Inspect charge air cooler and charge air hoses for leaks

AR09.41-W-6800B

22.6.10

ENGINE 904.9 in MODEL 375.1, 673.3, 674.3, 676.3, 970, 972, 975, 976

ENGINE 906.9 in MODEL 375.3, 950.5 /6, 952.5 /6, 953.6, 954.5

ENGINE 906.9 in MODEL 970, 972, 974, 975, 976

Inspect charge air cooler and charge air hoses for leaks

W09.41-0014-06

Shown on engine 904.9

1 Charge air cooler

2 Charge air hose (red)

3  Test flange (compressed air connection)

4  Testing unit

5  Test flange (testing unit connection)

6 Charge air hose (black)

7 Screw plug (engine 904.9 only)

	Checking
 Danger!	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.	AS60.80-Z-0001-01A
1	Tilt cab
	Notes on tilting the cab		AH60.80-N-0003-01A
2	Remove soundproofing on frame above on the right
3	Remove soundproofing on frame below	 Only for engine 904.9.
4	Unscrew screw plug (7) at charge air cooler (1) and drain off any collected engine oil, tighten screw plug (7)	 Only for engine 904.9. Collect engine oil which flows out.
5	Detach charge air hoses (2, 6) at both charge air pipes
6	Fit test flanges (3, 5) on to the charge air hoses (2, 6)	 The test flanges (3, 5) must be additionally supported at the openings of the two charge air pipes.
			*BA09.41-N-1010-01B
			*904589076300
7	Attach testing unit (4) to test flange (5)		*442589012100
			*904589076300
8	Fill charge air cooler (1) and charge air hoses (2, 6) with compressed air at test flange (3)	 Do not exceed test pressure otherwise the charge air cooler (1) or the charge air hoses (2, 6) may be damaged	*BE09.41-N-1001-01A
9	Observe indication on testing unit (4) to determine whether pressure drops	 Pay attention to test period. If pressure drops, inspect charge air cooler (1), screw plug (7) and charge air hoses (2, 6) for damage, replace if necessary.	*BE09.41-N-1001-01A
			*442589012100
10	Bleed compressed air at test flange (3)		*904589076300
11	Disconnect testing unit (4) and test flanges (2, 3)		*442589012100
			*904589076300
12	Install charge air hoses (2, 6) at both charge air pipes		*BA09.41-N-1010-01B
13	Install soundproofing on frame above on the right
14	Install soundproofing on frame below	 Only for engine 904.9.
 Danger!	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.	AS60.80-Z-0001-01A
15	Lower cab
	Notes on tilting the cab		AH60.80-N-0003-01A

Check values for charge air cooler

Number	Designation			Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9


BE09.41-N-1001-01A	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 904.9 in model 673, 674, 676	Engine 904.9 in model 374, 375, 958, 970, 972, 975, 976 Engine 906.9 in model 374, 375, 950, 952, 953, 954, 958, 970, 972, 974, 975, 976


BA09.41-N-1010-01B	Clamp, charge air hose to charge air manifold/charge air pipe and charge air cooler	Nm	8	8

904 589 07 63 00

Test flange

Tester

442 589 01 21 00

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