about 30% of my heating bill. I have enough oil stockpiled to do better this year but I'll need to run more than seven hours/day.

Thanks again to all who provided me a great pile of help when I was building the system.

Jack
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Thu, Oct 8, 2015 11:49 AM
old-iron-habit
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I would put supply to the bottom and add a bleeder valve above the top. I would also install a good quality ball valve on the return line at the top top to choke it down a wee bit as necessary to insure it fills completely with oil and pushes all the air out the bleeder. Once full open the valve completely.
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Thu, Oct 8, 2015 12:15 PM
Jack
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Reply to old-iron-habit:
I would put supply to the bottom and add a bleeder valve above the top. I would also install a good quality ball valve on the return line at the top top to choke it down a wee bit as necessary to insure it fills completely with oil and pushes all the air out the bleeder. Once full open the valve completely.
That was my first thought, Old Iron. Could there be some problem with pushing the flow up from the bottom with an air bleeder at the top of the system? Is there some reason why Cat ran the flow downward? Am I giving this a lot more thought than necessary?

At this point I'm going with Old Iron Habit's idea, except for the valve in the return line. I guess the relief valve built into the system would prevent a catastrophy if the valve wasn't opened, but the D2 oil pump is bigger than some tractor hydraulic pumps. Could it possibly fail to push an air bubble through? Isn't there some of this air bubble effect every time you change oil anyway? On some engines it's impossible to prefill the filter.
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Fri, Oct 9, 2015 1:04 AM
Old Magnet
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Reply to Jack:
That was my first thought, Old Iron. Could there be some problem with pushing the flow up from the bottom with an air bleeder at the top of the system? Is there some reason why Cat ran the flow downward? Am I giving this a lot more thought than necessary?

At this point I'm going with Old Iron Habit's idea, except for the valve in the return line. I guess the relief valve built into the system would prevent a catastrophy if the valve wasn't opened, but the D2 oil pump is bigger than some tractor hydraulic pumps. Could it possibly fail to push an air bubble through? Isn't there some of this air bubble effect every time you change oil anyway? On some engines it's impossible to prefill the filter.
No big mystery. Just duplicate Cat's oil cooler arrangement.
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Fri, Oct 9, 2015 2:21 AM
drujinin
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Reply to Old Magnet:
No big mystery. Just duplicate Cat's oil cooler arrangement.
Let me know how that works out!
If you had said finned tubes, I would have thought 3 as plenty but not so sure you'll get the temperature drop you are looking for? Any chance you can get a Thermocouple down in the crankcase oil? Before and after would have been nice but any data is better than no data!
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Fri, Oct 9, 2015 3:42 AM
Jack
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Reply to drujinin:
Let me know how that works out!
If you had said finned tubes, I would have thought 3 as plenty but not so sure you'll get the temperature drop you are looking for? Any chance you can get a Thermocouple down in the crankcase oil? Before and after would have been nice but any data is better than no data!
Here's a couple pics of the cooler. I made a mistake. I settled on four tubes, not three. They are about 16 in long and are soldered into all of the fins. The little tin doghouse behind it holds a refridgeration condenser fan, about 1/10 HP. There's a bunch of heat radiation area in this thing, but no upper or lower tanks. I'm now trying to make up my mind before I buy the other hose. Check out the ag hydraulic/NPT line adaptors of my own design. I couldn't find any of them either, had to make them.
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Fri, Oct 9, 2015 4:19 AM
old-iron-habit
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Reply to Jack:
Here's a couple pics of the cooler. I made a mistake. I settled on four tubes, not three. They are about 16 in long and are soldered into all of the fins. The little tin doghouse behind it holds a refridgeration condenser fan, about 1/10 HP. There's a bunch of heat radiation area in this thing, but no upper or lower tanks. I'm now trying to make up my mind before I buy the other hose. Check out the ag hydraulic/NPT line adaptors of my own design. I couldn't find any of them either, had to make them.
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It takes the same pressue to push all the tubes full from the bottom as it takes to push the oil to the top and let it run down. (learned this in concreting pumping 101 when we switched to pumping bridge and building columns from the bottom via a port.) My thought on pushing from the bottom fills the entire cooler insuring you are getting the max out of your cooler.
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Fri, Oct 9, 2015 5:32 AM
drujinin
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Reply to old-iron-habit:


It takes the same pressue to push all the tubes full from the bottom as it takes to push the oil to the top and let it run down. (learned this in concreting pumping 101 when we switched to pumping bridge and building columns from the bottom via a port.) My thought on pushing from the bottom fills the entire cooler insuring you are getting the max out of your cooler.
OH! If there are fins and 4 tubes, it ought to dissipate a lot of heat! Still like to see T/C measurements.
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Fri, Oct 9, 2015 6:56 AM
Jack
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Reply to drujinin:
OH! If there are fins and 4 tubes, it ought to dissipate a lot of heat! Still like to see T/C measurements.
I'll know a lot about temp drop after a day of running just by the red-hand test! Quickest way to get oil temp is to put a was of insulation on an oil pipe and stick Momma Bear's cooking thermometer under it, against the tube. Trouble is, I didn't bother to go past the red-hand test before I installed the cooler.

Old-iron-habit, I wasn't so concerned about pressure so much as trapped air in the top of the system. Maybe that's not a problem;maybe the top air bleeder on D2 is more for draining the cooler than for bleeding the air out???
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Fri, Oct 9, 2015 7:41 AM
edb
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Reply to Jack:
I'll know a lot about temp drop after a day of running just by the red-hand test! Quickest way to get oil temp is to put a was of insulation on an oil pipe and stick Momma Bear's cooking thermometer under it, against the tube. Trouble is, I didn't bother to go past the red-hand test before I installed the cooler.

Old-iron-habit, I wasn't so concerned about pressure so much as trapped air in the top of the system. Maybe that's not a problem;maybe the top air bleeder on D2 is more for draining the cooler than for bleeding the air out???
Hi Jack,
according to the U D4 & D6 OMI's the oil cooler (Vent Valve in Cat speak) bleed screw is indeed for more rapidly draining the oil from the cooler when changing the engine oil.
Your rig has come a long way since Day 1 on here. Especially after getting some true reading gauges on the sparking department output wires.
Keep at it.
Eddie B.
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Fri, Oct 9, 2015 9:28 AM
Jack
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Reply to edb:
Hi Jack,
according to the U D4 & D6 OMI's the oil cooler (Vent Valve in Cat speak) bleed screw is indeed for more rapidly draining the oil from the cooler when changing the engine oil.
Your rig has come a long way since Day 1 on here. Especially after getting some true reading gauges on the sparking department output wires.
Keep at it.
Eddie B.
So it looks like the oil system can push an air bubble through without any problem, I gather. Should be nothing to worry about. Thank you to all for your thoughts. Good to hear from you again, edb.

I'll have it running again in a few days, I suppose. We're getting uncommonly warm weather again this fall, no need to light it up just yet.

I still have to oil it and adjust the valves. I had to replace the lower rocker box gasket that was leaking. I also had to replace the oil seal between the injection pump and accessory drive. I pulled an injector, found no evidence of coking.

Things look pretty good.

Jack
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Sat, Oct 10, 2015 12:31 AM
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