Remove and install heat exchanger

AR43.30-T-0006B

Remove and install heat exchanger

15.2.12

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 Danger!

Risk of injury caused by touching hot retarder and by scalding from hot retarder oil. Risk of injury to skin or eyes caused by retarder oil escaping under high pressure

Do not carry out any work unless retarder is switched off. Wear suitable protective clothing and safety glasses when working on the hot retarder.

AS43.30-Z-0001-01A

 Danger!

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

 

Remove/install

1

Warm up retarder oil to operating temperature

 To do so perform a perform a road test and switch the retarder on and off several times during the test drive.

2

Disconnect battery

 To do so release and pull out the battery tray, see operator's manual.

3

Remove lower engine compartment paneling

For model 613.355/358/388/455/485,

AR61.20-T-1105B

For model 613.364/365

AR61.20-T-1105C

4

Remove proportional valve

AR43.30-T-0001B

5

Drain coolant



Drain/fill in coolant

AP20.00-T-2080-01B



Notes on coolant

All engines

AH20.00-N-2080-01A

6

Remove coolant hose from heat exchanger (3)

7

Remove coolant connection (1) on heat exchanger (3)

 Installation: The seals of the coolant connection (1) must be replaced.



*BA43.30-N-1001-01D



*000589642100

8

Drain oil on retarder

 Installation: If the oil drain screw has an integrated plastic sealing ring then if the plastic sealing ring is damaged the oil drain screw must be replaced. If the oil drain screw has a copper sealing ring then the copper sealing ring must be replaced.



Retarder - oil change

For model 613.355 with transmission 714.668 with Voith retarder R115 (integrated) code B10 and for model 613.355/455/485 with transmission 714.690/691 with Voith retarder R115 (integrated) code B10.

AP43.30-T-4301A



Retarder - oil change

For model 613.365 with transmission 714.690/692 with Voith retarder R115 (integrated) code B10, for model 613.364 with transmission 714.120 with Voith retarder R115 (integrated) code B10 and for model 613.358/388 with transmission 714.140 with Voith retarder R115 (integrated) code B10.

AP43.30-T-4301B

9

Remove bolts (2)

 Installation: If the bolts (2) have shims then the shims must be replaced. If the bolts (2) have a flange then the bolts (2) must be replaced.

 Bolt (2), heat exchanger (3) to retarder housing (5)

*BA43.30-N-1010-01D



*000589642100

10

Remove heat exchanger (3)

 Installation: Before installation of the heat exchanger (3) the sealant must be applied to the sealing surfaces on the retarder housing (5). 

Apply sealant to retarder housing

AR43.30-T-0006-03B

 Installation: On retarders the gap between the heat exchanger (3) and retarder housing (5) after installation of the heat exchanger (3) must be sealed in the upper area using sealant (arrow), to prevent any corrosion damage to the heat exchanger (3).

*BR00.45-Z-1075-01A

11

Remove O-rings (4)

 Installation: Replace O-rings (4) and coat with Vaseline.

*BR00.45-Z-1015-06A

12

Check heat exchanger (3)

AR43.30-T-0007B

13

Install in the reverse order

14

Conduct a road test

 Bleed retarder:

-If present and possible, switch off retarder foot control

-Drive vehicle at 50 km/h.

-Switch on retarder in first brake stage 5 times for approx. 5 seconds each.

Number

Designation

Model 613
with code B10

BA43.30-N-1001-01D

Bolt, coolant connection to heat exchanger of retarder

M8

Nm

30

BA43.30-N-1010-01D

Bolt, heat exchanger to retarder housing

Torque angle gauge

Stage 1

Nm

50

Stage 2

°

30

Torque wrench

Stage 1

Nm

50

Stage 2

Nm

130

Number

Designation

Order number

BR00.45-Z-1075-01A

Sealing compound Dirko S Profi Press HT

A 004 989 65 20

BR00.45-Z-1015-06A

Vaseline

Karl Käppler GmbH & Co. KG, Liebknechtstr. 48,
D-70565 Stuttgart
Tel. +49 711 7868-481
Fax +49 711 7868-489
www.karl-kaeppler.de