Replacement of the Coolant, Electric Vehicle
- Remove the fill cap from the surge tank. See Fig..
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Powertrain/Battery Loop Surge Tank
Fig. 1, Surge Tank
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- Place a large container under the radiator.
- Open the drain valve at the bottom of the radiator. See
Fig..
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Drain Valve
Fig. 2, Radiator Drain Valve
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- Locate the petcock valves under the center of the cab and
open the valves to drain the coolant faster. See Fig..
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Petcock Valves
Fig. 3, Accessing the Petcock Valves
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- Remove the 1 inch hose from the three coolant pump inlets
and replace them with longer 1 inch lines to drain into a bucket.
See Fig..
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Coolant Heaters Plugs
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Coolant Pump Inlets
Fig. 4, Coolant Heater Plugs and Pump Inlets
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- When the coolant has completely drained, remove the longer 1 inch lines.
- Install the original 1 inch lines removed from the coolant pump inlets in the previous step and secure the lines.
- Disconnect the 5/8 inch supply and return lines from the
high-voltage battery pack. Drain any coolant in the lines or batteries
into a bucket. See Fig..
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Supply Lines
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Return Lines
Fig. 5, High-Voltage Battery Supply and Return Lines
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- Once the coolant has been drained, install and secure the 5/8 inch supply and return lines on the high-voltage battery pack.
- Remove the hose from the inverter inlet and drain the coolant into a bucket.
- Once the coolant is completely drained, install and secure
the invertor hose. See Fig..
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Invertor Line
Fig. 6, Invertor Inlet Hose
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- Close all of the petcock valves. See Fig..
- Close the drain valve on the radiator. See Fig..
- Install any coolant lines that were removed to drain the coolant.
- Fill the surge tank to the COLD FULL mark on the tank with organic acid technology (OAT) coolant at a rate of 3 gallons per minute (GPM).
- Once the vehicle is filled to the COLD FULL mark, start the vehicle and allow it to run for 10 minutes.
- After the vehicle has run 10 minutes, turn it off and open all of the petcock valves, shown in Fig. to release air in the system.
- With the petcock valves open, check the coolant level again and add coolant to the COLD FULL mark. If coolant is seen coming from any of the petcock valves, close them immediately.
- Ensure that the powertrain/battery loop surge tank is at the full mark. Do not let the pumps run dry.
- Fill the dash/body heater surge tank until the sight glass is filled with coolant.
- Start the vehicle, then set the heater control to hot and run the blower. Allow the vehicle to run for 30 minutes to deaerate.
- Add coolant until the sight glass is filled and ensure that the coolant level is within limits on the surge tank.
Warning: Do not remove or loosen the radiator cap until the motor and cooling system have completely cooled. Use extreme care when removing the cap. A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause serious personal injury.
Note: Additional hoses at other locations can be removed and shop air applied to help drain the coolant; draining coolant from the batteries is also recommended.
Important: The powertrain/battery loop surge tank must be filled first. Ensure that the dash controls are set to cold and the blower is off.
Supplemental coolant additives (SCAs) are not used with OAT coolant.
Notice: Distilled water must always be used when mixing a 50/50 mixture of coolant concentrate and water. Normal tap water will lead to corrosion of the powertrain and battery coolant loops. This type of damage is not covered by warranty.
If a pre-mixed coolant/water solution is used, distilled water does not need to be added.
Important: Fill the dash/body heater surge tank after the powertrain/battery loop surge tank. Starting the vehicle automatically turns on the pumps for the powertrain/battery loop; these pumps must not be ran without the proper amount of coolant in the system. The dash/body heater pump activates when the dash control is set to hot and the blower is running.