Modification notes |
12.07.2019 | Work procedure updated | Whole document. | AR47.70-S-0005-01F |
23.07.2019 | Work procedure updated | Operation steps 2, 3, 4, | AR47.70-S-0002-00F |
23.07.2019 | Basic data values added | Operation steps 10, 11 | AR47.70-S-0002-00F |
08.08.2019 | Work procedure updated | Operation steps 3, 4, 6 | AR47.70-S-0002-00F |
28.08.2019 | Basic data added | Operation step 4 | AR47.70-S-0005-01F |
16.12.2019 | Work procedure updated | The whole document |
D47.70-A052-79
Shown with code E4T (high-voltage battery (47 kWh)) |
1 | High-voltage battery | 5 | End plate | 12 | High-voltage connection | ||
2 | High-voltage battery | 9 | Bracket | 13 | High-voltage lines | ||
3 | High-voltage battery | 10 | Bracket | 14 | High-voltage lines | ||
4 | High-voltage battery | 11 | Bracket | 15 | High-voltage lines |
D47.70-A053-79
Shown on high-voltage battery 2 (2) |
2 | High-voltage battery | 8 | Electrical connector | 19 | Ground cable | ||
6 | Coolant hose lines | 17 | Bolts | 22 | Cover | ||
7 | Electrical connector |
D47.70-A054-79
Shown with code E4T (high-voltage battery (47 kWh)) |
4 | High-voltage battery | 6 | Coolant hose lines | 18 | Screw |
D47.70-A055-79
Shown with code E4T (high-voltage battery (47 kWh)) |
1 | High-voltage battery | 4 | High-voltage battery | 21 | Adapter cable | ||
2 | High-voltage battery | 16 | Lifting platform | 23 | Battery diagnostic unit | ||
3 | High-voltage battery | 20 | Diagnostic system | 24 | Contact socket housing |
Danger | Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | |
Danger | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | |
Danger | Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. | No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers. | |
Warning | Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities. | No parts of the body or limbs should be within the operating area of mechanical components when moving components. | |
Topical note | General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on battery | ||
| Remove | ||
1 | Remove underfloor panelings from the high-voltage battery module. | ||
2 | Secure vehicle on vehicle lift. | ||
Commercially available devices/tools | |||
3 | Print out "Analysis sheet on transportability of high-voltage batteries". | ||
| Analysis sheet for transportability of high-voltage batteries, form | ||
| Check | ||
4 | Wear personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
| Service Information: Personal protective equipment for working on high-voltage on-board electrical systems | ||
5 | Check hazard potential of the corresponding high-voltage battery (1, 2, 3, 4) and enter findings in "Analysis sheet on the transportability of high-voltage batteries". | ||
6 | Check housing of the corresponding high-voltage battery (1, 2, 3, 4) in the visible area and enter findings in "Analysis sheet on the transportability of high-voltage batteries". | ||
If there is a problem, | |||
| |||
connect Market Performance Center (MPC) and general distributor. | |||
7 | Take off personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
8 | Drain coolant of auxiliary circuit. | ||
9 | Remove voltage of high-voltage on-board electrical system. | ||
10 | Remove respective end plate (5). | ||
| 000 588 11 62 00 Major assembly mount | ||
| 000 588 10 62 00 Support plate | ||
To do this, unscrew screws. | |||
11 | Remove coolant hose lines (6) from the corresponding high-voltage battery (1, 2, 3, 4). | ||
Seal connections. Collect escaping coolant. | |||
Commercially available devices/tools | |||
Set of protective caps | |||
12 | Disconnect respective electrical connector (7). | ||
13 | Disconnect respective electrical connector (8). | ||
14.1 | Remove brackets (9, 10) from the bracket at high-voltage battery 1 (1). | If high-voltage battery 1 (1) is removed. | |
14.2 | Remove brackets (11) from the bracket at high-voltage battery 2 (2). | If high-voltage battery 2 (2) is removed. | |
15 | Remove respective high-voltage plug (12) from the corresponding high-voltage battery (1, 2, 3, 4). | ||
16.1 | Place high voltage lines (13, 14, 15) to one side. | If high-voltage battery 1 (1) is removed. | |
16.2 | Place high-voltage lines (14, 15) to one side. | If high-voltage battery 2 (2) is removed. | |
16.3 | Place high voltage lines (15) to one side. | If high-voltage battery 3 (3) is removed. | |
17 | Cover high-voltage plugs (12) and high-voltage connections of the corresponding high-voltage battery (1, 2, 3, 4) with protective covers. | Set of protective covers | |
18 | Position lifting platform (16) below the corresponding high-voltage battery (1, 2, 3, 4) and align mounts. | ||
| 000 588 03 62 00 Lifting platform | ||
| |||
| Check | ||
19 | Check positioning of the mounts of the lifting platform (16) relative to the corresponding high-voltage battery (1, 2, 3, 4). | If the mounts of the lifting platform (16) are not correctly aligned with the high-voltage battery (1, 2, 3, 4), | |
| |||
Lower lifting platform (16) and realign mounts. | |||
20 | Remove screws (17) of the assembly brackets of the corresponding high-voltage battery (1, 2, 3, 4). | ||
21 | Remove screws (18). | Engine 780.703 in model 910 | |
22 | Lower lifting platform (16) with the corresponding high-voltage battery (1, 2, 3, 4) until the ground line (19) is accessible. | ||
23 | Remove ground line (19) from the corresponding high-voltage battery (1, 2, 3, 4). | To do this, undo screw/bolt. | |
24 | Lower corresponding high-voltage battery (1, 2, 3, 4). | ||
| Check | ||
25 | Wear personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
26 | Check the previously non-visible areas of the housing of the corresponding high-voltage battery (1, 2, 3, 4) and enter findings in "Analysis sheet on the transportability of high-voltage batteries". | If there is a problem, | |
| |||
connect the MPC and general distributor and store the respective high-voltage battery (1, 2, 3, 4) in the specified container. | |||
27 | Perform check with diagnostic system (20). | If a new high-voltage battery (1, 2, 3, 4) is installed. | |
Assessment of battery management system | |||
| 000 586 00 99 00 Battery diagnostic unit | ||
The operation steps must be performed exactly as per XENTRY Diagnosis Software. | |||
To do this, connect diagnostic system (20) with the adapter cable (21) and battery diagnostic unit (23) to the respective high-voltage battery (1, 2, 3, 4). | |||
Select the following menu path: | |||
Adapter cable | |||
If the high-voltage battery (1, 2, 3, 4) is assessed as "not safe to transport", | |||
| |||
store affected high-voltage battery (1, 2, 3, 4) as "unsafe" in the specified container and retry the check after 7 days. | |||
An assessment as "not safe to transport" can occur as a result of various influences. | |||
If no changed values are shown after a repeated check, | |||
| |||
the affected high-voltage battery (1, 2, 3, 4) is to be considered "safe to transport". | |||
If the assessment "not safe to transport" continues to occur after a repeated check, | |||
| |||
connect the MPC and general distributor and store the affected high-voltage battery (1, 2, 3, 4) in the specified container. | |||
28 | Take off personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
29 | Change the cap (22) of the removed high-voltage battery (1, 2, 3, 4) on the new high-voltage battery (1, 2, 3, 4). | If the cap (22) on the new high-voltage battery (1, 2, 3, 4) is not installed. | |
30 | Change contact socket housing (24) from the removed high-voltage battery (1, 2, 3, 4) on the new high-voltage battery (1, 2, 3, 4). | If a new high-voltage battery (1, 2, 3, 4) is installed. | |
To do so, release contact socket housing (24) (arrows). | |||
31 | Attach lifting device to the corresponding removed high-voltage battery (1, 2, 3, 4). | If a new corresponding transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Commercially available devices/tools | |||
Adaptation | |||
Lifting device | |||
32 | Lift corresponding high-voltage battery (1, 2, 3, 4) from the lifting platform (16) with engine hoist and set down on the transport box. | If a new corresponding transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Commercially available devices/tools | |||
33 | Remove lifting device from the corresponding high-voltage battery (1, 2, 3, 4). | If a new transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Adaptation | |||
Lifting device | |||
34 | Print out and sign the "Control unit log" and the "Analysis sheet 'Safe transportation of the lithium-ion battery'" for the corresponding old high-voltage battery (1, 2, 3, 4). | If a new transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
35 | Properly pack the corresponding old high-voltage battery (1, 2, 3, 4) for return delivery. | If a new transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Old high-voltage batteries (1, 2, 3, 4) may be handed over for transportation only when the transportability of each one has been verified and documented and proper packaging has been ensured. | |||
| Install | ||
36 | Attach lifting device to the corresponding new high-voltage battery (1, 2, 3, 4). | If a new corresponding transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Commercially available devices/tools | |||
Adaptation | |||
Lifting device | |||
37 | Lift corresponding new high-voltage battery (1, 2, 3, 4) with engine hoist and remove from the transport box. | If a new corresponding transport-capable high-voltage battery (1, 2, 3, 4) is installed. | |
Commercially available devices/tools | |||
38 | Position lifting platform (16) below the corresponding new high-voltage battery (1, 2, 3, 4) and align mounts. | If a corresponding transport-capable high-voltage battery (1, 2, 3, 4) was replaced. | |
| 000 588 03 62 00 Lifting platform | ||
| |||
| Check | ||
39 | Check positioning of the mounts of the lifting platform (16) relative to the corresponding new high-voltage battery (1, 2, 3, 4). | If a corresponding transport-capable high-voltage battery (1, 2, 3, 4) was replaced. | |
If the mounts of the lifting platform (16) are not correctly aligned with the high-voltage battery (1, 2, 3, 4), | |||
| |||
lift new high-voltage battery (1, 2, 3, 4) and realign mounts. | |||
40 | Remove lifting device from the corresponding new high-voltage battery (1, 2, 3, 4). | If a corresponding transport-capable high-voltage battery (1, 2, 3, 4) was replaced. | |
Bolt, assembly holder to high-voltage battery | |||
Screw, high-voltage wiring harness holder to high-voltage battery/high-voltage battery module | |||
Adaptation | |||
Lifting device | |||
| Check | ||
41 | Check ground line (19). | Check ground lines for high-voltage on-board electrical system potential equalization | |
Nut, potential equalization ground line to high-voltage battery module | |||
42 | Lift corresponding high-voltage battery (1, 2, 3, 4) with lifting platform (16) until the ground line (19) can be attached. | ||
| 000 588 03 62 00 Lifting platform | ||
| |||
Aid of helper required. | |||
43 | Attach ground line (19) to the corresponding high-voltage battery (1, 2, 3, 4). | Screw, potential equalization ground line to high-voltage battery | |
44 | Align corresponding high-voltage battery (1, 2, 3, 4) and lift up to attachment. | Aid of helper required. | |
45 | Fit the screws (18). | Engine 780.703 in model 910 | |
46 | First, position screws (17) of the corresponding high-voltage battery (1, 2, 3, 4) and then tighten. | Screw, assembly holder to high-voltage battery module | |
47 | Tighten bolts (18) . | Engine 780.703 in model 910 | |
Bolt, assembly holder to high-voltage battery | |||
48 | Lower lifting platform (16) and take out of the working area. | ||
| 000 588 03 62 00 Lifting platform | ||
49 | Connect electrical connectors (7, 8). | ||
50 | Remove protective covers and attach coolant hose lines (6) to the corresponding high-voltage battery (1, 2, 3, 4). | ||
Set of protective caps | |||
51 | Remove protective covers and attach high-voltage plug (12) to the corresponding high-voltage battery (1, 2, 3, 4). | ||
Safety screw, locking element to high-voltage battery high-voltage plug | |||
Set of protective covers | |||
52.1 | Position high voltage lines (13, 14, 15). | If high-voltage battery 1 (1) was removed. | |
52.2 | Position high voltage lines (14, 15). | If high-voltage battery 2 (2) was removed. | |
52.3 | Position high voltage lines (15). | If high-voltage battery 3 (3) was removed. | |
53.1 | Attach brackets (9, 10) to the bracket on high-voltage battery 1 (1). | If high-voltage battery 1 (1) was removed. | |
53.2 | Attach brackets (11) to the bracket on high-voltage battery 2 (2). | If high-voltage battery 2 (2) was removed. | |
54 | Install removed end plates (5). | ||
Topical note | Notes on self-locking nuts and bolts | ||
| 000 588 11 62 00 Major assembly mount | ||
| 000 588 10 62 00 Support plate | ||
Bolt, end plate to assembly holder | |||
55 | Remove fuse of the vehicle. | ||
56 | Put the high-voltage on-board electrical system into operation. | ||
57 | Pour in coolant for the auxiliary circuit and bleed auxiliary circuit. | ||
58 | Attach charger to on-board electrical system battery. | If a new corresponding high-voltage battery (1, 2, 3, 4) was installed. | |
| |||
Follow the operating instructions for the charger. | |||
Use the charger to ensure that an adequate voltage (min. 12.5 V) is provided for the on-board electrical system battery. | |||
59 | Perform commissioning of the respective battery management system with the diagnostic system. | If a new corresponding high-voltage battery (1, 2, 3, 4) was installed. | |
| |||
Menu path in the respective battery management system (BMS) control unit: | |||
60 | Remove vehicle diagnosis system. | If a new corresponding high-voltage battery (1, 2, 3, 4) was installed. | |
61 | Disconnect charger. | If a new corresponding high-voltage battery (1, 2, 3, 4) was installed. | |
62 | Install underfloor panelings on the high-voltage battery module. |
177 589 03 62 00
Adaptation
222 589 00 62 00
Lifting device
001 589 00 91 00
Set of protective caps
001 589 01 91 00
Set of protective covers
222 589 04 63 00
Adapter cable
Henviste dokumenter
- ad0000d200006ts
- ah0000n000101a Oplysninger om selvlåsende bolte og møtrikker
- ah0000z030001a Generelle oplysninger ved køretøjer med højvoltsnet og/eller litium-ion-batteri og/eller gasdrivsystem samt personligt beskyttelsesudstyr
- ah5400p000101a Oplysninger med henblik på at undgå skader på elektroniske komponenter på grund af elektrostatisk afladning
- ah5410p000101a Oplysninger om batterier
- ah5410p000101a
- ar0060d010001ts
- ar0850d0022te
- ar0850p001801eq
- ar4770d000000te
- ar4770d1000te
- ar4770d102001te
- ar4770s000200f
- ar4770s000201f
- ar4770s000501f
- ar5410d1127ts
- ar6130d1002te
- as0000z000901a Fare for personskade som følge af klemning af legemsdele, i værste fald fare forafskæring af legemsdele ved indgreb i mekanikken
- as0000z001001a Livsfare, hvis køretøjet glider ned fra eller tipper på liften.
- as0000z003501a Livsfare ved arbejde på komponenter og systemer med U >= 30 V vekselspænding (AC) eller U >= 60 V jævnspænding (DC)
- as5410z000101a Brand-/eksplosionsfare på grund af kortslutning og udsivende knaldgas. Forbrændingsfare/fare for personskade ved ætsning af øjne, hud og sliminder på grund af batterielektrolyt/-tåge, kortslutning og lysbuepåvirkning. Fare for
- of4770d300100te
- si5410p0047a Serviceinformation: Personligt beskyttelsesudstyr ved arbejde på køretøjets højvoltsnet
- ws0100p0091a
- ws0100p0092b
- ws2600p3309b
- ws5400p0033c