Perform Measurement Of Insulation Resistance - AR54.10-P-4000SRE
MODEL 453.091/391/491
MODIFICATION NOTES
| 18.12.2017 | Expiration of insulation resistance measurement revised. | ||
| 18.12.2017 | Replace the refrigerant, added. | Operation step 17 |
Shown on vehicle except code 908 (Onboard charger, 22 kW)
Shown on vehicle except code 908 (Onboard charger, 22 kW)
Shown on vehicle except code 908 (Onboard charger, 22 kW)
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch damaged or defective 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 | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01SRE | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| Remove | |||
| 1 | Actuate electric fan of electric motor using diagnostic system and run for 5 min | ||
| AD00.00-P-2000-06SR | |||
| 2 | Perform power disable of high-voltage on-board electrical system | AR54.10-P-1160SRE | |
| 3 | Disconnect the high-voltage connector (1) at high-voltage connection (2) of high-voltage battery and cover high-voltage connector (1) with protective cover | AR54.00-P-0051-01SRE | |
| Fig 1 | |||
| 4 | Connect test adapter to high-voltage connection (2) of high-voltage battery | Fig 2 | |
| Measure | |||
| 5 | Perform insulation resistance measurements of high-voltage battery at test adapter | AR54.10-P-1160-01SRE | |
| Fig 2 | |||
| If the measured values are not OK. ↓ Replace high-voltage battery. |
AR54.10-P-1140SRE | ||
| 6 | Disconnect test adapter and connect high-voltage connector (1) at high-voltage connection (2) of high-voltage battery | AR54.00-P-0051-01SRE | |
| 7 | Disconnect high-voltage connector (3) at high-voltage connection (4) and cover high-voltage connection (4) with protective cover | AR54.00-P-0051-01SRE | |
| Fig 1 | |||
| 8 | Remove covers (6, 7) from fuse box (5) | ||
| 9 | Check all fuses (8) in fuse box (5) for continuity | If the resistance is ≥ 1 Ω. ↓ Replace respective fuse (8). |
AR54.10-P-1111SRE |
| 10 | Measure insulation resistance at high-voltage test point | AR54.10-P-1160-01SRE | |
| If resistance is ≥ 1 MΩ. ↓ Continue with operation step 11. If resistance is less than 1 MΩ. ↓ Replace high voltage line between high-voltage battery and fuse box (5). |
AR54.00-P-0051-01SRE | ||
| Fig 1 | |||
| 11 | Disconnect high-voltage connector (9) at fuse box (5) and cover high-voltage connection at fuse box (5) with protective cover | AR54.00-P-0051-01SRE | |
| Fig 1 | |||
| 12 | Measure insulation resistance at high-voltage test point | AR54.10-P-1160-01SRE | |
| If resistance is ≥ 1 MΩ. ↓ Proceed with step 14. If resistance is less than 1 MΩ. ↓ Disconnect high-voltage connector (11) at high-voltage connection (12) at firewall and cover high-voltage connection (12) with protective cover. Connect high-voltage plug (9) to fuse box (5). |
AR54.00-P-0051-01SRE | ||
| Fig 1 | |||
| 13 | Repeat measurement of insulation resistance at high-voltage test point | AR54.10-P-1160-01SRE | |
| If resistance is less than 1 MΩ. ↓ Replace high voltage line between power electronics (21) and PTC heater. |
AR54.10-P-1403SRE | ||
| If resistance is ≥ 1 MΩ. ↓ Replace high voltage PTC heater. |
AR83.70-P-8001SRE | ||
| 14 | Disconnect high-voltage connector (13) at high-voltage connection (14) and cover high-voltage connection (14) with protective cover | AR54.00-P-0051-01SRE | |
| Fig 1 | |||
| 15 | Measure insulation resistance at high-voltage test point | AR54.10-P-1160-01SRE | |
| If resistance is ≥ 1 MΩ. ↓ Continue with operation step 19. If resistance is less than 1 MΩ. ↓ Release refrigerant compressor (17) and connect high-voltage plug (13) to high-voltage connection (14). |
AR83.55-P-5310SRE | ||
| 16 | Disconnect high-voltage connector (16) at high-voltage connection (18) and cover high-voltage connection (18) with protective cover | AR54.00-P-0051-01SRE | |
| Fig 1 | |||
| 17 | Repeat measurement of insulation resistance at high-voltage test point | If resistance is less than 1 MΩ. ↓ Replace refrigerant and continue with operation step 18. |
AR54.10-P-1160-01SRE |
| Model 453 with engine 780.997 with code I01 (Air conditioning Plus) Model 453 with engine 780.997 with code I77 (Air conditioning, manual) |
AR83.30-P-1760SRE | ||
| 18 | Repeat measurement of insulation resistance at high-voltage test point again | AR54.10-P-1160-01SRE | |
| If resistance is less than 1 MΩ. ↓ Replace high-voltage line (15). If resistance is ≥ 1 MΩ. ↓ Replace refrigerant compressor (17). |
AR83.55-P-5310SRE | ||
| 19 | Detach electrical lines (19) and the electrical plug (20) at power electronics (21) | AR08.20-P-0011SRE | |
| 20 | Insulate electrical lines (19) | ||
| 21 | Measure insulation resistance at high-voltage test point | AR54.10-P-1160-01SRE | |
| If resistance is less than 1 MΩ. ↓ Replace power electronics (21). |
AR08.20-P-0011SRE | ||
| If resistance is ≥ 1 MΩ. ↓ Replace electric motor. |
AR08.10-P-0010SRE | ||
| 22 | Disconnect high-voltage connector (23) at high-voltage connection (24) at power electronics (21) and cover high-voltage connection (24) with protective cover | Model 453.091/391/491 except code 908 (On-board charger 22kW) |
AR54.00-P-0051-01SRE |
| Fig 1 | |||
| 23 | Measure insulation resistance at high-voltage test point | Model 453.091/391/491 except code 908 (On-board charger 22kW) |
AR54.10-P-1160-01SRE |
| If resistance is less than 1 MΩ. ↓ Connect high-voltage connector (23) to high-voltage connection (24). |
AR54.00-P-0051-01SRE | ||
| 24 | Disconnect high-voltage connector (25) at charger (26) and cover high-voltage connector (25) and charger (26) with protective covers | Model 453.091/391/491 except code 908 (On-board charger 22kW) |
AR54.00-P-0051-01SRE |
| Fig 1 | |||
| 25 | Repeat measurement of insulation resistance at high-voltage test point | Model 453.091/391/491 except code 908 (On-board charger 22kW) |
AR54.10-P-1160-01SRE |
| If resistance is ≥ 1 MΩ. ↓ Replace high voltage line between charger (26) and power electronics (21). If resistance is less than 1 MΩ. ↓ Replace charger (26). |
AR54.10-P-5114SRE | ||
| Install | |||
| 26 | Attach electrical lines (19) and the electrical plug (20) at power electronics (21) | AR08.20-P-0011SRE | |
| 27 | Connect high-voltage plug (1, 3, 9, 11, 13, 16) to respective high-voltage connection | AR54.00-P-0051-01SRE | |
| 28 | Connect high-voltage plug (23, 25) to appropriate high-voltage connection | Model 453.091/391/491 except code 908 (On-board charger 22kW) |
AR54.00-P-0051-01SRE |
| 29 | Perform initial startup of high-voltage on-board electrical system | AR54.10-P-1160SRE |