222 589 02 63 00
Test adapter
222 589 05 63 00
Test adapter
Before starting testing work, the test log must be printed out, and filled out step by step during the test.
A 2-pin voltage tester is used as test equipment.
The voltage tester must be checked for proper operation before starting the test work in accordance with the manufacturer's specifications.
Information on voltage measurement between red female test connector (plus)/HV+ (wiring harness) and black female test connector (minus)/HV- (wiring harness)
During the test for power disable, if the voltage tester emits an acoustic signal as a result instead of a voltage value, this is not a malfunction.
In this case, the detectable voltage is below the display range of the voltage tester, which automatically activates the continuity check.
In this case, the voltage value of 0 V is to be entered in the test log.
Carefully connect probes of the voltage tester to the high-voltage connection points.
Otherwise the high-voltage connection points may be damaged.
1 | High-voltage battery connector |
4 | HV connector for high-voltage on-board electrical system |
A | Test adapter |
P54.10-4117-05
Perform voltage tests on the high-voltage battery connection (1) |
Use test adapter 222 589 02 63 00 (A).
1 | Connect voltage tester to test adapter (A) between the red female test connector (HV +) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
2 | Connect voltage tester to test adapter (A) between the black female test connector (HV -) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
3 | Connect voltage tester to test adapter (A) between the red female test connector (HV +) and black female test connector (HV -) and ensure that no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
4 | Enter recorded values on the corresponding test log section. |
4 | HV connector for high-voltage on-board electrical system |
P54.10-4120-06
Perform voltage tests on the HV connector of the high-voltage on-board electrical system (4)
5 | Connect the voltage tester to the HV connector for the high-voltage on-board electrical system between connector 1 (HV +) and vehicle ground and ensure no voltage is applied. |
6 | Connect the voltage tester to the HV connector for the high-voltage on-board electrical system between connector 2 (HV -) and vehicle ground and ensure no voltage is applied. |
7 | Connect voltage tester to HV connector for the high-voltage on-board electrical system between connector 1 (HV +) and connector 2 (HV -) and ensure no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
8 | Enter recorded values on the corresponding test log section. |
1 | High-voltage battery connector |
2 | DC/DC converter connection |
3 | High-voltage battery charger connection |
B | Test adapter |
P54.10-4114-06
Perform voltage tests on the DC/DC converter connection (2) of the high-voltage battery |
Use test adapter 222 589 05 63 00 (B).
9 | Connect voltage tester to test adapter (B) between the red female test connector (HV +) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
10 | Connect voltage tester to test adapter (B) between the black female test connector (HV -) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
11 | Connect voltage tester to test adapter (B) between the red female test connector (HV +) and black female test connector (HV -) and ensure that no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
12 | Enter recorded values on the corresponding test log section. |
Shown is the voltage test on the DC/DC converter connector |
P54.10-4121-05
Perform voltage tests on the DC/DC converter connector |
13 | Connect the voltage tester to the DC/DC converter connector between connector 1 (HV +) and the vehicle ground and ensure no voltage is applied. |
14 | Connect the voltage tester to the DC/DC converter connector between connector 2 (HV -) and the vehicle ground and ensure no voltage is applied. |
15 | Connect the voltage tester to the DC/DC converter connector between connector 1 (HV +) and connector 2 (HV -) and ensure no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
16 | Enter recorded values on the corresponding test log section. |
1 | High-voltage battery connector |
2 | DC/DC converter connection |
3 | High-voltage battery charger connection |
B | Test adapter |
P54.10-4116-06
Perform voltage tests on the high-voltage battery charger connection (3) on the high-voltage battery |
Use test adapter 222 589 05 63 00 (B).
17 | Connect voltage tester to test adapter (B) between the red female test connector (HV +) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
18 | Connect voltage tester to test adapter (B) between the black female test connector (HV -) and brown female test connector (vehicle ground) and ensure that no voltage is applied. |
19 | Connect voltage tester to test adapter (B) between the red female test connector (HV +) and black female test connector (HV -) and ensure that no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
20 | Enter recorded values on the corresponding test log section. |
Shown is the voltage test on the high-voltage battery charger connector |
P54.10-4121-05
Perform voltage tests on the high-voltage battery charger connector on the high-voltage battery
21 | Connect the voltage tester to the high-voltage battery charger connector between connector 1 (HV +) and vehicle ground and ensure no voltage is applied. |
22 | Connect the voltage tester to the high-voltage battery charger connector between connector 2 (HV -) and vehicle ground and ensure no voltage is applied. |
23 | Connect voltage tester to high-voltage battery charger connector between connector 1 (HV +) and connector 2 (HV -) and ensure no voltage is applied. |
If a voltage of 60 V DC is measured for one of the tests, the test must be repeated after 5 min. |
If a voltage 60 V DC is still measured after the second test:
Notify the responsible market support department immediately.
24 | Enter recorded values on the corresponding test log section. |
25 | The test log is to be placed behind the front window until renewed initial startup, and then enclosed along with the repair documentation after initial startup has been conducted. |