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Is there a testing guideline to follow to determine if a Charge Air Cooler is leaking out of specification?

Yes. The rule of thumb is to pressure the Charge Air Cooler up to 30 psig and that it should hold air for at least 15 seconds. If there is a pressure loss of 5 psig or more within the 15 seconds, the Charge Air Cooler is leaking out of specification (Leak Down Rate Specification) and it should be replaced immediately. This is only a guideline and it is very important to check the engine manufacturers Leak Down Rate Specification (some common specifications are noted below). Please also reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website for additional information on the basic procedure.

Leak Down Rate Specifications:

Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB, ISC, N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11)  5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Volvo 5 psig in 15 seconds @ 30 psig

            

               

           

                

   

 

* psig (pound-force per square inch gauge)