010-027 Charge-Air Cooler (CAC) : Preparatory Steps

Charge-Air Cooler (CAC) Page 1 of 11
010-027 Charge-Air Cooler (CAC)
Preparatory Steps
WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.
Use compressed air to clean

debris from the outside of the
charge air cooler.
Remove the charge air cooler

piping. Refer to Procedure
Procedure 010-019, (Air
Crossover).
Initial Check
Inspect the charge air cooler

for cracks, holes, and
damage.
Inspect the tubes, fins, and

welds for tears, breaks, or
other damage.
If any damage causes the

charge air cooler to fail the
mk:@MSITStore:C:\Users\jorispc\Downloads\Quick%20Serve%20DVD\MR_D.CHM::/e... 15-Mar-19
air leak check, the charge air

cooler must be replaced.

plumbing for cracks and
damage.
Remove
Remove the charge air

cooler. Refer to the OEM
service manual.
Clean
NOTE: If the engine

experiences a turbocharger
failure or any other occasion
where oil or debris is put into
the charge air cooler, the
charge air cooler must be
cleaned.
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.
CAUTION
Do not use caustic cleaners

to clean the charge air
cooler. Damage to the
charge air cooler will result.
Flush the charge air cooler

internally with solvent in the
opposite direction of normal
airflow. Shake the charge air
cooler and lightly tap on the
end tanks with a rubber mallet
to dislodge trapped debris.
Continue flushing until all
debris or oil is removed (i.e.,
the water runs clear).
NOTE: Make sure that the

tubes are in the vertical
direction when flushing.
If the debris can not be totally

removed from the charge air
cooler, the charge air cooler
must be replaced.
WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.
CAUTION
The charge air cooler must

be rinsed, dried, and
cleaned of solvent, oil, and
debris, or engine damage
will result.
After the charge air cooler has

been thoroughly cleaned of all
oil and debris with solvent,
wash the charge air cooler
internally with hot, soapy water
to remove the remaining
solvent. Rinse thoroughly with
clean water.
Blow compressed air through

the inside of the charge air
cooler in the opposite direction
of normal airflow until the
charge air cooler is dry
internally.
Pressure Test
Obtain two pressure gauges,

Part Number 3823205.
Check both gauges on the
same pressure source at
206 kPa [30 psi] to verify
consistency.
Install one pressure gauge in

the 1/8-inch fitting in the
turbocharger compressor
outlet elbow. Install the other
pressure gauge in the intake
manifold.
Another alternative to
measure the intake manifold
pressure would be to use the
monitor mode on the
INSITE™ service tool.
Operate the engine at rated

rpm and load. Record the
readings on the two gauges.
If the differential pressure is

greater than 20.6 kPa [3 psi],
check the charge air cooler
and associated piping for
plugging, restrictions, or
damage.
Clean or replace, if
necessary.
Leak Test
WARNING
To reduce the possibility of
injury if either plug blows off
during the test, secure safety
chains on the test plugs to

any convenient capscrew on
the radiator assembly. This
test must not be performed
without securely fastened
safety chains.
To check the charge air cooler

for cracked tubes or header,
remove the inlet and outlet
hoses from the cooler. The
charge air cooler does not
have to be removed from the
chassis.
To perform the leak test, use

tool 3824556. Install the cap
over the outlet side of the
cooler. Install the gauge end
of the tool with a regulated
shop air supply line and a
shutoff valve to the inlet side
of the cooler.
Apply air pressure to the

cooler until the pressure
gauge reads a steady 207
kPa [30 psi] of air pressure.
Shut off the airflow to the

cooler and start a stopwatch
at the same time. Record the
leakage at 15 seconds.
If the pressure drop is 48

kPa [7 psi] or less in 15
seconds, the cooler is
operational.
If the pressure drop is

greater than 48 kPa [7 psi] in
15 seconds, check all

connections again.
Determine if the pressure

drop is caused by a leak in
the charge air cooler or from
a leaky connection. Use a
spray bottle filled with soapy
water applied to all hose
connections, and watch for
bubbles to appear at the
location of the leak.

caused by a leaky
connection, repair the
connection and repeat the
test. If the leak is within the
charge air cooler, repeat the
test to verify the accuracy of
the pressure drop
measurement. Similar
pressure drop readings must
be obtained in at least three
consecutive tests before the
reading can be considered
accurate.
NOTE: If a charge air

cooler leaks more than 48
kPa [7 psi] in 15 seconds,
it will appear as a major
leak in a leak tank.

greater than 48 kPa [7 psi] in
15 seconds, the charge air
cooler must be replaced.
Refer to the OEM service

manual for replacement
instructions.
NOTE: Charge air coolers

are not designed to be
100-percent leak free. If the
pressure drop is less than
48 kPa [7 psi] in 15
seconds, then the charge
air cooler does not need to
be replaced.
Install
Install the charge air cooler.
Refer to the OEM service

manual for instructions.
Finishing Steps
Install the charge air cooler

piping. Refer to Procedure
Procedure 010-019 (Air
Crossover)
Operate the engine and

check for leaks.
Temperature Differential Test

fins for obstructions to
airflow. Remove obstructions
such as a winterfront or
debris. Manually lock
shutters in the open position,
if equipped.
Lock the fan drive in the ON

mode to prevent erratic test
results. This can be done by
installing a jumper wire
across the temperature
switch.
Install the thermocouple

bead probe Part Number
3154498.
Connect the digital

multimeter, Part Number
3164488, and the
temperature adaptor, Part
Number 3164499 to the
thermocouple bead probe to
read intake air temperature.
Another alternative would be

to use the monitor mode on
the INSITE™ service tool.
Install another thermocouple

at the air cleaner inlet to
measure ambient air
temperature.
Perform a road test with the

engine at peak power and a
vehicle speed of 48 km/h [30
mph] or greater.
Record the intake manifold

temperature and the ambient
air temperature.
Calculate the differential

temperature:
Intake manifold temperature

- ambient air temperature =
differential temperature.
l Differential
temperature, delta T =
21°C [38°F].
If the temperature differential

is greater than the
specifications, check the
charge air cooler for dirt and
debris on the fins and clean
as necessary. If the problem
still exists, check the charge
air cooler for debris in the
fins or between the charge
air cooler and radiator.
Confirm full-fan engagement.
Last Modified: 07-Mar-2013
Copyright © 2000-2010 Cummins Inc. All rights reserved.

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Charge-Air Cooler (CAC) Page 1 of 11

010-027 Charge-Air Cooler (CAC)

Use compressed air to clean

Remove the charge air cooler

Inspect the charge air cooler

Inspect the tubes, fins, and

If any damage causes the

air leak check, the charge air

Inspect the charge air cooler

Remove the charge air

NOTE: If the engine

Do not use caustic cleaners

Flush the charge air cooler

NOTE: Make sure that the

If the debris can not be totally

The charge air cooler must

After the charge air cooler has

Blow compressed air through

Obtain two pressure gauges,

Install one pressure gauge in

Operate the engine at rated

If the differential pressure is

chains on the test plugs to

To check the charge air cooler

To perform the leak test, use

Apply air pressure to the

Shut off the airflow to the

If the pressure drop is 48

If the pressure drop is

15 seconds, check all

Determine if the pressure

If the pressure drop is

NOTE: If a charge air

If the pressure drop is

Refer to the OEM service

NOTE: Charge air coolers

Install the charge air cooler.

Refer to the OEM service

Install the charge air cooler

Operate the engine and

Temperature Differential Test

Inspect the charge air cooler

Lock the fan drive in the ON

Install the thermocouple

Connect the digital

Another alternative would be

Install another thermocouple

Perform a road test with the

Record the intake manifold

Calculate the differential

Intake manifold temperature

If the temperature differential

Last Modified: 07-Mar-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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