Pour in coolant and bleed cooling circuit

AR08.50-D-0017-01TE

Pour in coolant and bleed cooling circuit

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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 containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

AH00.00-Z-0300-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes on coolant level

AH20.00-P-1142-01CW

Engine

780.703 in model 910

Modification notes

20.07.2020

Method modified.

Operation steps 34, 38, 39, 40, 41, 42, 43

20.07.2020

Special tool 124 589 24 21 00 pressure pump added.

Operation steps 38, 39, 41, 42

 Cooling system

Number

Designation

Engine 780.703 in model 910

BF08.50-N-1001-01TE

Filling capacity for cooling system

Main circuit

l

 4,8

Auxiliary circuit with 3 high-voltage batteries

l

 9,6

Auxiliary circuit with 4 high-voltage batteries

l

 10,4

Main circuit and auxiliary circuit with 3 high-voltage batteries in repair case

l

 14,4

Main circuit and auxiliary circuit with 4 high-voltage batteries in repair case

l

 15,2

Mixing ratio for antifreeze/water (to -37 °C)

%

50/50

Coolant specifications

BB00.40-P-0310-01A

Specification

BB00.40-P-0325-05A

1

It must   Pour coolant into the coolant reservoir (7).

 Fill level in coolant reservoir (7) must exceed the max. filling capacity of the respective cooling circuit by approx. 30%. 
Air can otherwise be intaken into cooling circuit.

2

Note down fill level of coolant reservoir (7).

 Position coolant reservoir (7) for this purpose on a horizontal surface.

3

 Attach tester cap (1) to respective coolant expansion reservoir.

4

Attach control unit (2) to the  tester cap (1).

5

Attach venturi nozzle (3) to control unit (2).

6

Close feed valve (4) and drain valve (5).

7

Attach feed hose (6) to coolant reservoir (7).

8

Insert waste air hose (8) into an empty container.

9

Connect compressed-air hose (9) to venturi nozzle (3) and apply compressed air.

10

Open drain valve (5).

11

Open feed valve (4) until feed hose (6) has filled.

12

Close drain valve (5) if display of the control unit (2) is in the green area.

13

Remove compressed-air hose (9) from the venturi nozzle (3).

14

Based on the indicator of the control unit (2), check whether the vacuum remains stable for 30 s.

If the vacuum does not remain stable,



Check hoses, connections and component parts of respective cooling circuit, eliminate causes and restart evacuation process.

15

Bring the switch (11) of the  electrical vacuum pump (18) to the "0" position.

16

Connect POSITIVE and NEGATIVE terminals of  electric vacuum pump (18) to a suitable 12 V voltage source (e. g. an on-board electrical system battery).

 Observe polarity of POSITIVE and NEGATIVE terminals.

17

Attach bracket (12), as shown, to  NTKL adaptation (13).

18

Attach hose (14) to  NTKL adaptation (13).

19

Close off shutoff valves (15, 16, 17).

20

Attach hose (20) to  NTKL adaptation (13).

21

Remove Y-distributor from hose (20).

22

Remove venturi nozzle (3) from the control unit (2).

23

Attach hose (20) to the control unit (2).

 Secure hose (20) to connection fitting using suitable clamp.

24

 Switch on electrical vacuum pump (18).

25

Open stopcock (15).

 The feed valve (4) remains closed.

 Vacuum indicator (19) must at least show -0.9 bar.

If -0.9 bar is not reached,



Check cause, rectify it, and set up vacuum again.

26

Open drain valve (5) and evacuate cooling circuit for 5 min.

 In this connection, observe vacuum indicator (19).
The vacuum must remain stable at -0.9 bar.

If the vacuum does not remain stable,



Check hoses, connections and component parts of cooling circuit, eliminate causes and restart evacuation.

27

drain valve (5).

28

 Switch off electrical vacuum pump (18).

29

Remove hose (14) from  NTKL adaptation (13).

 Vacuum in  NTKL adaptation (13) is thereby reduced until vacuum indicator (19) shows 0.0 bar.

30

Based on the indicator of the control unit (2), check whether the vacuum remains stable for 30 s.

If the vacuum does not remain stable,



Check hoses, connections and component parts of cooling circuit, eliminate causes and restart evacuation.

31

Open feed valve (4).

 Cooling circuit is now filled.
Filling process is complete when display of control unit (2) has reached 0.0 bar.

32

Open drain valve (5).

Once coolant is no longer flowing in cooling circuit.

 The remaining existing vacuum will be removed in this way.

33

Compare fill level of coolant reservoir (7) with noted fill level.

 Filled in coolant quantity of cooling circuit should be > 75% of filling capacity.
Malfunctions can otherwise occur during the subsequent ventilation.

 Position coolant reservoir (7) for this purpose on a horizontal surface.

If less than 75% of coolant filling capacity was filled,



drain coolant again and repeat entire process.

34

Remove control unit (2) with all connections.

  Do not yet remove tester cap (1).

35

Remove hose (20) from control unit (2).

36

Attach Y-distributor to hose (20).

 Replace clamp.

37

 Remove electric vacuum pump (18) from  NTKL adaptation (13).

Shown on auxiliary circuit

38

 Attach pressure pump (10) to  tester cap (1).

39

Using  pressure pump (10), generate a pressure of 1 to 1.5 bar.

40.1

If auxiliary circuit will be bled.
Bleed auxiliary circuit.

 Electric coolant pumps are automatically unlocked during bleeding.

 Fully execute specified process for bleeding auxiliary circuit.
To do so, select following menu items:
Powertrain (CPC) 
Special procedures 
Bleeding of passenger compartment high-voltage battery coolant circuit

 Duration of bleeding process of auxiliary circuit approx. 30 min.

40.2

If main circuit will be bled.
Bleed main circuit.

 Electric coolant pumps are automatically unlocked during bleeding.

 Fully execute specified process for bleeding main circuit.
To do so, select following menu items:
Powertrain (CPC) 
Special procedures 
Bleeding of coolant circuit for electric drive

 Duration of bleeding process of main circuit approx. 15 min.

41

Reduce pressure at  pressure pump (10).

42

 Remove pressure pump (10) from  tester cap (1).

43

 Remove tester cap (1) from coolant expansion reservoir.