Remove/Install DC/DC Converter For 48 V On-Board Electrical System - AR54.10-P-1351S

Model 223 with engine 176 

with code B01 (48V technology) 

Model 223 with engine 256 

with code B01 (48V technology) 

except code 9U8 (Control code - Major assembly technical further development) 

Model 223 with engine 656 

with code B01 (48V technology) 

except code M30 (Displacement 3.0 liter) 

Courtesy of MERCEDES-BENZ USA

	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
Notice	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
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	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.		AR54.10-P-0051S
2	Remove dust filter with air duct segment.
			AP83.00-P-8381I
3	Remove strut (1).
4	Disconnect electrical connectors (2).
5	Detach electrical lines (3).
6	Remove screws (4).
7	Carefully loosen DC/DC converter control unit (N83/12) from 48 V battery (G1/3) using long wedge, and remove.	The DC/DC converter control unit (N83/12) must be detached upward vertically from the 48 V battery (G1/3). Otherwise the contact pin (7) will be damaged.
		Ensure that DC/DC converter control unit (N83/12) is not tilted. The DC/DC converter control unit (N83/12) is bonded to the 48 V battery (G1/3) by the thermal compound applied between them.
		Long wedge	Fig 1
	Check
8	Check contact pin (7) and associated contact sleeve in DC/DC converter control unit (N83/12) for damage.	If damage is present, ↓ Replace 48 V battery (G1/3) or DC/DC converter control unit (N83/12).
		Remove/install 48 V battery (G1/3)	AR54.10-P-0022S
9	Check threads (5) for damage and soiling.	If damage is present, ↓ recut corresponding threads (5).
10	Check seal (6) for damage.	If damage is present, ↓ Replace gasket (6).
11	Check contact surface of 48 V battery (G1/3) for damage.	If damage is present, ↓ replace 48 V battery (G1/3).
			AR54.10-P-0022S
12	Check contact surface of DC/DC converter control unit (N83/12) for damage.	If damage is present, ↓ Replace DC/DC converter control unit (N83/12).
	Clean
13	Thoroughly clean contact surface of 48 V battery (G1/3).	When reusing 48 V battery (G1/3). Use a commercially available plastic spatula for cleaning.
14	Thoroughly clean contact surface of DC/DC converter control unit (N83/12).	When reusing DC/DC converter control unit (N83/12). Use a commercially available plastic spatula for cleaning.
	Install
15	Apply thermal compound to contact surface of 48 V battery (G1/3).		AR54.10-P-1351-02WT
		The thermal compound must be processed with a period of 1 h. Commercially available devices/tools  50 ml double-cartridge gun
		Thermal compound	*BR00.45-Z-1002-14A
16	Carefully position DC/DC converter control unit (N83/12) on 48 V battery (G1/3) and press on evenly.	The DC/DC converter control unit (N83/12) must be positioned vertically downward onto the 48 V battery (G1/3). Otherwise the contact pin (7) will be damaged.
		Ensure that DC/DC converter control unit (N83/12) is not tilted.
17	Screw in screws/bolts (4).	Screw control unit DC/DC converter to 48 V battery	*BA54.10-P-1015-01N
18	Attach electric lines (3).	Nut, positive line/ground line to DC/DC converter control unit/on-board electrical system battery (48 Volt)/voltage dip limiter/current limiting module	*BA54.10-P-1013-01N
19	Connect electrical connectors (2).
20	Install strut (1).	Screw, center strut to longitudinal member mounting console	*BA62.30-P-1009-02P
21	Install dust filter with air duct segment.
			AP83.00-P-8381I
22	Connect ground line of on-board electrical system battery.		AR54.10-P-0051S
23	Commission DC/DC converter control unit (N83/12).	When replacing DC/DC converter control unit (N83/12).
			AD00.00-P-2000-06FR

Fig 1: Identifying Long Wedge (115 589 03 59 00)

Courtesy of MERCEDES-BENZ USA