| Working on vehicles with a high-voltage system (hybrid vehicles) |
WARNING | Danger from unexpected engine starting |
| When performing general work on vehicles with a high-voltage system, switch off the ignition and remove the ignition key from the passenger compartment. |
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WARNING | Working with high-voltage cables: |
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| Never lean on or rest tools on high-voltage cables and their components --> Insulation damage. |
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| Take care not to kink high-voltage cables or bend them excessively --> Insulation damage. |
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| The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. Attention must be paid to this encoding when plugging in the round high-voltage connectors so as to avoid mechanical damage to the connectors. |
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DANGER! | Potentially fatal high voltage if high-voltage components are damaged |
| Heed the following when working in the vicinity of high-voltage components and high-voltage cables: |
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| Metal-cutting, forming and sharp-edged tools as well as heat sources such as welding, soldering, hot air and thermal bonding, are prohibited. |
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| Perform a visual inspection before starting work on the high-voltage components in the working area. |
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| When working in the engine compartment, the power electronics -JX1-, the electric drive motor -V141-, the air conditioner compressor -V470- and the high-voltage cables are to be subjected to a visual inspection. |
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| Visually inspect the high-voltage cables and covers when working on the vehicle floor. |
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| Before working on the rear section of the vehicle, visually inspect the high-voltage wiring and the electro-box with the maintenance connector for high-voltage system - TW -. |
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| All potential equalisation cables are to be subjected to a visual inspection. |
| Heed the following when performing visual inspection: |
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| Components must not exhibit any signs of external damage. |
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| The insulation of the high-voltage and potential equalisation cables must be intact. |
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| The high-voltage cables must not exhibit any signs of abnormal deformation. |
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| All high-voltage components must be identified by a red warning sticker. |
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| Isolation of high-voltage system from supply |
DANGER! | Potentially fatal high voltage |
| Risk of fatal or serious injury from electric shocks. |
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| High voltage at high-voltage system! |
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| For safety reasons, work on the high-voltage system is not to be performed by persons wearing electronic/medical life and health-preserving devices in or on the body. Life and health-preserving devices include internal painkiller pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. |
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| The high-voltage system is only to be isolated from the supply by an appropriately qualified person (Audi high-voltage engineer). |
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| It must be ensured beyond all doubt that the high-voltage system has been isolated from the supply. Isolation from the supply is to be determined solely by way of the Vehicle diagnostic tester employing the „Guided fault-finding“ routine. |
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| The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the locking cap -T40262- to ensure that the system cannot be re-energised. The ignition key and the maintenance connector for high-voltage system - TW - should then be stored in a safe place by the qualified person. |
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| The qualified person (Audi high-voltage engineer) attaches signs to mark the vehicle accordingly. |
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| Isolation of high-voltage system from supply: |
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| Connect the vehicle diagnostic tester |
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| Select Guided fault-finding mode |
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| Use the Go to key to consecutively select the following menu items |
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| Function/component list |
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| Systems with self-diagnosis capability |
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| 8C - Hybrid battery management -J840 |
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| 8C - Hybrid battery management, functions |
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| 51 - Isolation of high-voltage system from supply (Rep. Gr. 93) |
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| Before starting work on the high-voltage system, a high-voltage engineer must isolate the high-voltage system from the supply → Electrical system; Rep. gr.93. |
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| Work requiring isolation of the high-voltage system from the supply is described in each of the sequences of operations; for further information, refer to → Electrical system; Rep. gr.93. |
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| When working on hybrid vehicle components connected to the high-voltage system (e.g. the electrically driven air conditioner compressor), the high-voltage system must always be isolated from the supply before starting work. |
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| Certain work on hybrid vehicle components fitted in the vicinity of the high-voltage system components (e.g. at the battery cooling module, at the expansion valve to the air conditioning unit on the Audi Q5) requires isolation of the high-voltage system from the supply before starting work → Electrical system; Rep. gr.93 and → Air conditioning; Rep. gr.87. |
| Re-activation of high-voltage system |
DANGER! | Potentially fatal high voltage |
| Risk of fatal or serious injury from electric shocks |
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| High voltage at high-voltage system! |
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| For safety reasons, work on the high-voltage system is not to be performed by persons wearing electronic/medical life and health-preserving devices in or on the body. Life and health-preserving devices include internal painkiller pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. |
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| The high-voltage system is only to be re-activated by an appropriately qualified person (Audi high-voltage engineer). |
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| Re-activation is to be determined solely by way of the Vehicle diagnostic tester employing the „Guided fault-finding“ routine. |
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| The qualified person (Audi high-voltage engineer) re-activates the vehicle. |
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| The qualified person (Audi high-voltage engineer) attaches signs to mark the vehicle accordingly. |
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| High-voltage system re-activation: |
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| Connect the vehicle diagnostic tester |
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| Select Guided fault-finding mode |
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| Use the Go to key to consecutively select the following menu items |
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| Function/component list |
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| Systems with self-diagnosis capability |
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| 8C - Hybrid battery management -J840 |
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| 8C - Hybrid battery management, functions |
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| 51 - Re-activation of high-voltage system (Rep. Gr. 93) |
| Working with ignition switched on or high-voltage system active |
DANGER! | Danger from unexpected engine starting and risk of poisoning in enclosed areas when working with the ignition switched on or with READY activated. Risk of parts of the body and/or clothing becoming trapped or caught up. |
| Take the following action before switching on the ignition: |
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| Move the selector lever to position P |
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| Activate the parking brake |
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| Switch off the ignition |
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| Connect a charger, e.g. Battery charger -VAS 5095A- to the jump start points of the 12 V vehicle electrical system |
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| Working on vehicles with a high-voltage system |
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| If work is necessary in the vicinity of high-voltage system components, perform „Visual inspection of high-voltage components and cables for damage“ → Chapter and heed the „General warnings for working on high-voltage system“ → Electrical system; Rep. gr.93 |
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| For checking and measurement work where READY has to be active or the ignition switched on, set the selector lever to position „P“, activate the parking brake, arrange the necessary tools such that they cannot come into contact with rotating engine components and be sure to keep well away from rotating components when the engine is running. |
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| The selector lever is also to be set to position „P“ and the parking brake activated for checking and measurement work where the ignition has to be switched on but READY does not have to be active. |
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| READY is displayed in the control unit in dash panel insert -J285- via the „Powermeter“ → Owner's manual. |
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| For READY activation and deactivation, refer to → Owner's manual (heed the display in the control unit in dash panel insert -J285- when doing so). |
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