CAR-connect Adapter Cable VAS 6558A/39-1 User Manual
Document information
Imprint
[email protected]www.car-connect.cc
1 Concept
The adapter cable is designed as per the latest measurement and control technology regulations. The adapter cable corresponds with the state of the art and fulfils the VW standard 75174, the relevant European standards as well as partially fulfilling international standards for measuring equipment accessories. Despite high standards for development, production and quality, only careful handling and proper use can ensure that there is no damage and resulting consequences. For this reason, this operating manual should be read and understood in full.
1.1 Read the operating manual
Read these operating instructions through carefully, before using the adapter cable. In this operating manual, the intended use and hazards of handling the product are described. In addition to this operating manual, other regulations may be binding for diagnosis or troubleshooting of intrinsically safe high-voltage systems in road vehicles. These include, among other things, the manuals of the vehicle manufacturer as well as the instructions of the employers’ liability insurance association. Please ensure that all information on the product and its scope of application is available to you before you use the adapter cable. Please use the adapter cable only if you have fully understood all information pertaining to its use.
1.2 Structure of the document
For a better understanding of the information contained in this operating manual, additional descriptive pictograms are used. These markings indicate particularly relevant information and the images indicate the significance within a description or an operation step.
Therefore, please follow the instructions and information in this operating manual, so that there is no bodily injury or property damage when used in the high-voltage section of the vehicle.The following table contains all the pictograms, warning symbols and symbols that may appear in this manual.
2 Safety instructions
The basic safety instructions given below must be followed to avert bodily injury to people and property damage while using the adapter cable.
2.1 General safety instructions
Most incidences of damage to property and personal injury are primarily due to ignorance or negligence and can be avoided from the outset if the following general safety instructions are observed:
- Read the operating manual carefully before use.
- Only people who can provide valid proof of technical knowledge of working on high-voltage systems in motor vehicles may perform measurements on high-voltage systems.
- Follow the instructions given in the vehicle manufacturer’s guided troubleshooting such as the application description in PIWIS Tester.
- Use the adapter cable testing adapter only in closed and dry spaces.
- Follow the instructions of the trade association or government institutions for the repair of hybrid- and all-battery electric vehicles.
- Check the adapter cable regularly before use, as per the vehicle manufacturer’s instructions.
- Use the adapter cable solely for the intended use — as specified by the vehicle manufacturer.
- Use the product solely for its intended purpose.
- Immediately replace a defective or damaged product.
- Never attempt to modify or manipulate the adapter cable.
- Never attempt to supply current or voltage to other devices through the adapter cable.
- Do not use aggressive liquids to clean the product.
- Prevent the adapter cable from coming in contact with aggressive operating fluids such as brake fluid and coolant.
2.2 Intended use
The adapter cable VAS 6558A / 39-1 is a connection cable that is used along with the adapter cable VAS 6558A / 39-2 for diagnosis on highvoltage systems of road vehicles manufactured by Volkswagen. When the vehicle is de-energized on removal of the high-voltage battery, this adapter cable set enables the restoration of the communication interfaces between the high-voltage battery and the vehicle. For this, the work instructions in the guided troubleshooting must be followed.
2.3 Improper use
Any use of the product deviating from the intended use is considered improper use. Use of a manipulated or defective adapter cable will be considered in exactly the same way as disregarding or disobeying the instructions of the operating manual. This behavior, in addition to limiting the guarantee and the loss of warranty claims, can also lead to bodily injury to people or damage to property under certain circumstances.
2.4 Obligations of the operator
The operator must ensure that appropriate and capable staff is appointed by them to work on vehicle-specific high-voltage system. The proof of qualification required for this is based on successful participation in appropriate training. The operator must ensure that the measuring equipment and accessories are in a faultless condition and they do not have any defects.Regular inspection periods for the measuring equipment, accessories and testing adapters are set out in an instruction manual. Also, it is the operator’s responsibility to note the replacement of the adapter cable set on reaching the number of operation cycles. The operator must ensure that servicing staff regularly participate in refresher training courses for repairs of high-voltage systems and pass these successfully as well.
2.5 User’s qualifications
The user has proven expertise to carry out work on high-voltage systems of fully battery-operated, plug-in hybrid or e-traction road vehicles. In addition, the user should have experience in taking cascade measurements, whereby active and passive measurements are taken simultaneously.
3 Transport
The product comes in recyclable disposable packaging, which is not suitable for storing the product after use.
3.1 Unpacking and checking for completeness
Check the condition and completeness of the contents based on the shipping documents and the delivery note. In case of any damage or defective components, contact the manufacturer immediately.
3.2 Transport during normal working hours
The adapter cable VAS 6558A/39-1 is used along with the adapter cable VAS 6558A/9-2 as a set and should be transported after diagnosis in a suitable transport container. Please ensure that moisture and dirt do not enter the container.
3.3 Safekeeping and storage
In order to avoid damage to the adapter cable or to prevent the loss of accessories, always keep the cable in a transport case. This procedure gives you a quick overview and the assurance that the step is complete in all respects. The diagnosis is complete when all the parts that belong to a set are returned to the appropriate place in the case.
4 The adapter cable
After removing the high-voltage batteries, the missing communication connection between vehicle electronics and high voltage batteries must be restored for system diagnosis. An adapter cable set, made up of two cables with different configurations (VAS 6558A/39-1 and VAS 6558A/39-2), is required between the high-voltage batteries and the vehicle E-Box for interface connections. With the adapter cable VAS 6558A/39-1, the connection of the communication interface between the high-voltage batteries (level 1 to level 2) is restored.
The adapter cable has a length of 3 meters and is almost completely clad with a braided sheath to protect against damages. To prevent the braided sheath from slipping, it is fixed at the ends with shrink-on sleeve end pieces.
The connector housings are encoded to prevent polarity reversal at the interfaces. The two-wire adapter cable (yellow and green) is additionally equipped with two white wires on the socket housing end, which provide strain relief.
4.1 Product labelling
Product labelling on the adapter cables is done using plastic tags. The following tables describe individual tags and explain the signs shown. Labelling on the front side has the following data.
On the back of the pair of tags you will find the following information.
4.2 Technical specifications
5 Operation
Before you can start testing the high-voltage components, ensure that the vehicle is de-energized. Follow the guidelines given in the guided diagnostics in the PIWIS Tester. Additionally, observe the following safety rules.
INFORMATION: Before beginning work, read all maintenance and repair information from the vehicle’s manufacturer.
NOTE: While working on the high-voltage system, avoid static discharges, as they may damage the electronic components.
5.1 Insert adapter cable
The adapter cable VAS 6558A/39-1 is inserted and used as per the vehicle manufacturer’s specifications. Please follow the instructions in the guided vehicle diagnostics in the PIWIS Tester.
6 Maintenance/Care
No provisions are made by the device manufacturer for maintenance of the adapter cable.
INFORMATION: In addition to this operating manual, also read the operating instruction from the vehicle manufacturer and operator.
6.1 Clean adapter cable
The adapter cable should only be cleaned with a dust-absorbing cloth made of antistatic material. The line must never come into contact with liquid cleaners, aggressive cleaning agents or water in any form (splash water, dripping water, high-pressure cleaning water).
7 Disposal
Note: The product must not go into domestic waste at the end of its working life. The operator is the owner responsible for disposal according to the applicable European law and bears the responsibility for appropriate disposal. If other laws governing the disposal or recycling of electrical appliances have priority regarding validity and application, these country-specific regulations are binding for the process.
7.1 Product life cycle
DANGER: The product life cycle of the adapter cable is coupled with the operating cycles in which it is adapted in the high-voltage system. With more than 2000 cycles, the adapter cable must be replaced and must not be used any longer.
7.2 Environmentally responsible waste disposal
If the product’s life cycle has come to an end, the adapter cable must be taken away for sorted disposal. The adapter cable operator bears the responsibility for this as the owner responsible for disposal. The sale or gratuitous licensing for the purpose of disposal must be documented.
8 Customer service
If you have any questions about the product or need additional service information, then you can contact Customer Service at:
CAR-connect GmbHCaller Str. 117 D-38518 GiffordTelephone: +49 (0) 5373 92197- 0Fax:+49 (0) 5373 92197-88[email protected]www.car-connect.cc
References
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