Additive tank: extracting fluid and filling new additive
Additive tank: extracting fluid and filling new additive
Safety measures and code of conduct when working on additive tank system
achtung image   WARNING
Please note the following for all procedures:
  The diesel additive fluid is hazardous to health.
  Read safety instructions on new additive fluid container!
achtung image   WARNING
Please note the following for all procedures:
  Information concerning “Danger to health and environment”, “Protective and hygiene measures”, “Behaviour in case of danger” → ServiceNet, Genuine parts, safety data sheets and operating instructions; Diesel fuel additive for particulate filter.
  Before starting work, place extraction hose of switched on exhaust extraction system near the connections of additive tank, to ensure the released additive emissions are extracted.
  If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow.
achtung image   WARNING
Please note the following for all procedures:
  For all assembly work on the additive tank system always wear eye protection and fuel resistant protective gloves (avoid additive contact with skin)!
  Always perform assembly work on open system in well ventilated rooms!
  Do not inhale vapours of additive fluid!
  Keep additive fluid away from heat, sparks and open flame.
  The fluid vapours in combination with air can create an explosive mixture.
  Vapours are heavier than air and can spread to igniting sources near ground level.
achtung image   WARNING
Please note the following for all procedures:
  The diesel additive must not drain into sewerage and not soak into the soil. If leaks occur, immediately bind and eliminate.
  The additive tank is under pressure! Before opening the system, place a cloth around the connection, and reduce pressure by carefully loosening the connection!
  Collect fluid in a container e.g. when lines are drained empty etc.!
  Route lines of all types, e.g. fuel lines, additive lines as well as electrical wires, so that the cable guide is in original condition.
  Make sure that there is sufficient clearance to all moving or hot components.
Vorsicht image   Caution
Information concerning storage and disposal → ServiceNet → Environmental protection → Workshop disposal. Ask your importer about country-specific information on storage and disposal.
The refill container must be disposed of in accordance with environmental regulations.
General information
hinweis  Note
  The additive tank connections are found behind a cover on the tank cap.
  The additive tank has a capacity of approx. 4.5 to 5 litres.
  Only use new fluid.
  The part number of the 1.0 litre container is -G 052 143 A2-
  If the residual capacity in the additive tank is less than 0.3 litres, this is shown on display in the dash panel insert.
   
Removing sealing plug
–  Open tank flap and remove tank cap.
–  Place cap -2- at top of tank flap.
  N01-10225
The connections for the additive tank system are found behind the cover -1-
–  Carefully pull cover out of mounting -arrow-.
hinweis  Note
Now the cover is only secured to the drain hose.
  N01-10231
–  Turn cover -B- at drain hose connection -C- approx. 90 degrees anti-clockwise so that the connections are visible.
The connections are located on tank filler neck -arrow A-
hinweis  Note
Always note safety measures when working on additive tank!
  N01-10232
–  First pull sealing plug off VENTILATION -arrow B-, → Chapter!
–  Then pull sealing plug off EXTRACTION/FILLING -arrow A- → Chapter
–  Before opening the system, place a cloth around the connection, and reduce pressure by carefully loosening the connection!
  N01-10233
Pull off sealing plug as follows:
-Arrow A- round connector side.
-Arrow B- flat connector side.
–  Push securing ring in at round side of connector -arrow A- by hand or with suitable tool and pull off connector.
  N01-10226
Connections for fuel additive tank
VENTILATION -arrow B- (smaller connection diameter).
EXTRACTION/FILLING -arrow A- (larger connection diameter).
Extracting and replenishing with fluid
Special tools, testers, measuring instruments and auxiliary items required
  N01-10233
  Extraction unit -VAS 6277/1-
  W00-10233
  Filling device -VAS 6277/2-
  Overflow protection -VAS 6277/3-
  N01-10228
  Hose clamp -3094-
Extracting fluid:
hinweis  Note
Observe instruction manual for extraction unit -VAS 6277/1-.
–  Push connector -4- of extraction unit -VAS 6277/1- onto connection for EXTRACTION/FILLING, respective connections → Chapter.
  W00-0079
–  Connect compressed air supply -2- to extraction unit -VAS 6277/1-.
–  Extract fluid by carefully pulling metering lever -3-.
achtung image   WARNING
  Turn ventilation -1- in direction of the well ventilated room, do not inhale emitting vapours.
  Ensure the extraction container of the extraction unit -VAS 6277/1- is not overfilled during extraction process. A danger of overflowing exists.
  Finish extraction process when the container is approx. 2/3 full, see -arrow 5-.
  If necessary repeat extraction process.
  Do not reuse extracted (used) additive fluid.
  Dispose of extracted (used) additive fluid according to operating instructions → ServiceNet; HSO; Environmental Handbook 3.
–  If the total quantity of fluid has been extracted, separate compressed air supply.
  N01-10228
Replenishing fluid:
–  Bolt container with new additive fluid -1- to filling device -VAS 6277/2-.
–  Connect filling device -VAS 6277/2- and overflow protection -VAS 6277/3- with connections -3- and -4- to respective connections → Chapter.
–  Additionally secure hose clamp e.g.hose clamp -VAS 6277/2- on hose end of filling device -3094-
hinweis  Note
The hose clamp prevents that after filling and when pulling off hose, fluid is drained from filler hose.
The additive tank has a capacity of approx. 4.5 to 5 litres.
–  Open valve -2-, and drain fluid into additive tank.
hinweis  Note
  The system must not be overfilled.
  In case of overfilling fluid is visible on hose of overflow protection -VAS 6277/3-.
  N01-10227
–  Seal valve -2-, and clamp off filler hose using e.g. hose clamp -3094-.
  N01-10227
–  Separate filling device -VAS 6277/2- and overflow protection -VAS 6277/3- from additive tank connections -arrows A + B-.
  N01-10233
–  Connect both sealing plugs onto connections.
–  Reinstall cover -1-.
–  Seal tank filler neck.
Final checks
–  Unscrew additive tank from filling device -VAS 6277/2-.
–  Drain all fluid from filling device -VAS 6277/2-, so that no residual fluid will remain in the hose or cut-off valve.
hinweis  Note
Residual fluid crystallises in combination with oxygen.
Vorsicht image   Caution
Crystallised fluid may cause malfunctions in the additive system.
achtung image   WARNING
Remove spilt fluid with absorbing, non-flammable material (binding agent).
Dispose of materials which are soaked with fluid, e.g. cloths or binding agents, in a suitable container which can be closed, observe hazardous material regulations!
–  If fluid has been extracted from the additive tank system, fill used fluid of extraction unit -VAS 6277/1- into empty original tank of new fluid. Observe hazardous material regulations!
achtung image   WARNING
Always store additive fluid in the original container in a dry and well ventilated area.
  N01-10225