Inspect cooling system for leaks

AR20.00-W-1010H

Inspect cooling system for leaks

09.09.2016

Engine

470.9 in model 963, 964

Engine

471.9 in model 963, 964

Engine

473.9 in model 963, 964

Engine

936.9 in model 963, 964

Modification notes

27.07.2016

Procedure for external leakage of the retarder, added.

Operation step 13

AR43.30-W-0058WR

27.07.2016

Check exhaust gas recirculation cooler, added.

Operation step 13

AR14.20-W-7680MD

27.07.2016

Check exhaust gas recirculation cooler, added.

Operation step 13

AR14.20-W-7680H

Shown on vehicle with front expansion reservoir

1

Expansion reservoir

2

Clamp

3

Test equipment

4

Knurled nut

5

Adapter

Pfeil

Cap contact surface

 Danger !

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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 avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Notes on coolant

AH20.00-N-2080-01A



Notes on tilting the cab

AH60.80-N-0003-01A



Check

1

Open maintenance flap

2

Tilt cab

Only for vehicles with an expansion reservoir (1) at the rear.

3

Unscrew cap on expansion reservoir (1)

4

Check coolant level; correct if necessary

 Do not fill up the expansion reservoir (1) up to the coolant filler neck. The adapter (5) must not immerse in the coolant during the testing.

 Adapter

*655589006300

5

Dry rub coolant filler neck on the inside on the expansion reservoir (1)

6

Turn rubber seal on adapter (5) until it fits the inside diameter of the coolant filler neck

7

Screw knurled nut (4) onto adapter (5)

8

Tighten test equipment (3) onto adapter (5)

 Tester

*001589832100

9

Attach adapter (5) with test equipment (3) to expansion reservoir (1)

 The seal on the adapter (5) must be dry.

10

Hook clamp (2) on adapter (5) and below the thrust surface of the cap (arrows)

 Clamp

*950589126300

11

Pretension the clamp (2) using the knurled nut (4)

12

Apply compressed air to engine cooling system on test equipment (3) and check for leaktightness


Observe test pressure and test period.
Otherwise damage can lead to damage to engine cooling system.

Pressure drop in cooling system for

*BE20.30-N-1001-01H

13

Perform a visual inspection on all assembly components carrying coolant

Only for a pressure drop.

For a pressure drop with visible coolant loss.



Check radiator, heater cooler, coolant pump, coolant hoses, coolant lines and their connections, hose clamps, cylinder head gasket, retarder, core plug cover or core plug screws; remove leaks in engine cooling system.

Procedure for external leakage of the retarder
Only on vehicles with code B3H (Secondary Water Retarder).

AR43.30-W-0058WR

For a pressure drop without visible coolant loss.



Check cylinder head for cracks and exhaust gas recirculation cooler for leaktightness.

Check exhaust gas recirculation cooler for leaktightness
Engine 936.9

AR14.20-W-7680MD

Check exhaust gas recirculation cooler for leaktightness
Engine 470.9, 471.9, 473.9

AR14.20-W-7680H

14

Relieve test pressure at test equipment (3) completely

15

Loosen knurled nut (4) and remove clamp (2)

16

Remove adapter (5) with test equipment (3) on expansion reservoir (1)

17

Check coolant level, pour in coolant if necessary



Coolant specifications

BB00.40-P-0310-01A



Anticorrosion agent/antifreeze (specification 325.5)

BB00.40-P-0325-05A

 If antifreeze in the coolant is too low, either add more antifreeze or change the coolant.

18

Tighten cap on expansion reservoir (1)

19

Tilt back cab

Only for vehicles with an expansion reservoir (1) at the rear.

20

Close maintenance flap

Check values for cooling system

Number

Designation

Engine 470.9, 471.9, 473.9, 934.9, 936.9

BE20.30-N-1001-01H

Pressure drop in cooling system for

test pressure 1.0 bar and test period 5 to 10 min.

bar

0