Series 55 – Section 6.5 Charge Air Cooler

Section 6.5
Charge Air Cooler

A CAC is normally mounted ahead of 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" .‪

1.Turbocharger‪	5.Charge Air Cooler Outlet Duct‪
2.Flexible Coupling‪	6.Charge Air Cooler‪
3.Coupling Hose Clamp‪	7.Radiator‪
4.Charge Air Cooler Inlet Duct‪	‪

Figure 1. Typical Charge Air Cooler

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

Cooling is accomplished by incoming air flowing past the tubes and fins of the charge air cooler. 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.Fins and Tubes Cross-sectional View‪

‪

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.Turbocharger‪	5.Charge Air Cooler Outlet Duct‪
2.Flexible Coupling‪	6.Charge Air Cooler‪
3.Coupling Hose Clamp‪	7.Radiator‪
4.Charge Air Cooler Inlet Duct‪	‪

Figure 3. Charge Air Cooler and Related Parts

Section 6.5.1
Repair or Replacement of Charge Air Cooler

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

Section 6.5.2
Cleaning and Removal of Charge Air Cooler

Refer to the OEM guidelines for CAC service procedures.‪

Section 6.5.3
Installation of Charge Air Cooler

Refer to the OEM guidelines for CAC installation procedures. ‪

When installation is completed, refer to "11.6.2.2 Run-in Procedure" for engine test.‪