Perform Measurement Of Insulation Resistance - AR54.10-P-4000GQA
MODEL 166.063
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch damaged or defective 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 | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-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 | ||
| Remove/install | |||
| 1 | Perform manual power disconnect for high-voltage on-board electrical system | AR54.10-P-1039GQA | |
| 2 | Disconnect battery ground line | AR54.10-P-0003GZ | |
| 3 | Remove load compartment floor | AR68.80-P-5800GQA | |
| Measure | |||
| 4 | Plug test adapter into high-voltage on-board electrical system connection (1) | AR08.00-P-0101-01LFH | |
| *BA54.10-P-1008-02G | |||
| Figure | |||
| 5 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is < 1 MΩ ↓ Replace high-voltage battery (9) |
Figure | ||
| AR54.10-P-1140GQA | |||
| 6 | Unplug test adapter from high-voltage on-board electrical system connection (1) | AR08.00-P-0101-01LFH | |
| Figure | |||
| 7 | Plug test adapter into DC/DC converter connection (2) of high-voltage battery (9) | Fig 2 | |
| 8 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is < 1 MΩ ↓ Replace high-voltage battery (9) |
Fig 2 | ||
| AR54.10-P-1140GQA | |||
| 9 | Unplug test adapter from DC/DC converter connection (2) of high-voltage battery (9) | Fig 2 | |
| 10 | Plug test adapter into high-voltage battery charger connection (3) of high-voltage battery (9) | Fig 2 | |
| 11 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is < 1 MΩ ↓ Replace high-voltage battery (9) |
Fig 2 | ||
| AR54.10-P-1140GQA | |||
| 12 | Unplug test adapter from high-voltage battery charger connection (3) of high-voltage battery (9) | Fig 2 | |
| 13 | Measure insulation resistance at DC/DC converter HV connector (5) | If the measured value is > 1 MΩ ↓ Continue with operation step 16 If the measured value is < 1 MΩ ↓ Disconnect HV connector from DC/DC converter (7) and continue with operation step 14 |
AR54.10-P-1160-01GQA |
| 14 | Plug test adapter into HV connection on DC/DC converter (7) | Fig 2 | |
| 15 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Replace high-voltage line from high-voltage battery (9) to DC/DC converter (7) If the measured value is < 1 MΩ ↓ Replace DC/DC converter (7) |
Fig 2 | ||
| 16 | Measure insulation resistance at high-voltage battery charger HV connector (6) | If the measured value is > 1 MΩ ↓ Continue with operation step 19 If the measured value is < 1 MΩ ↓ Disconnect HV connector (10) from high-voltage battery charger (8) and continue with operation step 17 |
AR54.10-P-1160-01GQA |
| 17 | Plug test adapter into HV connection on high-voltage battery charger (8) | Fig 2 | |
| 18 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Replace high-voltage line from high-voltage battery (9) to high-voltage battery charger (8) If the measured value is < 1 MΩ ↓ Replace high-voltage battery charger (8) |
Fig 2 | ||
| 19 | Measure insulation resistance at high-voltage on-board electrical system HV connector (4) | If the measured value is > 1 MΩ ↓ Continue with operation step 34 If the measured value is < 1 MΩ ↓ Continue with operation step 20 |
AR54.10-P-1160-01GQA |
| 20 | Remove right side underfloor paneling at the front | AR61.30-P-1001GQ | |
| 21 | Remove heat shield from high-voltage distributor (14) | ||
| 22 | Disconnect high-voltage on-board electrical system HV connector (11) from high-voltage distributor (14) | AR08.00-P-0101-01LFH | |
| *BA54.10-P-1001-03E | |||
| 23 | Plug test adapter into high-voltage on-board electrical system connection (12) on high-voltage distributor (14) | AR08.00-P-0101-01LFH | |
| *BA54.10-P-1001-03E | |||
| Figure | |||
| 24 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Replace high-voltage line from high-voltage battery (9) to high-voltage distributor (14) If the measured value is < 1 MΩ ↓ Disconnect electric refrigerant compressor HV connector (16) from high-voltage distributor (14) and continue with operation step 25 |
Figure | ||
| 25 | Measure insulation resistance at test adapter again | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Continue with operation step 26 If the measured value is < 1 MΩ ↓ Continue with operation step 28 |
Figure | ||
| 26 | Disconnect HV connector from electric refrigerant compressor and plug in test adapter | AR83.55-P-5311GQA | |
| Fig 2 | |||
| 27 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Replace high-voltage line from high-voltage distributor (14) to electric refrigerant compressor If the measured value is < 1 MΩ ↓ Replace electric refrigerant compressor |
Fig 2 | ||
| AR83.55-P-5311GQA | |||
| 28 | Disconnect PTC heater HV connector (13) from high-voltage distributor (14) | ||
| 29 | Measure insulation resistance at test adapter | AR54.10-P-1160-01GQA | |
If the measured value is > 1 MΩ ↓ Replace high-voltage PTC heater |
Fig 2 | ||
| If the measured value is < 1 MΩ ↓ Disconnect high-voltage distributor (14) from power electronics (15) and continue with operation step 30 |
AR83.70-P-8001GQA | ||
| AR54.10-P-1400-01GQA | |||
| 30 | Measure insulation resistance at contacts (U or V or W) of high-voltage distributor (14) | If the measured value is > 1 MΩ ↓ Continue with operation step 31 If the measured value is < 1 MΩ ↓ Continue with operation step 32 |
AR54.10-P-1160-01GQA |
| 31 | Measure insulation resistance at contacts (U1 or V1 or W1) of power electronics (15) | AR54.10-P-1160-01GQA | |
| If the measured value is > 1 MΩ ↓ Continue with operation step 32 If the measured value is < 1 MΩ ↓ Replace power electronics (15) |
AR08.20-P-0011GQA | ||
| 32 | Separate 3-phase connector at automatic transmission | AR54.10-P-1400GQA | |
| 33 | Measure insulation resistance at contacts (U or V or W) of high-voltage distributor (14) again | If the measured value is > 1 MΩ ↓ Replace electrical machine |
AR54.10-P-1160-01GQA |
| Model 166.063 with transmission 724.2 If the measured value is < 1 MΩ ↓ Replace high-voltage distributor (14) |
AR08.10-P-0012EH | ||
| AR54.10-P-1400GQA | |||
| 34 | Remove test adapter | AR08.00-P-0101-01LFH | |
| Fig 2 | |||
| Figure | |||
| 35 | Install remaining parts |
HIGH-VOLTAGE DISTRIBUTOR
| Number | Designation | Model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) | |
|---|---|---|---|
| BA54.10-P-1001-03E | Bolt, high-voltage connector to high-voltage distributor | Nm | 4 |
HIGH-VOLTAGE BATTERY
| Number | Designation | Model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) | |
|---|---|---|---|
| BA54.10-P-1008-02G | Screw/bolt, high-voltage connector to high-voltage battery | Nm | 4 |