AR47.70-S-1010-01F | 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
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All measurements in high-voltage on-board electrical system must only be performed with the approved special tools and workshop appliances.
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.
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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" on corresponding test adapter (1a, 1b, 1c).
Voltage measurement (B) is realized between black socket "Minus"/"HV-" and brown socket "Ground connection"/"HV" on corresponding test adapter (1a, 1b, 1c).
Voltage measurement (C) is realized between red socket "Positive"/"HV+" and black socket "Minus"/"HV-" on corresponding test adapter (1a, 1b, 1c).
If the measuring instrument (2) outputs an acoustic signal as a result instead of a voltage value 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.
After the end of the test and until the restart procedure, place the test log (form) behind the windshield.
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S47.70-A069-79
Shown on removed high-voltage battery module |
Perform voltage measurements (A, B, C) on high-voltage batteries (6, 7, 8)
1 | Release high-voltage plugs (3, 4, 5). |
For this purpose, turn safety screw counterclockwise until locking element has moved as far as end stop. |
2 | Disconnect high-voltage plugs (3, 4, 5) from high-voltage batteries (6, 7, 8). |
Do not pull on high-voltage lines. |
3 | Install test adapter (1a) on high-voltage battery 1 (6). |
4 | Perform voltage measurements (A, B, C) on 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), |
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cancel the manual test for absence of voltage and inform the market support team responsible immediately. |
5 | Remove test adapter (1a) from high-voltage battery 1 (6) and install on high-voltage battery 2 (7). |
6 | Perform voltage measurements (A, B, C) on 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. |
7 | Remove test adapter (1a) from high-voltage battery 2 (7) and install on high-voltage battery 3 (8). |
8 | Perform voltage measurements (A, B, C) on 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. |
9 | Remove test adapter (1a) from high-voltage battery 3 (8). |
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S47.70-A067-78
Perform voltage measurements (A, B, C) on electrical drivetrain on underbody
10 | Remove high-voltage lines of high-voltage plug (10) from holder on underbody high-voltage power distributor (9). |
11 | Release and disconnect high-voltage plug (10) on underbody high-voltage power distributor (9). |
12 | Install test adapter (1b) on high-voltage plug (10). |
13 | Perform voltage measurements (A, B, C) on 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. |
14 | Remove test adapter (1b) from high-voltage plug (10). |
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S47.70-A068-79
Perform voltage measurements (A, B, C) on engine compartment high-voltage power distributor (11)
15 | Remove high-voltage line (12) from holder on engine compartment high-voltage power distributor (11). |
16 | Release and disconnect high-voltage plug (13) on engine compartment high-voltage power distributor (11). |
The high-voltage plug (13) is located on connection 4 of the engine compartment high-voltage power distributor (11). |
17 | Attach test adapter (1c) to engine compartment high-voltage power distributor(11). |
18 | Perform voltage measurements (A, B, C) on 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. |
19 | Remove test adapter (1c) from engine compartment high-voltage power distributor (11). |
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Completion before commissioning
Connections of all high voltage components must be contacted again before commissioning.
20 | Attach high-voltage plugs (3, 4, 5) to high-voltage batteries (6, 7, 8). |
Do not handle high-voltage plugs (3, 4, 5) on high-voltage lines and do not twist when plugging in. |
Both retaining brackets must fully enclose holding lugs. |
To do so, insert associated high-voltage plugs (3, 4, 5) until retaining brackets engage on holding lugs. |
21 | Tighten safety screw of each high-voltage plug (3, 4, 5) . |
Ensure that respective locking element is fully locked. |
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22 | Attach and lock high-voltage plug (10). |
23 | Attach high-voltage lines for the high-voltage plug (10) on the holder for the underbody high-voltage power distributor (9). |
Check retaining clips for damage. |
If damage is present: |
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Replace damaged retaining clips. |
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24 | Attach high-voltage plug (13) to engine compartment high-voltage power distributor (11). |
25 | Attach high-voltage line (12) to holder for the engine compartment high-voltage power distributor (11). |
Check retaining clips for damage. |
If damage is present: |
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Replace damaged retaining clip. |