W20.00-1137-09
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 |
W20.00-1145-12
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. | |
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. | |
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. | |
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. | |
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. | |
Topical note | Notes on coolant | ||
Topical note | Notes on tilting the cab | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on influence of retarder on coolant/coolant sludging | ||
Notes on further operations for coolant sludging | |||
Notes on assessment of damage phases of coolant sludging | |||
Notes on disposal of flushing water when flushing the engine cooling system | |||
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: | |
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, | |||
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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. | ||
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7 | Drain the coolant completely. | ||
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8 | Install the opened coolant thermostat. | ||
| Open coolant thermostat for oil removal | ||
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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 | |||
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 | ||
Clamp, coolant hose for coolant circuit flushing unit | |||
If the hoses and hose connections are damaged or the clamps are loose, | |||
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Replace hoses concerned or tighten clamps. | |||
12 | Attach the coolant circuit flushing unit. | ||
| Model 963, 964 with engine 471.9 | ||
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 | |||
Connection fitting to crankcase | |||
Bolt, coolant connection to retarder housing | |||
Clamp | |||
Coolant circuit flushing unit | |||
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 | |
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. | | |
Mixing ratio: fresh water to cleaner 3:1. | |||
16 | Mix the cleaner in the container for the filling unit (17) with fresh water. | | |
Mixing ratio: fresh water to cleaner 3:1. | |||
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". | | |
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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 flushing process is completely menu-assisted under: | |||
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, | |||
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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 | ||
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). | | |
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). | | |
26 | Drain off coolant. | | |
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. | ||
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Clean the coolant thermostat before installation. | |||
32 | Replace coolant filter element. | ||
| Engine 471.9 in model 963, 964 with code M8T (Coolant filter) | ||
33 | Attach propeller shaft to transmission output. | ||
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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 |
000 589 54 37 00
Clamp
963 589 05 91 00
Coolant circuit flushing unit