TM 5-3810-307-24-2-2
3824556 Test Kit
Install a cap over the outlet side of the CAC. Install a
pressure gauge, air supply, and air pressure regulator
to the inlet side of the cooler.
WARNING
To prevent possible 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 be
performed with securely fastened safety
chains.
Apply 207 kPa [30 psi] of air pressure to the cooler.
Close the air pressure regulator.
Monitor the pressure gauge and determine the rate of
pressure decay with a stop watch.
If the pressure decay is 49 kPa [7 psi] or less in 15
seconds, the cooler is okay. If the pressure drop is
greater than 49 kPa [7 psi] in 15 seconds, check all
connections again.
Determine if pressure decay is caused by a leak in the
CAC or from a leaky connection. Use a spray bottle filled
with soapy water applied to all hose connections, and
watch for bubbles to appear at the location of the leak.
If the pressure decay is caused by a leaky connection,
repair the connection and repeat the test. If the leak is
within the CAC, repeat the test to verify the accuracy
of the pressure decay measurement. Similar pressure
decay readings must be obtained at least three
consecutive tests before the reading can be
considered accurate.
If the pressure drop is greater than 49 kPa [7 psi] in 15
seconds, the CAC must be replaced.
Refer to the manufacturer's repair manual for
replacement instructions.
NOTE
Charge air coolers are not designed to be
100% leak free. If the pressure decay is less
than 49 kPa [7 psi] in 15 seconds, then the
CAC does not need to be replaced.
10-10
