Drain coolant, fill up and check cooling system for leaks

AR20.00-S-1140EV

Drain coolant, fill up and check cooling system for leaks

25.05.2020

Engine

780.994 in model 639.603/703

with code MA0 (E-CELL 60 kW)

Electric motor cooling circuit

Modification notes

20.05.2020

Work procedure revised

The whole document

Shown on models 639.603 ## to 754075

1

Cap

2

Expansion reservoir

3

Cooler cooling circuit for electric motor

4

Drain screw

5

Drain hose

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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-N-1142-01EV



Remove

1

Open hood and secure against falling down.

2

Perform power disconnect of high-voltage on-board electrical system.

AR54.10-S-1160EV

3

Carefully turn cap (1) on expansion reservoir (2) counterclockwise through half a revolution, release overpressure, and remove cap (1).

4

Remove splash guard.

AR61.30-S-0010EV

Drain off

5

Attach drain hose (5) to drain valve of electric motor cooling circuit cooler (3).

 Use drain hose (5) from  vacuum-type cooling system filler.

 Cooler vacuum filling device

*285589002100

6

Open drain screw (4) on drain valve and drain off coolant.

 Collect coolant in container of  vacuum-type cooling system filler.

 Cooler vacuum filling device

*285589002100

7

Close drain screw (4) on drain valve.

 Drain screw at cooler (reference value)

*BA20.20-N-1001-01B

8

Remove drain hose (5).

Fill and bleed

9

Connect diagnostic system.



AD00.00-S-2000-04S

 For the subsequent bleeding of the engine cooling system, the low-temperature coolant pump must be actuated with the diagnostic system.

10

Pour in coolant and bleed engine cooling system.

AR20.00-S-1142-04EV



Service Information: Coolant

SI20.00-S-0001B

 Observe the operating instructions of the  vacuum-type cooling system filler.

 Commercially available devices/tools
Floor jack
Jack stands

 Engine 780.994Cooling circuit for electric motor

*BF20.00-N-1001-02A

 Mixture ratio for coolant

*BF20.00-N-1001-04A

 Cooler vacuum filling device

*285589002100

 Test cap

*639589009100



Check

11

Check engine cooling system for leak tightness.

Only when work has been conducted on component parts of the engine cooling system for the electric motor.

AR20.00-S-1010EV

 Do not perform commissioning of high-voltage on-board electrical system yet.



Install

12

Attach cap (1) to expansion reservoir (2).

13

Install splash guard.

AR61.30-S-0010EV

14

Perform initial startup of high voltage on-board electrical system.

AR54.10-S-1160EV



Check

15

Warm up vehicle to operating temperature with a test drive and then stop the vehicle.

16

Check coolant level on expansion reservoir (2).



Cooling system - check/correct fluid level. Inspect anticorrosion/antifreeze protection, adjust to correct concentration

AP08.30-S-0810EV

 Carefully turn cap (1) on expansion reservoir (2) counterclockwise through half a revolution, release overpressure, and close cap (1).

 Cooler, coolant hoses, coolant lines

Number

Designation

Engine 780.994 in model 639 with code MA0

BA20.20-N-1001-01B

Drain screw at cooler (reference value)

Nm

3

 Cooling system

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 ## as of 754076, 639.703 ## as of 717333
with code MA0 (E-CELL 60 kW)

BF20.00-N-1001-02A

Cooling circuit for electric motor

Total filling capacity

Liter

5,0

8,5

Filling capacity of anticorrosion or antifreeze agent down to ­37 °C

Liter

2,5

4,25

Filling capacity of anticorrosion or antifreeze agent down to -45 °C

Liter

3,5

4,75

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

BB00.40-P-0325-00A

Sheet

BB00.40-P-0325-05A

BB00.40-P-0325-05A

Sheet

-

BB00.40-P-0325-06A

Sheet

-

BB00.40-P-0326-06A

 Mixture ratio for coolant

Number

Designation

Engine all (BUS, Heavy transporter, Light transporter, TRUCK, UNIMOG)

BF20.00-N-1001-04A

Mixture ratio for coolant

Antifreeze/water down to -37 °C

%

50/50

Antifreeze/water down to -45 °C

%

55/45

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Sheet

BB00.40-P-0325-05A