Retrofit coolant preheater

AN20.30-G-0001US

Retrofit coolant preheater

11.5.15

Engine

936.971 in model 405.110/125/202/222

1

Engine block heater

1.1

Heat shield

1

Engine block heater

2

Electrical wiring harness

3

Fuse

4

2-part bracket

5

Electric connection line



Remove

1

Raise and secure dumper flatbed

 See owner's manual.

2

Tilt cab into repair position



AR60.80-G-0005B

3

Disconnect battery ground line



AR54.10-G-0003UG

4

Drain off coolant



AP20.00-G-2080U



Install

 Danger !

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

5

Retrofit engine block heater (1) together with the heat shield (1.1)

AN20.30-G-0001-04US



Notes on coolant

AH20.00-N-2080-01A

 Bolt, engine block heater to crankcase

*BA20.00-N-1002-01A

Grease, 1 kg

*BR00.45-Z-1035-06A

6

Route and connect electrical wiring harness (2) for engine block heater (1)

AN54.18-G-0032-01US

 Only workshops authorized to install electrical wiring to VDE Specifications may perform installation of the electrical wiring harness (2) for the engine block heater (1).

7

Pour in coolant



AP20.00-G-2080U

8

Connect ground line to battery



AR54.10-G-0003UG

9

Tilt back cab



AR60.80-G-0005B

10

Set back dumper flatbed

 See owner's manual.

11

Connect diagnostic system and start Xentry Diagnostics

12

Read out fault memory and clear

 Stored faults which may be caused by removed lines or by a simulation, must be processed and cleared in the fault memories after completing the work.

13

End Xentry Diagnostics and disconnect diagnostic system

Update Vehicle Documentation (VeDoc)

14

CODE M54 (electrical engine preheating), added

15

CODE MU04 (electrical 230 V coolant preheating ) added, also select "Engine" in the column "Use"

16

Add the special version type (SAA) Z540.075/01; also select "Engine" in the column "Use"

17

Attach note "engine block heater" and electrical wiring harness (parts kit A 004 540 20 05) as per AN20.30­G­0001US for ___ Bh retrofitted" under field organization texts on the KG 20 and KG 54



Check

 Danger !

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

18

Start engine and perform an engine test run

19

Turn off engine

20

Check engine cooling system for leaktightness

 Visual inspection.

21

Check coolant level



AP20.00-G-2010U

22

Check for proper operation of engine block heater (1)

 Engine block heater

Number

Designation

Engine 936.9 in model 405

BA20.00-N-1002-01A

Bolt, engine block heater to crankcase

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1035-06A

Grease, 1 kg

A 001 989 08 51

Parts ordering note

Part no.

Designation

Quantity

A 000 821 06 97

Protective hose 1 m

1

A 002 997 24 90

Cable tie (290 mm to 310 mm, fastening of protective hose to electrical line)

6

A 004 540 20 05

Parts kit for electrical wiring harness (contains: electrical wiring harness, fuse, 2­piece bracket and electrical connection line)

1

A 936 200 02 96

Engine block heater

1

A 936 203 02 92

Heat shield

1

N 910105 008011

Screw/bolt M8x20

2