Replacing The Bmid; Charging Cable And Data Wires; Inspecting Cables, Wires And Connectors - Webasto PosiCharge DVS Field Service Manual

DVS/GSE
3.2.4

Replacing the BMID

1. Disconnect the thermistor connector from the BMID.
2. Disconnect the Red and Black power wires from the battery and retain the mounting
screws and washers.
3. Using the Delphi pin extractor, remove the White (pin A) and White/Orange (pin B) pins
from the Pilot / Data connector.
4. Remove the BMID from the battery and send to Webasto for analysis.
5. Place new BMID in location where failed BMID was installed.
6. Connect Black and Red wires to the battery.
7. Route White and White/Orange wires to location of Pilot / Data connector and install.
Make sure all wires are properly routed and secured with tie wraps to prevent damage to
wires.
3.3

CHARGING CABLE AND DATA WIRES

Periodically inspect charging cables, data wires and associated connectors for damage. Exposed
conductors are a safety hazard and require immediate replacement of the charging cable. If this
condition is found, take the charger out of service and repla ce the cable.
3.3.1

Inspecting Cables, Wires and Connectors

1. Locate the connectors between the battery cable assembly and the charger cable
assembly. Ensure that all of the power and signal connectors are completely mated,
and that there is no physical damage to the connector or pitting on the contact that
could cause poor connections.
2. Check that the communication and pilot wires are connected to the unit. Check that
all pins are seated correctly in each connector.
3. Visually inspect the insulation on all of the wires and verify that there are no shorts or
burnt spots on any of the wires. Check the continuity between the wire and chassis
ground using a multi-meter.
4. Verify that the BMID is installed properly (Refer to BMID manual).
09030-78B
GSE
Webasto Charging Systems, Inc.
32 49
of
DVS
Field Service Manual