Perform measurement of insulation resistance - AR54.10-P-4000MEV
MODEL 451.390/392/490/492
MODIFICATION NOTES
| 28.9.15 | Screw, high voltage connector to high voltage battery | Model 451.390/392/490/492 except Code 908 (Bordlader 22kW) | BA54.10-P-1006-01H |
| 28.9.15 | Screw, high voltage connector to high voltage battery | Model 451.390/392/490/492 with Code 908 (Bordlader 22kW) | BA54.10-P-1006-01H |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch 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 | |
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01MEV | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| Remove | |||
| 1 | Perform manual power disconnect for high-voltage on-board electrical system | AR54.10-P-1039MEV | |
| 2 | Remove interior flap above engine | AR88.40-P-1100-03MCC | |
| 3 | Disconnect battery ground line | AR54.10-P-0003MCC | |
| 4 | Raise vehicle with vehicle lift | ||
| 5 | Connect test adapter to high-voltage connection of high-voltage battery (G5) | *BA54.10-P-1006-01H | |
| Figure | |||
| Measure | |||
| 6 | Measure insulation ohm test adapter | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | WS54.00-P-0046B | ||
If the measured value is OK ↓ Proceed with step 7. If the measured value is not OK ↓ |
Figure | ||
| Replace high-voltage battery (G5). | AR54.10-P-1140MEX | ||
| 7 | Disconnect test adapter and pull cover over connection on high-voltage battery (G5) | Figure | |
| 8 | Measure insulation resistance on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ Continue with operation step 29. If the measured value is not OK ↓ |
WS54.00-P-0046B | |
| Disconnect high-voltage connector from electric refrigerant compressor (A9/6) and proceed with operation step 9. | AR83.55-P-5300MEX | ||
| 9 | Measure insulation resistance again on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ |
WS54.00-P-0046B | |
| Replace electric refrigerant compressor (A9/6) and proceed with operation step 29. If the measured value is not OK ↓ Proceed with operation step 10. |
AR83.55-P-5300MEX | ||
| 10 | Detach high-voltage connector from high voltage PTC heater (N33/5) on PDU high-voltage distributor control unit (N116/5) | AR54.10-P-1400MEX | |
| 11 | Measure insulation resistance again on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ |
WS54.00-P-0046B | |
| Detach high-voltage connector from high-voltage PTC heater (N33/5) and proceed with operation step 12. If the measured value is not OK ↓ Continue with operation step 13. |
AR83.70-P-8001MEX | ||
| 12 | Measure insulation resistance again on connector of high voltage PTC heater (N33/5), which was connected to the PDU high-voltage distributor control unit (N116/5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ |
WS54.00-P-0046B | |
| Replace high-voltage PTC heater (N33/5) and proceed with operation step 27. If the measured value is not OK ↓ Replace line between high-voltage PTC heater (N33/5) and PDU high-voltage distributor control unit (N116/5) and proceed with operation step 28. |
AR83.70-P-8001MEX | ||
| 13 | Detach high-voltage connector from 3 kW on-board charger (N83) or 22 kW on-board charger (N83/10) | Model 451.390/392/490/492 with engine 780.993 except code 908 (Bordlader 22kW) |
AR54.10-P-5106MEX |
| Model 451.390/392/490/492 with engine 780.993 with code 908 (Bordlader 22kW) |
AR54.10-P-5106MEZ | ||
| 14 | Measure insulation resistance again on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ |
WS54.00-P-0046B | |
| Replace 3 kW onboard charger (N83) and proceed with operation step 26. Model 451.390/392/490/492 with engine 780.993 except code 908 (Bordlader 22kW) |
AR54.10-P-5106MEX | ||
| Replace 22 kW onboard charger (N83/5) and proceed with operation step 26. Model 451.390/392/490/492 with engine 780.993 with code 908 (Bordlader 22kW) If the measured value is not OK ↓ Proceed with operation step 15. |
AR54.10-P-5106MEZ | ||
| 15 | Detach high-voltage connector from drive electric motor (N5) | AR08.10-P-0010MEX | |
| 16 | Measure insulation resistance again on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ |
WS54.00-P-0046B | |
| Replace drive electric motor (N5) If the measured value is not OK ↓ Continue with operation step 17. |
AR08.10-P-0010MEX | ||
| 17 | Remove power electronics (N129/1) with power distributor (N116/5) | AR08.10-P-0011MEX | |
| 18 | Disconnect PDU high-voltage distributor (N116/5) from power electronics (N129/1) | AR54.10-P-1401MEX | |
| 19 | Measure insulation resistance again on high-voltage connector (2) of high-voltage battery (G5) | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ Continue with operation step 20. If the measured value is not OK ↓ Replace PDU high-voltage distributor (N116/5) |
WS54.00-P-0046B | |
| 20 | Perform measurement at contacts U, V, W | AR54.10-P-1160-01LF | |
| 000 588 00 19 00 Insulation measuring unit | If the measured value is OK ↓ Replace power electronics (N129/1) If the measured value is not OK ↓ Replace PDU high-voltage distributor (N116/5) |
WS54.00-P-0046B | |
| Install | |||
| 21 | Connect high-voltage connector to PDU high-voltage distributor control unit (N116/5) | AR54.10-P-1400MEX | |
| 22 | Connect high-voltage connector to drive electric motor (M5) | AR08.10-P-0010MEX | |
| 23 | Connect PDU high-voltage distributor (N116/5) to power electronics control unit (N129/1) | AR08.10-P-0011MEX | |
| 24 | Connect high-voltage connector to 3 kW on-board charger (N83) or 22 kW on-board charger (N83/10) | Model 451.390/392/490/492 with engine 780.993 with code 908 (Bordlader 22kW) |
AR54.10-P-5106MEZ |
| Model 451.390/392/490/492 with engine 780.993 except code 908 (Bordlader 22kW) |
AR54.10-P-5106MEX | ||
| 25 | Connect high-voltage connector to high voltage PTC heater (N33/5) | AR83.70-P-8001MEX | |
| 26 | Connect high-voltage connector to high voltage PTC heater (N33/5) on PDU high-voltage distributor control unit (N116/5) | AR54.10-P-1400MEX | |
| 27 | Connect high-voltage connector to electric refrigerant compressor (A9/6) | ||
| 28 | Remove cover from connection of high-voltage battery (G5) and connect high-voltage connector (2) to high-voltage battery (G5) and tighten screw/bolt (1) | *BA54.10-P-1006-01H | |
| 29 | Connect vent line (3) to high-voltage battery (G5) | ||
| 30 | Lower vehicle with vehicle lift | ||
| 31 | Connect ground cable to battery | AR54.10-P-0003MCC | |
| 32 | Install interior flap above engine | AR88.40-P-1100-03MCC | |
| 33 | Connect diagnostic system and conduct initial startup of high voltage on-board electrical system | ||
| AD00.00-P-2000-04MCC |
BATTERY
| Number | Designation | Model 451.390/392/490/492 except code 908 (Bordlader 22kW) | Model 451.390/392/490/49 2 with code 908 (Bordlader 22kW) | |
|---|---|---|---|---|
| BA54.10-P-1006-01H | Screw/bolt, high-voltage connector to high-voltage battery | Nm | 5, 5 | 5, 5 |