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A808 AdBlue supply module - flushing process

A808 AdBlue® supply module (EMITEC) - flushing

Key

1 Compressed-air supply, input

2 Electrical connection of solenoid valve for compressed-air control
3 Electrical connection for pump control and heating system
4 AdBlue® input - AdBlue®-IN (union with bar sieve filter)
5 AdBlue® mixture output - AdBlue® Mix-OUT
6 AdBlue® return line
Important information

DANGER
Risk of accident from uncontrolled movement of vehicle
If the vehicle is not secured to prevent it from rolling away, it could begin to move. Persons could suffer
severe or fatal injury.
Therefore:
• Take precautions to prevent the vehicle from rolling away.

Observe the safety notices. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage.
Before commencing work, ensure that the latest documentation is used.
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DANGER
Risk of accident from uncontrolled movement of vehicle
When releasing compressed-air, the vehicle may lower itself. Persons could suffer severe or fatal injury.
Therefore:
• Secure the area around the vehicle when releasing compressed-air.

WARNING
Risk of injury from compressed air
Uncontrolled movement of lines can cause severe injuries.
Therefore:
• Release the pressure of the compressed-air circuit completely prior to removing the compressed-air
lines.
• Wear suitable personal protective equipment.

WARNING
Risk of injury from compressed air
When releasing compressed air, small items and particles of dirt could be stirred.
Therefore:
• Release the pressure of the compressed-air circuit completely prior to removing the compressed-air
lines. Persons could suffer injury.
• Wear suitable personal protective equipment.

WARNING
Risk of injury from hot components
The exhaust system may be very hot. Persons could suffer injury upon contact.
Therefore:
• Do not touch a hot engine with bare hands.
• Wear suitable personal protective equipment.
• Allow components to cool down before removing.

WARNING
Risk of injury from reducing agent (AdBlue®)
The reducing agent (AdBlue®)is a non-flammable, colourless, odourless and water-soluble liquid. If the
reducing agent (AdBlue®) comes into contact with the skin or eyes, it can cause injuries.
Therefore:
• Ensure that the reducing agent (AdBlue®) does not come into contact with skin, eyes or clothing.
• Wear suitable protective clothing (safety goggles, protective gloves).

NOTE
Fuel, water or other additives (e.g. winter additives) must not be mixed into the reducing agent
(AdBlue®).
Components of the exhaust gas cleaning system could fail (e.g. catalytic converter) or be damaged
beyond repair (e.g. seals / gaskets).
Therefore:
• Only pour reducing agent (AdBlue®) in the dedicated AdBlue® tank.

NOTE
Contaminants should not find their way into the AdBlue® tank for the reducing agent (AdBlue®).
Components of the exhaust gas cleaning system and the injection system can fail (e.g. blocked injectors).
Therefore:
• Ensure cleanliness.

Observe the safety notices. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage.
Before commencing work, ensure that the latest documentation is used.
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NOTE
When the reducing agent (AdBlue®) is replenished, it could escape through the tank breather. If the
AdBlue® tank is overfilled, it could burst when temperatures drop to freezing point. Reducing agent
(AdBlue®) is highly corrosive and causes even keys and locks to rust.
Therefore:
• Therefore, only replenish the AdBlue® tank up to the point at which the nozzle shuts off.
• If the reducing agent (AdBlue®) comes into contact with metallic surfaces (sheet steel or aluminium,
even painted), wash immediately with plenty of clear water.
• Keep keys clean. Wash off as necessary with plenty of clear water.

NOTE
Reducing agent (AdBlue®) must not be stored in cans that previously held diesel or similar
substances.
Even light contamination with diesel fuel is enough to damage the supply module.
Therefore:
• Ensure cleanliness.

ENVIRONMENTAL NOTE
Reducing agent (AdBlue®)
Do not allow large quantities of the reducing agent (AdBlue®) to enter the sewage system, surface water,
groundwater or the earth.
Dilute the reducing agent (AdBlue®) in emergency using plenty of clear water.

Special tools
1 Flushing kit AdBlue supply module Emitec 80.99629-6042
Quantity 1
Flush the AdBlue supply module Emitec

2 Supplementary test kit 80.99607-6082

Quantity 1
Testing of the AdBlue injection quantity, exhaust system,
EURO VI in conjunction with 80.99607-6052

Service products
Seal .....................................................................................................................................   06.56631-0105  
Preparatory measures
►Relieving the supply pressure
►Start MAN-cats and connect the Vehicle Communication Interface (VCI) to the X200 diagnostics socket
HD-OBD of the vehicles
►Establish access to the connections of the A808 AdBlue® supply module
Tip for users
Ensure power supply for MAN-cats
Open lines and connections must always be sealed after being opened so that no dirt can enter them

Observe the safety notices. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage.
Before commencing work, ensure that the latest documentation is used.
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Key

1 Flushing line (from the vehicle's compressed-air line to the reservoir)

2 Reservoir
3 Flushing line (from the reservoir to the compressed-air connection of the A808 AdBlue® supply module)
4 Compressed-air connection A808 AdBlue® supply module
5 Compressed-air line (vehicle) - compressed-air supply
Technical data
Tightening torques
4 Compressed-air connection A808 AdBlue® supply module - M12x1.5...............  12.5...............  ± 10% Nm
compressed-air supply..............................................................

Connecting the flushing kit to the A808 AdBlue®supply module

►Fill the reservoir 2 with 250ml of warm, distilled water using the filling bottle from the flushing kit
►Attach the reservoir 2 to a suitable place in vertical position using magnets
►Unscrew the union of the compressed-air supply and lay the compressed air line 5 aside. Respectively
connect the corresponding flushing kit adapter to the compressed-air connection of the A808 AdBlue®
supply module 4 and compressed-air line 5.
►Connect the flushing line 3 between the reservoir 2 and the compressed-air connection of the A808
AdBlue® supply module 4
►Connect the flushing line 1 between the reservoir 2 and the compressed-air line 5 .
Tip for users
When using the adapter with a flexible line, the seal is required for sealing.

Observe the safety notices. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage.
Before commencing work, ensure that the latest documentation is used.
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Key

1 Clamping ring AdBlue® injection line

2 Flushing line to collecting tank
3 Collecting tank
Connecting the flushing kit to the AdBlue® injection line (transfer point - exhaust silencer)
►Press the clamping ring 1 together and pull off the AdBlue® injection line
►Position the flushing line 2 of the collecting tank to the AdBlue® injection line and lock the quick
coupling
►Put the collecting tank 3 in a suitable location.
Start the flushing process
►Ensure the supply pressure in the compressed-air system
►Start the air unit test with MAN-cats under "Exhaust gas aftertreatment > AdBlue® system".
►Repeat the air unit test or flushing process several times
►The flushing process is finished as soon as only compressed-air is left in the collecting tank.
Concluding measures
►Read out and delete the diagnostic memory of the complete vehicle using MAN-cats
►Close the MAN-cats and Vehicle Communication Interface (VCI)
►Clean the reservoir and the collecting tank including the hoses with warm water
►Connect the AdBlue®injection line to the transfer point (exhaust silencer)
►Mount the union on the A808 AdBlue® supply module and connect the compressed-air line
►Check the AdBlue® supply module and connections for leaks.

Observe the safety notices. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage.
Before commencing work, ensure that the latest documentation is used.