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Retrofitting additional battery - AN54.10-P-0002I: Notes

MODEL 220 

customer service solution 

Fig 1: Identifying Additional Battery
G04849750
REMOVING Remove     
DANGER Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking.
Wear acid-resistant gloves, clothing and safety glasses. Pour battery acid only into suitable and appropriately marked containers.		 AS54.10-Z-0001-01A
NOTES Notes on battery All models AH54.10-P-0001-01A
1 Remove battery NOTES Do not connect a quiescent current retention device.
IMPORTANT Part discontinued.		  
REFER TO TESTING & REPAIR     AR54.10-P-0005I
REFER TO FORMS Dispose of battery All models OS54.10-P-0001-01Z
2 Remove coverings in trunk IMPORTANT Trunk floor paneling and right side paneling.  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
3 Remove ground lead IMPORTANT Part discontinued.  
4 Remove rear bumper    
REFER TO TESTING & REPAIR     AR88.20-P-2200M
5 Remove inner fender from rear fender IMPORTANT Passenger side.  
DANGER Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. AS00.00-Z-0007-01A
6 Prepare to retrofit battery frame   AN54.10-P-0002-01I 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, Ø70 mm dia. *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Jumbotherm K-25-R flat nozzle hot air blower with integrated scraper *WH58.30-Z-1004-20A 
    COMMERCIALLY AVAILABLE TOOLS Replacement scraper for Jumbotherm K-25-R hot air blower *WH58.30-Z-1005-20A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
7 Supplement standard underbody protection with MB permanent underbody sealant    
REFER TO TESTING & REPAIR     AR97.20-P-0500-03A
    SATA-UBE underfloor protection spray gun for 1 kg one-way screw-top can *WE58.40-Z-1002-08A 
    Airless unit *WH58.30-Z-1001-41A 
8 Cutting out paneling in trunk   AN68.30-P-0002-01I
INSTALLING Install     
9 Install trim panel in luggage compartment IMPORTANT Right side paneling.  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
10 Convert battery   AN54.10-P-0002-02I 
  Install battery (G1) NOTES Do not connect leads. New part.  
REFER TO TESTING & REPAIR     AR54.10-P-0005I
11 Retrofit separation switch   AN54.10-P-0002-03I 
    TORQUE SPECIFICATION Adapter on battery positive pole *BA54.10-P-1003-01C 
12 Install additional battery (G1/1) NOTES New part.
IMPORTANT Fasten additional battery on battery frame with battery mount and M8 x 16 screws.		  
13 Connect additional battery positive lead (G1/1)    
14 Connect additional battery ground lead (G1/1)    
15 Install gas line IMPORTANT Cut to length of approx. 300mm. Connect additional battery (G1/1) with battery (G1).  
16 Switch on separation switch    
17 Glue in sign IMPORTANT Sign "When working on batteries actuate separation switch". If required always replace both batteries! Only install batteries with same capacity! Glue in sign so that it is clearly visible.  
18 Install trim panel in luggage compartment IMPORTANT Trunk floor paneling
New part.
Cut old part out in area of battery frame on customer request.		  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
19 Install battery paneling IMPORTANT New part.  
20 Install rear bumper    
REFER TO TESTING & REPAIR     AR88.20-P-2200M
21 Install inner fender in rear fender    
22 Perform synchronization    
23 Read out fault memory and erase IMPORTANT STAR diagnosis tool.  
TORQUE SPECIFICATION BATTERY

Number Designation Model 220
BA54.10-P-1003-01C Adapter on positive battery terminal Nm 20
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1004-20A Hot-air gun
WH58.30-Z-1005-20A Replacement scraper for heat gun
WH58.30-Z-1001-40A Tarp (fire-resistant)
WH58.30-Z-1001-41A Airless unit
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1002-08A Underfloor protection-spray gun for 1 kg one-way screw-type unit
PARTS ORDERING NOTES

Part no. Designation Quantity
HKW 220 820 L 023 Battery frame 1
HKW 078 022 A 008 Battery bracket 1
HKW 220 821 L 004 Mount for additional parts 1
HKW 220 690 L 000 Battery cover 1
A 220 440 04 30 Positive lead (additional battery on 1st battery) 1
A 220 540 00 41 Ground lead (additional battery and 1st and battery) 2
A 220 540 01 41 Ground lead (separation switch on body) 1
A 000 541 00 72 Nut (adapter on battery positive terminal) 1
A 001 546 09 44 Battery terminal 1
A 000 545 76 08 Separation switch 1
N 910 105 006 033 Screw M6 x 20 3
N 910 105 006 002 Bolt M6 X 12 2
N 910 105 008 041 Screw M8 x 16 2
N 910 143 006 001 Screw M6 x 16 4
N 913 023 006 001 Nut M6 8
A 003 994 17 45 Box nut M6 1
A 005 541 10 01 AGM battery 2
A 002 997 24 86 Plug 1
A 024 997 49 82 Hose (approx. 300 mm) 1
A 000 990 38 72 Distributor fitting 2
HKW 220 680 L 017 Trunk floor paneling 1
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