Remove/install contacts from coupling housing of high-voltage disconnect device

AR47.70-S-1000-01F

Remove/install contacts from coupling housing of high-voltage disconnect device

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Model

447 with engine 780.701/702

Model

910 with engine 780.703

Remove contacts from coupling housing (2) of high-voltage disconnect device.

1

Using side cutting pliers (1), remove bars (arrows A) at both sides of coupling housing (2).

2

Release fuse (4) on jumper plug (3) and pull out in the direction of the arrow (B).

3

Press in fuse (4) in the direction of the arrow (C) and remove jumper plug (3) from the coupling housing (2) completely in the direction of the arrow (D).

4

Dispose of jumper plug (3).

5

Release secondary lock (5) in coupling housing (2) in direction of the arrow (E) using a suitable tool.

6

Mark or note down the installation position of all electric lines.

7

Insert  release tool with MLK 1.2_bushing ejector (7) from the front in the direction of the arrow (F), through the opening in the coupling housing (2) up to the end stop.

 The spring shackle on the contact socket (6) is pressed down.

8

Pull the contact socket (6) out in the direction of the arrow (G).

9

Remove the remaining contact sockets (6) from the coupling housing (2) in the same way.

 Repeat operation steps 7 and 8 accordingly.

Example illustration on a 6-pin connector

Install contacts in the coupling housing (2) of the high-voltage disconnect device

10

Replace the corresponding contact socket (6) with the  basic wiring harness repair kit or the  supplement wiring harness repair kit for passenger cars.

If a contact socket (6) is damaged.

11

Replace coupling housing (2).

 Transfer the markings to the new coupling housing (2).

12

Install all electric lines with the contact sockets (6), in the direction of arrow (H), in the correct slot of coupling housing (2).

 Observe the markings or notes applied.
Otherwise the high-voltage disconnect device will not function or damage to the electrical system may occur.

13

Release secondary lock (5) in coupling housing (2) in the direction of arrow (I) using a suitable tool.

14

Insert new jumper plug (3) into coupling housing (2).

15

Lift the shackle in the direction of the arrow (K), press in the fuse (4) in the direction of the arrow (J) and push the jumper plug (3) into coupling housing (2) in the direction of the arrow (L).

 Carefully push jumper plug (3) into coupling housing (2).
Otherwise, the high-voltage disconnect device may be damaged.

16

Push in fuse (4) in the direction of the arrow (M) until it engages.