Check high-voltage on-board electrical system for damage

AR47.70-S-0019F

Check high-voltage on-board electrical system for damage

26.06.2020

Engine

780.701/702 in model 447

General overview, shown with engine 780.701

A9/6

Electric refrigerant compressor

N33/8

Battery heater control unit

A79/1

Electric machine

N83/3

DC/DC converter control unit

A79/3

Electric machine control unit

N83/11

AC charger for high-voltage battery

G1/18

High-voltage battery 1

N116/5

High-voltage distributor module 1

G1/27

High-voltage battery 2

N116/10

High-voltage distributor module 2

G1/28

High-voltage battery 3

X58/23

230 V feed socket

N33/7

High-voltage PTC heater control unit

General overview, shown with engine 780.702

A9/6

Electric refrigerant compressor

N33/7

High-voltage PTC heater control unit

A79/1

Electric machine

N33/8

Battery heater control unit

A79/3

Power electronics control unit

N83/3

DC/DC converter control unit

G1/29

High-voltage battery

N83/11

AC charger for high-voltage battery

G10

DC/AC charging vehicle socket

N116/11

High-voltage power distributor

Component part overview, shown with engine 780.701

12

Condenser

N83/3

DC/DC converter control unit

13

Heat exchanger

N83/11

AC charger for high-voltage battery

A9/6

Electric refrigerant compressor

N116/5

High-voltage distributor module 1

M56

Electric vacuum pump

Y16/10

Condensation prevention switchover valve

Component part overview, shown with engine 780.702

12

Condenser

N83/3

DC/DC converter control unit

13

Heat exchanger

N83/11

AC charger for high-voltage battery

A9/6

Electric refrigerant compressor

N116/11

High-voltage power distributor

M56

Electric vacuum pump

Y16/10

Condensation prevention switchover valve

 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.

AS54.10-Z-0001-01A

 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.

AS00.00-Z-0035-01A

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

AH00.00-Z-0300-01A

Topical note

Notes on battery

AH54.10-P-0001-01A



Check

1

Check whether you have the required qualification for assessing the safety of high-voltage on-board electrical systems.



Service Information: Qualification measures for working on high-voltage on-board electrical systems, lithium-ion batteries and gaseous fuel drive systems

SI00.00-S-0156A

Checks before entry into the workshop for a vehicle with a fault in the high-voltage on-board electrical system or accident damage

2

Before entry into the workshop, check the orange high-voltage lines, high voltage components/detachable parts near the high voltage components via a visual check for a fire, smoke development, the consequences of a fire, or internal heat development.

 Smoke is often an early indication of fire.

If smoke development, tarnishing or scorched component parts are identifiable:



Immediately make an emergency call using the appropriate location- and country-specific emergency call number; do not touch the high voltage components. Exit the danger zone.

3

Before entry into the workshop, check whether accident damage to the underbody or in the area of the high voltage components is present.



Service Information: Handling high-voltage batteries after an accident with airbag and/or pyrofuse triggering

SI54.10-P-0035A

4

Before entry into the workshop, check lithium-ion batteries for acute hazards.

AR47.70-S-0017F

5

Bring vehicle into the workshop.

If no problems were determined during operation steps 2 to 4.

Additional checks in the workshop for a vehicle with faults in the high-voltage on-board electrical system or accident damage

6

Connect diagnostic system and run quick test.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-S-2000-04E

If there is a fault message for a high-voltage component or there is an insulation fault,



rectify these problems as part of the maintenance work in accordance with the repair documentation.

7

Carry out additional checks of the lithium-ion batteries in the workshop.

If it can be assumed that there is damage because of a fire or accident damage near the lithium-ion batteries or there is a fault message in the diagnostic system.

AR47.70-S-0017F

8

Remove voltage of high-voltage on-board electrical system.

If it can be assumed that orange high-voltage lines or high voltage components are damaged due to a fire or accident damage in the area of high voltage components or a fault message in the diagnostic system.

Engine 780.701 in model 447

AR47.70-S-1000F

Engine 780.702 in model 447

AR47.70-S-1000G

9

Check orange high-voltage lines and sockets in the fire area or accident area for damage.

If an orange high-voltage line or existing socket is damaged,



rectify these problems as part of the maintenance work in accordance with the repair documentation.