Pour in coolant and bleed cooling system

AR20.00-S-1142-04EV

Pour in coolant and bleed cooling system

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01A

Notes on coolant level

AH20.00-N-1142-01EV

Engine

780.994 in model 639.603/703

with code MA0 (E-CELL 60 kW)

 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

 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)

BF20.00-N-1002-02A

High-voltage cooling circuit with connected high-voltage battery cooling system

Total filling capacity

Liter

15,0

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

Liter

7,5

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

Liter

9

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Sheet

BB00.40-P-0325-05A

 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)

BF20.00-N-1003-02A

High-voltage cooling circuit with shut-down high-voltage battery cooling system

Total filling capacity

Liter

4,0

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

Liter

2,0

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

Liter

2,25

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Sheet

BB00.40-P-0325-05A

1

Lift vehicle at front until level of high-voltage battery module at the front is higher than at the rear.

 Commercially available tools
Floor jack

2

Support vehicle.

 Commercially available tools
Jack stands

3.1

For charging and bleeding the electric motor cooling circuit.
 Screw tester cap (2) onto cooling circuit electric motor expansion reservoir (1).

3.2

For charging and bleeding the high voltage cooling circuit.
Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
Screw  adapter onto high-voltage cooling circuit expansion reservoir.

 The high voltage cooling circuit expansion reservoir is located next to the engine compartment fuse box.

4.1

For charging and bleeding the electric motor cooling circuit.
Attach the control unit (5) to the  tester cap (2) .

4.2

For charging and bleeding the high voltage cooling circuit.
Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
Place controller unit (5) on the  adapter.

5

Attach Venturi nozzle (8) to control unit (5).

6

Close drain valve (6) and feed valve (4).

7

Attach feed hose (3) to coolant reservoir (10).
 
Engine 780.994 
Model 639.603 ## up to 754075, model 639.703 ## up to 717332 
Model 639.603 ## up to 754075, model 639.703 ## up to 717332 

 Make sure that there is more coolant than the maximum filling capacity in the coolant reservoir (10). Otherwise air will be drawn in when the cooling circuit is filled. The coolant reservoir (10) must be at the same level as the electric motor cooling circuit expansion reservoir (1) or high voltage cooling circuit expansion reservoir.

8

Insert drain hose (9) into an empty container (11).

9

Connect compressed-air hose (7) to Venturi nozzle (8) and apply pressure.

10

Open drain valve (6).

 A vacuum is created in the cooling circuit.

11

Open feed valve (4) until the feed hose (3) has filled with coolant.

12

Close drain valve (6) if the display of the control unit (5) is in the green area.

13

Remove compressed-air hose (7) from Venturi nozzle (8) and observe whether vacuum remains stable for 30 s.

If this is not the case,



Check hoses and connection, remove leaks and again generate vacuum.

14

Open feed valve (4).

 The cooling circuit will be filled.

15

Open drain valve (6) when no more coolant is drawn in from the coolant reservoir (10).

16.1

For charging and bleeding the electric motor cooling circuit.
Remove controller unit (5) with all connections and  the tester cap (2) electric motor cooling circuit expansion reservoir (1).

16.2

For charging and bleeding the high voltage cooling circuit.
Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
Remove controller unit (5) with all connections and  adapter on high voltage cooling circuit expansion reservoir .

17.1

For charging and bleeding the electric motor cooling circuit.
Using the diagnostic system actuate the low temperature coolant pump to stage 2 until there is no further air in the electric motor cooling circuit.

17.2

For charging and bleeding the high voltage cooling circuit.
Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)
Using the diagnostic system actuate the high-voltage battery coolant pump until there is no further air in the high voltage cooling circuit.

18

Remove jack stands.

19

Lower vehicle using floor jack completely.

20

Disconnect diagnostic system.

21

Correct the coolant level on the electric motor cooling circuit expansion reservoir (1) or high voltage cooling circuit expansion reservoir.

 The coolant level must not exceed the "MAX" mark on the electric motor cooling circuit expansion reservoir (1) or on the high voltage cooling circuit expansion reservoir.