Volkswagen ID.3: Electric drive. High-voltage battery unit, edge of upper part of battery housing with wax

• Overview of fitting locations - battery modules
• Overview of fitting locations - battery modules
• Overview of fitting locations - battery modules
• Overview of fitting locations - battery connectors
• Assembly overview - high-voltage battery (removed)
• Assembly overview - high-voltage battery (removed)
• Assembly overview - battery modules
• Assembly overview - switching unit for high-voltage battery
• Assembly overview - switching unit for high-voltage battery
• Assembly overview – high-voltage battery, connector strip
• Assembly overview – high-voltage battery, connector strip
• Removing battery module
• Installing battery module
• Removing and installing battery modules control unit
• Removing and installing connector strip
• Removing and installing connector strip
• Removing and installing connector strip
• Removing and installing switching unit for high-voltage battery, negative terminal SX7
• Removing and installing switching unit for high-voltage battery, positive terminal SX8

Overview of fitting locations - battery modules

Overview of fitting locations - battery modules

1 - Battery module 1 -J991-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

2 - Battery module 2 -J992-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

3 - Battery module 3 -J993-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

4 - Battery module 4 -J994-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

5 - Battery module 5 -J995-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

6 - Battery module 6 -J996-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

7 - Battery module 7 -J997-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

8 - Battery module 8 -J998-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

9 - Battery modules control unit -J1208-

❏ → Rep. gr.93; Removing and installing battery modules control unit

10 - Battery modules control unit 5 -J1212-

❏ → Rep. gr.93; Removing and installing battery modules control unit

Overview of fitting locations - battery modules

Overview of fitting locations - battery modules

1 - Battery module 1 -J991-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

2 - Not fitted

3 - Not fitted

4 - Not fitted

5 - Battery module 5 -J995-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

6 - Battery module 6 -J996-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

7 - Battery module 7 -J997-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

8 - Battery module 8 -J998-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

9 - Battery module 9 -J999-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

10 - Battery module 10 -J1000-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

11 - Battery module 11 -J1001-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

12 - Battery module 12 -J1002-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

13 - Battery modules control unit 9 -J1216-

❏ → Rep. gr.93; Removing and installing battery modules control unit

14 - Battery modules control unit 5 -J1212-

❏ → Rep. gr.93; Removing and installing battery modules control unit

15 - Battery modules control unit -J1208-

❏ → Rep. gr.93; Removing and installing battery modules control unit

Overview of fitting locations - battery modules

Overview of fitting locations - battery modules

1 - Battery module 1 -J991-

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

2 - Battery module 2 -J992-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

3 - Battery module 3 -J993-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

4 - Battery module 4 -J994-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

5 - Battery module 5 -J995-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

6 - Battery module 6 -J996-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

7 - Battery module 7 -J997-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

8 - Battery module 8 -J998-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

9 - Battery module 9 -J999-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

10 - Battery module 10 -J1000-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

11 - Battery module 11 -J1001-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

12 - Battery module 12 -J1002-

❏ → Rep. gr.93; Installing battery module

❏ → Rep. gr.93; Removing battery module

13 - Battery modules control unit -J1208-

❏ → Rep. gr.93; Removing and installing battery modules control unit

14 - Battery modules control unit 5 -J1212-

❏ → Rep. gr.93; Removing and installing battery modules control unit

15 - Battery modules control unit 9 -J1216-

❏ → Rep. gr.93; Removing and installing battery modules control unit

Overview of fitting locations - battery connectors

Overview of fitting locations - battery connectors

Overview shows high-voltage battery, 82 kWh as an example

1 - Battery module 1 -J991-

2 - Battery module 2 -J992-

3 - Battery module 3 -J993-

4 - Battery module 4 -J994-

5 - Battery module 5 -J995-

6 - Battery module 6 -J996-

7 - Battery module 7 -J997-

8 - Battery module 8 -J998-

9 - Battery module 9 -J999-

10 - Battery module 10 -J1000-

11 - Battery module 11 -J1001-

12 - Battery module 12 -J1002-

Assembly overview - high-voltage battery (removed)

Assembly overview - high-voltage battery (removed)

1 - Upper part of battery housing

❏ → Rep. gr.93; Opening high-voltage battery 1 AX2

❏ → Rep. gr.93; Checking whether upper part of battery housing can be reused

❏ → Rep. gr.93; Closing high-voltage battery 1 AX2

2 - Bolt

❏ Qty. 14

❏ Renew after removing

❏ → Fig.

❏ M5×18

3 - Small fastener

❏ Qty. 2

❏ Renew after removing

❏ → Fig.

4 - Large fastener

❏ Qty. 2

❏ Renew after removing

❏ → Fig.

5 - Spacer

❏ Qty. 8

6 - Bolt

❏ Qty. 72

❏ Renew after removing

❏ → Fig.

❏ → Fig.

7 - Separating film

❏ Renew after removal of high-voltage battery 1 -AX2-

❏ Qty. 14

8 - Lower part of battery housing

9 - Bolt

❏ Qty. 16

❏ Renew after removing

❏ M5×25

❏ 4.5 Nm

10 - Pressure relief valve

❏ Renew after removing

11 - Potential equalisation

12 - Nut

❏ M6×10

❏ 8 Nm

Upper part of battery housing – specified torque and tightening sequence 1

StageBoltsSpecified torque/turning further angle1.1 -1- through -4- 100 Nm1.2 -5- through -18- 5.5 Nm + 90°

Upper part of battery housing – specified torque and tightening sequence 2 for production condition and repair bolt stage 2

StageBoltsSpecified torque2.1 -A-, -B-, -C-, -D- 8 Nm2.2 -1- through -72- 8 Nm

Upper part of battery housing – specified torque and tightening sequence 2 for repair bolt stage 1

StageBoltsSpecified torque2.1 -A-, -B-, -C-, -D- 5 Nm2.2 -1- through -72- 5 Nm

Assembly overview - high-voltage battery (removed)

Assembly overview - high-voltage battery (removed)

1 - Upper part of battery housing

❏ → Rep. gr.93; Opening high-voltage battery 1 AX2

❏ → Rep. gr.93; Checking whether upper part of battery housing can be reused

❏ → Rep. gr.93; Closing high-voltage battery 1 AX2

2 - Bolt

❏ Qty. 22

❏ Renew after removing

❏ → Fig.

❏ M5×18

3 - Small fastener

❏ Qty. 2

❏ Renew after removing

❏ → Fig.

4 - Large fastener

❏ Qty. 2

❏ Renew after removing

❏ → Fig.

5 - Spacer

❏ Qty. 8

6 - Bolt

❏ Qty. 82

❏ Renew after removing

❏ → Fig.

❏ → Fig.

7 - Separating film

❏ Renew after removal of high-voltage battery 1 -AX2-

❏ Qty. 22

8 - Lower part of battery housing

9 - Bolt

❏ Qty. 16

❏ Renew after removing

❏ M5×25

❏ 4.5 Nm

10 - Pressure relief valve

❏ Renew after removing

11 - Potential equalisation line

12 - Nut

❏ M6×10

❏ 8 Nm

Upper part of battery housing – specified torque and tightening sequence 1

StageBoltsSpecified torque/turning further angle1.1 -1- through -4- 100 Nm1.2 -5- through -26- 5.5 Nm + 90°

Upper part of battery housing – specified torque and tightening sequence 2 for production condition and repair bolt stage 2

StageBoltsSpecified torque2.1 -A-, -B-, -C-, -D- 8 Nm2.2 -1- through -82- 8 Nm

Upper part of battery housing – specified torque and tightening sequence 2 for repair bolt stage 1

StageBoltsSpecified torque2.1 -A-, -B-, -C-, -D- 5 Nm2.2 -1- through -82- 5 Nm

Assembly overview - battery modules

Assembly overview - battery modules

1 - Battery modules control unit

❏ → Rep. gr.93; Removing and installing battery modules control unit

2 - Bolt

❏ Qty. 2

❏ M5 x 25

❏ 4.5 Nm

3 - Bolt

❏ Qty. 4

❏ Renew after removing

❏ M8 x 72

❏ 16 Nm + 180°

4 - Battery module

❏ → Rep. gr.93; Removing battery module

❏ → Rep. gr.93; Installing battery module

5 - Bolt

❏ Qty. 2

❏ M6 x 20

❏ 8 Nm

6 - High-voltage connector

7 - Bolt

❏ Qty. 3

❏ M8 x 25

❏ 20 Nm

8 - Reinforcement for high-voltage battery body aperture

❏ Depending on equipment/version

Assembly overview - switching unit for high-voltage battery

Assembly overview - switching unit for high-voltage battery

1 - Cover

❏ 2x

2 - Bolt

❏ 7x

❏ Renew after removing

❏ M6 x 20

❏ 8 Nm

3 - Bridge

4 - Bolt

❏ 9x

❏ M6 x 52

❏ 8 Nm

5 - Switching unit for high-voltage battery, positive terminal -SX8-

❏ → Rep. gr.93; Removing and installing switching unit for high-voltage battery, positive terminal SX8

6 - Bolt

❏ Renew after removing

❏ M6 x 20

❏ 8 Nm

7 - Switching unit for high-voltage battery, negative terminal -SX7-

❏ With high-voltage battery isolation igniter -N563-

❏ → Rep. gr.93; Removing and installing switching unit for high-voltage battery, negative terminal SX7

8 - Bolt

❏ M6 x 20

❏ 8 Nm

9 - Electrical wire

10 - Battery regulation control unit -J840-

❏ → Rep. gr.93; Removing and installing battery regulation control unit J840

11 - Electrical wire

Assembly overview - switching unit for high-voltage battery

Assembly overview - switching unit for high-voltage battery

1 - Cover

❏ 2x

2 - Bolt

❏ 2x

❏ Renew after removing

❏ M6 x 20

❏ 8 Nm

3 - Bolt

❏ 5x

❏ Renew after removing

❏ M6 x 20

❏ 8 Nm

4 - Bridge

5 - Bolt

❏ 9x

❏ M6 x 52

❏ 8 Nm

6 - Switching unit for high-voltage battery, negative terminal -SX7-

❏ With high-voltage battery isolation igniter -N563-

❏ → Rep. gr.93; Removing and installing switching unit for high-voltage battery, negative terminal SX7

7 - Electrical wire

8 - Switching unit for high-voltage battery, positive terminal -SX8-

❏ → Rep. gr.93; Removing and installing switching unit for high-voltage battery, positive terminal SX8

9 - Bolt for high-voltage connecting bracket

❏ M6 x 20

❏ 8 Nm

10 - Electrical wire

11 - Battery regulation control unit -J840-

❏ → Rep. gr.93; Removing and installing battery regulation control unit J840

Assembly overview – high-voltage battery, connector strip

Assembly overview – high-voltage battery, connector strip

1 - Connector strip

❏ → Rep. gr.93; Removing and installing connector strip

2 - Bolt

❏ Qty. 5

❏ Renew after removing

❏ Specified torque and tightening sequence → Fig.

❏ M6×20

3 - Bolt

❏ Qty. 16

❏ Renew after removing

❏ Specified torque and tightening sequence → Fig.

❏ M5×25

Connector strip – specified torque and tightening sequence

StageBoltsSpecified torque1-1.1- to -4.4-4.5 Nm2-2- to -6-8 Nm

Assembly overview – high-voltage battery, connector strip

Assembly overview – high-voltage battery, connector strip

1 - Connector strip

❏ → Rep. gr.93; Removing and installing connector strip

2 - Bolt

❏ Qty. 5

❏ Renew after removing

❏ Specified torque and tightening sequence → Fig.

❏ M6×20

3 - Bolt

❏ Qty. 16

❏ Renew after removing

❏ Specified torque and tightening sequence → Fig.

❏ M5×25

Connection strip – specified torque and tightening sequence

StageBoltsSpecified torque1-1.1- to -4.4-4.5 Nm2-2- to -6-8 Nm

Removing battery module

Removing battery module

Special tools and workshop equipment required

♦ Contact protection -T10608-

♦ High-voltage tool kit -VAS 6762-

♦ High-voltage tool kit -VAS 6883A-

♦ adapter -10-222A/14-

♦ contact protection -T10628-

♦ hook -10-222A/10-

♦ lifting tackle -3033-

♦ lifting tackle -T10619-

♦ removal wedge set -VAS 895 015-

♦ shackle -10-222A/12-

♦ support bracket -10-222B-

♦ workshop hoist -VAS 6100-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment → Electronic parts catalogue (ETKA) before performing the following work steps:

♦ Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V

♦ Safety shoes with ESD protection

– → Rep. gr.93; Open high-voltage battery 1 AX2.

– → Rep. gr.93; Interrupt electrical circuit.

– → Rep. gr.93; Charging and discharging battery modules

– Mark installation position of electrical connectors and high-voltage connecting brackets.

– Unplug electrical connector -2-.

– Fit contact protection -T10628- -A- on battery module -1-.

– Remove bolts -3-.

– Remove high-voltage connecting bracket -4-.

– Fit contact protection -T10608- on open high-voltage connection at battery module.

Important

● Contact protection -T10608- -B- must be fitted.

– Fit contact protection -T10628- -A-.

– Remove bolts -2-.

– Remove high-voltage connecting bracket -3-.

– Fit contact protection -T10608- on open high-voltage connection at battery module.

Important

● Contact protection -T10608- -2- must be fitted on open high-voltage connections.

– Remove bolts -3-.

NOTICE

Mechanical forces on connector housing of battery modules control unit

Risk of damage to battery modules control unit

– Unplug electrical connector of battery modules control unit in vicinity of battery module that is to be removed.

– Prepare support bracket -10-222B- -1- and adapter -10-222A/14- -2- and position over centre of battery module.

– Connect battery module to lifting tackle -T10619- -3-, shackle -10-222A/12- -4- and hook -10-222A/10- -5-.

– Lift battery module off lower part of battery housing at outside in direction of -arrow- until battery module is released.

– Remove support bracket -10-222B- -1- and adapter -10-222A/14- -2-.

– Attach lifting tackle -3033- -B- to workshop hoist -VAS 6100- -A-.

– Lift battery module -1- using workshop hoist -VAS 6100- -A-, lifting tackle -T10619- -D-, shackle -10-222A/12- -C- and lifting tackle -3033- -B-.

– Set battery module down on a clean surface.

Important

● After the module has been lifted, the 2-component thermal grease must be renewed.

NOTICE

Risk of leaks in high-voltage battery 1 -AX2-.

– Do not remove 2-component thermal grease from sealant on inner edge of lower part of battery housing. If 2-component thermal grease is touching sealant, leave approx. 3 mm of 2-component thermal grease on sealant.

– Carefully remove 2-component thermal grease residue from lower part of battery housing using a suitable scraper from removal wedge set -VAS 895 015-.

If reusing battery module

– Remove 2-component thermal grease from battery module, making sure no residue is left.

Installing battery module

Installing battery module

Special tools and workshop equipment required

♦ High-voltage tool kit -VAS 6762-

♦ High-voltage tool kit -VAS 6883A-

♦ Torque wrench -VAS 6883/1A-

♦ accidental contact protection -T10608-

♦ accidental contact protection insert -T10628-

♦ cartridge opener -VAS 221 005-

♦ double cartridge gun -VAS 5237-

♦ lifting bracket -T10619-

♦ lifting tackle -3033-

♦ reversible ratchet -VAS 6762/29-

♦ shackle -10-222A/12-

♦ template -T10606-

♦ workshop hoist -VAS 6100-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on the required protective equipment for the subsequent work steps → Electronic parts catalogue (ETKA):

♦ Arc flash resistant clothing (at least APC 2, at least 318 kJ)

♦ Helmet with arc flash resistant visor (at least APC 2, at least 318 kJ)

♦ Arc flash resistant gloves with nitrile glove liners (at least APC 2, at least 318 kJ), insulating up to at least 500 V

♦ Safety shoes with ESD protection

Installing

– On removed battery module, check if separating film of lower part of battery housing -2- is present and undamaged.

– Only affix separating film -2- on inner edges of lower part of battery housing -1-.

Important

● Removed battery modules must be inserted in lower part of battery housing with 2-pack thermal grease → Electronic parts catalogue (ETKA).

● Before installing, adhere to cleaning solution flash-off time of 10 minutes.

● Bonding surfaces are dry.

– Clean surfaces onto which 2-pack thermal compound is to be applied using cleaning solution → Electronic parts catalogue (ETKA).

– Insert template -T10606- -A- into lower part of battery housing. Push in direction of -arrows- up to position shown.

NOTICE

2-pack thermal grease application insufficient.

Thermal conductivity impaired.

– Apply 2-pack thermal grease in one pass and without bubbles.

Important

● Use cartridge opener -VAS 221 005- to open cartridge.

– Fill 2-pack thermal grease -A- using double cartridge gun -VAS 5237- -C- up to edge of template -T10606- -B-.

– Remove template -T10606- -B- from lower part of battery housing.

– Attach lifting tackle -3033- -B- to workshop hoist -VAS 6100- -A-.

– Position battery module -1- with workshop hoist -VAS 6100- -A-, lifting bracket -T10619- -D-, shackle -10-222A/12- -C- and lifting tackle -3033- -B- above lower part of battery housing.

– Screw in bolts of battery module by hand to continue guiding battery module.

– Lower battery module -1- into lower part of battery housing up to 3 cm before end position. Screw in bolts 3 to 4 turns of thread.

– Lower battery module -1- to final position.

Important

● Torque must be monitored by a 2nd person.

– Tighten bolts of battery module in diagonal sequence using torque wrench -VAS 6883/1A-.

– Tighten bolts of battery module to turning further angle in diagonal sequence using reversible ratchet -VAS 6762/29-.

Installing

Important

● Torque must be monitored by a 2nd person.

– Remove accidental contact protection -T10608- from battery module -1-.

– Fit accidental contact protection insert -T10628- -A-.

– Install battery connector -4-.

– Tighten bolts -3-.

– Test battery connector against housing for short circuit.

– Connect electrical connector -2-.

Important

● Torque must be monitored by a 2nd person.

– Remove accidental contact protection -T10608- -B- from battery module -1-.

– Fit accidental contact protection insert -T10628- -A-.

– Install battery connector -3-.

– Tighten bolts -2-.

– Test battery connector against housing for short circuit.

Tightening torques

♦ → Rep. gr.93; Assembly overview – high-voltage battery, battery modules

Removing and installing battery modules control unit

Removing and installing battery modules control unit

Special tools and workshop equipment required

♦ High-voltage tool kit -VAS 6762-

♦ Torque wrench, insulated -VAS 691 001-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment → Electronic parts catalogue (ETKA) before performing the following work steps:

♦ Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V

♦ Safety shoes with ESD protection

Battery modules control unit -J1208- is referred to as battery modules control unit below.

Battery modules control unit 5 -J1212- is referred to as battery modules control unit below.

Battery modules control unit 9 -J1216- is referred to as battery modules control unit below.

Removing

– → Rep. gr.93; Open high-voltage battery 1 AX2.

– → Rep. gr.93; Interrupt electrical circuit.

NOTICE

Risk of damage to high-voltage battery 1 -AX2- if components are interchanged.

– Mark installation position of electrical connectors, cable routing and installation position of battery modules control unit.

– Unplug electrical connectors -3- and -4- and move electrical wire to one side.

– Remove bolts -2-.

– Remove battery modules control unit -1-.

Installing

Installation is carried out in reverse order; note the following:

– Perform “Controller configuration” function with → Vehicle diagnostic tester → Rep. gr.00; Starting diagnosis.

Tightening torques

♦ → Rep. gr.93; Assembly overview - high-voltage battery, battery modules

Removing and installing connector strip

Removing and installing connector strip

Special tools and workshop equipment required

♦ High-voltage tool kit -VAS 6762-

♦ High-voltage tool kit -VAS 6883A-

♦ Torque wrench -VAS 6883/1A-

♦ contact protection -T10608-

♦ contact protection -T10628-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment → Electronic parts catalogue (ETKA) before performing the following work steps:

♦ Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V

♦ Safety shoes with ESD protection

Switching unit for high-voltage battery, negative terminal -SX7- is referred to below as switching unit, negative terminal.

Removing

– → Rep. gr.93; Open high-voltage battery 1 AX2.

– → Rep. gr.93; Interrupt electrical circuit.

– Fit contact protection -T10628- on battery module 2 -J992-.

– Unscrew bolts -2- from high-voltage connecting brackets -1- on switching unit, negative terminal -3- and battery module 2 -J992-.

– Remove high-voltage connecting bracket -1-.

– Fit contact protection -T10608- on open high-voltage connection at battery module 2 -J992-.

– Detach cap for switching unit, negative terminal -3-.

– Remove bolts -2-.

– Remove bolts -3-.

– Remove connector strip -1-.

Installing

Installation is carried out in reverse order; note the following:

Important

● Have a second person check all torques.

– Check that seal is not damaged.

– Clean sealing surface with cleaning solution → Electronic parts catalogue (ETKA).

– Apply sealant → Electronic parts catalogue (ETKA) all around outside of connector strip next to existing seal.

– Ensure lower part of battery housing makes contact with seal.

– Install high-voltage connecting bracket and check it for short circuit to lower part of battery housing.

Tightening torques

♦ → Rep. gr.93; Assembly overview - switching unit for high-voltage battery

♦ → Rep. gr.93; Assembly overview - high-voltage battery, connector strip

Removing and installing connector strip

Removing and installing connector strip

Special tools and workshop equipment required

♦ High-voltage tool kit -VAS 6762-

♦ High-voltage tool kit -VAS 6883A-

♦ Torque wrench -VAS 6883/1A-

♦ accidental contact protection -T10608-

♦ accidental contact protection insert -T10628-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on the required protective equipment for the subsequent work steps → Electronic parts catalogue (ETKA):

♦ Arc flash resistant clothing (at least APC 2, at least 318 kJ)

♦ Helmet with arc flash resistant visor (at least APC 2, at least 318 kJ)

♦ Arc flash resistant gloves with nitrile glove liners (at least APC 2, at least 318 kJ), insulating up to at least 500 V

♦ Safety shoes with ESD protection

Switching unit for high-voltage battery, negative terminal -SX7- is referred to hereafter as switching unit, negative terminal.

Removing

– → Rep. gr.93; Open high-voltage battery 1 [AX2].

– → Rep. gr.93; Open electrical circuit.

– Fit accidental contact protection insert -T10628- onto battery module 1 -J991-.

– Unscrew bolts -3- from high-voltage connector -2- on switching unit, negative terminal -1- and battery module 1 -J991-.

– Remove high-voltage connector -2-.

– Fit accidental contact protection -T10608- onto exposed high-voltage connection on battery module 1 -J991-.

– Detach cap for switching unit, negative terminal -1-.

– Unscrew bolts -2-.

– Unscrew bolts -3-.

– Remove connector strip -1-.

Installing

Install in reverse order of removal, observing the following:

Important

● Have an additional person observe all torque settings.

– Make sure not to damage seal.

– Clean sealing surface with cleaning solution → Electronic parts catalogue (ETKA).

– Apply sealant → Electronic parts catalogue (ETKA) all around on outer side of connector strip, next to existing seal.

– Make sure that seal makes contact with lower part of battery housing.

– Install high-voltage connector and check for short circuit to lower part of battery housing.

Tightening torques

♦ → Rep. gr.93; Assembly overview – switching unit for high-voltage battery

♦ → Rep. gr.93; Assembly overview – high-voltage battery, connector strip

Removing and installing connector strip

Removing and installing connector strip

Special tools and workshop equipment required

♦ High-voltage tool kit -VAS 6762-

♦ High-voltage tool kit -VAS 6883A-

♦ Torque wrench -VAS 6883/1A-

♦ contact protection -T10608-

♦ contact protection -T10628-

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

– Suitable personal protective equipment (PPE) must be worn for the following work.

– The following steps require a second suitably qualified person to be present to supervise.

– Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.

– The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment → Electronic parts catalogue (ETKA) before performing the following work steps:

♦ Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)

♦ Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V

♦ Safety shoes with ESD protection

Switching unit for high-voltage battery, negative terminal -SX7- is referred to below as switching unit, negative terminal.

Switching unit for high-voltage battery, positive terminal -SX8- is referred to below as switching unit, positive terminal.

Removing

– → Rep. gr.93; Open high-voltage battery 1 AX2.

– → Rep. gr.93; Interrupt electrical circuit.

– Fit contact protection -T10628- on battery module 1 -J991- and battery module 2 -J992-.

– Unscrew bolts -2- from high-voltage connecting brackets -1- on switching unit, negative terminal -3-, switching unit, positive terminal -3-, battery module 1 -J991- and battery module 2 -J992-.

– Remove high-voltage connecting bracket -1-.

– Fit contact protection -T10608- on open high-voltage connection on battery module 1 -J991- and battery module 2 -J992-.

– Detach caps for switching unit, negative terminal -3- and switching unit, positive terminal -3-.

– Remove bolts -2-.

– Remove bolts -3-.

– Remove connector strip -1-.

Installing

Installation is carried out in reverse order; note the following:

Important

● Have a second person check all torques.

– Check that seal is not damaged.

– Clean sealing surface with cleaning solution → Electronic parts catalogue (ETKA).

– Apply sealant → Electronic parts catalogue (ETKA) all around outside of connector strip next to existing seal.

– Ensure lower part of battery housing makes contact with seal.

– Install high-voltage connecting bracket and check it for short circuit to lower part of battery housing.

Tightening torques

♦ → Rep. gr.93; Assembly overview - switching unit for high-voltage battery

♦ → Rep. gr.93; Assembly overview - high-voltage battery, connector strip

Removing and installing switching unit for high-voltage battery, negative terminal SX7

Removing and installing switching unit for high-voltage battery, negative terminal SX7

Installing

– Battery regulation control unit -J840-, switching unit for high-voltage battery, negative terminal -SX7- and switching unit for high-voltage battery, positive terminal -SX8- must be renewed together → Rep. gr.93; Removing and installing battery regulation control unit [J840].

Removing and installing switching unit for high-voltage battery, positive terminal SX8

Removing and installing switching unit for high-voltage battery, positive terminal SX8

Installing

– Battery regulation control unit -J840-, switching unit for high-voltage battery, negative terminal -SX7- and switching unit for high-voltage battery, positive terminal -SX8- must be renewed together → Rep. gr.93; Removing and installing battery regulation control unit [J840].

Electric drive. High-voltage battery components, edge of upper part of battery housing without waxElectric drive. Power and control electronics for electric drive