AR47.70-D-1010-01TE | Manually check high-voltage on-board electrical system for absence of voltage | ||
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. | |
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 | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on battery | ||
Clip: Detach/attach high-voltage plug | |||
Clip: Remove/install high-voltage power distributor in engine compartment | |||
| 000 588 07 19 00 Measuring instrument |
000 589 94 63 00
Test adapter
000 589 96 63 00
Test adapter
222 589 02 63 00
Test adapter
S47.70-A046-77
All measurements in high-voltage on-board electrical system must only be performed with the approved special tools and workshop equipment.
High-voltage connecting points or high-voltage components will otherwise be damaged.
222 589 02 63 00: Test adapter (1a)
000 589 96 63 00: Test adapter (1b)
000 589 94 63 00: Test adapter (1c)
000 588 07 19 00: Measuring instrument (2)
Carefully contact the bushings with the probes of the measuring instrument (2).
The bushings or probes will otherwise be damaged.
Ensure cleanliness during entire work procedure.
High voltage components can otherwise be damaged.
Prior to conducting the voltage measurement, check the condition and functionality of the measuring instrument (2) according to the manufacturer's information.
S47.70-A046-77
Shown are measuring points during voltage measurements (A, B, C) |
Voltage measurement (A) is realized between red socket "Positive"/"HV+" and brown socket "Ground connection"/"HV" at corresponding test adapter (1a, 1b, 1c).
Voltage measurement (B) is realized between black socket "Minus"/"HV-" and brown socket "Ground connection"/"HV" at corresponding test adapter (1a, 1b, 1c).
Voltage measurement (C) is realized between red socket "Positive"/"HV+" and black socket "Minus"/"HV-" at corresponding test adapter (1a, 1b, 1c).
If an acoustic signal is output as a result instead of a voltage value by the measuring instrument (2) during a voltage measurement (A, B, C); this is not a malfunction.
In this case, the detected voltage is below the display range of the measuring instrument (2); this automatically activates the continuity check.
In this case, a voltage value of 0 V must be entered in the test log (form).
Fill in the printed out test log (form) on a step-by-step basis during the tests.
Test log (form) must be placed behind windshield at the end of the test and by the restart procedure.
S47.70-A046-77
Perform voltage measurements (A, B, C) at high-voltage batteries (3, 4, 5)
1 | Remove high-voltage lines (9, 10, 11) of high-voltage plugs (6, 7, 8) from holders directly behind respective high-voltage plug (6, 7, 8). |
2 | Release high-voltage plugs (6, 7, 8). |
For this purpose, turn safety screw counterclockwise until locking element has moved as far as end stop. |
Shown on installed HV battery module |
D47.70-A009-82
3 | Disconnect high-voltage plugs (6, 7, 8) at high-voltage batteries (3, 4, 5). |
Do not pull on high-voltage lines (9, 10, 11). |
4 | Install test adapter (1a) at high-voltage battery 1 (3). |
5 | Perform voltage measurements (A, B, C) at sockets of test adapter (1a), evaluate and enter in test log. |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
6 | Remove test adapter (1a) from high-voltage battery 1 (3) and install at high-voltage battery 2 (4). |
7 | Perform voltage measurements (A, B, C) at sockets of test adapter (1a), evaluate and enter in test log. |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
8 | Remove test adapter (1a) from high-voltage battery 2 (4) and install at high-voltage battery 3 (5). |
9 | Perform voltage measurements (A, B, C) at sockets of test adapter (1a), evaluate and enter in test log. |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
10 | Remove test adapter (1a) from high-voltage battery 3 (5). |
S47.70-A046-77
D47.70-A010-78
Shown with code E4T (high-voltage battery (47 kWh)) |
Perform voltage measurements (A, B, C) at high-voltage battery 4 (12)
11 | Engine 780.703 in model 910 |
12 | Engine 780.703 in model 910 |
For this purpose, turn safety screw counterclockwise until locking element has moved as far as end stop. |
13 | Engine 780.703 in model 910 |
Do not pull on high voltage lines (14). |
14 | Engine 780.703 in model 910 |
15 | Engine 780.703 in model 910 |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
16 | Engine 780.703 in model 910 |
S47.70-A046-77
D47.70-A013-78
Perform voltage measurements (A, B, C) at electrical drivetrain at underbody
17 | Remove high-voltage lines of high-voltage plug (16) from holder at underbody high-voltage power distributor (15). |
18 | Release and disconnect high-voltage plug (16) at underbody high-voltage power distributor (15). |
19 | Install test adapter (1b) at high-voltage plug (16). |
20 | Perform voltage measurements (A, B, C) at sockets of test adapter (1b), evaluate and enter in test log. |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
21 | Remove test adapter (1b) at high-voltage plug (16). |
S47.70-A046-77
D47.70-A082-78
Perform voltage measurements (A, B, C) at engine compartment high-voltage power distributor (17)
22 | Release and disconnect high-voltage plug (18) at engine compartment high-voltage power distributor (17). |
High-voltage plug (18) without high voltage line is located at connection 4 of engine compartment high-voltage power distributor (17). |
23 | Attach test adapter (1c) to engine compartment high-voltage power distributor (17). |
24 | Perform voltage measurements (A, B, C) at sockets of test adapter (1c), evaluate and enter in test log. |
If a direct voltage 60 V DC is present for one of the three voltage measurements (A, B, C) |
|
cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
25 | Remove test adapter (1c) from engine compartment high-voltage power distributor (17). |
Completion before commissioning
Connections of all high-voltage components must be contacted again before commissioning.
26 | Attach high-voltage plugs (6, 7, 8) to high-voltage batteries (3, 4, 5). |
Do not handle high-voltage plugs (6, 7, 8) on high-voltage lines (9, 10, 11) and do not twist during attachment. |
Both retaining brackets must fully enclose holding lugs. |
For this purpose, insert respective high-voltage plugs (6, 7, 8) until engagement of retaining brackets on holding lugs. |
D47.70-A009-82
27 | Tighten safety screw of respective high-voltage plug (6, 7, 8) . |
Ensure that respective locking element is fully locked. |
28 | Install high-voltage lines (9, 10, 11) at holders directly behind respective high-voltage plug (6, 7, 8). |
Check retaining clips for damage. |
If damage is present: |
|
Replace damaged retaining clips. |
D47.70-A010-78
Shown with code E4T (high-voltage battery (47 kWh)) |
29 | Engine 780.703 in model 910 |
Do not handle high-voltage plug (13) at high-voltage lines (14) and do not twist during attachment. |
Both retaining brackets must fully enclose holding lugs. |
For this purpose, insert high-voltage plug (13) until engagement of retaining brackets on holding lugs. |
30 | Engine 780.703 in model 910 |
Ensure that locking element is fully locked. |
31 | Engine 780.703 in model 910 |
Check retaining clips for damage. |
If damage is present: |
|
Replace damaged retaining clips. |
D47.70-A013-78
32 | Install and lock high-voltage plug (16). |
33 | Install high-voltage lines of high-voltage plug (16) at holder at underbody high-voltage power distributor (15). |
Check retaining clips for damage. |
If damage is present: |
|
Replace damaged retaining clips. |
D47.70-A082-78
34 | Attach high-voltage plug (18) to engine compartment high-voltage power distributor (17). |