B5.9G, B5.9LPG, B Gas Plus, B LPG Plus – 010-027   Charge-Air Cooler

General Information

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The long-term integrity of a charge-air cooler system is the responsibility of the vehicle and component manufacturers; however, the following can be checked by any Cummins® Authorized Repair Location.

NOTE: If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air cooler, the charge-air cooler must be cleaned.

 
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Initial Check

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Inspect the charge-air cooler for cracks, holes, and damage.

Inspect the tubes, fins, and welds for tears, breaks, and other damage. If any damage causes the charge-air cooler to fail the air leak check, the charge-air cooler must be replaced.

Inspect the charge-air cooler plumbing for cracks and damage.

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Remove

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 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 plumbing.

Remove the charge-air cooler. Refer to the OEM service manual.

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Clean and Inspect for Reuse

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NOTE: If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air cooler, the charge-air cooler must be cleaned.

Remove the charge-air cooler from the vehicle. Refer to the OEM service manual.

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 WARNING 

When using solvents, acid, or alkaline material for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.
 CAUTION 

If internal debris cannot be removed, replace the charge-air cooler.
 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.

NOTE: Make sure the tubes are oriented vertically.

If the debris can not be totally removed from the charge-air cooler, the charge-air cooler must be replaced.

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 WARNING 

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause bodily injury.
 CAUTION 

The charge-air cooler must be rinsed, dried, and free 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 into the charge-air cooler in the opposite direction of normal air flow until the charge-air cooler is dry internally.

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Inspect the charge-air cooler for cracks, holes, or damage.

Inspect the tubes, fins, and welds for tears, breaks, or other damage.

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Install

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Install the charge-air cooler and plumbing.

Refer to the OEM service manual for instructions.

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Pressure Test

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Install pressure gauge, Part Number ST-1273, to the fitting in the turbocharger outlet.

Install another pressure gauge, Part Number. ST-1273, in the intake manifold.

Operate the engine at rated rpm and load. Record the readings on the two gauges.

If the pressure differential is greater than 21 kPa [3 psi], inspect the charge-air cooler for plugging.

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Leak Test

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 WARNING 

To reduce the possibility of personal 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 charger air cooler does not need to be removed from the chassis.

Install a plug or cup over the outlet side of the cooler. Install a pressure gauge and a regulated shop air supply line with a shutoff valve to the inlet side of the cooler.

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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 pressure every 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 components again.

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Determine if the pressure drop is caused by a leaky charge-air cooler or a leaky connection. Spray soapy water on all hose connections, and watch for bubbles to appear at the location of the leak.

If the pressure drop is 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.

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If the pressure drop is greater than 48 kPa [7 psi] or less in 15 seconds, the charge-air cooler must be replaced.

Refer to the equipment 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.

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Temperature Differential Test

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Install a temperature gauge in the intake manifold.

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 or supplying shop air to the fan. Refer to the fan drive manufacturer for lockup procedure.

NOTE: Some OEM’s have installed a manual switch that will lock the fan on.

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Operate the engine at rated rpm and load. Record the intake manifold temperature.

Measure the ambient temperature at least 2 feet in front of the vehicle.

The maximum temperature differential must not be greater than 25°C OR 45°F.

If the temperature differential is greater than 25°C OR 45°F, check the charge-air cooler for dirt and debris on the fins, and clean as necessary. If the problem still exists, check the cooler for internal contamination or plugging.

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Last Modified:  25-Jan-2010