PISTON 2603497 - Caterpillar

Inlet Manifold Pressure
Normal inlet manifold pressure with high exhaust temperature can be caused by blockage of the fins of the aftercooler core. Clean the fins of the aftercooler core. Refer to "Visual Inspection" for the cleaning procedure.Low inlet manifold pressure and high exhaust manifold temperature can be caused by any of the following conditions:Plugged air cleaner - Clean the air cleaner or replace the air cleaner, as required. Refer to the Operation and Maintenance Manual, "Engine Air Cleaner Element - Clean/Replace".Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.Aftercooler core leakage - Aftercooler core leakage should be pressure tested. Refer to "Aftercooler Core Leakage" topic for the testing procedure.Leakage of the induction system - Any leakage from the pressure side of the induction system should be repaired.Inlet manifold leak - An inlet manifold leak can be caused by the following conditions: loose fittings and plugs, missing fittings and plugs, damaged fittings and plugs and leaking inlet manifold gasket.Aftercooler Core Leakage
Illustration 1 g01429946
FT1984 Aftercooler Testing Group
(1) Regulator and valve assembly
(2) Nipple
(3) Relief valve
(4) Tee
(5) Coupler
(6) Aftercooler
(7) Dust plug
(8) Chain
(9) Dust plug A low-power problem in the engine can be the result of aftercooler leakage. Aftercooler system leakage can result in the following problems:
Low power
Low boost pressure
Black smoke
High exhaust temperature
Remove all air leaks from the system to prevent engine damage. In some operating conditions, the engine can pull a manifold vacuum for short periods of time. A leak in the aftercooler or air lines can let dirt and other foreign material into the engine and cause rapid wear and/or damage to engine parts.
A large leak of the aftercooler core can often be found by making a visual inspection. To check for smaller leaks, use the following procedure:
Disconnect the air pipes from the inlet and outlet side of the aftercooler core.
Dust plug chains must be installed to the aftercooler core or to the radiator brackets to prevent possible injury while you are testing. Do not stand in front of the dust plugs while you are testing.
Install couplers (5) on each side of the aftercooler core. Also, install dust plugs (7) and (8). These items are included with the FT1984 Aftercooler Testing Group. Note: Installation of additional hose clamps on the hump hoses is recommended in order to prevent the hoses from bulging while the aftercooler core is being pressurized.
Do not use more than 345 kPa (50 psi) of air pressure or damage to the aftercooler core can be the result.
Install the regulator and valve assembly (1) on the outlet side of the aftercooler core assembly. Also, attach the air supply.
Open the air valve and pressurize the aftercooler to 207 kPa (30 psi). Shut off the air supply.
Inspect all connection points for air leakage.
The aftercooler system's pressure should not drop more than 28 kPa (4 psi) in 15 seconds.
If the pressure drop is more than the specified amount, use a solution of soap and water to check all areas for