From: Goshorn Kenneth [kenneth.goshorn@volvo.com] Sent: Friday, September 24, 2004 6:30 AM To: Jeff Clark Cc: Shank Greg Subject: FW: T-12 Engine Rebuild Kit Jeff: This is a copy of a letter, including the attachments, sent earlier this week to specifically Jim Moritz, Jim Matasic, and Bob Campbell. As you might have surmised from yesterday's conversation during the teleconference, Scott Richards (Andy) and Riccardo Conti had similar information previously, but in a more piece-meal fashion, as we worked to put together a couple of runnable T-12s in order to find out if the concept would even work. I had also sent a copy to Ron Buck as a heads up. I've done a little bit of wordsmithing by the addition of a note about the current to the EGR valve, and a couple other minor things. It says nothing yet about the blocks or oil pumps. Clean it up however you see fit, to include in the minutes of yesterday's tele. > KDG > > > <<240gb5240.tif>> > > <> > > <> > By the end of Sept. you should receive from us at no charge a complete kit, consisting of the following list of parts, to convert one T-11 engine into a T-12. I say T-11 because the T-12 will use the same low swirl heads, power cyl. parts, and main and rod bearings as the T-11, plus the ECU, but a T-10 can also be converted linto a T-12 with the addition of the T-11 heads, cyl. kit, bearings, etc. > > 631GC5176 M7 1 - turbo > 681GC538 1 - turbo drain tube > 670GC450 1 - turbo oil supply tube > 590GB48 2 - turbo gaskets > 616GC279M 4 - turbo mounting studs > 189AM2 4 - turbo mtg. stud nuts > > 104GC5194M 1 - exhaust manifold center section > 104GC5164M 2 - exhaust manifold end sections > 573GB260 6 - exhaust manifold gaskets > > 28GB519 2 - EGR coolers > 670GC579 2 - EGR hot tube > 260GB215 4 - clamps > 449GC236M 4 - gaskets > 744GB360 2 - stepped hoses > 180GB330M58 2 - clamps > 180GB330M47 6 - clamps > 744GB261 2 - hoses > 491GC412 1 - heat shield > > 691GC514C 1 - EGR valve > 573GB323 2 - EGR valve gaskets > 616GC228M3 4 - EGR mtg. studs > 142GC247M 4 - EGR mtg. stud nuts > 744GB357 1 - EGR valve oil drain hose ass'y. > 744GB356 1 - EGR valve oil supply hose ass'y. > no p/n handfull of connectors and pins to connect to the EGR valve - Gary Golden has these. > > 736GB419M3 6 - injection nozzles > 203GC4380AM 6 - injection lines > > The primary changes from a T-11 to a T-12 are the inclusion of the two prod. style EGR coolers plumbed in parallel, a prod. style EGR valve and exhaust manifold, and a variable geometry second stage turbo to facilitate considerably higher EGR flow during both phases of the test than the T-10 had. There will be some cutting and welding of piping required. The attached schematic, labelled T10_VGT.xls, gives an idea of the layout. Soon, we hope to have a set of photos to distribute which will illustrate how we believe all of this hardware can be modified and mounted. There will be at least one special adapter required to mate the VGT to the elbow between the turbos. See attached a copy of the sketch for it, labelled T12vgtFLG.xls. You can either make your own, or we'll look into having some available from TEI. The VGT requires a stand alone precision air pressure regulator, capable of supplying up to 96 PSI to fully close the vanes (the 0-80 PSI shown on the schematic is in error). The normal position of the EGR valve is closed so it will require a maximum of 1.6 amps, 12 volts to fully open it. It should see no more than the maximum 1.6 amps, or the coil can be damaged. We're also recommending the use of a larger Modine intercooler, P/N 1A16656D. I'm working with our Service Parts group now to make sure those are available, perhaps through TEI . Because of its larger size, this intercooler> will require new end covers. You can make your own per the attached 240GB5240.tif (mislabelled:should have been 200GC5240) drawing, or perhaps we can make those available from TEI as well. > > Very soon information will be coming out defining the specific test conditions for running the T-12 test. > > > > > > >