High Voltage Enabling
High Voltage Enabling
Danger:
Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.
Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
* Identify how to disable high voltage.
* Identify how to test for the presence of high voltage.
* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures exactly as written may result in serious injury or death.
Review the high voltage safety information prior to performing the High Voltage Enabling procedure. Refer to High Voltage Safety High Voltage Safety.
1. Verify that the 12 V battery is disconnected.
• If the 12 V battery is connected
Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
• If the 12 V battery is disconnected
Note:
Always tighten the high voltage fasteners to the specified torque. Insufficient or excessive torque will cause malfunctions or damage.
2. After completing testing or any repairs on the high voltage systems and before closing the S15 hybrid/EV battery pack high voltage manual disconnect lever, inspect for the following:
* Verify that all tools and loose components have been removed from the A4 hybrid/EV battery pack area and all items are accounted for.
* Verify high voltage system integrity and that all connectors are installed.
* Install any components or connectors that have been removed or replaced during diagnosis.
Danger:
High voltage insulation gloves with leather protectors MUST be worn at all times when the A4 hybrid/EV battery pack cover has been removed. When testing within the A4 hybrid/EV battery pack, 60 V WILL be present. If the S15 hybrid/EV battery pack high voltage manual disconnect lever is compromised and stuck closed, 120 V WILL be present. Failure to follow the procedures exactly as written may result in serious injury or death.
3. If the battery terminals at the C4A hybrid/EV battery section 1 and C4B hybrid/EV battery section 2 have been removed, reconnect the high voltage battery cables in the order shown above and close the battery terminal covers. Torque fasteners to 9 Nm (80 lb in).
4. If the A4 hybrid/EV battery pack cover has been removed, reinstall the cover. Refer to Generator Control Module Cover Replacement Generator Control Module Cover Replacement.
5. Connect the U, V, and W 3-phase cables. Torque fasteners to 9 Nm (80 lb in).
6. Connect the 12 V battery cable at the K59 starter/generator control module. Torque fastener to 9 Nm (80 lb in).
7. Install the F102 hybrid/EV battery pack cable cover. Torque fastener to 9 Nm (80 lb in).
8. Push in the red safety plunger and flip the S15 hybrid/EV battery pack high voltage manual disconnect lever (1) to the closed position.
9. Slide the white interconnect switch (2) to the closed position and push in the blue CPA (3).
10. Connect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
11. Start the engine, then turn the ignition OFF.
12. Ignition ON, clear all DTC Information with a scan tool.
13. Ignition OFF, wait 2 minutes, I\ignition ON.
14. Verify no DTCs are set.
• If any DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Trouble Code (DTC) List - Vehicle.
• If no DTCs are set
15. Start and idle the engine for 2 minutes.
16. Ignition OFF, wait 5 minutes, ignition ON.
17. Verify that the following DTCs have Ran Since Code Clear and have not set:
* Contactor DTCs P0ADB, P0ADC, P0AE6, or P0AE7
* Discharge and Pre-charge DTCs P0C77 or P0AFB.
* High voltage loss of isolation DTCs P0AA6 or P1AF0
• If any of the DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Trouble Code (DTC) List - Vehicle.
• If any of the DTCs have not Ran Since Code Clear
Review and operate the vehicle according to the DTC Conditions for Running and ensure the DTCs run and pass.
• If all the DTCs have Ran Since Code Clear and are not set
18. All OK.