1 | High-voltage battery disconnect switch |
2 | Retaining cap |
3 | High-voltage connector |
A902 | High-voltage battery module |
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1 | High-voltage battery disconnect switch |
4 | Voltage tester |
A902 | High-voltage battery module |
W54.10-1098-11
4 | Voltage tester |
5 | Safety plug |
6 | High-voltage plug |
A902 | High-voltage battery module |
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5 | Safety plug |
6 | High-voltage plug |
7 | Dust cap |
A902 | High-voltage battery module |
W54.10-1108-11
Power disable | |||
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 | Notes on self-locking nuts and bolts | ||
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 | ||
Topical note | Notes on battery | ||
1 | Secure vehicle against rolling | ||
2 | Connect Star Diagnosis and in Xentry Diagnostics select "Control units direct entry" | Star Diagnosis must be connected to SDconnect, otherwise access to the energy management (ENM) control unit is not possible. | |
3 | Read out faulty memory in "Energy management ENM control unit" | Any insulation resistance faults stored in the fault memory may only be processed after disabling. | |
For disabling: | |||
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Perform operation steps 1 to 15. | |||
For processing any stored insulation resistance faults: | |||
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Perform operation step 16. | |||
4 | Switch off voltage of high-voltage on-board electrical system using Xentry Diagnostics | The voltage switch-off process is menu-assisted, at: | |
5 | Print out vehicle power disable event log | ||
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Fill in the vehicle power disable event log after carrying out the operation steps necessary for disabling and store together with the event log for shutting off voltage for the high-voltage on-board electrical system. | |||
6 | Switch off ignition and remove vehicle key | To prevent the vehicle from being switched back on again, the vehicle key and the key for unlocking the high-voltage battery disconnect switch (1) must be kept in a secure location. | |
7 | Operate high-voltage battery disconnect switch (1) on high-voltage battery module (A902) | ||
8 | Visually inspect all the high-voltage system components for signs of damage | ||
9 | Remove retaining cap (2) from high-voltage connector (3) | ||
10 | Disconnect high-voltage connector (3) from high-voltage battery module (A902) | Do not detach the high-voltage connector (3) until 3 minutes after the high-voltage battery disconnect switch (1) is operated. | |
11 | Check for zero potential on the high-voltage connection of the high-voltage battery module (A902) | ||
| 000 588 07 19 00 Measuring instrument | ||
The voltage indicator of the 2-pin voltage tester (4) must show less than 40 volts. | |||
12 | Check for zero potential on the high-voltage plug connector (6) of the high-voltage line | ||
| 000 588 07 19 00 Measuring instrument | ||
The voltage indicator of the 2-pin voltage tester (4) must show less than 40 volts. | |||
13 | Plug safety plug (5) onto high-voltage connector of high-voltage battery module (A902) | Set of safety plugs | |
14 | Fit dust cap (7) to high-voltage plug connector (6) | Set of safety plugs | |
15 | Place vehicle power disable event log into order folder | ||
16 | Perform measurement of insulation resistance on high-voltage system | Only for processing any stored insulation resistance faults from operation step 3. | |
Bolt, retaining cap to high-voltage connectorBolt, retaining cap to high-voltage connector | |||
Set of safety plugs | |||
Initial startup | |||
17 | Print out vehicle initial startup log | ||
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Fill out vehicle initial startup log after performing the operation steps required for initial startup. | |||
18 | Check whether the high-voltage system is ready for initial startup | All work on the high-voltage system must be completed and the 24 V on-board electrical system must be operational. | |
19 | Visually inspect all the high-voltage system components for signs of damage | ||
20 | Remove safety plug (5) from high-voltage connector of high-voltage battery module (A902) | Set of safety plugs | |
21 | Remove dust cap (7) | Set of safety plugs | |
22 | Connect high-voltage connector (3) to high-voltage battery module (A902) | ||
23 | Fit retaining cap (2) onto high-voltage connector (3) | Bolt, retaining cap to high-voltage connectorBolt, retaining cap to high-voltage connector | |
24 | Check whether all high-voltage connectors in the high-voltage components have latched properly into place and that they are securely fitted | ||
25 | Release high-voltage battery disconnect switch (1) on high-voltage battery module (A902) with key | ||
26 | Switch on ignition and check warning lamps in the instrument | ||
27 | Connect Star Diagnosis and read out fault memory, reset if necessary | Star Diagnosis must be connected to SDconnect. Faults in the high-voltage system are not displayed in the quick-routine test and they must be read out in the "Energy management ENM control unit". | |
28 | Place vehicle initial startup log into order folder |
970 589 03 63 00
Set of safety plugs