Charge Air Cooler Tester
The Dura-Lite™ charge air cooler Tester-Kit™ is the fastest and most reliable on the market.
Find out if you have a leak in 20 minutes or less
With Dura-Lite’s charge air cooler Tester-Kit, testing your charge air cooler is as easy as checking your oil. The kit comes complete with everything you need to make pressure testing your charge air cooler safe and easy.
Your engine isn’t performing at its best.
We’ll Prove It.
These are the signs that your charge air cooler may be leaking and costing you $100K per year on fuel with a fleet of 25 vehicles!
Loss of engine power
Increased fuel consumption
Elevated soot levels in your oil
Premature piston, ring, and valve failure
Turbocharger or exhaust manifold failure
Elevated coolant temperatures
What’s included in our Tester-Kit?
- The Tester-Kit comes complete with everything required to test the majority of charge air coolers.
- The Tester-Kit components are made with high-quality materials and coatings to help resist corrosion and extend the longevity of the kit.
- 1 Year Warranty.
- Dura-Lite also offers replacement parts for its testing kit along with non-standard Rubber Test Plug sizes for special applications.
Tester-Kit Contents:
| Description | Item # | Quantity |
|---|---|---|
| Tightening Handle | DTK003 | 2 |
| Flange Nut | DTK039 | 2 |
| Plug Stem Solid | DTK002 | 1 |
| Plug Stem With Male Connector | DTK037 | 1 |
| Plastic Washer (Test Plug Assembly) | DTK005 | 4 |
| 2” [50.8mm] Washer (Round Center Hole) | DTK006 | 2 |
| 2” [50.8mm] Washer (Oval Center Slot) | DTK041 | 2 |
| 3” [76.2mm] Washer (Round Center Hole) | DTK007 | 2 |
| 3” [76.2mm] Washer (Oval Center Slot) | DTK040 | 2 |
| Clamp Assembly | DTK020 | 2 |
| Gauge Assembly | DTK026 | 1 |
| Lubricant Bottle | DTK029 | 1 |
| Rubber Test Plug 2.500” [63.5mm] | DTK008 | 2 |
| Rubber Test Plug 2.750” [69.9mm] | DTK009 | 2 |
| Rubber Test Plug 3.000” [76.2mm] | DTK010 | 2 |
| Rubber Test Plug 3.250” [82.6mm] | DTK011 | 2 |
| Rubber Test Plug 3.500” [88.9mm] | DTK012 | 2 |
| Rubber Test Plug 3.750” [95.3mm] | DTK013 | 2 |
Tester-Kit Accessories:
| Description | Item # |
|---|---|
| Rubber Test Plug 2.250” [57.2mm] | DTK044 |
| Rubber Test Plug 4.000” [101.6mm] | DTK045 |
| Rubber Test Plug 4.250” [108.0mm] | DTK046 |
| Rubber Test Plug 4.500” [114.3mm] | DTK047 |
| Rubber Test Plug 4.750” [120.7mm] | DTK048 |
| Plug Stem (Oval Center Slot) | DTK001 |
| Plug Stem With 2” [50.8mm] Washer (Oval Center Slot) | DTK051 |
| Plug Stem With 3” [76.2mm] Washer (Oval Center Slot) | DTK052 |
| Plug Stem Solid With 2” [50.8mm] Washer (Oval Center Slot) | DTK053 |
| Plug Stem Solid With 3” [76.2mm] Washer (Oval Center Slot) | DTK054 |
| Pressure Gauge (For Use With Pressure Regulator Item # DTK049) | DTK021 |
| Pressure Regulator | DTK049 |
| Valve Stem With Plastic Cap | DTK024 |
| Male Connector (For Use With Quick Coupler Item # DTK023) | DTK004 |
| Quick Coupler (For Use With Male Connector Item # DTK004) | DTK023 |
| Pressure Relief Valve (For Use With Pressure Regulator Item # DTK049) | DTK025 |
| Plastic Washer (Clamp Assembly) | DTK061 |
How it Works
Step 1
Remove turbo hoses and clamps.
Step 2
Install Tester-Kit plugs and clamps. Mount gauge and double check system.
Step 3
Apply 30 psig of air. Remove air supply and check gauge. See chart (below) for Leak Down Rate Specifications. If leakage occurs beyond these specifications, it is strongly recommended that you replace your existing cooler with a Dura-Lite Evolution® Charge Air Cooler.
Step 4
Release air. Test is now complete.
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) | |
Learn how to use Dura-Lite’s Charge Air Cooler Tester-Kit
Stop wasting time and losing money
Get the Dura-Lite difference
If your charge air cooler is leaking, it’s time to replace it with the world’s best. Being an industry leader for more than 29-years fuels our passion for creating superior products and allows us to proudly stand behind Evolution® charge air coolers with a 7-year, million-mile guarantee.
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