Unlocking and disconnecting various plug connections in electrical and hybrid vehicles

Attention!

Observe the following instructions for handling high-voltage plug connections:

Damaged high-voltage plug connections must be replaced completely. Repair is not permitted.
Dirt contamination must be removed before opening the plug connection.

Disconnect the Hirschmann high-voltage connector:

Press the lock (1) on the left and right on the connector in the direction of the arrow.

Detach connector (2) in arrow direction.

IMPORTANT: Connector (2) may be difficult to detach.
In the event of damage to high-voltage connector (2), the complete high-voltage cable must be replaced!

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Connect the Hirschmann high-voltage connectors:

Slide the connector (1) on in the direction of the arrow.

NOTE: Connector (2) must lock audibly.

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Disconnect the Kostal high-voltage connector:

Unlock and disconnect high-voltage interlock loop (1).

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Push the lock (1) fully to the front.

Lift the connector (2) and remove it entirely.

IMPORTANT: Plug connection (3) may be difficult to detach.
The connector (2) must be completely detached from the opposite housing in one step. Damage may be caused to contact protection if connector is only partly detached and then closed again!

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Check the Kostal high-voltage connector and connection for damage:

Check the contact protection for damage and correct positioning (1).

WARNING: Do not touch unprotected connector (2)!
If the contact protection (1) has been pushed to the bottom (2), the high-voltage connector must be refitted.
If contact protection (1) remains in bottom position (2) after reinstallation, the contact protection is faulty and the component must be replaced!

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Check the high-voltage connector (1) for damage.

WARNING: In the event of damage to the high-voltage connector (1), the complete high-voltage cable must be replaced!

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Connect the Kostal high-voltage connector:

Connect the connector (2) in one single movement to the counter-housing.

Push the lock (1) fully to the rear.

IMPORTANT: Plug connection (3) must be correctly locked by lock (2), otherwise there is a risk of damage.

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Connect the connector for the high-voltage interlock.

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Three-phase high-voltage connector:

Connect and disconnect the connector straight.

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IMPORTANT: The system is designed to only offer limited protection against damage caused by connectors that are inserted at an angle.
Increased tilted connections will increase the connecting force and the risk of danger.

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Disconnect the high-voltage connector from the high-voltage connection of the KLE:

Slide locking mechanism (1) in arrow direction up to stop.

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Press lock (1).

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Open the lock (1) completely and disconnect the connector (2).

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Connect the high-voltage connector to the high-voltage connection of the KLE:

Insert the connector (1) up to the stop and close the lock (2).

IMPORTANT: Lock (2) must snap audibly into place.
The retaining lug of the lock (2) must be positioned completely under the lock (2).

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Slide the lock (1) on to the stop in the direction of the arrow.

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High-voltage connector on the high-voltage connection of the high-voltage battery unit:

Press down unlocking mechanism (1) in arrow direction and detach connector in arrow direction (2).

Attention!

Contact protection is no longer provided in the event of a damaged connector housing.

In this case, contact technical support.

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High-voltage connector on the cell module I01:

Press unlocking mechanism (1) together and detach connector upwards (2).

Attention!

Contact protection is no longer provided in the event of a damaged connector housing.

In this case, contact technical support.

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High-voltage connector on the cell module (cell module connecting line):

Press unlocking mechanism (1) in arrow direction and detach connector in arrow direction (2).

Attention!

Contact protection is no longer provided in the event of a damaged connector housing.

In this case, contact technical support.

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