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02-13 HVDU Maintenance Manual
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Procedure
LOTO (Lock-Out Tag-Out) procedure must have been done and HV Safety Training must have been completed prior to doing any of the following work.
If the HVDU PN is 50003032-0101-E04 or 50003034-0101-E04, go to step
3 . This is known as the “Belleville” HVDU.If the HVDU PN is 50001758_00 or 10101362-50002288 go to step
23 . This is known as the “Loctite” HVDU.
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Belleville HVDU inspection
Remove the 6 bolts attaching the top cover to the housing.
Inspect all HV bolted connections.
Make sure all torque marks are still aligned.
If not aligned, see below for all connection torque specifications.
Battery Connections:
- Bus bar torques.
Ground strap torque
BCI20 negative bus bar torques
- Accessory connection negative bus bar.
- Accessory fuse torque.
- Positive Bus bar torque
- Fuse and wire connections.
- Cable gland torques.
- Bus bar MCU positive.
- MCU Negative cable
- BCI20 positive bus bar.
- BCI20 fuse connections.
- MCU fuse connections.
- Re-adjust the limit switch so that they make proper contact with the top cover.
- Replace the seal and torque the cover bolts to 6Nm.
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Loctite HVDU inspection
Remove top cover with 6 bolts on top
If there are washers present on the bolts securing the HV components, stop inspection and call Lion Electric to have the HVDU recall performed.
Inspect top layer components and visible fuses.
Make sure no dust is present, no signs of water ingress or any sign of heating or warping.
Wiggle the wires connected to the small fuses and confirm everything is secured properly.
- Remove the large fuses present (1 or 2, depending on options).
Perform wiggle test on main (+) and (-) wires.
If all is good re-assemble top fuses. Acquire Loctite 248, clean the threads and re-apply Loctite 248 to threads of bolts and torque to 26Nm for the 80A fuse and 37Nm for the 450A fuse.
- Re-adjust the limit switch so that they make proper contact with the top cover.
- Replace the seal of the cover and torque the six cover bolts to 1.5Nm using a torque screwdriver.
