Wanted to get a smoke test done but we started with a charge air cooler test. Power test charge air coolers replace the vehicular aftercooler for testing air to air aftercooled power test charge air coolers replace the vehicular aftercooler for testing air to air aftercooled engines in a test cell. Otc 5039 charged air cooler tester for class 7 and class 8 trucks, chrome. If electricallydriven coolant pumps are used in the system, an additional degree of freedom in combustion control is available. A charge air cooler cac, also referred to as an intercooler or aftercooler, is used on diesel engines to cool engine air thats passed through the compressor the turbocharger or supercharger before it enters the engine. A chargeair cooler cac is used to cool engine intake air after it passes through the compressor either turbocharger or supercharger prior to the engine intake manifold for increased power and improved fuel economy. Bar plate chargeair coolers modine manufacturing company. A leaking charge air cooler can reduce horsepower and lower fuel economy by more than a 12 mile per gallon. Leaks are not all that uncommon, they can easily be caused by a rock or tree branch or any other foreign object coming through the grill. T e c h n i c a l b u l l e t i n national highway traffic. Leaks are not all that uncommon, they can easily be caused by a rock or tree branch or.
Dec 09, 2011 you need to pressure check the charge air cooler, block one side, pressure it up to around 2530 psi, and see how much it leaks down. Otc 5039 charged air cooler tester for class 7 and class 8 trucks in air conditioning line repair tools. The duralite testerkit is designed and manufactured to be used to pressure test charge air coolers in a safe and efficient manner. You need to pressure check the charge air cooler, block one side, pressure it up to around 2530 psi, and see how much it leaks down.
You can also choose from gb charge air cooler pipe there are 146 suppliers who sells charge air cooler pipe on, mainly located in asia. P007b charge air cooler temperature sensor circuit range. Key wordsintercooler, charge air cooling,thermodynamic, thermal sign i. Charge air cooler power test dyno we make your testing. A highpressure smoke machine can greatly reduce diagnostic time and help eliminate comebacks, helping to quickly locate leaks in turboboost, charge air cooler, exhaust system, wind and water, cabin, intake system, seals, gasket, hoses, fittings and more. Detail design process of charge air cooler is illustrated. With the duralite testerkit, testing the cac will become as automatic as checking the oil and will give you. Just looking for tips on how to do it from anyone one who has been. Also check for proper alignment of the charge air cooler pipe bracket and bolt hole. If it doesnt leak, all you are out is the cost of the test.
A charge air cooler cac is used to cool engine intake air after it passes through the compressor either turbocharger or supercharger prior to the engine intake manifold for increased power and improved fuel economy. We build relationships with all of our customers and look forward to helping you with all of your charge air cooler, turbo intercooler, or aftercooler needs. Phoenix charge air coolers, construction intercooler, turbo. Includes a pair of safety clamps for operator protection during testing and an air regulator and shutoff valve. A newly designed charge air cooler is now available. This diagnostic trouble code dtc is a generic powertrain code, which means it applies to obdii equipped vehicles that have a charge air cooler temperature sensor chevy, ford, toyota, mitsubishi, audi, vw, etc.
Dropping the temperature of a given volume of gas will drop its pressure. We help you find the heavy duty truck parts that you need. Charge air cooler temperature sensor circuit rangeperformance bank 1. Pull over and my plastic pipe is blown up at the connection to the throttle body. Charge air cooler leak ford powerstroke diesel forum. The tester features a large 212, 060 psi pressure gauge, regulator and relief valve, and two safety cables. So when it flows into the intake side of the engine, the increased density improves horsepower, fuel economy and reduces emissions.
Air side pressure loss with indirect charge air cooling can be 40 to 80% lower than with direct charge air cooling due to. The compressed air going through the charge air cooler is then cooled by the ambient air flowing across the cooler fins. Internal water temperature is maintained through the use of a simple, reliable mechanical control valve. Phoenix charge air coolers, construction intercooler. Radiator works is among the most respected names of aftermarket heavy truck heat transfer in the trucking industry. Internal water temperature is maintained through the use of a.
Oct 08, 2017 test for leaks using the smoke test procedure in the charge air cooler diagnosis document service information document id. In most cases you can test the charge air cooler without removing it from the truck. Chargeair cooler price matching consultation free shipping. Charge air coolers are often referred to as an intercooler, aftercooler or turbo intercooler. At todays fuel prices, this can add up to a lot of money over 150,000 miles.
The purpose of the charge air cooler is to reduce the air inlet temperature thereby increasing air density thus giving an increase in engine efficiency. Detroit radiator corporation heavy duty truck radiators. Anybody know how to do the home charge air cooler test. It is the rating design where we have determined the thermal performance of charge air cooler. Charge air cooler power test dyno we make your testing easy. Aluminum bar plate heat exchangers provide a lowvolume, flexible platform to produce radiators, oil coolers, chargeair coolers or combocoolers in which multicircuit cooling needs are combined into one cooler, which are manufactured in either a vacuum or controlled atmosphere brazing process. If your charge air cooler is silver, it is most likely going to leak. An intercooler, or charge air cooler, is an air to air or air toliquid heat exchange device used on turbocharged and supercharged forced induction internal combustion engines to improve their volumetric efficiency by increasing intake air charge density through isochoric cooling. Half way home on a mile road trip i hear a bang and black smoke no acceleration and no turbo spool. To do a proper test on the charge air cooler or intercooler as its more commonly called. I had 3 screaming kids, a new puppy, and a mad wife. I am going to be replacing the water pump soon so while i had the radiator drained i thought i would look into cleaning the inside the charge air cooler. Heavy duty radiators, radiator cores, charge air coolers, ac condensers, coolant tubes, fan shrouds, air brake tanks, and all metal surge tanks are our specialty.
Charge air cooler fixture and leak detection equipment. These analytical results are then compared with test results. Test for leaks using the smoke test procedure in the charge air cooler diagnosis document service information document id. The leader in american manufacturing for heavy duty truck radiators and cooling components for offroad and industrial applications. The cac performance and pressure drop characteristics can be optimized to meet any specific application needs through.
Testing charge air coolers and other large heat exchangers can be both time consuming and risky if you dont have johnsons charge air cooler test set. Check out 34 hino charge air cooler parts for sale. For example, it would be possible to warm up the charge air at low ambient temperatures to reduce the white smoke emissions. If a leak is determined, replace the charge air cooler. Aluminum bar plate heat exchangers provide a lowvolume, flexible platform to produce radiators, oil coolers, charge air coolers or combocoolers in which multicircuit cooling needs are combined into one cooler, which are manufactured in either a vacuum or controlled atmosphere brazing process. The kit comes complete with everything required to pressure test most charge air coolers. The benefits of highpressure leak detectors vehicle. If these conditions are found, perform a smoke leak test of the charge air cooler. Charge air cooler cleaning question the diesel stop. I am loosing power on freightliner classic xl detroit. We are pleased to present our all new product application catalog for 20. This is by far the best way to test the charge air coolers on many different trucks, we use this weekly and have nothing but great things to say about it.
Charge air coolers for freightliner, volvo, peterbilt. Intake manifold temperature of 140 o f at 32 o f ambient will help considerably in white smoke control. The silver charge air coolers were bad around leaking around the seam. The secondary cooling system uses coolant flowing in a circuit separate from the primary engine cooling system. A secondary enginedriven coolant pump provides for coolant flow. Charge air cooler detroit diesel troubleshooting diagrams. Started losing boost at about a pound a min to about 27 pounds. A wide variety of charge air cooler pipe options are available to you, such as technique, standard. Indirect charge air coolers can be integrated directly into the intake manifold, figure 8. The compressed air going through the chargeair cooler is then cooled by the ambient air flowing across the cooler fins. The intercooler is a radiator that sheds some of this heat energy, cooling the intake charge. An intercooler, or chargeair cooler, is an airtoair or airtoliquid heat exchange device used on turbocharged and supercharged forced induction internal combustion engines to improve their volumetric efficiency by increasing intake aircharge density through isochoric cooling.
In cold temperatures, ambient and pcv moisture can freeze in the charge air cooler, which would restrict flow and cause dtcs p0299 andor p2227. The top countries of supplier is china, from which the percentage of charge air cooler pipe supply is 100% respectively. We stock thousands of new heavy truck complete radiators, charge air coolers, condenser, ac components, and radiator cores. Extraheavyduty test plugs with cast handles adaptable to fit six different sizes, with 212 up to 4 rubbers, a unique tester that features an air stem, 212 gauge. It also has quick disconnect air fittings that attach to a 3, 3. This diagnostic trouble code dtc is a generic powertrain code, which means it applies to obdii equipped vehicles that have a charge air cooler temperature sensor. Cooler air contains more oxygen per cubic inch, which boosts horsepower, and it reduces the odds of fuel preignition and uncontrolled detonation. When duralite started on this project, we knew that we had to engineer a charge air cooler that met the required oe engine performance specifications. Testing charge air coolers and other large heat exchangers can be both time consuming and risky if you dont have a johnson charge air cooler test set. Has anyone cleaned their charge air cooler and if so how did you do it.
Feb 12, 2018 a highpressure smoke machine can greatly reduce diagnostic time and help eliminate comebacks, helping to quickly locate leaks in turboboost, charge air cooler, exhaust system, wind and water, cabin, intake system, seals, gasket, hoses, fittings and more. Charge air coolers from day one, duralite has been committed to solving the charge air cooler durability problems vehicle owner operators face. Our direct replacement charge air coolers, from lkq company radiator works, replicate original oem construction and. Half way home on a mile road trip i hear a bang and black smoke no acceleration and no turbo.