Remove/Install Battery Of 48V On-Board Electrical System - AR54.10-P-0022LWO

Model 205, 213, 238, 253 

with code B01 (48V technology) 

Shown on model 213 with engine 654 

Courtesy of MERCEDES-BENZ USA

Shown on model 213 with engine 654 

Courtesy of MERCEDES-BENZ USA

	Risk of injury.  Moving parts can pinch, crush or, in extreme cases even sever extremities.	No parts of the body or limbs should be within the operating area of mechanical components when moving components.	AS00.00-Z-0009-01A
	Risk of injury  to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning  from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of fire/risk  of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.	No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on coolant	Model 205, 253 with engine 264 with code B01 (48V technology) Model 213 with engine 256, 264, 274, 654 with code B01 (48V technology) Model 238 with engine 256, 264 with code B01 (48V technology)	AH20.00-N-2080-01A
	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on battery		AH54.10-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove/install
1	Commission 48 V on-board electrical system battery (G1/3).	When replacing 48 V on-board electrical system battery (G1/3).
		Model 205, 213, 253 with code B01 (48V technology)	AD00.00-P-2000-04B
		Model 238 with code B01 (48V technology)	AD00.00-P-2000-06LWO
2	Remove dust filter with air duct segment.
		Model 205 with code B01 (48V technology)	AP83.00-P-8381B
		Model 213, 238, 253 with code B01 (48V technology)	AP83.00-P-8381C
3	Print out analysis sheet.
	Analysis sheet for lithium-ion battery 48 V, form		OF54.10-P-3000-15FR
	Check
4	Check for potential hazards of 48 V on-board electrical system battery (G1/3).	When replacing 48 V on-board electrical system battery (G1/3). In the event of smoke generation or fire, notify the fire department. Using analysis sheet, check whether 48 V battery (G1/3) presents an acute hazard.
5	Check housing of 48 V on-board electrical system battery (G1/3) for mechanical damage.	Check non-visible area on housing after removal of 48 V battery (G1/3). Use the analysis sheet to check whether there is damage to the 48 V on-board electrical system battery (G1/3) causing electrolyte to leak out. If there is an electrolyte leakage, ↓ Notify MPC/general representative.
6	Disconnect ground line from 12 V on-board electrical system battery.	Model 205, 213, 253 with code B01 (48V technology)	AR54.10-P-0003LW
		Model 238 with code B01 (48V technology) The 48 V on-board electrical system is automatically disconnected from power supply at the latest 10 s after disconnecting the ground line from the 12 V on-board electrical system battery.	AR54.10-P-0003LWO
7	Detach electrical lines (6, 7, 8) and place to one side.	Nut, positive line/ground line to DC/DC converter control unit/on-board electrical system battery (48V)	*BA54.10-P-1012-01A
8	Disconnect electrical connectors (4, 5).
9	Open caps (10) and detach electrical lines from engine compartment 48 V on-board electrical system fuse box (F153/2).	Model 213, 238 with engine 256.9 with code B01 (48V technology) Model 213, 238 with engine 654 with code B01 (48V technology) Nut, positive line/ground line to fuse box (48Volt)	*BA54.15-P-1006-01K
10	Cut cable ties (11) and remove electric lines from fuse box in 48 V on-board electrical system engine compartment (F153/2).	Model 213, 238 with engine 256.9 with code B01 (48V technology) Model 213, 238 with engine 654 with code B01 (48V technology) Replace cable ties (11).
11	Disconnect coolant lines (12).	Clamp	Fig 1
12	Release and detach coolant lines (12).	Model 205, 253 with engine 264 with code B01 (48V technology) Model 213 with engine 256, 264, 274, 654 with code B01 (48V technology) Model 238 with engine 256, 264 with code B01 (48V technology) Collect escaping coolant using suitable vessel.	AR20.20-P-7441-01RQ
13	Release and detach degassing pipe (9).		AR54.10-P-0022-01FR
14	Unscrew screw (13) and remove with mounting rail (14).	Screw/bolt, battery mounting rail to battery frame	*BA54.10-P-1001-01A
15.1	Remove 48 V on-board electrical system battery (G1/3) with DC/DC converter control unit (N83/1) and fuse box in 48 V on-board electrical system engine compartment (F153/2).	Model 213, 238 with engine 256.9 with code B01 (48V technology) Model 213, 238 with engine 654 with code B01 (48V technology)
15.2	Remove 48 V battery (G1/3) with DC/DC converter control unit (N83/1).	Model 205, 253 with code B01 (48V technology) Model 213, 238 with engine 264 with code B01 (48V technology)
16	Disconnect DC/DC converter control unit (N83/1) from 48 V on-board electrical system battery (G1/3).	When replacing 48 V on-board electrical system battery (G1/3).	AR54.10-P-1351LWO
17	Unscrew screws (15) and disconnect engine compartment 48 V on-board electrical system fuse box (F153/2) from 48 V on-board electrical system battery (G1/3).	Model 213, 238 with engine 256.9 with code B01 (48V technology) Model 213, 238 with engine 654 with code B01 (48V technology) When replacing 48 V on-board electrical system battery (G1/3).
18	Install in the reverse order.
19	Pour in coolant and bleed engine cooling system.	Model 213 with engine 264 with code B01 (48V technology) Model 238 with engine 264 with code B01 (48V technology)	AR20.00-P-1142MRH
		Model 213 with engine 256.9 with code B01 (48V technology) Model 238 with engine 256.9 with code B01 (48V technology)	AR20.00-P-1142MSA
		Model 213 with engine 274, 654 with code B01 (48V technology)	AR20.00-P-1142OLC
		Model 205, 253 with engine 264 with code B01 (48V technology)	AR20.00-P-1142MRI

Fig 1: Identifying Clamp (000 589 40 37 00)

Courtesy of MERCEDES-BENZ USA