Perform Measurement Of Insulation Resistance - AR54.10-P-4000LVH

Model 253.354/954

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on battery		AH54.10-P-0001-01A
	Measure
1	Perform manual power disconnect for high-voltage on-board electrical system		AR54.10-P-1039LVH
2	Disconnect battery ground line		AR54.10-P-0003LW
3	Remove load compartment floor
4	Plug test adapter into high-voltage on-board electrical system connection (1)	Test adapter	Figure
5	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter If the measured value is < 1 MΩ ↓ replace high-voltage battery (9)	Figure
			AR54.10-P-1140LVH
6	Disconnect test adapter from high-voltage on-board electrical system connection (1)		AR08.00-P-0101-01LFH
		Test adapter	Figure
7	Plug test adapter onto DC/DC converter connection (2)	Test adapter	Figure
8	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter If the measured value is < 1 MΩ ↓ replace high-voltage battery (9)	Figure
			AR54.10-P-1140LVH
9	Unplug test adapter from DC/DC converter connection (2)	Test adapter	Figure
10	Plug test adapter into high-voltage battery charger connection (3)	Test adapter	Figure
11	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter If the measured value is < 1 MΩ ↓ replace high-voltage battery (9)	Figure
			AR54.10-P-1140LVH
12	Disconnect test adapter from high-voltage battery charger connection (3)	Test adapter	Figure
13	Measure insulation resistance at high-voltage connector to DC/DC converter (5)	If the measured value is > 1 MΩ ↓ continue with operation step 16 If the measured value is < 1 MΩ ↓ disconnect high-voltage connector from DC/DC converter (7) and continue with operation step 14	AR54.10-P-1160-01LVH
14	Plug test adapter into high-voltage connection on DC/DC converter (7)	Test adapter	Figure
15	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter 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)	Figure
			AR54.10-P-1350LVH
16	Measure insulation resistance at high-voltage connector to high-voltage battery charger (6)	If the measured value is > 1 MΩ ↓ continue with operation step 19 If the measured value is < 1 MΩ ↓ disconnect high-voltage connector from high-voltage battery charger (8) and continue with operation step 17 The high-voltage plug of the high-voltage line to the vehicle socket does not need to be disconnected.	AR54.10-P-1160-01LVH
17	Plug test adapter into high-voltage connection on high-voltage battery charger (8)	Test adapter	Figure
18	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter 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)	Figure
			AR54.10-P-5114LVH
19	Measure insulation resistance at high-voltage on-board electrical system high-voltage 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-1160-01LVH
20	Remove left underfloor paneling		AR61.30-P-1001LW
21	Disconnect high-volt connector (11) from high-voltage distributor (14)	Bolt, high-voltage connector to high-voltage distributor	*BA54.10-P-1001-03E
22	Plug test adapter into high-voltage on-board electrical system connection (12) on high-voltage distributor (14)	Test adapter	Figure
23	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter 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 ↓ unplug high-voltage connector (16) from high-voltage distributor (14) and continue with operation step 24	Figure
24	Measure insulation resistance at test adapter again		AR54.10-P-1160-01LVH
		Test adapter If the measured value is < 1 MΩ ↓ continue with operation step 28 If the measured value is > 1 MΩ ↓ continue with operation step 25	Figure
25	Disconnect high-voltage connector from electric refrigerant compressor and plug in test adapter	Test adapter	Figure
26	Measure insulation resistance at test adapter		AR54.10-P-1160-01LVH
		Test adapter If the measured value is < 1 MΩ ↓ replace electric refrigerant compressor	Figure
		If the measured value is > 1 MΩ ↓ unplug high-voltage connector from PTC heater and continue with operation step 27	AR83.55-P-5311LWH
			AR83.70-P-8001LWH
27	Measure insulation resistance at high-voltage connector of electric refrigerant compressor	If the measured value is < 1 MΩ ↓ replace PDU with high-voltage lines If the measured value is > 1 MΩ ↓ continue with operation step 28	AR54.10-P-1160-01LVH
28	Detach high-voltage distributor (14) from power electronics (15)		AR54.10-P-1400-01LVH
		Bolt, high-voltage distributor to power electronics	*BA54.10-P-1003-03E
		Long wedge	Figure
		Set of protective covers	Figure
		Cover	Figure
29	Measure insulation resistance at test adapter again	If the measured value is > 1 MΩ ↓ continue with operation step 30 If the measured value is < 1 MΩ ↓ continue with operation step 31
30	Measure insulation resistance at contacts (U1, V1, W1) of power electronics (15)	If the measured value is < 1 MΩ ↓ replace power electronics (15) If the measured value is > 1 MΩ ↓ replace PTC heater	AR54.10-P-1160-01LVH
		The PTC heater itself cannot be tested. The findings are provided with this measurement by a process of elimination.	AR83.70-P-8001LWH
31	Lower transmission and detach 3-phase connector from electrical machine		AR54.10-P-1400LVH
32	Measure insulation resistance at contacts (U, V, W) of high-voltage distributor (14)	If the measured value is < 1 MΩ ↓ replace high-voltage distributor (14)	AR54.10-P-1160-01LVH
		If the measured value is > 1 MΩ ↓ replace electrical machine	AR54.10-P-1400LVH
33	Remove both test adapters
34	Connect detached electrical connections		AR08.00-P-0101-01LFH
		Bolt, high-voltage connector to high-voltage battery	*BA54.10-P-1006-02H
35	Connect ground cable to battery		AR54.10-P-0003LW
36	Perform restart procedure for high-voltage on-board electrical system		AR54.10-P-1150LVH
37	Install remaining parts