說明講稿奔馳s400technical summary victor en

1、S400 Technical Summary (201112)MBCLRegion EastVictor LuoMercedes-Benz (China) Ltd.Topic: Vehicle idle time/charge retention HV batteryModel: 221 hybridSpecification: SI54.10-P-0027A After a 6 week idle period, check/charge HV battery. If the vehicle is parked for an extended period, the HV battery s

2、hould have reached the maximum achievable charge level of 55% SOC for an internal combustion engine. A charge retention via 12 V battery will not prevent the HV battery from self-discharging. HV battery charge retention is not possible. Basic 1. Maximum possible charge level with internal combustion

3、 engine 55% SOC data: 2. Minimum charge level (automatic start of internal combustion engine) 30% SOC 3. Minimum charge level (start capability) 15% SOC Self-discharge of HV battery 10% SOC per 4 weeksBest case: 55% SOC -15% SOC (start capability) =40% SOC = 16 weeksWorst case: 30% SOC -15% SOC (sta

4、rt capability) = 15% SOC = 6 weeksMercedes-Benz (China) Ltd.Region East After-SalesMercedes-Benz (China) Ltd.Topic: Deep discharged single cell HV batteryModel: 221 hybridCause: Contamination in cell chemistry results in increased self-discharge of single cells. ( 2 mV/day)Remedy: Replace HV battery

5、Diagnosis: Xentry diagnosis access via BMS control unit Actual values Single cell voltages and fault code entries: 0BBE00 / 0BBD00 in BMS control unitDamage code: 54719Replacement part: A 221 343 05 00Standard: Various quality measures at suppliers and a screening of the single cell voltages on the

6、line enabled a major reduction in early failures to be achieved. Implementation: 2211A 302290Mercedes-Benz (China) Ltd.Region East After-SalesMercedes-Benz (China) Ltd.Topic: Deep discharged single cell HV batteryExample: Diagnosis printout for single cell voltages Discharged single cellsMercedes-Be

7、nz (China) Ltd.Region East After-SalesMercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Topic: Excessively discharged single cell of the high voltage battery (self discharge)Type: 221.095 & 221.195 (S400 Hybrid)Cause: Contaminants e.g. iron or copper particles either from dentrites over time or me

8、chanically break through the seperator during the production of the cellDTC: SG-BMS 0BBD00, 0BBE00Remedy (Series): - Optimized pre-treatment of the materials in the cell production Extended individual battery testing in the vehicle plan before installation in the vehicle. Clean point: 092011 (FIN: W

9、DD2211951A441817)Remedy (service): Perform replacement of the high voltage batteryMercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Cause: Please refer to TIPS document LI01.10-P-048929Remedy: Under investigation from R/D TIPS Case mandatory !Technical solution will be communicated case by case vi

10、a the TIPS case moduleModel: S400 Hybrid (221195)Complaint: Abnormal engine noiseMercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Test GuidelineIf the complaint could be confirmed as an abnormal engine noise, please1.) Open a TIPS case and implement the following: Pre-Order or Job card with custo

11、mer signature Initial Quick Test Log from DAS with actual DAS Add-On installed Control Unit Log from ME Repair History of the vehicle Check & verify the complaint as per TIPS Document LI01.10-P-048929 Confirm the engine speed on which this noise get noticed Make a sound record of the engine sound an

12、d attach it to the TIPS case Send TIPS case to Regional Office If the engine noise could be confirmed as per LI01.10-P-048929, then please follow step 2.), if not, then follow the step 3.) Mercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.2.) RO will check the TIPS case and advise the workshop to

13、Remove the alternator belt (for test purpose only) and check the influence of the noise Shut off the cylinder 1 to 6 and check if there is any influence of the noise Check also the influence of the noise from parking position into “N” and into “D” Take three video clips (incl. sound!) for belt drive

14、 at left engine side (oil temperature 90., coolant temperature 90.) 1. With alternator belt for constant engine RPM with the noise for at least 30s 2. Without alternator belt for constant engine RPM with the noise for at least 30s 3. Without alternator belt, increase the engine speed to 2,500 rpm an

15、d then release the gas pedal until the engine speed come down to app. 1,500 rpm, repeat at least 10 times Mercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Send the TIPS Case with all the details back to the Regional Office Follow step 3.) 3.) Central Office will take over the case, check it and i

16、f necessary forward it to DAG. Wait for further instructions via the TIPS case module. Note: Never dismantle the engine without pre-approval via TIPS case through the Regional or Central Office for such complaint. Take pictures from the crank case as the sample besides (Both the numbers from the low

17、er part and the pins from the upper part!) Mercedes-Benz (China) Ltd.Topic: Mounting bolt for HV connector to HV battery broken during assemblyModel: 221 Hybrid (221.095 and 221.195)Cause: Excessive stress on mounting bolt as a consequence of not adhering to tightening torque of 5 Nm.Remedy: Replace

18、 mounting bolt as described in TIPS document GI54.10-P-048638. A special repair kit (A 000 542 33 73) has been defined at GLC for this purpose.Standard: Material change for mounting bolt from brass to steel (CW 06/10) tightening torque remains 5 Nm!Damage code: 5960A 06Note: Tightening torque of 5 N

19、m must be observed!Mercedes-Benz (China) Ltd.Region East After-SalesMercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Complaint: Check engine light is on, Fault code P06DA00 engine oil pump valve fault)Cause: engine oil pump valve Y130Solution：There is no individual part available. The oil pump is

20、 to replaceOil pump valveY130 Oil pump valveModel: S400 with M272.974Mercedes-Benz (China) Ltd.Cause: The contact of the ground line between the DC/DC converter and vehicle body is inadequate. DC/DC converter is in standby mode (FC:P1C7000).1. Ground terminal on housing2. Ground terminal on vehicleT

21、opic: Engine start / stop system; engine starts up or 12V on-board electrical system voltage too lowType: 221.095 & 221.195 (S400 Hybrid)Mercedes-Benz (China) Ltd.Color residue on contact surface1. Ground cable crimp 2. Torque insufficientOxidation on housing Topic: Engine start / stop system: engin

22、e starts up or 12V on-board electrical system voltage too lowType: 221.095 & 221.195 (S400 Hybrid)Cause：Mercedes-Benz (China) Ltd.Remedy: 1. Rework contact surface of the ground terminal at the housing of the DC/DC converter according to TIPS document GI54.10-P-0489992. Perform programming of the DC

23、/DC converter with current SW (10.20.00)3. Check resistance of the ground line with DAS/XD guided test（as of 03/11）4. Perform SCN coding to the SAM driver (Modified charging current regulation of the generator)Further measurementsPerform engine control unit programming as of DAS/XD 05/2011. (In case

24、 of 12V under voltage, the yellow “READY” indication lamp will be displayed permanently in the IC and no automatic engine stop will be available)Perform programming to the DC/DC converter as of DAS/XD 07/2011 (threshold adaptation regarding ground line)Series: Modification of the ground terminal con

25、nection (M8 instead of M6), new DC/DC converter software will be in production as of 07/2011Topic: Engine start / stop system; engine starts up or 12V on-board electrical system voltage too lowType: 221.095 & 221.195 (S400 Hybrid)Mercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Topic: defective f

26、use (150A) of the HV batteryType: 221.095 & 221.195 (S400 Hybrid)Cause: Thermo-mechanical aging as a result of alternating electrical load (Bending)DTC: SG-BMS 0AA700, 0C7800, 0A1F04Remedy (Series): Use of the Fuse Temperature Control Function (FTCF) software for reduced temperature differences on t

27、he high voltage fuse. This means significantly lower mechanical and thermal stressClean point: 092011 (FIN: WDD2211951A441817)Remedy (Service):Current complaint: Replacement of the high voltage batteryPreventive: Service measure is currently in preparation (re-programming of the SG-BMS)Mercedes-Benz

28、 (China) Ltd.Mercedes-Benz (China) Ltd.Topic: High decrementation of the contractor aging counter of the high voltage batteryType: 221.095 & 221.195 (S400 Hybrid)Function: The counter describes the wear of the HV relay contacts when opening the contacts by spark erosion over lifetime. When the conta

29、cts open, the counter is decremented in dependence of the current intensity (see table). The counter is factory set to “200.000” when opening the contactor under normal conditions (e.g. ignition “OFF”) the counter will be decremented by “1”DAS/XD: Counter value in SG-BMS control unit protocolService

30、: From a counter value of “150.000” a message is displayed in the DAS/XD as of now to have the workshop create a TIPS case.Mercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Topic: Air conditioning is permanently inoperable defective 60A fuse inside PDU -Type: 221.095 & 221.195 (S400 Hybrid)Cause:

31、Thermally induced material fatigue as a result of a variety of electrical pulsesDTC: No error code in DAS/XentryService:Function test of the 60A fuse according TIPS document GI83.30-P-050078.If the fuse is defective, the power electronics (incl. PDU) has to be replaced.Mercedes-Benz (China) Ltd.Merc

32、edes-Benz (China) Ltd.Topic: Defect of the DC-link capacitor (PCC) of the power electronics unit (1/2)Type: 221.095 & 221.195 (S400 Hybrid)Cause: Loss of contact between bus bar and capacitor package. This leads to a progressive loss of capacity of the PCC capacitor. As a result of the loss of capac

33、ity the voltage ripple in the DC link increases followed by a defect of the power supply for the power electronics. Depending on the level of the voltage ripple, the 30A fuse of the high voltage battery might be damaged.DTC: P0A1E00,P0AFB00,P0A5D00,P0A6000,P0A6300Service: Replace the power electroni

34、cs unitMercedes-Benz (China) Ltd.Mercedes-Benz (China) Ltd.Topic: Defect of the DC-link capacitor (PCC) of the power electronics unit (2/2)Cause: As a result of the effect, the 60F capacitor in the DC/DC converter takes over the smoothing function increasingly. The increases the peak currents which might lead into triggering the 30A fuse in the high voltage battery.DTC: No DTCs in DAS/XentryServic