Check high-voltage battery cooling system for leak tightness

AR08.50-S-0011F

Check high-voltage battery cooling system for leak tightness

18.12.2019

Engine

780.701/702 in model 447

Modification notes

16.12.2019

Method extended

Operation steps 7.2, 9.2

Shown with engine 780.701

1

Cap

3

Tester cap

2

Expansion reservoir

4

Pressure pump

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 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 battery

AH54.10-P-0001-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes on coolant level for high-voltage battery cooling system

AH08.50-S-0051-01F



Check

1

Remove cap (1) from the expansion reservoir (2).

 Turn cap (1) of expansion reservoir (2) counterclockwise only up to the safety catch and relieve overpressure. Then unscrew cap (1).

2

Check coolant level in expansion reservoir (2).

If the coolant level is not correct,



Correct coolant level.

 Electric drive cooling system

*BF08.50-N-1001-01F

3

Attach tester cap (3) to expansion reservoir (2).

 Test cap

*210589009100

4

Attach pressure pump (4) to tester cap (3).

 Pressure pump

*124589242100

 Test cap

*210589009100

5

Apply test pressure to high-voltage battery cooling system.


Do not exceed the specified test pressure.
Damage can occur to high-voltage battery cooling system otherwise.

Test pressure, high-voltage battery cooling system

*BE08.50-N-1003-01F

6

Check high-voltage battery cooling system for leaks.

 Carry out visual check of the engine compartment from above.

If coolant is being lost



Localize and eliminate cause.

7.1

Remove underbody paneling.

Engine 780.701 in model 447

AR61.30-S-1001F

7.2

Remove engine compartment lining.

Engine 780.702 in model 447

AR61.20-S-1105E

8

Check high-voltage battery cooling system for leaks.

 Perform visual check of engine compartment, high-voltage battery and coolant lines from below.

If coolant loss has occurred,



Localize and eliminate cause.

9.1

Install underbody paneling.

Engine 780.701 in model 447

AR61.30-S-1001F

9.2

Install engine compartment lining.

Engine 780.702 in model 447

AR61.20-S-1105E

10

Actuate pressure release button at pressure pump (4) and reduce test pressure in high-voltage battery cooling system.

 Pressure pump

*124589242100

11

Remove pressure pump (4) at tester cap (3).

 Pressure pump

*124589242100

 Test cap

*210589009100

12

Detach tester cap (3) from expansion reservoir (2).

 Test cap

*210589009100

13

Check coolant level in expansion reservoir (2).

If the coolant level is not correct,



Correct coolant level.

 Electric drive cooling system

*BF08.50-N-1001-01F

14

Fit cap (1) on expansion reservoir (2).

Cooling system

Number

Designation

Engine 780.701/702 in model 447

BE08.50-N-1003-01F

Test pressure, high-voltage battery cooling system

bar

1,4

 Cooling system

Number

Designation

Engine 780.701/702 in model 447

BF08.50-N-1001-01F

Electric drive cooling system

Cooling system of high-voltage battery and vehicle interior

Filling capacity

Liter

 10

Cooling system of electric motor

Filling capacity

Liter

 5

For both cooling systems, entire filling capacity, in the workshop

Filling capacity

Liter

 15

Antifreeze/water

Down to -37 °C

%

50/50

Coolant specifications

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-05A