Remove/install power electronics with power distributor - AR08.10-P-0011MEX

ENGINE 780.993 in MODEL 451.390/392/490/492

MODIFICATION NOTES

28.09.2015	Screw, high voltage plug to high voltage battery	Model 451.390/392/490/492 except Code 908 (Wheel loader 22kW)	BA54.10-P-1006-01H
28.09.2015	Screw, high voltage plug to high voltage battery	Model 451.390/392/490/492 with Code 908 (Wheel loader 22kW)	BA54.10-P-1006-01H

Fig 1: Identifying Power Electronics With Power Distributor Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Power Electronics With Power Distributor Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Power Electronics With Power Distributor Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

	Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. 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 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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on coolant		AH20.00-N-2080-01A
	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/install
1	Remove transmitter key and mains plug
2	Connect diagnostic system and disable high-voltage on-board electrical system
		Print the power disable event log and add to the vehicle file. : Put the high-voltage on-board electrical system into operation.	AD00.00-P-2000-04MCC
3	Disconnect battery ground line		AR54.10-P-0003MCC
4	Remove interior flap above engine		AR88.40-P-1100-03MCC
5	Remove charger	Engine 780.993 in model 451.390/392/490/492 with code 908 (Wheel loader 22kW)	AR54.10-P-5106MEZ
6	Remove refrigerant lines on A/C compressor until the refrigerant lines can be placed to one side		AR83.30-P-7810MEX
	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 the vehicle manufacturer.	AS00.00-Z-0010-01A
7	Raise vehicle with vehicle lift
8	Unfasten clamp (19) on coolant pump drive switchover valve (Y133/1) with hose clamp pliers and push onto the coolant hose (18) to the rear	Hose clamp pliers	Figure
9	Detach coolant hose (18) from connection fitting and drain off coolant	Collect escaping coolant in a suitable container and seal the connection fittings using suitable stop plugs. : Check clamp (19) and coolant hose (18) for damage; replace if necessary.
10	Remove fender liner in right rear fender	Engine 780.993 in model 451.390/392/490/492 except code 494 (US version)	AR88.10-P-1400MCC
		Engine 780.993 in model 451.390/392/490/492 with code 494 (US version)	AR88.10-P-1400MCU
11	Disconnect electric motor drive high voltage connector (2) from electric motor drive
12	Pull protective cover on the line side and the component side over the electric motor drive high voltage connector (2)	Protect electric motor drive high voltage connector (2) against dirt and moisture. Otherwise, consequential damage may occur on the high voltage on-board electrical system. Set of protective caps	Figure
13	Remove screw/bolt (3) on high-voltage battery high voltage connector (1) and disconnect high-voltage battery high voltage connector (1) from high-voltage battery	Screw/bolt (3) serves as the removal and pulling in device and is integrated in the high voltage connector. Screw/bolt, high-voltage connector to high-voltage battery	*BA54.10-P-1006-01H
14	Pull protective cover on the line side and the component side over the high-voltage battery high voltage connector (1)	Protect high voltage battery high voltage connector (1) against dirt and moisture. Otherwise, consequential damage may occur on the high voltage on-board electrical system. Set of protective caps	Figure
15	Remove screw/bolts (4) from bracket (5)
16	Pull out bracket (5) with lines until the nut (6) is accessible
17	Unscrew nut (6) and take off bracket (5)
18	Lead electrical line for high-voltage battery upwards and lay on integral carrier
19	Lower vehicle with lifting platform
20	Disconnect PTC heater booster high voltage connector (7), A/C compressor control unit connector (EAC) (N116/1x1) and onboard charger high voltage connectors (10)
21	Pull protective cover on the line side and the component side over the PTC heater booster high voltage connector (7), A/C compressor control unit connector (EAC) (N116/1x1) and onboard charger high voltage connectors (10)	Protect the PTC heater booster high voltage connector (7), A/C compressor control unit (EAC) (N116/1x1) and onboard charger (10) against dirt and moisture. Otherwise, consequential damage may occur on the high voltage on-board electrical system. Set of protective caps	Fig 6
22	Remove cable ties (9)	: Replace cable tie (9).
23	Disconnect power electronics control unit low voltage connector (8) and A/C compressor control unit connector (EAC) (N116/1x1)
24	Unscrew nut (12) on bracket (11) and remove bracket (11)
25	Remove positive line (15) and place to one side
26	Remove ground line (16) and place to one side	Ensure that the contact surfaces are absolutely clean. Contact problems can otherwise occur and cause damage to the high-voltage on-board electrical system. Screw/bolt, ground line to line electronics control unit	*BA54.10-P-1009-01H
27	Unfasten clamps (13, 14) on power electronics control unit (N129/1) with hose clamp pliers and push on the coolant hoses to the rear	Hose clamp pliers	Figure
28	Detach coolant hoses from connection fitting	Collect escaping coolant in a suitable container and seal the connection fittings using suitable stop plugs. : Check coolant clamps (13, 14) and coolant hoses for damage; replace if necessary.
29	Remove screws/bolts (17) from power electronics control unit (N129/1)	Screw/bolt, line electronics control unit to bracket	*BA54.10-P-1005-01H
30	Remove power electronics control unit (N129/1) with high-voltage distributor PDU control unit (N116/5)
31	Install in the reverse order
32	Bleed cooling system using diagnostic system
			AD00.00-P-2000-04MCC
			AR20.00-P-1142-06MEX
		Filling device	Figure
		Pressure pump	Figure
33	Check cooling system for leaktightness		AR20.00-P-1010MCC