Perform Measurement Of Insulation Resistance - AR54.10-P-4000LWH
Model 205.047/147/247
| 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. | AS00.00-Z-0035-01A | |
| General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | AH00.00-Z-0300-01A | ||
| Notes on battery | AH54.10-P-0001-01A | ||
| Notes on safety-relevant components | AH00.00-Z-0019-01A | ||
| Measure | |||
| 1 | Perform manual power disconnect for high voltage on-board electrical system. | AR54.10-P-1039LWH | |
| 2 | Remove ground line from battery. | AR54.10-P-0003LW | |
| 3 | Connect high-voltage plug (4) of test adapter (A) to high-voltage battery (1). | Fig 1 | |
| 4 | Perform insulation resistance measurement at test adapter (A). | AR54.10-P-1160-01LWH | |
If the measured value is > 1 MΩ: ↓ |
Fig 1 | ||
| continue with operation step 6. If the measured value is < 1 MΩ: ↓ replace high-voltage battery (1). |
AR54.10-P-1140LWH | ||
| 5 | Disconnect high-voltage plug (4) from high-voltage battery (1). | ||
| 6 | Connect high-voltage plug (6) of test adapter (B) to high-voltage battery (1). | Fig 2 | |
| 7 | Perform insulation resistance measurement at test adapter (B). | AR54.10-P-1160-01LWH | |
If the measured value is > 1 MΩ: ↓ continue with operation step 9. |
Fig 2 | ||
| If the measured value is < 1 MΩ: ↓ replace high-voltage battery (1). |
AR54.10-P-1140LWH | ||
| 8 | Disconnect high-voltage plug (6) from high-voltage battery (1). | ||
| 9 | Perform insulation resistance measurement at high-voltage plug to high-voltage battery charger (3). | If the measured value is > 1 MΩ: ↓ Continue with operation step 13. If the measured value is < 1 MΩ: ↓ Disconnect high-voltage plug from high-voltage battery charger and continue with operation step 10. |
AR54.10-P-1160-01LWH |
| 10 | Connect high-voltage plug (6) of test adapter (B) to high-voltage battery charger. | Fig 2 | |
| 11 | Perform insulation resistance measurement at test adapter (B). | AR54.10-P-1160-01LWH | |
If the measured value is < 1 MΩ: ↓ Replace high-voltage battery charger. |
Fig 2 | ||
| If the measured value is > 1 MΩ: ↓ replace high voltage line between high-voltage battery charger and high-voltage battery (1). |
AR54.10-P-5106LWH | ||
| 12 | Perform insulation resistance measurement at high-voltage plug of battery wiring harness (2). | If the measured value is < 1 MΩ: ↓ Continue with operation step 13. If the measured value is > 1 MΩ: ↓ Continue with operation step 26. |
AR54.10-P-1160-01LWH |
| 13 | Disconnect high-voltage plug (5) at electrical refrigerant compressor. | Model 205.047/147/247 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) | AR83.55-P-5311LWH |
| 14 | Connect high-voltage plug (6) of test adapter (B) to electric refrigerant compressor. | Fig 2 | |
| 15 | Perform insulation resistance measurement at test adapter (B). | AR54.10-P-1160-01LWH | |
If the measured value is < 1 MΩ: ↓ |
Fig 2 | ||
| Replace electric refrigerant compressor. Model 205.047/147/247 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) If the measured value is > 1 MΩ: ↓ continue with operation step 16. |
AR83.55-P-5311LWH | ||
| 16 | Disconnect high-voltage plug (7) to PTC heater from high-voltage distributor (8). | ||
| 17 | Perform insulation resistance measurement at high-voltage plug of battery wiring harness (2) again. | If the measured value is < 1 MΩ: ↓ continue with operation step 20. If the measured value is > 1 MΩ: ↓ Connect high-voltage plug (7) going to PTC heater at high-voltage distributor (8) and continue with operation step 18. |
AR54.10-P-1160-01LWH |
| 18 | Expose PTC heater and disconnect high-voltage plug from PTC heater. | AR83.70-P-8001LWH | |
| 19 | Perform insulation resistance measurement at high-voltage plug of battery wiring harness (2) again. | If the measured value is > 1 MΩ: ↓ replace PTC heater. If the measured value is < 1 MΩ: ↓ replace high-voltage line from high-voltage distributor (8) to PTC heater. |
AR83.70-P-8001LWH |
| 20 | Remove high-voltage distributor (8) from power electronics (9). | AR54.10-P-1400LW | |
| 21 | Perform insulation resistance measurement at high-voltage plug of battery wiring harness (2) again. | If the measured value is > 1 MΩ: ↓ continue with operation step 22. |
AR54.10-P-1160-01LWH |
| If the measured value is < 1 MΩ: ↓ replace high-voltage distributor (8). |
AR54.10-P-1400LW | ||
| 22 | Check insulation resistance at contacts (U1, V1, W1) of power electronics (9). | If the measured value is < 1 MΩ: ↓ Replace power electronics (9). |
AR54.10-P-1160-01LWH |
| If the measured value is > 1 MΩ: ↓ Proceed with operation step 23. |
AR08.20-P-0011LW | ||
| 23 | Lower transmission and detach 3-phase connector from electrical machine. | AR54.10-P-1400LW | |
| 24 | Perform insulation resistance measurement at contacts (U, V, W) of high-voltage distributor (8). | If the measured value is > 1 MΩ: ↓ Replace electric machine. |
AR54.10-P-1160-01LWH |
| Model 205.047/147/247 with transmission 724.2 If the measured value is < 1 MΩ: ↓ |
AR08.10-P-0012EH | ||
| replace high-voltage distributor (8). | AR54.10-P-1400LW | ||
| 25 | Remove test adapters (A, B). | ||
| 26 | Connect disconnected electrical connectors. | ||
| 27 | Install ground line at battery. | AR54.10-P-0003LW | |
| 28 | Perform initial startup of high voltage on-board electrical system. | AR54.10-P-1150LW | |
| 29 | Install remaining parts. |