Remove/Install DC/DC Converter For 48V On-Board Electrical System - AR54.10-P-1351LWO
Model 205, 213, 238, 253
with code B01 (48V technology)
| 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 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 | ||
| 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 | |||
| 1 | Detach ground line of 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) | AR54.10-P-0003LWO | ||
| 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 | Disconnect electrical connectors (1). | ||
| 4 | Unscrew nuts (2) and remove electric lines (3) from DC/DC converter control unit (N83/1). | ||
| 5 | Remove screws/bolts (4). | ||
| 6 | Disconnect DC/DC converter control unit (N83/1) from 48 V on-board electrical system battery (G1/3). | ||
| Check | |||
| 7 | Check contact pin (16) and associated contact sleeve in DC/DC converter control unit (N83/1) for damage. | If damage is present, ↓ Replace 48 V on-board electrical system battery (G1/3) or DC/DC converter control unit (N83/1). |
AR54.10-P-0022LWO |
| 8 | Check thread (7) for damage. | If damage is present, ↓ Recut corresponding threads (7). |
|
| 9 | Check seal (8) for damage. | If damage is present, ↓ Replace seal (8). |
|
| 10 | Check contact surface of 48 V on-board electrical system battery (G1/3) for damage. | If damage is present, ↓ Replace 48 V on-board electrical system battery (G1/3). |
AR54.10-P-0022LWO |
| 11 | Check contact surface of DC/DC converter control unit (N83/1) for damage. | If damage is present, ↓ Replace DC/DC converter control unit (N83/1) |
|
| Clean | |||
| 12 | Thoroughly clean contact surface of 48 V onboard electrical system battery (G1/3). | When reusing 48 V on-board electrical system battery (G1/3). |
|
| 13 | Thoroughly clean contact surface of DC/DC converter control unit (N83/1). | When reusing the DC/DC converter control unit (N83/1). |
|
| Install | |||
| 14 | Apply thermal compound to contact surface of DC/DC converter control unit (N83/1). | AR54.10-P-1351-01LWO | |
| *BR00.45-Z-1002-14A | |||
| 15 | Place DC/DC converter control unit (N83/1) onto 48 V on-board electrical system battery (G1/3) and press down evenly. | ||
| 16 | Screw in screws/bolts (4). | *BA54.10-P-1011-01A | |
| 17 | Connect electric lines (3) to DC/DC converter control unit (N83/1) and attach nuts (2). | *BA54.10-P-1012-01A | |
| 18 | Connect electrical connectors (1). | ||
| 19 | Install dust filter with air duct segment. | ||
| Model 213, 238, 253 with code B01 (48V technology) | AP83.00-P-8381C | ||
| Model 205 with code B01 (48V technology) | AP83.00-P-8381B | ||
| 20 | Connect ground line of on-board electrical system battery. | Model 238 with code B01 (48V technology) | AR54.10-P-0003LWO |
| Model 205, 213, 253 with code B01 (48V technology) | AR54.10-P-0003LW |
BATTERY
| Number | Designation | Model 205 | Model 213 | ||
|---|---|---|---|---|---|
| BA54.10-P-1011-01A | Bolt, DC/DC converter control unit to on-board electrical system battery (48V) | M5 | Nm | 6 | 6 |
BATTERY
| Number | Designation | Model 238 | Model 253 | ||
|---|---|---|---|---|---|
| BA54.10-P-1011-01A | Bolt, DC/DC converter control unit to on-board electrical system battery (48V) | M5 | Nm | 6 | 6 |
BATTERY
| Number | Designation | Model 205 | Model 213 | ||
|---|---|---|---|---|---|
| BA54.10-P-1012-01A | Nut, positive line/ground line to DC/DC converter control unit/on-board electrical system battery (48V) | M8 | Nm | 16 | 16 |
BATTERY
| Number | Designation | Model 238 | Model 253 | ||
|---|---|---|---|---|---|
| BA54.10-P-1012-01A | Nut, positive line/ground line to DC/DC converter control unit/on-board electrical system battery (48V) | M8 | Nm | 16 | 16 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1002-14A | Thermal compound | A 222 989 00 00 |