Series 50 – Section 6.7 Charge Air Cooler

Section 6.7
Charge Air Cooler

A CAC is normally mounted ahead of or beside the cooling system radiator. The compressed air leaving the turbocharger is directed through the charge air cooler before it goes to the air inlet side of the intake manifold, see Figure "Typical Charge Air Cooler" .‪

In Series 50 gas engines operating with the low pressure fuel system, fuel is introduced ahead of the turbocharger. The following components are filled with combustible air-fuel mixture: turbocharger charge cooler inlet duct, charge cooler, charge cooler outlet duct, throttle and the intake manifold.‪

Figure 1. Typical Charge Air Cooler

The CAC is used to reduce the temperature of the compressed air or air-fuel mixture leaving the turbocharger before it reaches the intake manifold. This permits a more dense charge to be delivered to the engine.‪

Cooling is accomplished by incoming air flowing past the tubes and fins of the intercooler. The compressed intake charge flowing inside the CAC core transfers the heat to the tubes and fins where it is picked up by the incoming outside air. See Figure "Charge Air Cooler Cross Section " . ‪

1. Cross Section Charge Air Cooler‪

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Figure 2. Charge Air Cooler Cross Section

Metal ductwork is used to transfer the air from the turbocharger outlet to the CAC, and from there to the intake manifold. See Figure "Charge Air Cooler and Related Parts" .‪

Flexible rubber couplings and hose clamps are used to secure the ductwork to the turbocharger, the CAC inlet and outlet, and the intake manifold.‪

1. Flexible Coupling‪	4. Charged Air Cooler (CAC)‪
2. CAC Outlet Duct‪	5. Turbocharger‪
3. CAC Inlet Duct‪	‪

Figure 3. Charge Air Cooler and Related Parts

Section 6.7.1
Repair or Replacement of Charge Air Cooler

Refer to the OEM guidelines to for CAC repair and replacement procedures.‪

Section 6.7.2
Cleaning and Removal of Charge Air Cooler

Refer to the OEM guidelines for CAC service procedures.‪

Section 6.7.2.1
Inspection of Charged Air Cooler

After a turbocharger failure, inspect charged air cooler as follows:‪

PERSONAL INJURY ‪
To avoid injury when working near or on an operating engine, remove loose items of clothing and jewelry. Tie back or contain long hair that could be caught in any moving part causing injury.‪

NOTICE:
To avoid charged air cooler damage while cleaning or inspecting, observe all NOTICES, CAUTIONS, WARNINGS, etc. provided by the OEM  cooler manufacturer.‪

1. Remove all the piping to and from the charged air cooler and the air intake manifold.

   NOTICE:
   If the charged air cooler is contaminated with metal particles resulting from a damaged turbocharger, it must be replaced with a new charged air cooler. Any debris left in the charged air cooler, especially metal particles, can cause severe engine damage.‪

2. Inspect all parts carefully for metal and oil contamination.

   If the charged air cooler is contaminated with engine oil, contact the vehicle OEM and obtain the charged air cooler manufacturer's recommendations on cleaning and inspection.‪

3. Remove and inspect the air intake manifold for any accumulation of oil. Remove the oil from the manifold and from the area above the valves before replacing the charged air cooler system.

   NOTICE:
   Failure to remove residual lubricating oil from charge air cooler may allow the oil to act as an external fuel source at engine startup. This can cause a sudden engine overspeed condition, which may result in severe engine damage.‪

Section 6.7.3
Installation of Charge Air Cooler

Refer to the OEM guidelines for CAC installation procedures.‪