Cooling and heating system - Check condition of radiator, lines and hoses - AP20.00-P-2050G

ENGINES 102, 110, 115, 602, 616, 617 in MODEL 460 

ENGINES 102, 602, 612, 642 in MODEL 461 

ENGINES 102, 103, 104, 112, 113, 117, 273, 602, 603, 606, 612, 628, 642 in MODEL 463 

Engine 612.965 

Engine 642.975 

Engine 642.970 

	Checking
	Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning  caused by 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
		Only perform the leak test when the engine is cold.
1	Set vehicle heating to maximum heat output on operating unit
2	Open radiator or coolant expansion reservoir	Slowly screw open end cover (1) and release pressure, then unscrew end cover (1). Replace the cap (1) if corroded.
3	Check coolant level and correct if necessary
		Engine 642 in model 461, 463, engine 273 in model 463	AP20.00-P-2010GY
		Engine 102 in model 460, 461.217/219/223/227/229/238/239/249/266/267, 463.200/204/220/221/224/225, engine 103 in model 463.207/227/228, Engine 104 in model 463.208/230/231, Engine 110 in model 460, Engine 115 in model 460, Engine 117 in model 463.228, Engine 602 in model 460, 461.321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459, 463.304/324/325, engine 603 in model 463.300/307/320/321/327/328, Engine 606 in model 463.308/330/331, Engine 616 in model 460, Engine 617 in model 460, Engine 612.965 in model 463.322/323, engine 612.966 in model 461.302/331/332/342/345, Engine 628.962 in model 463.309/332/333	AP20.00-P-2010G
		Engine 112.945 in model 463.209/232/233/244/245/250, Engine 113.962 in model 463.206/240/241/247/248/249/254, Engine 113.982 in model 463.241/243/246, Engine 113.993 in model 463.270/271	AP20.00-P-2010GA
	Notes on coolant		AH20.00-N-2080-01A
4	Attach tester cap and pressure pump	Pressure pump	Fig 5
		Tester cap	Fig 6
		Tester cap	Fig 7
5	Build up test pressure using pressure pump	The test pressure must be the same as the opening pressure of the cap (1). The code number on the cap (1) indicates the opening pressure.
6	Check components of the engine cooling system and heating system	Check that the following components are in good condition, are fitted securely and are not leaking: Engine and bolted-on major assemblies Freeze plug Radiator Coolant pump Coolant expansion reservoir Heating system heat exchanger Heating regulating valve Stationary heater unit Check that the following components are in good condition, are not leaking, are fitted securely and are routed correctly: Coolant lines and hoses as well as their attachments Tighten the screw clamps if necessary. Rectify all defects against a separate repair order.
7	Check radiator fins	Check that the fins are in good condition and are not dirty. Replace the radiator if fins are broken or deformed. Clean the radiator if its fins are clogged with dirt.
8	Release test pressure and detach pressure pump and tester cap
9	Check coolant level and correct if necessary	Engine 642 in model 461, 463, engine 273 in model 463	AP20.00-P-2010GY
		Engine 102 in model 460, 461.217/219/223/227/229/238/239/249/266/267, 463.200/204/220/221/224/225, engine 103 in model 463.207/227/228, Engine 104 in model 463.208/230/231, Engine 110 in model 460, Engine 115 in model 460, Engine 117 in model 463.228, Engine 602 in model 460, 461.321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459, 463.304/324/325, engine 603 in model 463.300/307/320/321/327/328, Engine 606 in model 463.308/330/331, Engine 616 in model 460, Engine 617 in model 460, Engine 612.965 in model 463.322/323, engine 612.966 in model 461.302/331/332/342/345, Engine 628.962 in model 463.309/332/333	AP20.00-P-2010G
		Engine 112.945 in model 463.209/232/233/244/245/250, Engine 113.962 in model 463.206/240/241/247/248/249/254, Engine 113.982 in model 463.241/243/246, Engine 113.993 in model 463.270/271	AP20.00-P-2010GA
10	Close radiator or expansion reservoir for coolant using cap (1)