Remove/install high-pressure line from high-pressure fuel circuit gas distributor to pressure regulating unit

AR47.60-P-0037RFW

Remove/install high-pressure line from high-pressure fuel circuit gas distributor to pressure regulating unit

28.11.2018

Engine

780 in model 253.992/993

1

High pressure pipe

4

Line bracket

2

Union nut

5

Screw

3

Union nut

6

Check strap

S7

High-voltage disconnect device

 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

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Release pressure in fuel cell system with vehicle diagnosis system.

AR06.00-P-1001RFW

If the diagnosis-based pressure release cannot be performed,



Manually release pressure in fuel cell system

AR06.00-P-1000RFW

2

Ensure that the requirements for driving into the workshop are fulfilled.

Topical note

Requirements for driving into the workshop

AH00.00-P-0021-01RFW

3

Print out "tank system, fuel cell, form event log," fill out, and attach to the vehicle somewhere clearly visible.



OF00.00-P-3000-21RFW

4

Activate high-voltage disconnect device (S7), as shown in picture sequence (A, B, C), and lock it with a shackle-type lock.

 Installation:
Carefully connect high-voltage disconnect device (S7), as show in picture sequence (D, E, F).
Otherwise the high-voltage disconnect device (S7) will be damaged.

 For the electrical interruption of the tank components.

 Keep the key for the shackle-type lock of the high-voltage disconnect device (S7) in a separate location accessible to authorized personnel only.

 Installation: Check high-voltage disconnect device (S7) for damage.

If damage is present,



Remove contacts from coupling housing of high-voltage disconnect device (S7) and replace high-voltage disconnect device (S7).

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

AR00.19-P-0120-31A

 New passenger car wiring harness repair kit

*220589049900

 Unlocker with ejector MLK 1.2_plug

*220589019925

 Wiring harness repair kit, basic

*000589139900

5

Remove underfloor paneling in the area of the high-pressure line (1).

AR61.30-P-1001RFW

 Installation: Do not install underfloor paneling until after the leak test has been performed.

6

Unscrew the screw (5) and place check strap (6) to one side.

 Bolt, assembly frame for rear fuel tank tensioning strap to body

*BA47.60-P-1004-01B

7

Unscrew union nut (2) for high-pressure line (1).

 Wear protective gloves.

 Union nut, hydrogen line to gas distributor/valve unit

*BA47.60-P-1018-01B

8

Unscrew union nut (3) for high-pressure line (1).

 Wear protective gloves.

 Union nut, hydrogen line to gas distributor/valve unit

*BA47.60-P-1018-01B

9

Unclip the high-pressure line (1) from the line brackets (4).

10

Remove high-pressure line (1).

11

Seal open lines and connections.

 Set of protective caps

*001589009100

 Record plug

*129589009100

12

Install in the reverse order.



Check

13

Perform fuel system leak test.

AR47.60-P-0001RFW

 Tank system

Number

Designation

Engine 780 in model 253.992/993
with code ME02 (Fuel cell)

BA47.60-P-1004-01B

Bolt, assembly frame for rear fuel tank tensioning strap to body

M8

Nm

18

 Tank system

Number

Designation

Engine 780 in model 253.992/993
with code ME02 (Fuel cell)

BA47.60-P-1018-01B

Union nut, hydrogen line to gas distributor/valve unit

Nm

20