Inspect cooling system for leaks

AR20.00-S-1010EV

Inspect cooling system for leaks

02.12.2019

Engine

780.994 in model 639.603/703

with code MA0 (E-CELL 60 kW)

Shown on model 639.6 up to vehicle identification number (VIN) 754075

1

Pressure pump

3

High voltage cooling circuit expansion reservoir (model 639.6 up to VIN 754075, model 639.7 up to VIN 717332)

5

Electric motor cooling circuit expansion reservoir

2

Adapter (model 639.6 up to VIN 754075, model 639.7 up to VIN 717332)

4

Tester cap

 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

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



Remove

1

Open engine hood and secure against falling down

2

Perform enable for the high voltage on-board electrical system

AR54.10-S-1160EV

3

Turn cap on high voltage cooling circuit expansion reservoir (3) carefully by a half revolution counterclockwise, relieve the overpressure and unscrew cap

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

4

Turn cap on electric motor cooling circuit expansion reservoir (5) carefully half a turn counterclockwise, release overpressure and then unscrew cap

When performing a leak test on the electric motor cooling circuit.



Check

5

Check coolant level on high voltage cooling circuit expansion reservoir (3); correct if necessary

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

Notes on coolant level

AH20.00-N-1142-01EV



Coolant specifications

BB00.40-P-0310-01A



Anticorrosion/antifreeze agents (Sheet 325.0)

BB00.40-P-0325-00A

6

Check coolant level on electric motor cooling circuit expansion reservoir (5); correct if necessary

When performing a leak test on the electric motor cooling circuit.

Notes on coolant level

AH20.00-N-1142-01EV



Coolant specifications

BB00.40-P-0310-01A



Anticorrosion/antifreeze agents (Sheet 325.0)

BB00.40-P-0325-00A

7

Attach adapter (2) to high voltage cooling circuit expansion reservoir (3)

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

 Adapter

*450589072107

8

Attach tester cap (4) to electric motor cooling circuit expansion reservoir (5)

When performing a leak test on the electric motor cooling circuit.

 Test cap

*639589009100

9

Connect pressure pump (1) to adapter (2)

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

 Pressure pump

*124589242100

10

Connect pressure pump (1) at tester cap (4)

When performing a leak test on the electric motor cooling circuit.

 Pressure pump

*124589242100

11

Apply specified pressure to cooling circuit using pressure pump (1)

Engine 780.994 in model 639.603 ## as of 754076, 639.703 ## as of 717333
with code MA0 (E-CELL 60 kW)
Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)Test pressure (electric motor cooling circuit)

*BE20.30-N-1003-01G

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
Test pressure (high voltage cooling circuit)Test pressure (high voltage cooling circuit)

*BE20.30-N-1006-01G

12

Check condition of coolant hoses and their connection points as well as for coolant loss; inspect condition and attachment of clamps

13

Relieve pressure in cooling circuit at pressure pump (1)

14

Remove pressure pump (1) and adapter (2)

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

 Pressure pump

*124589242100

 Adapter

*450589072107

15

Remove the pressure pump (1) and tester cap (4)

When performing a leak test on the electric motor cooling circuit.

 Pressure pump

*124589242100

 Test cap

*639589009100



Install

16

Screw cap onto high voltage cooling circuit expansion reservoir (3)

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
When performing a leak test on the high voltage cooling circuit.

17

Screw cap on electric motor cooling circuit expansion reservoir (5)

When performing a leak test on the electric motor cooling circuit.

18

Perform initial startup of high voltage on-board electrical system

AR54.10-S-1160EV

19

Close engine hood

Check values for cooling system cap

Number

Designation

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)

ENGINE 780.994 in MODEL 639.603/703

BE20.30-N-1003-01G

Test pressure (electric motor cooling circuit)

bar

1,0

1,0

Check values for cooling system cap

Number

Designation

Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)

BE20.30-N-1006-01G

Test pressure (high voltage cooling circuit)

bar

1,0