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

MODEL 222.163 

18.8.15

Change and extension to individual operation steps

Operation steps 1 to 39

Shown here as test on high-voltage battery charger 

Shown as test on DC/DC converter 

Shown as test on high-voltage distributor 

	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
	Note on high-voltage battery		AH54.10-P-0006-01MEV
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Measure
1	Perform manual power disconnect for high-voltage on-board electrical system		AR54.10-P-1039LFH
2	Detach ground line from battery		AR54.10-P-0003LF
3	Remove paneling in luggage compartment		AR68.30-P-4600LF
4	Plug test adapter to connection (12) DC/DC converter of high-voltage battery (1)	Protect all disconnected high-voltage plug connections, on which no measurements are being performed, from external influences. Set of protective covers	Figure
		Test adapter	Figure
5	Perform insulation resistance measurement at test adapter		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓ Proceed with operation step 6 If the measured value is < 1 MΩ ↓	Figure
		Replace high-voltage battery (1)	AR54.10-P-1140LFH
6	Detach test adapter from connection (12) DC/DC converter of high-voltage battery (1)	Test adapter	Figure
7	Plug test adapter onto connection (13) for high-voltage battery charger of high-voltage battery (1)	Test adapter	Figure
8	Perform insulation resistance measurement at test adapter		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓ Proceed with operation step 9 If the measured value is < 1 MΩ ↓	Figure
		Replace high-voltage battery (1)	AR54.10-P-1140LFH
9	Detach test adapter from connection (13) for high-voltage battery charger of high-voltage battery (1)	Test adapter	Figure
10	Plug test adapter onto connection (2) of high-voltage battery (1)		AR08.00-P-0101-01LFH
		Test adapter	Figure
11	Perform insulation resistance measurement at test adapter		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓ Continue with operation step 12 If the measured value is < 1 MΩ ↓	Figure
		Replace high-voltage battery (1)	AR54.10-P-1140LFH
12	Detach test adapter from connection (2) of high-voltage battery (1)	Test adapter	Figure
13	Measure insulation resistance at DC/DC converter high-voltage plug (4)	If the measured value is > 1 MΩ	AR54.10-P-1160-01LF
		↓ Continue with operation step 17 If the measured value is < 1 MΩ ↓ Detach high-voltage electrical line from DC/DC converter (14) and continue with operation step 14	AR54.10-P-1350LFH
14	Fit test adapter onto connection (16) of DC/DC converter (14)	Test adapter	Figure
15	Measure insulation resistance at test adapter for DC/DC converter (14)	If the measured value is < 1 MΩ ↓ Replace DC/DC converter (14)	AR54.10-P-1160-01LF
		If the measured value is > 1 MΩ ↓	AR54.10-P-1350LFH
		Replace high-voltage electrical line between DC/DC converter (14) and high- voltage battery (1)	AR54.10-P-1350LFH
16	Detach test adapter from connection (16) for DC/DC converter (14)	Test adapter	Figure
17	Perform insulation resistance measurement at high-voltage plug on high-voltage battery charger (5)	If the measured value is > 1 MΩ ↓ Continue with operation step 21 If the measured value is < 1 MΩ ↓ Detach high-voltage plug from high-voltage battery charger (15) and continue with operation step 18	AR54.10-P-1160-01LF
18	Plug test adapter onto connection (17) for high-voltage battery charger (5)	Test adapter	Figure
19	Measure insulation resistance at test adapter on high-voltage battery charger (15)	If the measured value is < 1 MΩ ↓ Replace high-voltage battery charger (15)	AR54.10-P-1160-01LF
		If the measured value is > 1 MΩ ↓ Replace high-voltage electrical line between high-voltage battery charger (15) and high- voltage battery (1)	AR54.10-P-5106LFH
20	Detach test adapter from connection (17) of high-voltage battery charger (15)	Test adapter	Figure
21	Measure insulation resistance at high-voltage plug (3) on high-voltage battery (1)	If the measured value is < 1 MΩ ↓ Detach high-voltage plug (6) from high-voltage distributor (8) and continue with operation step 22 If the measured value is > 1 MΩ ↓ Continue with operation step 34	AR54.10-P-1160-01LF
22	Fit test adapter onto connection (18) for high- voltage distributor (8)		AR08.00-P-0101-01LFH
		Test adapter	Figure
23	Perform insulation resistance measurement at test adapter		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓	Figure
		Replace high-voltage electrical line between high-voltage battery (1) and high-voltage distributor (8) If the measured value is < 1 MΩ ↓ Continue with operation step 24
24	Detach high-voltage plug (7) from high-voltage distributor (8)
25	Perform insulation resistance measurement at test adapter again		AR54.10-P-1160-01LF
		Test adapter If the measured value is < 1 MΩ ↓ Continue with operation step 28 If the measured value is > 1 MΩ ↓	Figure
		Detach high-voltage plug (11) from high- voltage PTC heater (10) and continue with operation step 26	AR83.70-P-8001LFH
26	Fit high-voltage plug (7) onto high-voltage distributor (8)	Detach high-voltage plug (11) from high voltage PTC heater (10).
27	Perform insulation resistance measurement at test adapter again		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓ Replace high voltage PTC heater (10)	Figure
		If the measured value is < 1 MΩ ↓ Replace high-voltage electrical line between high-voltage PTC heater (10) and high-voltage distributor (8)	AR83.70-P-8001LFH
28	Disconnect high-voltage plug on electrical A/C compressor		AR83.55-P-5311LFH
29	Measure insulation on test adapter again		AR54.10-P-1160-01LF
		Test adapter If the measured value is > 1 MΩ ↓ Replace electric refrigerant compressor	Figure
		If the measured value is < 1 MΩ ↓	AR83.55-P-5311LFH
		Detach high-voltage distributor (8) from power electronics (9) and continue with operation step 30	AR08.20-P-0011LF
30	Measure insulation on test adapter again	With power electronics (9) detached from high- voltage distributor (8)	AR54.10-P-1160-01LF
		Test adapter If the measured value is < 1 MΩ ↓ Replace high-voltage distributor (8)	Figure
		If the measured value is > 1 MΩ ↓ Continue with operation step 31	AR54.10-P-1400LF
31	Measure insulation resistance at contacts (U1 or V1 or W1) for the power electronics (9)	If the measured value is < 1 MΩ ↓ Replace power electronics (9)	AR54.10-P-1160-01LF
		If the measured value is > 1 MΩ ↓ Continue with operation step 32	AR08.20-P-0011LF
32	Measure insulation resistance on contacts (U or V or W) of high-voltage distributor (8)	If the measured value is > 1 MΩ ↓ Continue with operation step 34	AR54.10-P-1160-01LF
		If the measured value is < 1 MΩ ↓	AR08.10-P-0012EH
		Detach high-voltage plug from automatic transmission and continue with operation step 33	AR27.10-P-0502LFH
33	Measure insulation resistance on contacts (U or V or W) of high-voltage distributor (8) again	Detach high-voltage plug from automatic transmission. If the measured value is > 1 MΩ ↓	AR54.10-P-1160-01LF
		Replace electrical machine If the measured value is < 1 MΩ ↓	AR08.10-P-0012EH
		Replace high-voltage distributor (8)	AR54.10-P-1400LF
34	Remove test adapter	Test adapter	Figure
		Test adapter	Figure
35	Connect open electrical connections
36	Attach ground line to battery		AR54.10-P-0003LF
37	Install paneling in trunk		AR68.30-P-4600LF
38	Perform restart procedure for high-voltage on- board electrical system		AR54.10-P-1039LFH