User Manual

200 ENGINE INSTALLATION & TESTING
Page 8-9
205218
INSPECTION
1. Carefully inspect entire system to determine
exact location and extent of damage.
2. Inspect cold fins and cold bars that run
horizontally in cooler.
3. Inspect all brazed or welded joints in header
tank.
4. Make sure area to be repaired is free of
surface oxide and foreign materials such as
oil, grease, dirt, etc. Prior to repair, prepare
surface with a clean stainless-steel brush.
TUNGSTEN-INERT (TIG) WELD METHOD
TIG-weld using 1/16–5/32 inch diameter
AWS ER 4043 filler rod. Welds should exhibit
complete fusion without excessive overlap or
undercut.
MACK recommends pressure-testing the
CMCAC system after repairs are complete.
CMCAC Preventive Maintenance
In case of engine and/or turbocharger failure,
perform the following steps to make sure CMCAC
system is free from debris:
1. Remove chassis-mounted cooler and flush
inside with a safety solvent to remove oil and
other foreign debris.
2. Shake cooler to remove large pieces.
3. Wash with hot soapy water. Rinse with clean
water and blow dry with compressed air in
reverse direction of flow.
4. Carefully inspect cooler to ensure
cleanliness. Do not use caustic cleaners.
Damage
Core
Failures
Recommended
Repair Procedure
System
Check
Repairable All header tank-to-core separations Tungsten-Inert (TIG) weld method Perform pressure/leak test
All header tank cracks Tungsten-Inert (TIG) weld method Perform pressure/leak test
Bent cold fins Straighten with small screwdriver or
pair of small needlenose pliers
Perform pressure/leak test
Tube plate cracks or welds not
exceeding 0.25 inch (6.35 mm) in
length
RTV method or Tungsten-Inert
(TIG) weld method
Perform pressure/leak test
Tube cracks or weld separations
exceeding 0.25 inch (6.35 mm) in
length
Tungsten-Inert (TIG) weld method Perform pressure/leak test
Nonrepairable Internal fins damaged and
separated from tube plate
No repair procedure is
recommended — replace unit
Perform pressure/leak test
Tube blockage No repair procedure is
recommended — replace unit
Perform pressure/leak test
Cold bar separations or openings
exceeding 0.25 inch (6.35 mm) in
length
No repair procedure is
recommended — replace unit
Perform pressure/leak test
Excessive cold fin damage (original
shape of fins distorted beyond
repair)
No repair procedure is
recommended — replace unit
Perform pressure/leak test
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM