Remove/install DC current charge-connection unit

AR47.70-S-0028G

Remove/install DC current charge-connection unit

10.03.2020

Engine

780.702 in model 447

1

Direct current charge connection unit

5

High-voltage plug

9

Electrical connector

2

High-voltage lines

6

High-voltage plug

10

Electrical wiring harness

3

Bracket

7

High-voltage plug

11

Electrical line

4

Bracket

8

Electrical connector

13

Ground cable

1

Direct current charge connection unit

12

Cover panel

13

Ground cable

14

Vent line

15

Nuts

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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

 

Remove/install

1

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

AR47.70-S-1000G

2

Remove high-voltage lines (2) from the brackets (3, 4).

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage exists,



Replace damaged retaining clips.

3

Release and disconnect high-voltage plug (5).

4

Disconnect high-voltage plug (6).

AR47.70-S-0005-01F

 Safety screw, locking element to DC current charge-connection unit high-voltage plug

*BA47.70-N-1001-07G

5

Release and disconnect high-voltage plug (7).

 WIS Service Media
wsm://04_ 201800_30

6

Disconnect electrical connectors (8, 9).

7

Remove electrical wiring harness (10).

 Installation: Check retaining clamp and retaining clip for damage.

 Clip remover

*452589016300

If damage exists,



replace retaining clamp and retaining clip.

8

Remove electric line (11) from DC current charge-connection unit (1) and place to one side.

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-S-1020-01G

 Installation: Check electric line (11).

 Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

*BA47.70-N-1014-02F

9

Cover high-voltage connections with suitable protective covers.

 Set of protective covers

*001589019100

10

Remove high-voltage power distributor from the tubular frame.

AR47.70-S-0003G

 Do not remove high-voltage lines.

11

Remove cover panel (12).

 To do this, remove left and right side screws.

 Screw, DC current charge-connection unit cover panel to side bracket

*BA47.70-N-1004-07G

12

Remove electric circulation pump and place to one side.

AR83.20-S-0002F

 Do not remove coolant hose lines.

13

Remove ground line (13) from the assembly carrier.

 Nut, potential equalization ground line to bracket for charger, DC/DC converter, heater

*BA47.70-N-1007-02F

14

Remove bleed line (14) of the expansion reservoir from the tubular frame and from the assembly carrier.

 Installation: Check retaining clips for damage.

If damage exists,



replace affected retaining clips.

15

Loosen screw of the ground line (13).

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-S-1020-01G

 Installation: Check ground line (13).

 Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

*BA47.70-N-1014-02F

16

Remove nuts (15).

 Nut, DC current charge-connection unit to DC current charge-connection unit bracket

*BA47.70-N-1002-07G

17

Remove DC current charge-connection unit (1).

18

Change ground line (13).

If DC current charge-connection unit (1) will be replaced.

19

Install in the reverse order.

20

Perform commissioning of DC current charge-connection unit (1) using vehicle diagnosis system.

If a new DC current charge-connection unit (1) was installed.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-S-2000-04E

 Direct current charge connection unit

Number

Designation

Engine 780.702 in model 447

BA47.70-N-1001-07G

Safety screw, locking element to DC current charge-connection unit high-voltage plug

Nm

4

 Direct current charge connection unit

Number

Designation

Engine 780.702 in model 447

BA47.70-N-1002-07G

Nut, DC current charge-connection unit to DC current charge-connection unit bracket

Nm

23

 Direct current charge connection unit

Number

Designation

Engine 780.702 in model 447

BA47.70-N-1004-07G

Screw, DC current charge-connection unit cover panel to side bracket

Nm

20

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.702 in model 447

BA47.70-N-1007-02F

Nut, potential equalization ground line to bracket for charger, DC/DC converter, heater

Nm

16

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.702 in model 447

BA47.70-N-1014-02F

Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

Nm

7