Test cooling system cap - AR20.30-P-4300FV

ENGINES 112,113

ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250

ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254

ENGINE 113.982 in MODELS 463.243 /246

ENGINE 113.993 in MODELS 463.270 /271

Fig 1: Identifying Cooling System Cap Test Components

	Remove
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. 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 bottles. Wear protective gloves, protective clothing and eye protection.	AS20.00-Z-0001-01A
1.1	Fit cap with detent (5)	For model 463.206/209/232/233/ 240/241 with cap with notch (5).
		Carefully rotate cap up to the first detent, release overpressure, then unscrew cap (5). If corrosion present at cap with detent (5), the cap must be replaced.
1.2	Remove 1 or 2-stage cap (5a)	A 1-stage cap (5a) is installed in model 163. In models 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/ 246/247/248/249/250/254/270/271 there are 2-stage caps (5a) installed.
		Turn 1 or 2-stage cap (5a) half a turn in an anti-clockwise direction, release pressure and then unscrew cap.
	Check cap with detent
2.1.1	Attach test cap (3) and adapter (4) to tester (2)	Only on model 463.206/209/232/233/240/ 241 with cap with notch (5).
		Tester	Figure
		Test cap	Figure
		Adapter	Fig 2
2.1.2	Screw cap (5) with detent onto the adapter (4)
2.1.3	Inspect pressure relief valve (6)	Only on model 463.206/209/232/233/240/ 241 with cap with notch (5).
		The pressure relief valve (6) must be resting against the rubber seal (arrow), it must be possible to lift it easily and it must spring back after being released.
		Determine the opening pressure of the cap with notch (5) by pump and replace cap with notch (5) if necessary.
		Cap code number	*BE20.30-P-1001-01A
		Pressure relief valve opens	*BE20.30-P-1002-01A
		Pressure relief valve opens (Reference value)	*BE20.30-P-1003-01A
		Test pressure	*BE20.30-P-1005-01A
	Test the 1 or 2-stage cap
2.2.1	Attach adapter (3a) to tester (2)	Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271.
		Tester	Figure
		Adapter for models 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271:
		Adapter	Fig 6
		Test cap for Model 163: ↓
		Test cap	Fig 5
2.2.2	Screw 1 and 2-stage cap (5a) onto adapter (3a)	Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271.
2.2.3	Inspect pressure relief valve	Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271.
		Determine opening pressure of the cap (5a) by pumping and replace cap (5) if necessary.
		Cap code number	*BE20.30-P-1001-01A
		Pressure relief valve opens	*BE20.30-P-1002-01A
		Vacuum valve opens (reference value)	*BE20.30-P-1003-01A
		Pressure relief valve opens	*BE20.30-P-1004-01A
		Test pressure	*BE20.30-P-1005-01A
	Installing
3.1	Fit cap with detent (5)	For model 463.206/209/232/233/240/241 with cap with notch (5).
3.2	Install Remove 1 or 2-stage cap (5a)	For models 140, 163, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271 with 1 or 2-stage cap (5a).

CAP OF RADIATOR OR EXPANSION RESERVOIR

Number	Designation			Cap	2-stage cap	1-stage cap model 163
BE20.30-P-1001-01A	Cap code number			140	140/200	-
BE20.30-P-1002-01A	Pressure relief valve opens	New	bar gage	1.4 (+0.1)	-	1.4 (+0.1)
BE20.30-P-1002-01A	Pressure relief valve opens	Used	bar gage	1.4 (-0.1)	-	1.4 (+0.1)
BE20.30-P-1003-01A	Vacuum valve opens (reference value)		bar vacuum	0.1	0.1	0.5
BE20.30-P-1004-01A	Pressure relief valve opens	1st stage	bar gage	-	1.4 ( ± 1)	-
		1st stage	Coolant temp.	-	≥ 130/134	-
		2nd stage	bar gage	-	2.0 (± 1)	-
		2nd stage	Coolant temp.	-	≥ 137/143	-
BE20.30-P-1005-01A	Test pressure for pressure-testing cooling system		bar gage	1.4	1.4	-

CAP OF RADIATOR OR EXPANSION RESERVOIR

Number	Designation			2-stage cap engine 113.968 in model 209	2-stage closing cover on model 211
BE20.30-P-1001-01A	Cap code number			140/200	-
BE20.30-P-1002-01A	Pressure relief valve opens	New	bar gage	-	1.5 (-0.2)
BE20.30-P-1002-01A	Pressure relief valve opens	Used	bar gage	-	1.5 (-0.2)
BE20.30-P-1003-01A	Vacuum valve opens (reference value)		bar vacuum	0.1	0.1
BE20.30-P-1004-01A	Pressure relief valve opens	1 st stage	bar gage	1.4 (± 1)	1.5 (-0.2)
		1 st stage	Coolant temp.	≥ 130/134	135 (+5)
		2nd stage	bar gage	2.0 (± 1)	1.5 (-0.2)
		2nd stage	Coolant temp.	≥ 137/143	145 (+5)
BE20.30-P-1005-01A	Test pressure for pressure-testing cooling system		bar gage	1.4	1.4

Fig 2: Identifying Adapter (000 589 77 63 00)

Fig 3: Identifying Test Cap (124 589 00 91 00)

Fig 4: Identifying Pressure Pump (124 589 24 21 00)

Fig 5: Identifying Test Cap (163 589 02 91 00)

Fig 6: Identifying Adapter (210 589 03 63 00)