AR09.41-W-6800C | Inspect charge air cooler and charge air hoses for leaks | 27.9.06 |
ENGINE 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
W09.41-1033-08
Shown on model 944
1 Charge air cooler
2 Charge air hose (black)
3 Test flange (compressed air connection)
4 Charge air pipe
9 Clip
10 Bracket
11 Test flange (testing unit connection)
12 Charge air hose (red)
5 Testing unit
6 Test line
7 Turbocharger
8 Charge air pipe
| 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 the end position and secure with the safety strut. | |
1 | Tilt cab | ||
| Notes on tilting the cab | ||
2 | Remove soundproofing on frame at top left and right | ||
3 | Detach charge air hose (12) on the charge air pipe (8) | ||
4 | Detach charge air pipe (8) on holder (10) and turbocharger (7) | ||
5 | Attach test flange (11) onto charge air hose (12) | Inspect clamp for damage, replace if necessary. | |
| |||
| |||
6 | Attach charge air pipe (8) to holder (10) and turbocharger (7) | The test flange (11) must be supported in the opening of the charge air pipe (8). | |
| |||
7 | Attach testing unit (5) with test line (6) on test flange (11) and lay testing unit (5) with test line (6) on the other side of the engine | ||
| |||
| |||
8 | Detach charge air hose (2) on the charge air pipe (4) | ||
9 | Install test flange (3) between charge air hose (2) and charge air pipe (4) | Inspect clamp for damage, replace if necessary. The test flange (3) must be supported in the opening of the charge air pipe (4). | |
| |||
10 | Apply compressed air to charge air cooler (1) and charge air hoses (2, 12) at test flange (3) | The test pressure on testing unit (5) must not be exceeded otherwise damage can occur to the charge air cooler (1) or charge air hoses (2, 12). | |
| |||
| |||
11 | Observe indication on testing unit (5) to determine whether pressure drops | Pay attention to test period. If pressure drops, inspect charge air cooler (1) and charge air hoses (2, 12) for damage; replace if necessary. | |
| |||
12 | Bleed compressed air at test flange (3) | | |
13 | Remove test flange (3) | | |
14 | Attach charge air hose (2) to charge air pipe (4) | Inspect clamp for damage, replace if necessary. | |
| |||
15 | Detach charge air pipe (8) on holder (10) and turbocharger (7) | ||
16 | Remove testing unit (5) and test flange (11) on charge air hose (12) | | |
| |||
17 | Attach charge air pipe (8) to holder (10) and turbocharger (7) | Clean sealing surfaces and inspect clamp (9); replace if necessary. Replace seal. | |
| |||
18 | Attach charge air hose (12) to charge air pipe (8) | Inspect clamp for damage, replace if necessary. | |
| |||
19 | Install soundproofing from frame on the upper left and right | ||
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 the end position and secure with the safety strut. | |
20 | Lower cab | ||
| Notes on tilting the cab |
Check values for charge air cooler
Number | Designation | Engine | ||
BE09.41-N-1001-01C | 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 | ||
BA09.41-N-1001-01K | Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler | Nm | 7.5 | |
BA09.41-N-1006-01K | Clamp, charge air pipe to turbocharger | Nm | 10 | |
442 589 13 63 00
Test flange
Testing unit
442 589 01 21 00