Circuit/System Testing
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 includes the following steps:
- 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 may result in serious injury or death.
For European Region, a face shield is required in place of safety glasses.
High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures may result in serious injury or death.
For European Region, a special voltage tester such as the EL-52229 may be required. A multimeter that can measure current is prohibited.
This vehicle is equipped with a high voltage battery that is completely isolated from the chassis ground. Never utilize AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high voltage system is grounded through the electric utility.
Failure to follow the procedure exactly as written may result in serious injury or death.
Before working internally on the high voltage battery, be sure to wear Personal Protection Equipment (PPE) in accordance with National Fire Protection Association (NFPA) 70E, PPE Category 2, Minimum Arc Rating 8 cal/cm 2:
- Safety face shield and sock hood/balaclava
- Safety rated long sleeve shirt and pants or safety rated coveralls.
- Hearing protection
- 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 these precautions could result in serious personal injury or death.
- Vehicle OFF, disable the high voltage at the A4 Hybrid/Electric Vehicle Battery Pack. High Voltage Disabling
- A4 Hybrid/Electric Vehicle Battery Pack - Remove - Hybrid/Electric Vehicle Battery Pack Removal and Installation
- Review the recorded CMA location scan tool parameter information.
- If the location parameter identified the applicable CMA location as pack 2 (lower) remove the high voltage battery cover, disassemble and lift pack 1 (upper) as an assembly.
- If the location parameter identified the applicable CMA location as pack 1 (upper) remove the high voltage cover.
- Using the recorded MAC address observe each CMA label in the corresponding pack (upper or lower) until a MAC address match is obtained.
- Replace the matching cell module assembly.
- Assemble and install the hybrid/electric vehicle battery pack, and perform the Cell Module Assembly MAC Address Learn Procedure.
Always obtain and record the MAC address from the NEW cell module assembly before reassembling the battery pack.