VOLVO 7900, HYBRID Decommissioning

IMPACT 4.07.
130 28/04/2022
ID telaio Percorso
B5LH 167888 3100/Repair//Hybrid electric vehicle, decommissioning
Modello Identità
B5LH (3) 161148794
Data pubblicazione ID/Operazione

26/01/2022 31002-1
31002-1 Hybrid electric vehicle, decommissioning

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠
Standard tightening torques
DANGER
Risk of electrical discharge.
Incorrect handling of the traction voltage system (>60 V DC) can cause electric shocks and arcs
resulting in serious burns or death.
▶ Decommissioning and commissioning must only be carried out by personnel with adequate
certification according to Safety regulations, electric vehicles, in function group 30.
▶ The steps described in the instruction are minimum requirements.
▶ Always comply with the local legislation or regulations with stricter safety requirements, including
but not limited to, measuring tools and personal protective equipment to be used.
Special tools
88800410 21249831 88800264 88890074 88890148

9998081
1 Do not carry out this operation if the cooling system after-run function is active.
Note
The after-run function can be active for up to 20 minutes.
2 Open the service hatches.
3 Switch off the ignition (0).

Note
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
Le informazioni contenute qui sono attuali al momento della distribuzione originale, ma sono soggette a cambiamenti. Il lettore è avvisato che le copie stampate non sono
controllate.
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IMPACT 4.07.130 28/04/2022
The vehicle may be equipped with an alternative starting device; in this case use it to
switch off the ignition.
4 Wait at least one minute.
5 Remove the key from the starter switch.

Note
If the vehicle has a key, remove the key from the starter switch and ensure that it cannot
be used to start the engine while work is under way.
6 Switch off the switch.
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
7 Switch off the battery switch.
8 Remove the screw.
9 Remove the battery cover.
the Volvo Group
controllate.
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10 Disconnect the cable terminal.
the Volvo Group
controllate.
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11 Install the plug.
Required material
PLUG 975827
12 Install the padlock.
the Volvo Group
controllate.
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WARNING
Risk of serious personal injury or death.
Inappropriate work on roofs could, among other things, result in serious fall injuries.
▶ Use equipment that is approved for work on roof. The equipment should have a platform.
▶ Use suitable lifting equipment. Do not carry anything heavy up or down the steps.
13 Position the work platform.
the Volvo Group
controllate.
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14 Unlock the cover.
the Volvo Group
controllate.
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15 Position a work platform on each side of the vehicle.
16 Move rolling equipment.
17 Open the cover.

Note
Obtain help to open the cover.
the Volvo Group
controllate.
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18 Secure the cover.
the Volvo Group
controllate.
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19 Disconnect the connector.
the Volvo Group
controllate.
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20 Use the rubber gloves from the tool kit.
Required material
KIT 88800410
DANGER
Defective gloves can result in electric shocks resulting in serious burns or death.
▶ Always use the gloves described in the instruction.
▶ Check gloves for leakage and damage before use, even if they are new.
▶ Ensure that gloves are completely dry before use.
21 Check the date mark on the gloves.

Note
If the gloves are new, check them and then mark them with the day's date.
22 Take the pump from the tool kit.
Required material
KIT 88800410
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
23 Inflate the gloves.
24 Totally immerse the gloves in water.
25 Check that the gloves leak no air.
26 Perform this procedure when the condition below is met.
Conditions
● If the gloves leak air.
▶ Replace the gloves.
▶ Check the new pair of gloves.
▶ Dry the gloves.
▶ Mark the gloves with the day's date.
27 Dry the gloves.
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
28 Set the multimeter to voltage (VDC) measurement.
Required material
MULTIMETER 88890074
the Volvo Group
controllate.
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29 Install the test cables.
30 Check the multimeter function.

Note
Do not switch off or change the multimeter settings until the measurement is completed.
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
31 Clean the junction box.

Note
Clean so that no dirt can enter the junction box.
Note
The work area must be kept dry.
32 Remove the screws.
33 Remove the cover.
the Volvo Group
controllate.
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34 Put on the rubber gloves (1).
35 Put on a second pair of gloves (2) to protect the rubber gloves.
the Volvo Group
controllate.
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36 Remove the cover.
the Volvo Group
controllate.
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DANGER
Residual voltages (> ±24VDC) can cause electric shocks and arcs that in turn can cause serious
burns or death.
▶ Read through the safety instructions carefully. Follow the instructions step by step.
37 Measure between the current bars for residual voltage (> ±24VDC).
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
38 Measure between the current bar and the junction box ground for residual voltage (> ±24VDC).
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
39 Measure between the current bar and the junction box ground for residual voltage (> ±24VDC).
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
40 Perform this procedure when the condition below is met.
Conditions
● If there is residual voltage.
▶ Install the cover on the junction box.
▶ Wait 10 minutes and measure the residual voltage again.
▶ If there is still residual voltage, contact technical support.
41 Check the multimeter function.
the Volvo Group
controllate.
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42 Take off the gloves.
the Volvo Group
controllate.
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43 Disconnect the connectors.
the Volvo Group
controllate.
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44 Install the tools.
Required material
CAP 21249831
the Volvo Group
controllate.
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45 Install the tool (A).
Required material
KIT 88800264
46 Lock the tool.

Note
Safeguard the key.
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
47 Install the cover.
48 Torque tighten.
Tightening torque
Cover, screw 3.5 ±0.3 Nm
Required material
TORQUE_WRENCH 9998081
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
49 Install the cover.
50 Install the screws.
51 Torque tighten.
Tightening torque
Cover, screw 24 ±0.4 Nm
Required material
TORQUE WRENCH 88890148
the Volvo Group
controllate.
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IMPACT 4.07.130 28/04/2022
the Volvo Group
controllate.
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IMPACT 4.07.

Data pubblicazione ID/Operazione

31002-1 Hybrid electric vehicle, decommissioning

▶ The steps described in the instruction are minimum requirements.

88800410 21249831 88800264 88890074 88890148

2 Open the service hatches.

3 Switch off the ignition (0).

4 Wait at least one minute.

5 Remove the key from the starter switch.

6 Switch off the switch.

7 Switch off the battery switch.

8 Remove the screw.

9 Remove the battery cover.

10 Disconnect the cable terminal.

11 Install the plug.

12 Install the padlock.

13 Position the work platform.

14 Unlock the cover.

15 Position a work platform on each side of the vehicle.

16 Move rolling equipment.

17 Open the cover.

18 Secure the cover.

19 Disconnect the connector.

20 Use the rubber gloves from the tool kit.

▶ Always use the gloves described in the instruction.

▶ Ensure that gloves are completely dry before use.

21 Check the date mark on the gloves.

22 Take the pump from the tool kit.

23 Inflate the gloves.

24 Totally immerse the gloves in water.

25 Check that the gloves leak no air.

26 Perform this procedure when the condition below is met.

▶ Replace the gloves.

▶ Check the new pair of gloves.

▶ Dry the gloves.

▶ Mark the gloves with the day's date.

27 Dry the gloves.

28 Set the multimeter to voltage (VDC) measurement.

29 Install the test cables.

30 Check the multimeter function.

31 Clean the junction box.

32 Remove the screws.

33 Remove the cover.

34 Put on the rubber gloves (1).

35 Put on a second pair of gloves (2) to protect the rubber gloves.

36 Remove the cover.

40 Perform this procedure when the condition below is met.

▶ Install the cover on the junction box.

▶ Wait 10 minutes and measure the residual voltage again.

▶ If there is still residual voltage, contact technical support.

41 Check the multimeter function.

42 Take off the gloves.

43 Disconnect the connectors.

44 Install the tools.

45 Install the tool (A).

46 Lock the tool.

47 Install the cover.

49 Install the cover.

50 Install the screws.