1/26/24, 9:23 PM Gmail - (no subject)
(no subject)
benjir shuvo <[email protected]> 26 January 2024 at 21:23
Draft
Aftercooler - Test (M0080693) exapand full screen
2004/12/23
SMCS - 1063 i02271000
Visual Inspection
Inspect the following parts at each oil change:
Air lines
Hoses
Gasket joints
Pressurized air can cause personal injury. When pressurized air is used for
cleaning, wear a protective face shield, protective clothing, and protective
shoes.
Ensure that the constant torque hose clamps are tightened to the correct torque.
Refer to Torque Specifications, , "Standard Torque for Constant Torque Hose
Clamps" for the correct torque. Check the welded joints for cracks. Ensure that
the brackets are tightened in the correct positions. Ensure that the brackets are in
good condition. Use compressed air to clean any debris or any dust from the
aftercooler core assembly. Inspect the fins of the aftercooler for the following
conditions:
Damage
Debris
Corrosion
Use a stainless steel brush to remove any corrosion.
Note: When parts of the aftercooler system are repaired or replaced, a leak test is
recommended.
Inlet Manifold Pressure
https://mail.google.com/mail/u/0/?ik=9abc2ff0eb&view=pt&search=drafts&permmsgid=msg-a:r8877543320267582457&dsqt=1&simpl=%23msg-a:r88… 1/3
1/26/24, 9:23 PM Gmail - (no subject)
Normal inlet manifold pressure with high exhaust temperature can be caused by
blockage of the aftercooler core. Clean the aftercooler core.
Low inlet manifold pressure and high exhaust manifold temperature can be
caused by any of the following conditions:
Plugged air cleaner - Clean the air cleaner or replace the air cleaner, as
required. Refer to the Operation and Maintenance Manual, "Engine Air Cleaner
Element (Dual Element) - Clean/Replace".
Blockage in the air lines - Blockage in the air lines between the air cleaner and
the turbocharger must be removed.
Aftercooler core leakage - Aftercooler core leakage should be pressure tested.
Refer to "Aftercooler Core Leakage" under this topic for the testing procedure.
Inlet manifold leak - An inlet manifold leak can be caused by the following
conditions: loose fittings and plugs, missing fittings and plugs, damaged fittings
and plugs and leaking inlet manifold gasket.
Aftercooler Core Leakage
A low power problem in the engine can be the result of aftercooler leakage.
Aftercooler system leakage can result in the following problems:
Low power
Low boost pressure
Black smoke
High exhaust temperature
A large leak of the aftercooler core can often be found by making a visual
inspection. To check for smaller leaks, use the following procedures:
Leak Test for the Sea Water Cooling System
Test for Water Leaks
1. Remove the aftercooler core from the engine. Refer to Disassembly and
Assembly, "Aftercooler and Aftercooler Core".
2. Thoroughly clean the aftercooler core.
3. Plug the fittings of the aftercooler core.
4. Pressurize the aftercooler core to 240 kPa (35 psi).
5. Spray the aftercooler core with a mixture of water and a soap solution. Look
for air bubbles that form on the aftercooler core.
Test for Air Leaks
https://mail.google.com/mail/u/0/?ik=9abc2ff0eb&view=pt&search=drafts&permmsgid=msg-a:r8877543320267582457&dsqt=1&simpl=%23msg-a:r88… 2/3
1/26/24, 9:23 PM Gmail - (no subject)
The bottom opening of the aftercooler must be closed in order to perform the
following pressure test. A cover may need to be fabricated in order to plug the
opening.
1. Remove the aftercooler from the engine. Refer to Disassembly and
Assembly, "Aftercooler and Aftercooler Core".
2. Assemble the aftercooler on the bench. Refer to Disassembly and
Assembly, "Aftercooler and Aftercooler Core".
3. Plug the openings of the aftercooler and pressurize the aftercooler to 205
kPa (30 psi).
4. Spray the aftercooler core with a mixture of water and a soap solution. Look
for air bubbles that form on the aftercooler core.
Turbocharger Failure
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using
pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for
cleaning purposes.
If a turbocharger failure occurs, remove the aftercooler core. Internally flush the
aftercooler core with a solvent that removes oil and other foreign substances.
Wash the aftercooler with hot, soapy water. Thoroughly rinse the aftercooler with
clean water and blow dry the aftercooler with compressed air. Blow dry the
assembly in the reverse direction of normal air flow. To make sure that the whole
system is clean, carefully inspect the system.
© 2024 Caterpillar Inc.
https://mail.google.com/mail/u/0/?ik=9abc2ff0eb&view=pt&search=drafts&permmsgid=msg-a:r8877543320267582457&dsqt=1&simpl=%23msg-a:r88… 3/3
