Flush engine cooling system before conversion of vehicle to code O2I

SM20.00-W-0009WR

Flush engine cooling system before conversion of vehicle to code O2I

20.03.2019

Engine

471.9 in model 963, 964

with code B3H (Water-type secondary retarder)

Only for vehicles with front coolant expansion reservoir

1

Flushing fitting

7

"Expansion reservoir cap" shutoff valve

12

Filling unit/flushing fitting hose

2

Compressed-air hose

8

"Bleed lines" shutoff valve

13

Fresh water hose

3

Pressure reducing valve

9

"Cooler short circuit" shutoff valve

14

Compressed air shutoff valve

4

"Retarder" shutoff valve

10

Fresh water shutoff valve

15

Sampling hose

5

"Engine" shutoff valve

11

Cleaning solution shutoff valve

16

Flushing water drain shutoff valve

6

"Heating" shutoff valve

12

Filling unit/flushing fitting hose

17

Filling device

18

Filling unit switchover valve

19

Pump

20

Hose

 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

 Danger

Risk of death to implant wearers from working on retarder

As a safe distance from the retarder, a minimum distance of 100 cm is to be maintained between the retarder and the body parts of the affected person for people with implants.

AS43.30-Z-0002-01A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on influence of retarder on coolant/coolant sludging

AH43.30-N-0003-01WR

Notes on further operations for coolant sludging

AH20.00-N-0002-02H

Notes on assessment of damage phases of coolant sludging

AH20.00-N-0002-01H

Notes on disposal of flushing water when flushing the engine cooling system

AH20.00-N-0002-03H

Preparation

1

Connect diagnostic system, start XENTRY and perform quick test.

 Only the specified fault codes may be present in the following control units. All other fault codes can impair the flushing process conducted using XENTRY:
-Engine management control unit (MCM): 080212, 6F0013, 580602
-Drive control (CPC) control unit: 57F3EC CE040C, 6F0005, B50D02, 580602, 2A0302, 2AF3EE, 6B000E, B60D0E, 870902
- Transmission control unit (TCM): 2BF3E7, 2AF3E7, 09F5E3, 2CF3EE, 4CF3EE
- Retarder control unit (RCM): 01E4E7, 00E4E0

2

Start engine and run at idle speed.

3

Check and, if necessary, correct the idle speed.

 The idle speed must be <600 rpm.

If the idle speed is >600 rpm,



adjust the idle speed.

4

Switch off engine.

5

Disconnect the electrical connection at the relay for the engine shutoff.

Only for vehicles with code JMJB (Engine shutoff, after 4 minute idling), JMJC (Engine shutoff, after 3 minute idling), JMJD (Engine shutoff, after 5 minute idling)

 The relay for the engine shutoff is located in the electronics compartment.

6

Remove the drive shaft at the transmission output.



AR41.10-W-0050H

7

Drain the coolant completely.



AR20.00-W-1142H

8

Install the opened coolant thermostat.



Open coolant thermostat for oil removal

WF58.50-W-2003-01H



AR20.10-W-2460H

 Installation of the opened coolant thermostat ensures that the engine cooling system has an optimum through-flow.

9

Pre-install the coolant circuit.

Only when putting coolant circuit flushing unit into operation for first time.

 Observe the connection diagram from the manufacturer.

 Coolant circuit flushing unit

*963589059100

10

Place the vent hose of the flushing fitting (1) in the open or with the extraction system.

11

Check all hoses, hose connections and clamps of coolant circuit flushing unit for damage and that they are seated securely.



Service information bulletin: Coolant circuit flushing unit workshop equipment 963 589 05 91 00

SI58.40-N-0013A

 Clamp, coolant hose for coolant circuit flushing unit

*BA20.20-N-1006-02A

If the hoses and hose connections are damaged or the clamps are loose,



Replace hoses concerned or tighten clamps.

12

Attach the coolant circuit flushing unit.



Model 963, 964 with engine 471.9

AR20.00-W-1251-01H

 If the flushing water for pre-flushing and final flushing cannot be disposed of via the oil separator, a second IBC container is required for flushing a vehicle.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

 Connection fitting to crankcase

*BA01.40-N-1009-02A

 Bolt, coolant connection to retarder housing

*BA43.30-N-1011-01F

 Clamp

*000589543700

 Coolant circuit flushing unit

*963589059100

13

Pull the pump (19) out of the container for the filling unit (17) and place it in the container for the cleaner.

Cleaner for engine cooling system with coolant sludging, 30 l

*BR00.45-Z-1094-04A

14

Push the hose (20) into the container for the filling unit (17).

15

Set the filling unit switchover valve (18) according to the direction of flow and, using the pump (19), pump enough cleaner into the container for the filling unit (17) so that sufficient fresh water can still be added.


Observe the mixing ratio.
An incorrect mixing ratio will cause damage to the engine cooling system.

 Mixing ratio: fresh water to cleaner 3:1.
Example: 90l of fresh water to 30l of cleaning solution. Dispose of cleaning solution in an environmentally acceptable manner.

16

Mix the cleaner in the container for the filling unit (17) with fresh water.


Mix cleaning solution outside of engine cooling system.
Pouring in the cleaner directly will damage parts of the engine cooling system.

 Mixing ratio: fresh water to cleaner 3:1.
Example: 90l of fresh water to 30l of cleaning solution. Dispose of cleaning solution in an environmentally acceptable manner.

17

Push the pump (19) back into the container for the filling unit (17).

18

Connect filling unit/flushing fitting hose (12) to cleaning solution shutoff valve (11).

19

Set the filling unit switchover valve (18) according to the direction of flow to the engine cooling system.

Flushing

20

Start Xentry and start "flushing of engine cooling system".


Fill the engine cooling system with coolant immediately after the flushing process.
Residual quantities of cleaning solution and flushing water will lead to corrosion on parts of the engine cooling system.


Do not open the fresh water shutoff valve (10) until the "heating" shutoff valve (6) or the flushing water drain shutoff valve (16) has been opened.
Water pressure that is unable to escape can cause damage to the engine and engine cooling system.

 Pre-flushing, cleaning and final flushing must always be performed one immediately after the other. Only one complete flushing procedure should be performed at a time.
The entire flushing procedure must be monitored and the equipment checked regularly for leaks.
The duration of the flushing procedure depends on the degree of contamination and takes approx. 2.5 hours. Owing to the duration of the procedure, the vehicle diagnosis system must be operated using the power supply unit.

 The flushing process is completely menu-assisted under:
special functions 
Flushing the engine cooling system

 The digital tachograph records while cleaning is performed with the cleaning solution. If necessary, set the digital tachograph to "out of scope".

If, when the retarder is switched on, it is found that the engine speed remains constant (no power loss) and/or that the engine cooling system does not heat up,



bleed retarder by opening cleaning solution shutoff valve (11), the "retarder" shutoff valve (4), the "heating" shutoff valve (6), the "expansion reservoir cap" shutoff valve (7) and the "bleed lines" (8) shutoff valve until cleaning solution is discharged.

21

Print out the XENTRY record of the flushing process and file in a tamperproof manner.

Final activities

22

Pull the pump (19) out of the container for the filling unit (17) and place it in the container with premixed coolant.



Service Information: Ordering and cost settlement of anticorrosion/antifreeze agents

SI20.00-W-0009A

23

Close all shutoff valves at flushing fitting (1).

24

Open the shutoff valves "expansion reservoir cap" (7), "bleed lines" (8), "heating" (6) and "cleaning solution" (11) and switch on the pump (19).


Fill the engine cooling system with coolant immediately after flushing.
Residual quantities of cleaning solution and flushing water will lead to corrosion on parts of the engine cooling system.

 The cooler and the heater core must NOT be connected during this procedure. Otherwise the flushed engine cooling system will be contaminated again.

 The engine cooling system is filled with coolant.

25

As soon as coolant is discharged at the hoses for the flushing fitting (1), close the "expansion reservoir cap" (7), "bleed lines" (8) and "heating" (6) shutoff valves. At the same as you close the last shutoff valve, close the shutoff valve "cleaning solution" (11) and switch off the pump (19).


Do not switch on the pump (19) when all of the shutoff valves are closed.
Pressure that is not relieved can damage the engine cooling system or pump (19).

26

Drain off coolant.


The coolant filled in after the flushing process must be disposed of.
The first passivation of the engine cooling system diminishes the chemistry of the coolant considerably. If this coolant is used again, this will again result in sludging.

27

Detach coolant circuit flushing unit from expansion reservoir, of heating, from bottom of cooler and from retarder.

28

Tilt cab.

29

Remove top coolant circuit flushing unit from the coolant hose.

30

Remove coolant circuit flushing unit from the connection fitting of the engine.

31

Replace an opened coolant thermostat by the previously removed coolant thermostat.



AR20.10-W-2460H

 Clean the coolant thermostat before installation.

32

Replace coolant filter element.



Engine 471.9 in model 963, 964 with code M8T (Coolant filter)

AP20.00-W-2040H

33

Attach propeller shaft to transmission output.



AR41.10-W-0050H

34

Connect electrical connector to the relay for the engine shutoff.

Only for vehicles with code JMJB (Engine shutoff, after 4 minutes of idling) or with code JMJC (Engine shutoff, after 3 minutes of idling) or with code JMJD (Engine shutoff, after 5 minutes of idling)

 The relay for the engine shutoff is located in the electronics compartment.

35

Attach the label indicating the flushing process behind the maintenance flap.

 On the front of the label, write "flushed on", the date and kilometer reading. Cross out "oil brand/viscosity". On the rear, enter antifreeze protection (example -37 °C) and stroke through all other fields. The order number is: HLI 000 000 00 88

 Crankcase, end cover

Number

Designation

Engine 471.9

BA01.40-N-1009-02A

Connection fitting to crankcase

Nm

30

 Engine radiator, coolant hoses, lines

Number

Designation

Engine 470.9, 471.9

BA20.20-N-1006-02A

Clamp, coolant hose for coolant circuit flushing unit

Clamping range Ø 50-70 mm

Nm

5

 Retarder

Number

Designation

MODEL 963, 964 with CODE B3H (Secondary water retarder)

BA43.30-N-1011-01F

Bolt, coolant connection to retarder housing

Nm

22

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67

BR00.45-Z-1094-04A

Cleaner for engine cooling system with coolant sludging, 30 l

A 000 989 27 02