Perform measurement of insulation resistance - AR54.10-P-4000SX

Model 221 

MODIFICATION NOTES

28.9.15

Screw high-voltage plug to the high-voltage battery

Type 221

BA54.10-P-1036-01C

Fig 1: Disconnecting High-Voltage Device Plug Connection

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	Risk of death  when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not  carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Note on high-voltage battery		AH54.10-P-0006-01MEV
	Measure
1	Perform manual power disconnect for high-voltage on-board electrical system		AR54.10-P-1039SX
		The safety plug (8) remains plugged in throughout the entire measurement on the high-voltage disconnect device plug connection (5).
2	Disconnect battery ground cable		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
3	Perform insulation resistance measurement at disconnect plug (3)		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		Close connections with new, clean covers.
		Set of protective covers If the measured value is OK. ↓ Proceed with operation step 5 If the measured value is not OK. ↓ Unplug disconnect plug (3) of high-voltage electrical line (3a) from DC/DC converter control unit.	Figure
		MODEL 221	AR54.10-P-1350SXH
4	Perform measurement at disconnect plug (3) again		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		If the measured value is OK. ↓
		Replace DC/DC converter MODEL 221 If the measured value is not OK. ↓ Replace high-voltage electrical line (3a).	AR54.10-P-1350SXH
5	Plug test adapter into high-voltage plug connection on high-voltage battery module (A100)	Screw/bolt, high-voltage connector to high-voltage battery	*BA54.10-P-1036-01C
		Test adapter	Figure
6	Measure insulation on test adapter		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		Test adapter If the measured value is OK. ↓ Proceed with operation step 7 If the measured value is not OK. ↓	Figure
		Replace high-voltage battery module (A100) MODEL 221	AR54.10-P-1140SXH
7	Perform insulation resistance measurement at high-voltage plug (1)		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		If the measured value is OK. ↓ Reassemble vehicle. If the measured value is not OK. ↓
		Disconnect electrical connector from electric refrigerant compressor MODEL 221	AR83.55-P-5300SXH
8	Perform insulation resistance measurement at high-voltage plug (1) again		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		If the measured value is OK. ↓
		Replace electric refrigerant compressor. MODEL 221 If the measured value is not OK. ↓ Proceed with operation step 9	AR83.55-P-5300SXH
9	Disconnect electrical connectors from electrical machine	MODEL 221 The electrical connectors must be insulated prior to the measurement. Otherwise erroneous measurements will be taken. There are 3 electrical connectors in total. The power electronics control unit (N129/1) remains installed. Close connections with new, clean covers.	AR08.10-P-0011SXH
		Set of protective covers	Figure
10	Perform insulation resistance measurement at high-voltage plug (1) again		AR54.10-P-1160-01LF
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		If the measured value is OK. ↓
		Replace integrated starter alternator MODEL 221.095/195 If the measured value is not OK. ↓	AR15.40-P-0003SXH
		Replace power electronics with power distributor. MODEL 221.095/195	AR08.10-P-0011SXH
11	Remove test adapter	Test adapter	Figure
12	Reconnect electrical connectors
13	Close any electrical connectors still open with covers	Set of protective covers	Figure
14	Connect ground line to battery		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A

BATTERY

Number	Designation		Model 221
BA54.10-P-1036-01C	Screw/bolt, high-voltage connector to high-voltage battery	Nm	5, 5

Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Test Adapter (222 589 01 63 00)

Courtesy of MERCEDES-BENZ USA