Perform fuel system leak test

AR47.60-P-0001RFW

11.02.2019

Engine

780 in model 253.992/993

1	Fuel cell cover

P06.00-2049-05

2	Filler neck

P06.00-A005-05

P06.00-A014-09

Pfeil A

High-pressure test point

P06.00-A006-09

Pfeil A

High-pressure test point

P06.00-A015-09

Manual valve

Pfeil A

High-pressure test point

P06.00-A013-09

Pfeil B

Medium-pressure test point

Pfeil B

Medium-pressure test point

P06.00-A011-06

Pfeil C

Medium-pressure test point

P06.00-A010-06

 Danger	Risk of suffocation due to inhalation of inert gases. Risk of injury when working on pressurized parts.	Wear safety glasses and protective gloves. Work in well-ventilated rooms only.	AS00.00-Z-0034-01RFW
 Danger	Risk of explosion caused by escaping hydrogen or overheating of the fuel tanks when working on the hydrogen system. Risk of frostbite to body parts caused by escaping gas and by touching component parts carrying gas when emptying fuel tanks. Risk of asphyxiation caused by inhalation of air diluted by hydrogen. Risk of burn injuries by coming into contact with an invisible pale blue hydrogen flame.		AS00.00-Z-0030-01B
Topical note	Notes on fuel cell system		AH00.00-P-0022-01RFW
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Check
1	Remove fuel cell cover (1).
2	Remove underfloor paneling in the area of the test points (arrows A, B).		AR61.30-P-1001RFW
3	Fill the high-pressure line system with 20 to 50 bar forming gas via the filler neck (2).
	000 588 21 21 00 leak tester		WS47.00-P-0045B
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04B
		Pressurize fuel system	AR47.60-P-0017-01RFW
		 The manual valves of both fuel tank must have been sealed.
		 Use commercially available forming gas bottle bundles.
4	Check specified value 20 to 50 bar with diagnostic system.
			AD00.00-P-2000-04B
5	Relieve pressure in filling nozzle and remove filling nozzle.
	000 588 21 21 00 Leak tester		WS47.00-P-0045B
			AR47.60-P-0017-01RFW
6	Perform a leak test at 20 to 50 bar on the high-pressure test points (arrows A).
	000 588 03 21 00 Gas detector		WS47.00-P-0019B
		 Use safety glasses and protective gloves.
		 Specified value at all high-pressure test points (arrows A): under 20 ppm with a measurement duration of 10 to 30 s.
		If the specified value is exceeded:
		
		Abort leak test and remove the leakage.
7	Fill the high-pressure line system with 700 bar forming gas via the filler neck (2).
	000 588 21 21 00 Leak tester		WS47.00-P-0045B
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04B
		Pressurize fuel system	AR47.60-P-0017-01RFW
		 Use commercially available forming gas bottle bundles.
8	Check specified value 700 bar with diagnostic system.
			AD00.00-P-2000-04B
9	Relieve pressure in filling nozzle and remove filling nozzle.
	000 588 21 21 00 Leak tester		WS47.00-P-0045B
			AR47.60-P-0017-01RFW
10	Perform a leak test on the high-pressure test points (arrows A) at 700 bar.
	000 588 03 21 00 Gas detector		WS47.00-P-0019B
		 Use safety glasses and protective gloves.
		 Specified value at all high-pressure test points (arrows A): under 20 ppm with a measurement duration of 10 to 30 s.
		If the specified value is exceeded:
		
		Abort leak test and remove the leakage.
11	Perform initial startup of high voltage on-board electrical system.		AR47.70-P-1000RFW
12	Fill the medium pressure line system with 9 to 14 bar forming gas via the diagnostic system.
			AD00.00-P-2000-04B
		 To do this, select the following menu item: Fuel cell control unit (N116/2)  Fuel cell stack (FCU)  Actuations  Leak test of the system pressure
		 The forming gas in the high-pressure line system is sufficient for filling.
13	Perform a leak test on the medium pressure test points (arrows B, C).
	000 588 03 21 00 Gas detector		WS47.00-P-0019B
		 Use safety glasses and protective gloves.
		 Specified value at all medium pressure test points (arrows B, C): under 20 ppm with a measurement duration of 10 to 30 s.
		If the specified value is exceeded:
		
		Abort leak test and remove the leakage.
14	Release pressure in fuel cell system with vehicle diagnosis system.		AR06.00-P-1001RFW
		 Depressurization of the forming gas does not have to take place in the open air. The fuel line system does not contain any hydrogen.
15	Slowly open the manual valves (3) of both fuel tanks completely and then turn them back a  revolution.	If no fuel tank has been inertized or replaced.
16	Slowly open the manual valve (3) of the inertized or replaced fuel tank(s) completely, and then turn them back a  revolution.	If one or both fuel tanks has/have been intertized or replaced.
17	Charge the high-voltage battery in the workshop to approx. 80 % charge level, then remove the charging cable.	 The charge level of the high-voltage battery module is necessary for the diagnosis routines as well as activating different valves.
18	Check the deactivation of the fuel cell in the powertrain control unit (N127).
			AD00.00-P-2000-04B
		 To do this, select the following menu item: Powertrain control unit (N127)  Powertrain (PTCU)  Actuations  Status of the start approval for the fuel cell system component.
		If deactivation of the fuel cell has not been set,
		
		Perform a diagnosis-based deactivation of the fuel cell in the powertrain control unit (N127).
		 If deactivation of the fuel cell has not been set, the fuel cell stack is damaged.
19	Exit the workshop using battery power.
20	Fill the tank until 50 bar hydrogen has been reached.
	000 588 12 82 00 Filling unit		WS06.00-P-0029B
		 It is necessary for the tank temperature to be in the range of 5 to 35 °C before the filling starts. Otherwise, the fuel tank will be damaged.
		 Do not undershoot the 24 bar hydrogen pressure in the fuel tanks. Otherwise, initialization for filling the tank at the public hydrogen filling station is not possible and the tank cannot be filled.
		 Alternatively, the tank can be filled to > 50 bar hydrogen. This increases the range that the vehicle can cover on its own power.
		 While filling the tank, monitor the tank temperature with the diagnostic system. Do not overshoot the specified value of 85 °C.
		 Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH.
		 To do this, select the following menu item: Fuel system control unit (N3/19)  Actuations  Flushing fuel tank 1 or 2 with hydrogen.
		If the tank temperature is close to 85 °C,
		
		Stop filling the tank until the tank temperature has fallen to the right level.
21	Flushing the fuel system	If one or both fuel tanks has/have been intertized or replaced.
			AR47.60-P-0024RFW
		 The leak test is ended in "Flushing the fuel system", so the subsequent work steps are no longer necessary.
22	Briefly fill the high-pressure line systems with  50 bar hydrogen via the filler neck (2).	If the supply pressure in the fuel tanks is sufficient and the tank was therefore not filled up to 50 bar hydrogen (work step 20).
	000 588 12 82 00 Filling unit		WS06.00-P-0029B
		 It is absolutely essential to perform the brief filling of the high-pressure line system. Otherwise, it will not be possible to start the fuel cell aggregate in the line system due to the pressure differences.
23	Perform a diagnosis-based activation of the fuel cell in the powertrain control unit (N127).
			AD00.00-P-2000-04B
		 To do this, select the following menu item: Powertrain control unit (N127)  Powertrain (PTCU)  Actuations  Status of the start approval for the fuel cell system component.
24	Start fuel cell system, let it run at a standstill for at least 5 min and read the fault messages in the instrument cluster.		AR06.00-P-0002-01RFW
		If a fault message appears in the instrument cluster,
		
		switch off fuel cell system and eliminate the fault.
25	Perform a brief diagnosis test.
			AD00.00-P-2000-04B
26	Fill the vehicle to 700 bar at a hydrogen filling station.	 If necessary, transport the vehicle on a passenger car transport trailer or a passenger car van.
27	Drive into the workshop.
28	Perform the "Special service, recurring check of gas system".
			AP00.20-P-1310E
29	Install underfloor paneling.		AR61.30-P-1001RFW
30	Install fuel cell cover (1).
31	Place all filled-out logs in the order folder and store it in an appropriate location.

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