Inspect charge air cooler and charge air hoses for leaks

AR09.41-G-6800H

Inspect charge air cooler and charge air hoses for leaks

08.08.2018

Engine

470.9, 471.9, 473.9 in model 800.310/320

1

Charge air cooler

4

Charge air pipe

7

Charge air hose (red)

2

Charge air hose (black)

5

Tester

8

Charge air pipe

3

Test flange (compressed air connection)

6

Test line

9

Test flange (testing unit connection)



Check

1

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

2

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

*BA09.41-N-1010-01P

 Test flange

*442589136300

3

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

 Tester

*442589012100

4

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

5

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

*BA09.41-N-1010-01P

 Test flange

*442589136300

6

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.
Otherwise, the charge air cooler (1) or the charge air hoses (2, 7) may be damaged.

Pressure drop in charge air cooler and charge air hoses

*BE09.41-N-1001-01E

7

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

*BE09.41-N-1001-01E

8

Lay test device (5) with test line (6) on the opposite side of the engine

9

Relieve test pressure at test flange (3)

10

Remove test flange (3)

11

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

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

*BA09.41-N-1010-01P

12

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

13

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

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

*BA09.41-N-1010-01P

Check values for charge air cooler

Number

Designation

Engine 470.9, 471.9, 473.9

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

 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 473.9

BA09.41-N-1010-01P

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

Nm

7,5