Procedure to Check the CGI (Clean Gas Induction) Cooler for Internal Leaks{105P} Caterpillar

On-Highway Engine:

C13 (S/N: LEE1-UP)

C15 (S/N: SDP1-UP)

C9 (S/N: C9S1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Certain CGI (Clean Gas Induction) Coolers are leaking coolant internally. The only sign of a internal leak is a low coolant level. If your engine has had low coolant levels and your engine shows no signs of external leaks, then follow the procedure below.

Solution

A cooling system pressure test will indicate if your CGI Cooler has an internal leak.

Illustration 1	g01492713
(1) Air Port (2) Port for Water (3) Ports on the CGI Cooler

1. Drain the coolant from the CGI Cooler.

2. Remove the CGI Cooler from the application.

3. Thoroughly flush the air passages on the CGI Cooler with clean water.

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NOTICE
Be careful when flushing the air passges. Acids will likely be present.

4. Stand the CGI Cooler on end as shown in Illustration 1. Plug the bottom air port and the bottom water port (3). Make sure the plugs are sealed so the ports do not leak water.

5. Fill the CGI Cooler with clean water through the top air port (1) .

6. Install pressurized air to the top water port (2) .

7. Pressurize the CGI Cooler to 206 kPa (30 psi).

8. Look for bubbles at the unplugged air port (1) .

9. When possible take digital pictures of the CGI Cooler leaking. Send the photos to Evans_Joshua_J@cat.com.