USING THE FT1984 AIR-TO-AIR AFTERCOOLER LEAK TEST GROUP{1063} Caterpillar

Introduction

The FT1984 Test Group can be used to leak test air-to-air aftercoolers on 3306B and 3406B Truck Engines. This group can be used with aftercoolers that have hoses with an inside diameter of 102 mm (4.0"), or 114 mm (4.5").

Dealers in the NACD, COSA and Caterpillar Americas can order drawings of Fabricated Tools (FT) from the address that follows. All other dealers can order drawings from their Subsidiary Service Department. When ordering be sure to include your dealer code along with the address so that your request will receive immediate attention.

Reference: Service Manual.

1. Coupler (two required)

2. Dust Plug (two required)

3. 8L6005 Tee (not as shown)

4. Relief Valve

5. 8T5225 Hose Assembly

6. 8T5193 Regulator

7. 8T5224 Gauge

8. 5S2403 Fitting

9. 1S8937 Valve

10. 3O8370 Adapter

11. Test Plug Assembly (made from item 2)

12. Retaining Chain (not shown) [two required - 200 mm (8") each]

NOTE: A reduced FT1984 Test Group drawing is included in this instruction and lists the source of parts needed that are not available through Caterpillar Inc.

Leak Testing Air-to-Air Aftercoolers

1. Disconnect the turbocharger compressor outlet at the aftercooler inlet. DO NOT remove the hump hose from the aftercooler.

2. Install coupler (1) into hump hose (2). Install and tighten clamps (3). Be sure that clamp (4) is also tight.

3. Install dust plug (5) into coupler (1) and LOCK into place with cam handles (6). Connect retaining chain (7) to radiator bracket (8).

Show/hide table

The dust plug retaining chains must be installed to the aftercooler core or radiator brackets to prevent possible injury while testing. Do not stand in front of the dust plugs while testing.

4. Disconnect the air inlet manifold at the aftercooler outlet. DO NOT remove the hump hose from the aftercooler.

5. Install coupler (9) into hump hose (10); install and tighten two clamps (11). Be sure that clamp (12) is also tight.

6. Install test plug assembly (13) into coupler (9), and LOCK into place with cam handles (14). Connect retaining chain (15) on radiator bracket (16).

Show/hide table

The dust plug retaining chains must be installed to the aftercooler core or radiator brackets to prevent possible injury while testing. Do not stand in front of the dust plugs while testing.

7. Install 8T5193 Regulator (17) and 8T5225 Hose Assembly (18) as shown in the photo. Install relief valve (19).

8. Connect air supply (20). CHECK ALL connections at this time. If possible TWO clamps should be used at all hose connections. Additional clamps should also be used over the hump area of each hose to prevent hoses from bulging.

Show/hide table

The dust plug retaining chains must be installed to the aftercooler core or radiator brackets to prevent possible injury while testing. Do not stand in front of the dust plugs while testing.

9. Open 1S8937 Valve (21) slightly, to increase air pressure SLOWLY, until 8T5224 Gauge (22) reads 205 kPa (30 psi). Close 1S8937 Valve (21). The system pressure should not drop (decrease) more than 35 kPa (5 psi) in 15 seconds. If the pressure decrease exceeds specifications, inspect for leaks in the hoses and/or aftercooler.

10. After testing, RELIEVE air pressure SLOWLY before removing the test group. Reconnect all air hoses and tighten all hose clamps.

FT1984 Drawing