S61.40-A000-79
4 | End plates | 5 | Bracket |
S54.10-A024-79
Shown on high-voltage battery 1 (1) |
1 | High-voltage battery | 9 | Equipotential bonding line | 13 | High-voltage lines | ||
1.1 | Assembly holder | 10 | Bolts | 14 | Electrical wiring harness | ||
6 | Coolant hose lines | 11 | Bracket | 15 | High-voltage plug | ||
7 | Electrical connector | 12 | High-voltage lines | 16 | Bolts | ||
8 | Electrical connector |
S54.10-A025-79
Shown on high-voltage battery 2 (2) |
2 | High-voltage battery | 9 | Equipotential bonding line | 15 | High-voltage plug | ||
6 | Coolant hose lines | 12 | High-voltage lines | 16 | Bolts | ||
7 | Electrical connector | 13 | High-voltage lines | 20 | Cover | ||
8 | Electrical connector |
S54.10-A026-79
Shown on high-voltage battery 3 (3) |
3 | High-voltage battery | 8 | Electrical connector | 15 | High-voltage plug | ||
3.1 | Assembly holder | 9 | Equipotential bonding line | 16 | Bolts | ||
6 | Coolant hose lines | 13 | High-voltage lines | 17 | Electrical wiring harness | ||
7 | Electrical connector |
S47.70-A010-78
Shown on high-voltage battery 1 (1) |
1 | High-voltage battery | 19 | Contact socket housing |
S54.10-A027-79
1 | High-voltage battery | 12 | High-voltage lines | 15 | High-voltage plug | ||
2 | High-voltage battery | 13 | High-voltage lines | 18 | Lifting platform | ||
3 | High-voltage battery |
Shown on high-voltage battery 1 (1) |
1 | High-voltage battery |
24 | Diagnostic system |
25 | Battery diagnostic unit |
26 | Adapter cable |
S47.70-A031-06
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. | |
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 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. | |
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 vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on battery | ||
| Remove | ||
1 | Secure vehicle on vehicle lift. | ||
2 | Remove left and right underfloor panelings. | ||
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 corresponding high-voltage battery (1, 2, 3) and enter in "Analysis sheet on transportability of high-voltage batteries". | ||
6 | Check housing of corresponding high-voltage battery (1, 2, 3) in visible area and enter findings in "Analysis sheet on 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 for high-voltage battery cooling system. | ||
9 | Remove voltage of high-voltage on-board electrical system. | ||
10 | Remove respective end plate (4). | ||
| 000 588 11 62 00 Major assembly mount | ||
| 000 588 10 62 00 Support plate | ||
11 | Open holders (5). | ||
12 | Remove coolant hose lines (6) at corresponding high-voltage battery (1, 2, 3). | ||
Seal connections. Collect escaping coolant. | |||
Commercially available tools/devices | |||
Set of protective caps | |||
13 | Disconnect respective electrical connector (7). | ||
14 | Disconnect respective electrical connector (8). | ||
15 | Remove screws (10). | If high-voltage battery 1 (1) will be removed. | |
16 | Unclip bracket (11) and place high voltage lines (12) to one side. | If high-voltage battery 1 (1) will be removed. | |
17.1 | Remove high voltage lines (12, 13) from high-voltage battery 1 (1). | If high-voltage battery 1 (1) will be removed. | |
17.2 | Remove high voltage lines (13) from high-voltage battery 2 (2). | If high-voltage battery 2 (2) will be removed. | |
18.1 | Place high voltage lines (12) to one side. | If high-voltage battery 2 (2) will be removed. | |
18.2 | Place high voltage lines (13) to one side. | If high-voltage battery 2 (2) will be removed. | |
19 | Remove high-voltage plug (15) from corresponding high-voltage battery (1, 2, 3). | ||
20 | Cover high-voltage plugs (15) and high-voltage connections of corresponding high-voltage battery (1, 2, 3) with protective covers. | Set of protective covers | |
Set of protective caps | |||
21.1 | Remove electrical wiring harness (14) from assembly holder (1.1) of high-voltage battery 1 (1). | If high-voltage battery 1 (1) will be removed. | |
21.2 | Remove electrical wiring harness (17) from assembly holder (3.1) of high-voltage battery 3 (3). | If high-voltage battery 3 (3) will be removed. | |
22 | Position lifting platform (18) under corresponding high-voltage battery (1, 2, 3) and align mounts. | ||
| 000 588 03 62 00 Lifting platform | ||
| |||
| Check | ||
23 | Check positioning of mounts of lifting platform (18) for corresponding high-voltage battery (1, 2, 3). | If mounts of lifting platform (18) are not correctly aligned with corresponding high-voltage battery (1, 2, 3), | |
| |||
lower lifting platform (18) and realign mounts. | |||
24 | Unscrew screws (16) of corresponding high-voltage battery (1, 2, 3). | ||
25 | Lower lifting platform (18) with corresponding high-voltage battery (1, 2, 3) until equipotential bonding line (9) can be accessed. | ||
26 | Remove equipotential bonding line (9) from corresponding high-voltage battery (1, 2, 3). | To do this, undo screw/bolt. | |
27 | Lower corresponding high-voltage battery (1, 2, 3). | ||
| Check | ||
28 | Wear personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
29 | Check previously non-visible areas of housing of corresponding high-voltage battery (1, 2, 3) and enter in "Analysis sheet on transportability of high-voltage batteries". | If there is a problem, | |
| |||
contact MPC and/or general representative and store respective high-voltage battery (1, 2, 3) in specified container. | |||
30 | Perform check of corresponding high-voltage battery (1, 2, 3) using vehicle diagnosis system (24). | If high-voltage battery (1, 2, 3) will be replaced. | |
| 000 586 00 99 00 Battery diagnostic unit | ||
The operation steps must be performed exactly as per XENTRY Diagnosis Software. | |||
For this purpose, connect vehicle diagnosis system (24) with adapter cable (26) and battery diagnostic unit (25) to respective high-voltage battery (1, 2, 3). | |||
Select the following menu path: | |||
Adapter cable | |||
If high-voltage battery (1, 2, 3) is assessed as "not safe to transport", | |||
| |||
temporarily store affected high-voltage battery (1, 2, 3) as "unsafe" in specified container and repeat test 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) must be considered as "safe to transport". | |||
If the assessment "not safe to transport" continues to occur after a repeated check, | |||
| |||
contact the MPC and/or general representative and store affected high-voltage battery (1, 2, 3) in specified container. | |||
31 | Take off personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.). | ||
32 | Transfer cap (20) of removed high-voltage battery (1, 2, 3) to new high-voltage battery (1, 2, 3). | If cap (20) on new high-voltage battery (1, 2, 3) is not installed. | |
33 | Transfer contact socket housing (19) from removed high-voltage battery (1, 2, 3) to new high-voltage battery (1, 2, 3). | If high-voltage battery (1, 2, 3) will be replaced. | |
To do so, release contact socket housing (19) (arrows). | |||
34 | Attach lifting device to corresponding removed high-voltage battery (1, 2, 3). | If a corresponding transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Commercially available devices/tools | |||
Adaptation | |||
Lifting device | |||
35 | Lift corresponding high-voltage battery (1, 2, 3) from lifting platform (18) using engine hoist and set down in transportation case. | If a corresponding transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Commercially available devices/tools | |||
36 | Remove lifting device from corresponding high-voltage battery (1, 2, 3). | If a transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Adaptation | |||
Lifting device | |||
37 | Print out and sign the "Control unit log" and the "Analysis sheet 'Safe transportation of lithium-ion battery'" for the corresponding old high-voltage battery (1, 2, 3). | If a transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
38 | Properly pack corresponding high-voltage battery (1, 2, 3) for return delivery. | If a transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Old high-voltage batteries (1, 2, 3) may only be handed over for transport if the respective transportability has been established, documented and proper packaging ensured. | |||
| Install | ||
39 | Attach lifting device to corresponding new high-voltage battery (1, 2, 3). | If a corresponding transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Commercially available devices/tools | |||
Adaptation | |||
Lifting device | |||
40 | Lift corresponding new high-voltage battery (1, 2, 3) using engine hoist and remove from transportation case. | If a corresponding transport-capable high-voltage battery (1, 2, 3) will be replaced. | |
Commercially available devices/tools | |||
41 | Position lifting platform (18) under corresponding new high-voltage battery (1, 2, 3) and align mounts. | If a corresponding transport-capable high-voltage battery (1, 2, 3) was replaced. | |
| 000 588 03 62 00 Lifting platform | ||
| |||
| Check | ||
42 | Check positioning of mounts of lifting platform (18) for corresponding new high-voltage battery (1, 2, 3). | If a corresponding transport-capable high-voltage battery (1, 2, 3) was replaced. | |
If mounts of lifting platform (18) are not correctly aligned with corresponding high-voltage battery (1, 2, 3), | |||
| |||
lift new high-voltage battery (1, 2, 3) and realign mounts. | |||
43 | Remove lifting device from corresponding new high-voltage battery (1, 2, 3). | If a corresponding transport-capable high-voltage battery (1, 2, 3) 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 | |||
44 | Check equipotential bonding line (9) of corresponding high-voltage battery (1, 2, 3). | Check ground lines for high-voltage on-board electrical system potential equalization | |
Nut, potential equalization ground line to high-voltage battery module | |||
45 | Carefully lift corresponding high-voltage battery (1, 2, 3) using lifting platform (18) until associated equipotential bonding line (9) can be attached. | ||
| 000 588 03 62 00 Lifting platform | ||
| |||
Aid of helper required. | |||
46 | Attach equipotential bonding line (9) to corresponding high-voltage battery (1, 2, 3). | Screw, potential equalization ground line to high-voltage battery | |
47 | Align corresponding high-voltage battery (1, 2, 3) with battery frame and lift up to contact surface. | Aid of helper required. | |
48 | First position screws (16) of corresponding high-voltage battery (1, 2, 3) and then tighten. | Screw, assembly holder to high-voltage battery module | |
49 | Lower lifting platform (18) and remove from working area. | ||
| 000 588 03 62 00 Lifting platform | ||
50.1 | Attach electrical wiring harness (14) to assembly holder (1.1) of high-voltage battery 1 (1). | If high-voltage battery 1 (1) was removed. | |
50.2 | Attach electrical wiring harness (17) to assembly holder (3.1) of high-voltage battery 3 (3). | If high-voltage battery 3 (3) was removed. | |
51 | Remove protective covers and attach high-voltage plug (15) to corresponding high-voltage battery (1, 2, 3). | ||
Safety screw for locking element on high-voltage plug | |||
Set of protective covers | |||
Set of protective caps | |||
52.1 | Attach high voltage lines (12, 13) to high-voltage battery 1 (1). | If high-voltage battery 1 (1) was removed. | |
52.2 | Attach high voltage lines (13) to high-voltage battery 2 (2). | If high-voltage battery 2 (2) was removed. | |
53 | Position high voltage lines (12) and clip on bracket (11). | If high-voltage battery 1 (1) was removed. | |
54 | Position high voltage lines (12, 13), attach screws (10) and tighten. | If high-voltage battery 1 (1) was removed. | |
Screw, high-voltage wiring harness holder to high-voltage battery/high-voltage battery module | |||
55 | Connect electrical connectors (7, 8). | ||
56 | Remove protective covers and attach coolant hose lines (6) to corresponding high-voltage battery (1, 2, 3). | ||
Set of protective caps | |||
57 | Align coolant lines and close brackets (5). | ||
58 | Install removed end plates (4). | ||
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 | |||
59 | Remove fuse of the vehicle. | ||
60 | Put the high-voltage on-board electrical system into operation. | ||
61 | Fill coolant for high-voltage battery cooling system and vent high-voltage battery cooling system. | ||
62 | Attach charger to on-board electrical system battery. | If a corresponding high-voltage battery (1, 2, 3) was replaced. | |
| |||
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. | |||
63 | Perform commissioning of corresponding high-voltage battery (1, 2, 3) using vehicle diagnosis system (24). | If a corresponding high-voltage battery (1, 2, 3) was replaced. | |
| |||
Menu path in the respective battery management system (BMS) control unit: | |||
64 | Remove vehicle diagnosis system (24). | If a corresponding high-voltage battery (1, 2, 3) was replaced. | |
65 | Disconnect charger. | If a corresponding high-voltage battery (1, 2, 3) was replaced. | |
66 | Install left and right underfloor panelings. |
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
001 589 02 91 00
Set of protective caps
222 589 04 63 00
Adapter cable
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