Manually deenergize high-voltage on-board electrical system

AR47.70-P-1010RFW

27.11.2019

Engine

780 in model 253.992/993

Manually deenergize high-voltage on-board electrical system

S7	High-voltage disconnect device

P54.10-4350-10

P54.10-4110-09

1	Jump-start connection point
2	Ground connection

P54.10-4735-12

3	Line bracket (4St.)
4	High-voltage battery frame
5.1	High-voltage plug for high-voltage distributor plate 1
6	High-voltage battery for alternating current charger high-voltage line
6.1	Alternating current charger high-voltage plug on high-voltage battery
A100	High-voltage battery module

P54.10-4736-06

P54.10-A003-09

6	High-voltage battery for alternating current charger high-voltage line		N83/11	Alternating current charger for high-voltage battery
6a.1	Alternating current charger high-voltage plug on high-voltage battery

P54.10-4737-09

7	High voltage line high-voltage distributor plate 2		N83/1	DC/DC converter control unit
7.1	High-voltage plug for high-voltage distributor plate 2

8	High voltage line electrical refrigerant compressor
8.1	High-voltage plug for electric refrigerant compressor
9	High voltage line for electrical compressor
9.1	High-voltage plug for electrical compressor
10	High voltage line for PTC heater
10.1	High-voltage plug for PTC heater
N129/8	Fuel cell DC/DC converter control unit

P54.10-4760-06

11	Bolts
12	Service cover
A	Dowel pin

P54.10-A042-06

 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
 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	Notes on fuel cell system		AH00.00-P-0022-01RFW
Topical note	General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system		AH00.00-Z-0300-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Topical note	Notes on battery		AH54.10-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Preparatory tasks
1	Ensure that the requirements for driving into the workshop are fulfilled.
Topical note	Requirements for driving into the workshop		AH00.00-P-0021-01RFW
2	Print out "tank system, fuel cell, form event log," fill out, and attach to the vehicle somewhere clearly visible.
			OF00.00-P-3000-21RFW
3	Print out the "Manually deenergize high-voltage on-board electrical system" form
			OF54.10-P-3000-50RFW
		 Before beginning the test work, print out the form and fill it out during the test.
		 No-one must be located in or on the vehicle throughout the entire power disable procedure.
4	Disconnect charging cable and attach a warning sign to socket flap in rear bumper to prevent cable from being reconnected.	 If the socket flap or the vehicle socket have to be removed during the following jobs, do not close the charging socket flap.
		 Warning label	*451589086300
5	Read out the fault memory in the fuel cell management system control unit (N116/5).
			AD00.00-P-2000-04B
		If no control unit communication with the fuel cell management system control unit (N116/5) is possible, or if the fault code C2E01B7 has been set, or the fault code C2E02B7 has been set,
		
		Abort the rest of the power disable sequence and notify the responsible market support department.
6	Perform a brief diagnosis test.
			AD00.00-P-2000-04B
7	Open hood.
8	Open tailgate.
9	Switch off all electrical consumers, and disconnect charger and vehicle diagnosis system.	If electrical consumers are active, a charger or a vehicle diagnosis system is connected.
			AD00.00-P-2000-04B
10	Switch off ignition and store transmitter key outside of transmitter range (min. 5 m).
11	Activate high-voltage disconnect device (S7), as shown in picture sequence (A, B, C), and secure it with a shackle-type lock.	 Keep the key for the shackle-type lock of the high-voltage disconnect device (S7) in a separate location accessible to authorized personnel only.
		 Wait the passive discharge time of 5 min before starting the test jobs.
12	Check 2-pin voltage tester for proper operation.
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Check 2-pin voltage tester for proper operation before starting the test work in accordance with the manufacturer's specifications.
	Check
13	Detach and cover the ground line of on-board electrical system battery.		AR54.10-P-0003LW
		 Before starting the test jobs, wait 10 s.
14	Remove load compartment floor.		AR68.80-P-5800RFW
15	Remove the charge air noise damper.		AR06.11-P-0008RFW
16	Use a 2-pin voltage tester to check that power has been disconnected between jump-start connection point (1) and ground connection (2)	 Target value < 1 V DC
		If the voltage is higher than the specified target value,
		
		Abort the rest of the power disable sequence and notify the responsible market support department.
17	Visually inspect high-voltage components, electrical connections and the electrical lines for damage.	 Ensure here that no high-voltage components are active, e.g. the electric refrigerant compressor must not be active, the heater booster must not be active (i.e. pump noise).
		If one of the components of the high-voltage on-board electrical system is damaged or active,
		
		Abort the rest of the power disable sequence and notify the responsible market support department.
18	Unclip line brackets (3) on the high-voltage battery frame (4).	 Clip remover	*452589016300
19	Unclip high voltage line for high-voltage battery alternating current charger (6) from the high-voltage battery frame (4).
20	Wear personal protective equipment.	 Personal protective equipment must always be worn when performing the following operation steps: arc-resistant jacket, face mask and electrical protective gloves.
21	Remove the high-voltage plug for the high-voltage distributor plate 1 (5.1) from the high-voltage battery module (A100).		AR08.00-P-0101-01RFW
		 Engine 780 in model 253.992/993 with code ME02 (Fuel cell)Bolt, high-voltage connector to high-voltage battery	*BA54.10-P-1006-02H
22	Check voltage at high-voltage distributor plate 1 connection on high-voltage battery module (A100).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*222589026300
23	Check voltage at high-voltage plug for high-voltage distributor plate 1 (5.1).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
24	Disconnect the high-voltage plug for the alternating current charger on the high-voltage battery (6.1) from the high-voltage battery module (A100).
25	Check voltage at high-voltage battery AC charger connection on high-voltage battery module (A100).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*000589926300
26	Disconnect the high-voltage plug for alternating current charger on high-voltage battery (6a.1) from the alternating current charger for high-voltage battery (N83/11).
27	Check voltage at high-voltage battery AC charger connection (N83/11).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*000589926300
28	Disconnect the high-voltage plug for high-voltage distributor plate 2 (7.1) from the DC/DC converter control unit (N83/1).
29	Expose high voltage line for high-voltage distributor plate 2 (7).
30	Check voltage at high-voltage distributor plate 2 connection on DC/DC converter control unit (N83/1).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*222589056300
31	Check voltage at high-voltage plug for high-voltage distributor plate 2 (7.1).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
32	Disconnect the high-voltage plug for electrical refrigerant compressor (8.1) from the fuel cell DC/DC converter control unit (N129/8).
33	Check voltage at electric refrigerant compressor connection on fuel cell DC/DC converter control unit (N129/8).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*222589056300
34	Check voltage at high-voltage plug for electric refrigerant compressor (8.1).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
35	Disconnect the high-voltage plug for electrical compressor (9.1) from the power electronics control unit (N129/1).
36	Check voltage at electric compressor connection on DC/DC converter control unit (N129/8).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Test adapter	*222589056300
37	Check voltage at high-voltage plug for electric compressor (9.1).		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
38	Disconnect the high-voltage plug for PTC heater (10.1) from the fuel cell DC/DC converter control unit (N129/8) and place high voltage lines (8, 9, 10) to one side.
39	Unscrew screws (11) and remove service cover (12), starting at the arrow.	 Remove service cover (12) without tilting it. Otherwise, the dowel pins or the service cover (12) will be damaged.
		 The service cover (12) is guided by two dowel pins.
		 Do not remove the insulation cover located beneath it.
		 Installation: Replace seal on service cover (12).
		 To prevent the dowel pins (A) from breaking off / tilting, the electro safety gloves can be temporarily taken off for this work stop in order to protect the component.
		 Screw, small/large service cover to voltage converter	*BA08.10-P-1006-03B
40	Put on electro safety gloves.	If these have been taken off in the previous step.
41	Check for continuity at test sockets of fuel cell DC/DC converter control unit (N129/8).
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
			AR54.10-P-1039-04RFW
		 Commercially available equipment/tools magnetic adapter, comparable with: Manufacturer: ELECTRO PJP Designation: MAG 66 IEC3 Magnet diameter: 6.6 mm Rated current: 4 A Rated voltage: 1,000 V CAT III / 600 V CAT IV
		 Personal protective equipment must always be worn when performing the following operation steps: arc-resistant jacket, face mask and electrical protective gloves.
42	Check voltages at test sockets of fuel cell DC/DC converter control unit (N129/8).
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
			AR54.10-P-1039-04RFW
		 Commercially available equipment/tools magnetic adapter, comparable with: Manufacturer: ELECTRO PJP Designation: MAG 66 IEC3 Magnet diameter: 6.6 mm Rated current: 4 A Rated voltage: 1,000 V CAT III / 600 V CAT IV
43	Connect ground line of on-board electrical system battery.		AR54.10-P-0003LW
44	Switch on ignition.
45	Check voltage at high-voltage distributor plate 1 connection on high-voltage battery module (A100) again.		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Perform the voltage test only between the red female test connector (HV+) and the black female test connector (HV -) on the test adapter.
		 Test adapter	*222589026300
46	Check voltage at high-voltage battery AC charger connection on high-voltage battery module (A100) again.		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Perform the voltage test only between the red female test connector (HV+) and the black female test connector (HV -) on the test adapter.
		 Test adapter	*000589926300
47	Check voltage at high-voltage battery AC charger connection (N83/11) again.		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Perform the voltage test only between the red female test connector (HV+) and the black female test connector (HV -) on the test adapter.
		 Test adapter	*000589926300
48	Check voltage at high-voltage distributor plate 2 connection on DC/DC converter control unit (N83/1) again.		AR54.10-P-1039-04RFW
	000 588 07 19 00 Measuring instrument		WS54.00-N-3005B
		 Perform the voltage test only between the red female test connector (HV+) and the black female test connector (HV -) on the test adapter.
		 Test adapter	*222589056300
49	Determine de-energized state.	 If a voltage of < 60 V DC is determined for all voltage tests, the high-voltage system in the vehicle is considered to be disabled.
	Reworking
50	Switch off ignition.
51	Remove personal protective equipment.
52	Seal off open high-voltage plugs and high-voltage couplings with protective covers.	 Set of protective caps	*001589009100
		 Set of protective covers	*001589019100
53	Complete the "Manually deenergize high-voltage on-board electrical system" form.
			OF54.10-P-3000-50RFW
		 Place the form behind the windshield until the restart procedure and add it to the repair documentation after restart procedure.
	Initial startup
54	Perform initial startup of high voltage on-board electrical system.		AR47.70-P-1000RFW
	Install
55	Install the charge air noise damper.		AR06.11-P-0008RFW
56	Install load compartment floor.		AR68.80-P-5800RFW

 Power electronics

Number	Designation			Engine 780 in model 253.992/993 with code ME02 (Fuel cell)
BA08.10-P-1006-03B	Screw, small/large service cover to voltage converter	M6	Nm	8