General, Technical Data (High Voltage Vehicle General Information) Audi Q5 I

EDUCATION, TRAINING AND RESPONSIBILITIES

QUESTIONS AND ANSWERS

Question: Can a high voltage vehicle be driven through a car wash?

Answer:-: A high voltage vehicle may be driven through a car washout without any special limitations.

Question: Is it permitted to wash the engine in a high voltage vehicle?

Answer: It is permitted to wash the engine in a high voltage vehicle while following all environmental regulations.

Question: Is there anything special to know when towing the vehicle?

Answer: There is no difference between towing a high voltage vehicle and a conventional vehicle, that is, it can be towed at maximum 50 km/h (31mph) and it must be flat-bed towed.

Question: Is it possible to charge and jump start a high voltage vehicle?

Answer: The electro-drive drive motor -V141-, which is integrated in the transmission, starts the Audi high voltage vehicle.

The charging source must be sufficient enough. This means, the charging current produced by the charger must ideally be at least 30 A or the charging vehicle must be of the same vehicle class as the Audi high voltage vehicle. The transfer of energy from the charger or from the other vehicle is displayed in the driver information system. The time it takes to charge the high voltage battery depends on the state of charge of the battery and the capacity of the charger or of the other vehicle. Jump starting using the battery jump start terminal may take longer when compared to non-hybrid vehicles.

Question: Does the customer need special training on the high voltage vehicle?

Answer: The customer does not need any special training on the vehicle. Any hybrid-specific instructions are in the Owner's Manual.

Question: It is possible to drive the high voltage vehicle without using the high voltage battery?

Answer: A malfunction in the high voltage battery triggers a malfunction mechanism in the system. The high voltage system turns off if the fault is more serious. It is possible to still drive the vehicle until the 12 V battery is empty. Once the high voltage turns off, it is not possible to charge is anymore.

Question: Is there anything special that must be done when the high voltage vehicle is being lifted on a vehicle hoist or an alignment rack or on a brake test stand?

Answer: Handle the high voltage vehicles just like a normal vehicle. Remember though that the internal combustion engine can start if the ignition is turned on.

Question: Is there anything special to do when a high voltage vehicle must be put on a dynamometer?

Answer: Handle the high voltage vehicles just like a normal vehicle. Select an operation mode on the vehicle diagnostic tester so that the vehicle is being driven only by the internal combustion engine. Turn off the ESP using the button inside the vehicle.

Question: Is there anything special to do when a high voltage vehicle must be brought into the paint shop?

Answer: The drying time for commercial paint repair work, depending on the material and the manufacturer, is between 30 and 60 minutes at 60 °C (140 °F). Normally the temperature in the drying rooms is 80 °C (176 °F).

Audi high voltage vehicles are equipped with a powerful lithium-ion battery. This type of battery is functional only up to 55 °C (131 °F). The cells can get damaged when the temperature goes above 70 °C (158 °F).

In order to not exceed 70 °C (158 °F), do not leave an Audi high voltage vehicle longer than 60 minutes in the paint drying cabin.

If the materials being used for the repair need a drying time longer than 60 minutes, then find an alternative method to dry them such as infrared heat.

Question: Which maintenance and service work must the customer have performed on the high voltage vehicle?

Answer: All maintenance work as on a conventional vehicle must be performed. Only a trained high voltage technician in an authorized dealership may work on the high voltage system following all the guidelines from Audi.

Question: Is there any additional work which must be performed during the delivery inspection?

Answer: In regards to the delivery inspection, there is no additional preparation work necessary for the high voltage components. Only the 12 V start battery needs to be checked during the delivery inspection. The electro-drive drive motor -V141- is used only as a generator when the vehicle is in transport mode. Therefore, it is not possible to drive electrically, to boost, to use the Start/Stop mode and the recuperation does not work. The high voltage battery is always being charged in the transport mode when the internal combustion engine is running.

Question: Is there anything special to do when a vehicle is going to be stored?

Answer: There is a company-wide check list for vehicles that are going to be stored. All activities are described in detail there.

EFFECTS AND AFTER-EFFECTS OF ELECTRIC SHOCK

Electric shock

Shock reaction below the release threshold and danger of injury caused by uncontrolled movements as well as disturbance of equilibrium

Thermal effect

Burning and carbonization at the current entry and exit points as well as internal burning. This can overload the kidneys which can lead to death.

Chemical effect

Blood and cell fluids will be electrolitically degenerated. The result will be poisoning with often time is noticed only after several days.

Effect on muscles

Muscles will cramp and brain functions will be impaired. Result: for example, impairing physical motions, cramping of the lungs (apnea) and irregular heart beat (ventricular fibrillation and heart stops pumping).

GUIDELINES FOR RESCUING PERSONS IN A CRASH WITH VOLTAGE STILL ON

Always follow and perform the following guidelines

1. Personal safety always comes first.
2. Do not directly touch any person who is in direct contact with the voltage.
3. If possible, de-energize the high voltage system immediately (turn off the ignition or remove the high voltage system maintenance connector -TW-.
4. Separate the victim or the electric conductor with a non-conductin object (a board, a broom stick, etc.) from the voltage.

FIRST AID GUIDELINES FOR ELECTRIC SHOCK

A - Guidelines for first aid workers when the crash victim is not responding

1. Check the pulse and breathing.
2. Call the EMS or have someone else call.
3. Perform artificial respiration and heart/lung massage (30:2) until the EMS arrives.
4. If the victim is not breathing: if necessary, use a defibrillator.

B - Guidelines when the crash victim is responding

1. Cool down any possible wounds caused by heat and then cover them with a sterile, lint-free cloth.
2. The crash victim must always be treated by a doctor to prevent any problems later.

GUIDELINES FOR CRASHES WITH BATTERIES/BATTERY CONTENTS

1. Rinse the main contact with a lot of water.
2. Make sure there is ample fresh air if breathing in gases.
3. Rinse your eyes with water if the gases come in contact with your eyes (10 minutes at least).
4. Drink a lot of water if you swallow any of the battery contents but try not to vomit.
5. Seek medical attention.

DAMAGE CAUSED BY CURRENT AND VOLTAGE

1. Alternating currents from 25 volts and direct currents from 60 volts are dangerous. "Electrification" occurs when a current greater than 5 mA flows through the human body. You feel a tingle but you are still able to let go of the electric conductor.
2. The so-called "release threshold" begins when 10 mA current flows through the body and the body contracts. You are no longer able to separate yourself from the voltage source. The duration of the voltage increases considerably. If the alternating current with 30 - 50 mA lasts longer, apnea and ventricular fibrillation will occur. The "death threshold" is reached when approximately 80 mA current flows through the human body.

DIFFERENCE BETWEEN AC AND DC CURRENTS?

Alternating voltage causes alternating current in the human body and produces vibrations in the muscles and in the heart. The lower the frequency is, the more dangerous is the alternating voltage. The ventricular fibrillation can occur and can be lethal without first aid.

With direct current, an electrolytic dissolution corrodes the webbing. This can produce materials that can lead to poisoning. This so-called direct current poisoning first appears a few days after a crash and can be lethal if it remains untreated.

There are safety mechanisms in place if the high voltage battery is faulty. As a rule, if the fault is more serious, the entire high voltage system turns off. The resulting danger potential caused by the high voltage battery is classified as low.

WORKSHOP PROCEDURES FOR HIGH VOLTAGE VEHICLES

Follow the procedures if a high voltage vehicle is brought to an Audi dealership. The workshop procedures for working with high voltage vehicles can be found in the training materials for "Audi high voltage technicians".

RECOGNIZING DAMAGE

Leaking electrolyte can be recognized by its odor. If this is the case, do not keep the vehicle in an enclosed space.

"Guided Fault Finding" contains a test program to be used for evaluating the high voltage battery. The test programs uses visual and thermal criteria to determine if the high voltage battery is in a critical condition.

Visual

1. Checking for traces of burning
2. Checking for deformation
3. Checking for moisture/water

Thermal

1. The high voltage battery is getting warm
2. The battery housing is discolored.
3. The plastic is deformed.

If the battery evaluation determines that the high voltage battery is in a critical condition, then a mandatory report or technical inquiry must be issued via the DISS system. Audi Product Support then decides on the necessary steps to be taken and, if necessary, sends a specially trained technician.

STORING AND TRANSPORTING

Temporarily storing the high voltage batteries while performing a repair on the vehicle

1. Do not store the high voltage battery temporarily out in the open or directly in areas where repairs are being performed.
2. Protect the high voltage battery from mechanical and thermal impacts as well as from moisture.
3. The high voltage battery being stored temporarily should not be accessible to other technicians or customers. (for example, in a storage room).

Replacing the high voltage batteries - the condition of the high voltage battery is not critical

1. The high voltage battery can be stored in its original packaging.
2. Place the removed high voltage battery back into its original packaging and ship it out in this packaging.
3. The high voltage battery weighs approximately 40 kg (88 lbs). There is a special tool to be used when moving the high voltage within the workshop.

Replacing the high voltage batteries - the condition of the high voltage battery is critical

1. Classifying the high voltage vehicle according to the following criteria using a test program.

1. Visible damage to the high voltage battery
2. Thermal abnormalities on the high voltage battery
3. Recognizable fluid or leaks on the high voltage battery

2. Storing high voltage vehicles with one of the points from 1 applies

1. The high voltage battery remains in the vehicle
2. The vehicles must be parked outside. Note the following when doing this
3. Do park the vehicle near buildings.
4. Park the vehicle on a surface that has been sealed and place a catch tray under the vehicle where the high voltage battery is located.
5. Place the high voltage sign VAS 6649 on the vehicles and secure the vehicle so that unauthorized persons cannot get access to the vehicle.
6. Cover the vehicle with a waterproof tarp to protect the vehicle from the weather if is going to stored outside.

If the battery evaluation determines that the high voltage battery is in a critical condition, then a mandatory report or technical inquiry must be issued via the DISS system. Audi Product Support then decides on the necessary steps to be taken and, if necessary, sends a specially trained technician.

HIGH VOLTAGE SYSTEM, DE-ENERGIZING AND ENERGIZING

1. Always de-energize and energize the high voltage system using Guided Fault Finding or Guided Functions , using the vehicle diagnostic tester.
2. Fill out the test protocols each time the high voltage system is de-energized and then energized again. The printer prints out the check protocols during testing. Fill them out, sign them and include them with the work order.

The repair information lists all the procedures for de-energizing the high voltage system .

HIGH VOLTAGE VEHICLE EXTERIOR FEATURES

The Audi high voltage vehicle can be recognized by the following exterior features

1. Hybrid badge on the fenders
2. Hybrid badge on the rear lid

HIGH VOLTAGE VEHICLE INTERIOR FEATURES

The Audi high voltage vehicle can be recognized by the following interior features

1. Hybrid badge on the design cover inside the engine compartment
2. Instrument cluster with power meter and hybrid displays
3. MMI with hybrid display
4. Hybrid badge on the sill panel strip
5. EV mode switch and selector mechanism with tip-5 function

VOLTAGE AND CURRENTS IN HIGH VOLTAGE AREA

In the active high voltage area, the electric A/C compressor, the high voltage battery and the power electronics use DC current. The electro-drive drive motor -V141- works with alternating current or the alternating current is present. The power electronics is also equipped with an energy storage device in the form of a capacitor. It discharges when the ignition is turned off.

SPECIAL TOOLS

High Voltage Warning Sticker with Thunderbolt Symbol VAS 6649

Scheme 1

Make sure the area around the vehicle is safe before starting any work on the high voltage vehicle. Place a "Warning! High Voltage!" sign on the vehicle so that it is visible to all.

High Voltage Warning Sticker, Switch VAS 6650A

Scheme 2

Place the "Do not switch on. Work in progress" sign on the vehicle so that it is visible to all after de-energizing the vehicle.

Hybrid Test Module VAS 6558

Scheme 3

1. The measuring module measures the high voltage insulation resistance and confirms the high voltage has been de-energized on high voltage vehicles.
2. Hybrid Test Adapter VAS 6558-1A is also needed for adapting measuring module VAS 6558.

Hybrid Test Adapter VAS 6558-1A

Scheme 4

The test adapter and the hybrid measuring module VAS 6558 are both used to diagnose the vehicle system. Measuring the insulation resistance is performed using the different adapters, which confirm the high voltage system has been de-energized and test the electric A/C compressor.

Test Adapter VAS 6606-10

Scheme 5

The test adapter and the breakout box with detachable terminals (196 pins) VAS 6606 measure the power electronics and the battery management system.

Locking Cap T40262

Scheme 6

The Safety Precautions for working on electric systems require that the high voltage system be secured from energizing again after it has been de-energized. Place the locking cap over the socket for the high voltage system maintenance connector -TW- and then lock it with the padlock.

Unlock Tool T40258

Scheme 7

The unlock tool locks and unlocks the high voltage connector on the power electronics on Audi high voltage vehicles.

Adapter T40259

Scheme 8

The adapters are attached to the high voltage battery at three defined locations. They are used when lifting the battery with a workshop crane. The set T40259 consists of three adapters.