Inspect charge air cooler and charge air hoses for leaks

AR09.41-W-6800H

Inspect charge air cooler and charge air hoses for leaks

17.10.2012

ENGINE

470.9, 471.9, 936.9 in MODEL 963, 964

1

Charge air cooler

4

Charge air pipe

7

Charge air hose (red)

2

Charge air hose (black)

5

Test equipment

8

Charge air pipe

3

Test flange (compressed air connection)

6

Test line

9

Test flange (testing unit connection)



Check

 Danger !

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A



Notes on tilting the cab

AH60.80-N-0003-01A

1

Tilt cab

2

Remove soundproofing

3

Remove charge air hose (7) from charge air pipe (8)

4

Attach test flange (9) to charge air hose (7)

 Check clamp for damage, replace if necessary.
 Select test flange (9) suitable for the diameter of the charge air hose (7).

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 936.9

*BA09.41-N-1010-01Q

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 470.9, 471.9

*BA09.41-N-1010-01P

 Test flange

*442589136300

 Test flange

*904589076300

5

Attach test equipment (5) with test line (6) to test flange (9) and lay test equipment (5) with test line (6) on the other side of the engine

 Tester

*442589012100

6

Remove charge air hose (2) from charge air pipe (4)

7

Install test flange (3) between charge air hose (2) and charge air pipe (4)

 Check clamp for damage, replace if necessary.
 Select test flange (3) suitable for the diameter of the charge air hose (2).

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 936.9

*BA09.41-N-1010-01Q

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 470.9, 471.9

*BA09.41-N-1010-01P

 Test flange

*442589136300

 Test flange

*904589076300

8

Apply compressed air to charge air cooler (1) and charge air hoses (2, 7) at test flange (3)


The test pressure must not be exceeded.
The charge air cooler (1) or the charge air hoses (2, 7) can get damaged otherwise.

Pressure drop in charge air cooler and charge air hoses, engine 936.9

*BE09.41-N-1001-01F

Pressure drop in charge air cooler and charge air hoses, engine 470.9, 471.9

*BE09.41-N-1001-01E

9

Check whether a pressure drop is recognizable on the test equipment (5) display

 Pay attention to test period.
If pressure drops, check charge air cooler (1) and charge air hoses (2, 7) for damage; replace if necessary.

Pressure drop in charge air cooler and charge air hoses, engine 936.9

*BE09.41-N-1001-01F

Pressure drop in charge air cooler and charge air hoses, engine 470.9, 471.9

*BE09.41-N-1001-01E

10

Bleed compressed air at test flange (3)

11

Remove test flange (3)

12

Attach charge air hose (2) to charge air pipe (4)

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 936.9

*BA09.41-N-1010-01Q

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 470.9, 471.9

*BA09.41-N-1010-01P

13

Remove test equipment (5) and test flange (9) on charge air hose (7)

14

Attach charge air hose (7) to charge air pipe (8)

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 936.9

*BA09.41-N-1010-01Q

 Clamp, charge air hose to charge air pipe and charge air cooler, engine 470.9, 471.9

*BA09.41-N-1010-01P

15

Install soundproofing

16

Tilt back cab

Check values for charge air cooler

Number

Designation

ENGINE 470.9, 471.9

BE09.41-N-1001-01E

Pressure drop in charge air cooler and charge air hoses

Test pressure 1.5 bar / test period 2 min

bar

0

Check values for charge air cooler

Number

Designation

ENGINE 936.9

BE09.41-N-1001-01F

Pressure drop in charge air cooler and charge air hose with test pressure 1.5 bar, test period 2 min

bar

0

 Charge air pipe/charge air cooling

Number

Designation

ENGINE 470.9

ENGINE 471.9

BA09.41-N-1010-01P

Clamp, charge air hose to charge air pipe and charge air cooler

Nm

7,5

7,5

 Charge air pipe/charge air cooling

Number

Designation

ENGINE 936.9

BA09.41-N-1010-01Q

Clamp, charge air hose to charge air pipe and charge air cooler

Nm

7,5