A123 Fisker Pack REPAIR Manual_finished_08!20!2012

FISKER K1 BATTERY PACK REPAIR MANUAL
Fisker K1 Battery Pack

Model No. 404313
Repair Manual
DOCUMENT NOTICE
The information contained in this manual is the property of A123 Systems, Inc ("A123 Systems") and is
subject to change without notice. This manual contains A123 Confidential and Proprietary Information
and may be used for the sole purpose of servicing the A123 Battery Pack. A123 Systems reserves the
right to make changes in the design of its products or components as progress in engineering and
manufacturing may warrant. It is the customer’s responsibility to satisfy itself as to whether the
information contained herein is adequate and sufficient for user's particular use. It is the further
responsibility of each user to ensure that all applications of A123 Systems' products are appropriate
and safe based on conditions anticipated or encountered during use. This document does not create
any additional obligation for A123 Systems and does not constitute additional warranties and
representations. The A123 Systems’ logo is a trademark and a service mark of A123 Systems, Inc.
Table of Contents
HOW TO USE THIS REPAIR MANUAL .............................................................................................................................. 1
GENERAL INFORMATION .................................................................................................................................................. 1
REPAIR MANUAL PDF FORMAT INFORMATION ....................................................................................................................... 1
ILLUSTRATION INFORMATION ............................................................................................................................................. 1
Component Location Views .................................................................................................................................... 1
Repair Procedure Step-by-Step Views ...................................................................................................................... 1
REPAIR MANUAL SECTION OUTLINE..................................................................................................................................... 2
Safety Information ................................................................................................................................................. 2
General Overview .................................................................................................................................................. 2
First Steps–Preparation For Battery Pack Repair ....................................................................................................... 2
Electronics Wing Repair Procedures ........................................................................................................................ 3
Battery Bank Repair Procedures .............................................................................................................................. 3
Final Assembly–Preparing Battery Pack For Return To Service ................................................................................... 3
Specifications ........................................................................................................................................................ 3
ACRONYM USAGE .......................................................................................................................................................... 4
SAFETY INFORMATION .................................................................................................................................................. 6
IMPORTANT SAFETY INFORMATION CONTAINED IN THIS MANUAL................................................................................................. 6
DANGER, WARNING AND CAUTION STATEMENT DEFINITIONS ...................................................................................................... 6
Danger .................................................................................................................................................................. 6
Warning ................................................................................................................................................................ 6
Caution ................................................................................................................................................................. 6
DANGER STATEMENTS ..................................................................................................................................................... 7
Battery Pack High Voltage Danger ........................................................................................................................... 7
Personal Protective Equipment (PPE) Danger ........................................................................................................... 7
Battery Pack Break-Down Danger ............................................................................................................................ 7
Battery Pack Reconnect Danger .............................................................................................................................. 7
Battery Pack Voltage Danger ................................................................................................................................... 7
Battery Pack Voltage Potential Danger..................................................................................................................... 8
Manual Service Disconnect (MSD) Danger................................................................................................................ 8
Buffer Zone Danger ................................................................................................................................................ 8
WARNING STATEMENTS ................................................................................................................................................... 9
Manual Service Disconnect (MSD) Warning.............................................................................................................. 9
Module 1 HV Cable Warning ................................................................................................................................... 9
CAUTION STATEMENTS .................................................................................................................................................. 10
Fastener Caution.................................................................................................................................................. 10
HVIL Contact Point Integrity Caution...................................................................................................................... 10
Battery Pack Lifting Caution .................................................................................................................................. 10
Replacement Fuse Caution ................................................................................................................................... 10
Thermal Gap Pad Caution ..................................................................................................................................... 10
Flat Washer Location Caution ............................................................................................................................... 11
Electrostatic Discharge (ESD) Caution .................................................................................................................... 11
PERSONAL PROTECTIVE EQUIPMENT (PPE) .......................................................................................................................... 12
PPE Protective Wear Inspection Procedure ............................................................................................................ 12
Required Clothing ................................................................................................................................................ 12
Work Area Preparation......................................................................................................................................... 13
Required Tools..................................................................................................................................................... 13
i
WORK AREA PRECAUTIONS AND BEST PRACTICES .................................................................................................................. 14
Work Area Must Be Indoors .................................................................................................................................. 14
Work Area Must Be Free Of Foreign Materials........................................................................................................ 14
Work Area Must Remain Dry................................................................................................................................. 14
Work Area Size Requirements ............................................................................................................................... 14
GENERAL OVERVIEW................................................................................................................................................... 15
BATTERY PACK ............................................................................................................................................................ 15
General Information............................................................................................................................................. 15
Battery Pack Serial Number Location ..................................................................................................................... 16
Battery Pack Dimensions ...................................................................................................................................... 17
Battery Pack Lifting Procedure .............................................................................................................................. 18
BATTERY BANK ............................................................................................................................................................ 20
Battery Bank - RH Side .......................................................................................................................................... 20
Battery Bank - LH Side .......................................................................................................................................... 20
Battery Module Cell Specifications ........................................................................................................................ 20
Battery Module Description/Service Part Numbers ................................................................................................. 20
ELECTRONICS WING ...................................................................................................................................................... 21
Electronic Module Identification & Bar Code Location (1) ........................................................................................ 21
BATTERY PACK FUSE IDENTIFICATION AND AMPERAGE RATINGS ................................................................................................. 22
Fuse Information ................................................................................................................................................. 22
FASTENERS................................................................................................................................................................. 23
Fastener Information ........................................................................................................................................... 23
Fastener Usage .................................................................................................................................................... 23
Fasteners Included With Service Parts ................................................................................................................... 23
LOSS OF ISOLATION DETECTION PROCESS ............................................................................................................................ 24
Pack and Meter Information ................................................................................................................................. 24
Detection Process ................................................................................................................................................ 24
FIRST STEPS – PREPARATION FOR BATTERY PACK REPAIR ............................................................................................. 29
GENERAL INFORMATION ................................................................................................................................................ 29
First Steps Explained ............................................................................................................................................ 29
STEP 1 - VERIFY MANUAL SERVICE DISCONNECT (MSD) REMOVAL ............................................................................................. 30
Description .......................................................................................................................................................... 30
Safety Information ............................................................................................................................................... 30
MSD Verification Procedure .................................................................................................................................. 31
MSD Removal Procedure ...................................................................................................................................... 31
STEP 2 - BATTERY COVER REMOVAL .................................................................................................................................. 34
Description .......................................................................................................................................................... 34
Removal .............................................................................................................................................................. 35
STEP 3 - BATTERY PACK HIGH VOLTAGE (HV) BREAK-DOWN PROCEDURE..................................................................................... 37
Description .......................................................................................................................................................... 37
Hardware and Tools ............................................................................................................................................. 37
Break-Down Procedure ........................................................................................................................................ 38
ELECTRONICS WING REPAIR PROCEDURES ................................................................................................................... 39
ELECTRONICS WING GENERAL INFORMATION ....................................................................................................................... 39
ii
Description .......................................................................................................................................................... 39
BATTERY CONTROL MODULE (BCM) ................................................................................................................................. 40
Description .......................................................................................................................................................... 40
HV Flexible Busbar and Cable Inspection ................................................................................................................ 41
Preparing Battery Pack For Repair ......................................................................................................................... 41
Removal .............................................................................................................................................................. 42
Installation .......................................................................................................................................................... 44
Preparing Battery Pack For Return To Service ......................................................................................................... 46
ELECTRICAL DISTRIBUTION MODULE (EDM) ........................................................................................................................ 47
Description .......................................................................................................................................................... 47
Removal .............................................................................................................................................................. 50
Installation .......................................................................................................................................................... 54
CURRENT SENSE MODULE (CSM) ..................................................................................................................................... 61
Description .......................................................................................................................................................... 61
Removal .............................................................................................................................................................. 64
Installation .......................................................................................................................................................... 70
FUSE 20A AND FUSE 30A (600 VOLT) ............................................................................................................................... 75
Description .......................................................................................................................................................... 75
Battery Pack Fuse Identification and Amperage Ratings .......................................................................................... 76
Removal .............................................................................................................................................................. 77
Installation .......................................................................................................................................................... 79
FUSE PANEL ............................................................................................................................................................... 81
Description .......................................................................................................................................................... 81
Removal .............................................................................................................................................................. 83
Installation .......................................................................................................................................................... 85
MANUAL SERVICE DISCONNECT (MSD) RECEPTACLE ASSEMBLY ................................................................................................. 91
Description .......................................................................................................................................................... 91
iii
Removal .............................................................................................................................................................. 93
Installation .......................................................................................................................................................... 94
GENERATOR INVERTER HV CONNECTOR.............................................................................................................................. 96
Description .......................................................................................................................................................... 96
Removal .............................................................................................................................................................. 99
Installation ........................................................................................................................................................ 101
Preparing Battery Pack For Return To Service ....................................................................................................... 103
MOTORS INVERTER HV CONNECTOR ............................................................................................................................... 104
Description ........................................................................................................................................................ 104
Safety Information ............................................................................................................................................. 104
Hardware and Tools ........................................................................................................................................... 105
HV Flexible Busbar and Cable Inspection .............................................................................................................. 105
Preparing Battery Pack For Repair ....................................................................................................................... 106
Removal ............................................................................................................................................................ 107
Installation ........................................................................................................................................................ 110
BATTERY MODULE REPAIR PROCEDURES ................................................................................................................... 114
BATTERY MODULE GENERAL INFORMATION ....................................................................................................................... 114
Description ........................................................................................................................................................ 114
THERMAL GAP PAD REPLACEMENT .................................................................................................................................. 115
Description ........................................................................................................................................................ 115
Installation ........................................................................................................................................................ 116
FLAT WASHER LOCATION/IDENTIFICATION ......................................................................................................................... 117
Description ........................................................................................................................................................ 117
Battery Pack RH Side Flat Washer Location .......................................................................................................... 117
Battery Pack LH Side Flat Washer Location ........................................................................................................... 117
BATTERY MODULE BUSHINGS ........................................................................................................................................ 118
Description ........................................................................................................................................................ 118
Battery Pack RH Side Bushing Location ................................................................................................................ 118
A. Metal Bushings ............................................................................................................................................. 118
Battery Pack LH Side Bushing Location ................................................................................................................. 118
A. Metal Bushings ............................................................................................................................................. 118
Removal ............................................................................................................................................................ 119
Installation ........................................................................................................................................................ 120
MODULE HOLD DOWN BOLT REMOVAL WITH STRIPPED CAGE NUT .......................................................................................... 121
Removal ............................................................................................................................................................ 121
BATTERY MODULES M2 AND M4 THROUGH M13 ............................................................................................................... 122
Description ........................................................................................................................................................ 122
Battery Bank - RH Side ........................................................................................................................................ 122
Battery Bank - LH Side ........................................................................................................................................ 122
Removal ............................................................................................................................................................ 124
iv
Installation ........................................................................................................................................................ 126
BATTERY MODULE M1 ................................................................................................................................................ 128
Description ........................................................................................................................................................ 128
Removal ............................................................................................................................................................ 130
Installation ........................................................................................................................................................ 134
BATTERY MODULE M3 ................................................................................................................................................ 136
Description ........................................................................................................................................................ 136
Removal ............................................................................................................................................................ 138
Installation ........................................................................................................................................................ 140
BATTERY MODULES M14 AND M15 ............................................................................................................................... 142
Description ........................................................................................................................................................ 142
Removal ............................................................................................................................................................ 144
Installation ........................................................................................................................................................ 146
COOLING PORTS ASSEMBLY........................................................................................................................................... 148
Description ........................................................................................................................................................ 148
Removal ............................................................................................................................................................ 150
Installation ........................................................................................................................................................ 151
COOLANT TEMPERATURE SENSOR ................................................................................................................................... 154
Description ........................................................................................................................................................ 154
Removal ............................................................................................................................................................ 156
Installation ........................................................................................................................................................ 157
FLAT BRAIDED JUMPERS – 30MM LENGTH (TYPICAL) ............................................................................................................ 159
Defective 30mm Jumper Example ....................................................................................................................... 159
FLAT BRAIDED JUMPERS – 61MM LENGTH (TYPICAL) ............................................................................................................ 160
v
Defective 61mm Jumper Example ....................................................................................................................... 161
MONITOR AND BALANCE BOARD (MBB) (TYPICAL).............................................................................................................. 162
Description ........................................................................................................................................................ 162
Removal ............................................................................................................................................................ 165
Installation ........................................................................................................................................................ 166
FLEXIBLE BUSBAR (TYPICAL) .......................................................................................................................................... 169
Description ........................................................................................................................................................ 169
Flexible Busbar Part Numbers ............................................................................................................................. 169
Removal ............................................................................................................................................................ 171
FINAL ASSEMBLY – RECONNECT AND REASSEMBLE BATTERY PACK ............................................................................. 178
GENERAL INFORMATION .............................................................................................................................................. 178
Final Assembly Explained .................................................................................................................................... 178
STEP 1 – BATTERY COVER SEAL (O-RING) INSPECTION .......................................................................................................... 179
Description ........................................................................................................................................................ 179
Inspection ......................................................................................................................................................... 180
Removal ............................................................................................................................................................ 180
Installation ........................................................................................................................................................ 180
STEP 2 – BATTERY PACK HIGH VOLTAGE (HV) RECONNECT PROCEDURE ..................................................................................... 182
Description ........................................................................................................................................................ 182
Secure High Voltage Connections ........................................................................................................................ 183
Reconnect Procedure ......................................................................................................................................... 184
STEP 3 – BATTERY COVER INSTALLATION ........................................................................................................................... 186
Description ........................................................................................................................................................ 186
Installation ........................................................................................................................................................ 187
BATTERY COVER INSERT REPAIR...................................................................................................................................... 189
Part One — Removing the Damaged Insert .......................................................................................................... 189
Part Two — Insert Installation ............................................................................................................................. 190
Part Three — Insert Installation Final Steps .......................................................................................................... 191
SPECIFICATIONS........................................................................................................................................................ 192
Battery Pack General Specifications ..................................................................................................................... 192
Battery Module Cell Specifications ...................................................................................................................... 192
Battery Pack Fuse Specifications.......................................................................................................................... 192
Battery Pack Fastener Specifications.................................................................................................................... 193
vi
Battery Pack Dimensions .................................................................................................................................... 194
vii
How To Use This Repair Manual
General Information
This repair manual is intended for use by professional, qualified technicians. Attempting repairs or service
without the appropriate training, tools and equipment could cause injury to you or others. This could also
damage the Battery Pack or cause the Battery Pack to operate improperly.
Repair Manual PDF Format Information

This repair manual is best used electronically in its PDF format to take full advantage of the linking and
illustrations.
Illustration Information
The illustrations in the repair manual are used for component identification and visual support of the repair
procedures.
Component Location Views
Directional arrows are used to indicate the direction of the Front of the Battery Pack
Component callout pointers are used to identify specific Battery Pack components
Repair Procedure Step-by-Step Views

Component callout pointers are used for specific components (fasteners, connectors, etc.)
1 How To Use This Repair Manual

Repair Manual Section Outline
Information within this repair manual is organized into seven main sections. Repair procedures, illustrations, and
the descriptive text have been arranged so that they will correspond with the repair procedure steps. The repair
manual provides component location views, and step-by-step illustrations to show detailed repair instructions.
The following information details the repair manual layout and section organization.
Safety Information
The Safety Information section MUST be read prior to beginning any repair work on the Battery Pack. This
manual contains Danger, Warning and Caution statements that MUST be observed carefully in order to reduce
the risk of injury to yourself or others. The Safety Information section also contains all necessary Personal
Protective Equipment (PPE) and the specific Work Area Precautions required to perform repairs on the Battery
Pack.
The Safety Information section contains information on the following topics:

Danger Statements
Warning Statements
Caution Statements
Personal Protective Equipment (PPE)
Work Area Precautions and Best Practices
General Overview
The General Overview section is intended to show and describe details of the Battery Pack.
Serial Number Location
Battery Pack Dimensions
Lifting Procedure
Battery Bank General Information
Electronics Wing General Information
Fastener Information
First Steps–Preparation For Battery Pack Repair

Perform these procedures first, before beginning ANY repair procedures on the Battery Pack.
Note: The procedures MUST be followed in sequential order.
Step 1 – Remove and Store the Manual Service Disconnect (MSD) (verify the MSD is
removed and securely stored)
Step 2 – Remove Battery Cover
Step 3 – Break-Down Battery Pack (disable Battery Pack’s full voltage potential)

Electronics Wing Repair Procedures
Go to this section to perform any repairs on the Electronics Wing of the Battery Pack. This section contains ALL
repair procedures associated with the Electronics Wing of the Battery Pack.
Battery Control Module (BCM)
Electrical Distribution Module (EDM)
Current Sense Module (CSM)
Fuse 20A and Fuse 30A
Fuse Panel
Manual Service Disconnect (MSD) Receptacle
Generator Inverter HV Connector
Motors Inverter HV Connector
Battery Bank Repair Procedures

Go to this section to perform any repairs on the Battery Bank portion of the Battery Pack. This section contains
ALL repair procedures associated with the Battery Bank portion of the Battery Pack.
Battery Module M2 and M4 through M13
Battery Module M1
Battery Module M3
Battery Modules M14 and M15
Cooling Ports
Coolant Temperature Sensor
30mm Flat Jumper
61mm Flat Jumper
Monitor and Balance Board (MBB)
Final Assembly–Preparing Battery Pack For Return To Service

Perform these procedures after completing ANY repair procedure on the Battery Pack.
Note: The procedures must be followed in sequential order.
Step 1 – Inspect Battery Cover Seal
Step 2 – Reconnect Battery Pack (reestablish Battery Pack’s full voltage potential)
Step 3 – Install Battery Cover
Specifications
This section contains all Battery Pack specifications.
Battery Pack General Specifications
Battery Module Cell Specifications
Battery Pack Fuse Specifications
Battery Pack Fastener Specifications

Acronym Usage
Information within this repair manual includes many acronyms. The following is a list of acronyms used within
this document:
Battery Pack Common Acronyms

HV High Voltage
LV Low Voltage
HVIL High Voltage Inter-Lock
LOBS Live On Both Sides
MBB Monitor and Balance Board
PPE Personal Protective Equipment
CSM Current Sense Module
EDM Electrical Distribution Module
BCM Battery Control Module

Safety Information
Important Safety Information Contained In This Manual

This manual contains various “Danger”, “Warning” and “Caution” statements that must be observed carefully in
order to reduce risk of death or personal injury during service or repair of this Battery Pack.
This manual is intended for use by professionally trained personnel. Attempting service or repairs without the
appropriate training, tools and equipment could cause injury to you or others.
The “Danger”, “Warning” and “Caution” statements are not exhaustive, and cannot possibly warn of all the
potentially hazardous consequences of your failure to follow these instructions.
Danger, Warning and Caution Statement Definitions

The following symbols are used throughout this manual to provide visual indications of hazardous conditions
that may exist during repair:
Danger
This symbol is used to inform you of a procedure which will result in death or serious personal injury if
the instructions are not followed.
(Example: Touching high voltage components without using the appropriate protective equipment will
result in electrocution.)
Warning
This symbol is used to inform you of an operation which may cause death, serious personal injury or
component damage if instructions are not followed.
Caution
This symbol is used to inform you of an operation which may cause personal injury or component
damage if instructions are not followed.
6 Safety Information
Danger Statements
The following Danger statements are referenced throughout this manual and placed at strategic locations to
provide visual indications of hazardous conditions that may exist during repair.
Battery Pack High Voltage Danger
The nominal battery pack voltage is 347 volts DC. A buffer zone must be set up before
servicing the Battery Pack. Failure to follow these instructions will result in severe personal injury or
death.
Personal Protective Equipment (PPE) Danger
The high-voltage battery contains high-voltage components and wiring. High-voltage

cables and wiring are orange in color. High-voltage insulated safety gloves and a face shield must be
worn when carrying out any repairs on the Battery Pack. Failure to follow these instructions will result
in severe personal injury or death.
Battery Pack Break-Down Danger
Before carrying out any removal and installation procedures of the high-voltage
battery system, the high-voltage Battery Pack must be broken-down. Failure to follow these
instructions will result in severe personal injury or death.
Battery Pack Reconnect Danger
Reconnecting the Battery Pack will cause the voltage level of the Battery Pack to be at
its full potential. Extreme caution must be followed when the Battery Pack is reconnected. Failure to
follow proper safety precautions will result in severe personal injury or death.
Battery Pack Voltage Danger
Before carrying out any removal and installation procedures of the high-voltage
battery system, the high-voltage Battery Pack must be broken-down. Failure to follow these
instructions will result in severe personal injury or death.
Battery Pack Voltage Potential Danger
Prior to being broke-down, the Battery Pack is at its full voltage potential. Extreme
caution must be followed when the Battery Pack is connected. Failure to follow proper safety
precautions will result in severe personal injury or death.
Manual Service Disconnect (MSD) Danger
Do not remove the MSD without wearing appropriate PPE to help protect from
potential danger. Failure to follow these instructions will result in severe personal injury or death.
Buffer Zone Danger
A buffer zone must be set-up before servicing the Battery Pack. Failure to follow
these instructions will result in severe personal injury or death.
Warning Statements
The following Warning statements are referenced throughout this manual and placed at strategic locations to
Manual Service Disconnect (MSD) Warning
To avoid unintended installation and risk of electrical shock, store the MSD in a secure
area. Failure to follow these instructions may result in severe personal injury or death.
Module 1 HV Cable Warning
Use extreme care when servicing the Module 1 HV cable. Insulate the Module 1 HV
cable thoroughly to avoid an accidental short circuit. Failure to follow these instructions may result in
severe personal injury or death.
Caution Statements
The following Caution statements are referenced throughout this manual and placed at strategic locations to
Fastener Caution
There is a risk of causing damage to the Battery Pack if improper fasteners are
used. Replace all used Battery Pack fasteners with new fasteners where indicated. All fasteners that
are identified as “Replace During Service” must be replaced during all installation procedures. Always
use the correct part number for the application. Failure to follow these instructions may result in
severe damage to the Battery Pack.
HVIL Contact Point Integrity Caution
Inspect all High-Voltage Interlock (HVIL) contact points for connection integrity. Look
for signs of discoloration and connection damage due to loose or damaged connection points. Failure
to follow these instructions may result in severe damage to the Battery Pack.
Battery Pack Lifting Caution
The weight of the Battery Pack must be evenly distributed throughout the entire
length of the Battery Pack. The Battery Pack Cover must be properly installed before attempting to lift
the Battery Pack. Failure to follow these instructions may result in severe damage to the Battery Pack.
Replacement Fuse Caution
Always replace a blown fuse with the proper amperage replacement fuse. Failure to
follow these instructions may result in severe damage to the Battery Pack.
Thermal Gap Pad Caution
Carefully install the Battery Module while observing the position of the Thermal Gap
Pad. The Thermal Gap Pad is extremely fragile and will damage easily. Failure to follow these
instructions may result in severe damage to the Battery Pack.
Flat Washer Location Caution
Proper location and usage of the flat washers on the Battery Modules, Flexible Busbar
and Braided Jumper Connectors is very important. Failure to install flat washers in the proper location
may result in severe damage to the Battery Pack.
Electrostatic Discharge (ESD) Caution
Electrostatic Discharge (ESD) can damage solid state components. Exercise caution
when handling all solid state electronic devices. Always discharge personal electricity by touching a
metal ground point before servicing any solid state electronic device. Failure to handle solid state
components safely may result in severe damage to the component.
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) refers to protective clothing, helmets, goggles, or other equipment
designed to protect the wearer's body from job-related occupational safety and health risks.
PPE Protective Wear Inspection Procedure
Inspect all PPE protective wear before beginning work. Do not use any damaged PPE items. Perform inspections
before and after use.
Personnel using the PPE protective wear should perform the following inspection and check for deterioration
and damage:
Insulated rubber gloves should be inspected for scratches, holes and tears.
Insulated safety boots should be inspected for holes, damage, nails, metal pieces, wear or other
problems on the soles.
Insulated rubber sheet should be inspected for tears.
Required Clothing
Insulated Gloves (rated for up to 1000 Volts)
Insulated Shoes (rated for up to 1000 Volts)
Face Shield or Safety Glasses
Work Area Preparation

Rubber Floor Mat
Non-Conductive Work Surface (Flat, Level, Stable, Heavy-Duty)
Insulated Rubber Sheet (for covering the Battery Pack when not being serviced)
Orange Cones (to establish a safety parameter around the Battery Pack)
Buffer Zone (a predetermined safe area around the Battery Pack)
Required Tools
Insulated Hand Tools
Work Area Precautions and Best Practices
A controlled work area is very critical when servicing a high voltage Battery Pack. The following work area
guidelines will help provide a safe and effective environment for the disassembly and repair of the Battery Pack.
Work Area Must Be Indoors

The work area must be located inside and protected from rain, snow, sand, and other substances.
The work area should be climate controlled to prevent condensation from forming as a result of high
temperature and humidity.
Work Area Must Be Free Of Foreign Materials

The work area should be isolated from other shop areas that might introduce airborne contaminates, such as
metal powders, oil or other foreign substances.
If necessary, use a plastic curtain or other means to block off the work area.
Work Area Must Remain Dry

The work area floor must be dry, do not allow rain soaked or snow covered vehicles to enter the work area.
Work Area Size Requirements

The work area space should be approximately the size of one vehicle, maintaining a secured area for
disassembly.
Display an appropriate warning sign in the work area indicating that disassembly is in progress.
Maintain a secured area to prevent unauthorized persons from entering.
General Overview
Battery Pack
1. Battery Module M1 6. Battery Module M6 11. Battery Module M11

5. Battery Module M5 10.Battery Module M10 15. Battery Module M15
General Information
The Fisker Karma Battery Pack’s purpose is to power the electric drivetrain and auxiliary systems in the Fisker
Karma automobile. The battery management system is designed to monitor and adjust cell voltage, current and
temperatures to ensure safe operation and maximize the life expectancy of the battery modules.
15 General Overview
The A123’s battery system design takes advantage of a patented Nanophosphate® cell technology which delivers
high power, excellent safety, and long life. The high-performance cells are incorporated into battery modules
which serve as the building blocks for the advanced energy storage systems. The modules and systems are built
with automotive-grade components, battery management systems, and thermal management for long battery
life and retained capacity.
The Battery Pack contains the following components:
15 Separate Battery Modules (with Monitor and Balance Board (MBB))

21 Cells in each Battery Module - 7 in series, 3 in parallel (7S3P)
Cooling Ports Assembly
Fuse Enclosure
Various Flexible Busbars and High Voltage (HV) Cables
Connections for Vehicle Drive and Auxiliary Systems
Low Voltage Vehicle Communication Wiring Connection
3 Auxiliary Connectors
1 Charge Connector
Battery Pack Serial Number Location

Internal I.D. Location External I.D. Location
16 General Overview
17 General Overview
Battery Pack Lifting Procedure
Lifting of the Battery Pack should only occur at the four recommended lift points, with the Battery Cover in place
and fully secured with all perimeter fasteners properly torqued.
Note: When lifting the Battery Pack, the weight must be evenly distributed throughout the entire length of the
Battery Pack.
Improper lifting will damage the Battery Pack. Refer to Battery Pack Lifting Caution in Safety
Information.
1) Install the eye bolts in the four locations (1) on the Battery Pack.
2) Tighten the four eye bolt nuts (1).
18 General Overview
3) Place the lift hooks (1) of the lift sling into each eye bolt.
4) Using an appropriate lifting device, lift the Battery Pack and locate it to the desired location.
Note: Before lifting the Battery Pack, ensure the lift sling straps (1) are properly routed and free of
knots.
19 General Overview
Battery Bank
General Information
The Battery Bank is made up of 15 Battery Modules. Each module is equipped with battery management
electronics for cell balancing, voltage, temperature and State of Charge (SOC) measurement. The lithium ion
Battery Modules deliver high energy without compromising power, performance, or safety. The Battery
Modules offer an extensive cycle life in a compact package.
Battery Bank - RH Side
Battery Bank - LH Side

Fisker Battery Module - Common Elements
Cells in Parallel 3
Cells in Series 7
Total Cells per module 21
Modules in Pack 15
Battery Module Description/Service Part Numbers

Fisker Battery Module Types
Module Location Module Isolator
Part Number Orientation MBB Position LOBS
Number(s) Configuration Position
M1, M7, M11,
405396-003 Module 7S3P Horizontal Negative (-) No L
M15
M2 405396-103 Module 7S3P Horizontal Positive (+) No L
M3 405396-403 Module 7S3P Vertical Negative (-) No L
M4, M6, M8,
405396-203 Module 7S3P Horizontal Positive (+) Yes L
M10, M12, M14
M5, M9, M13 405396-303 Module 7S3P Horizontal Negative (-) Yes L
(LOBS) (Live On Both Sides)
20 General Overview
Electronics Wing
General Information
The Electronics Wing of the Battery Pack is a complex system designed to maintain the health of the battery
modules by monitoring the voltage, current and temperature. It is comprised of three electronic modules, the
Battery Control Module (BCM), Electrical Distribution Module (EDM), and the Current Sense Module (CSM). It
also contains the Manual Service Disconnect (MSD) receptacle and Fuse Panel Assembly.
Electronic Module Identification & Bar Code Location (1)

Battery Control Module Electrical Distribution Module Current Sense Module
BCM EDM CSM
21 General Overview
Battery Pack Fuse Identification and Amperage Ratings
1. A/C Compressor Fuse (30A) 3. PTC Heater Fuse (30A)

(Littelfuse 30A-Part No. 0HEV030.SXC) (Littelfuse 30A-Part No. 0HEV030.SXC)
2. 12V DC/DC Auxiliary Power Module Fuse (30A) 4. Charger Fuse (20A)
(Littelfuse 30A-Part No. 0HEV030.SXC (Littelfuse 20A-Part No. 0HEV020.SXC)
Fuse Information
The Fuse Panel houses four high amperage fuses. The fuses should be checked prior to condemning any Battery
Pack component or wiring.
22 General Overview
Fasteners
Fastener Information
Fasteners and torque specification references in this Repair Manual are identified in metric format.
During any repair procedures, it is important before reassembly to replace all fasteners (nuts, bolts, etc.) that are identified
in the Hardware and Tools table as “Replace During Service”.
Fastener Usage
When replacing fasteners, always use the correct part number for the application. Use of an incorrect fastener may result in
component damage. Failure to follow these instructions may result in personal injury or death.
·Fasteners requiring replacement or fasteners requiring thread locker are identified in

the repair procedure.
·Always replace any Battery Pack fasteners with new fasteners where indicated.
·Refer to Fastener Caution in Safety Information for further details.
Fasteners Included With Service Parts

When replacing a component with an authorized A123 service part, always install the service part with the fasteners
included with the service part kit. Reusing a used fastener, or using an incorrect fastener may result in component damage.
23 General Overview
Loss of Isolation Detection Process
Pack and Meter Information

DATE:_______________ TEST LOCATION:_________________ Initial:___________________
PACK NUMBER: ______________________________________________________________________
Note: Do not remove the pack cover until after the initial isolation measurements are complete.
Record the Manufacturer, Model Number, and Serial Number of the insulation meter and digital multimeter
(DMM) used in this procedure. These meters must be used for the execution of this process.
Insulation Meter
o Manufacturer:_________________________________________________________________
o Module Number : ______________________________________________________________
o Serial Number: ________________________________________________________________
DMM Meter
o Manufacturer:_________________________________________________________________
o Module Number : ______________________________________________________________
o Serial Number: ________________________________________________________________
Detection Process
1) ____ Install the Manual Service Disconnect (MSD) into the battery pack.
2) ____ Configure the test setup and make all connections to the battery pack low voltage (LV)
and high voltage (HV) systems.
3) ____ Use Fisker Service Tool to verify that the isolation issue is still present in the battery pack:
Close the battery pack contactors.
Record the Current Sense Module (CSM) isolation measurement: __________________Ω
Record the batter pack voltage: _____________________________________________Vdc
Record any Diagnostic Trouble Codes (DTCs): _________________________________
4) ____ Use Fisker Service Tool to disable the CSM isolation measurements.
Use the DMM to measure and record the DC voltages between the following points:
o Traction Battery(-) to Chassis Ground: _________________________________Vdc
o Traction Battery(+) to Chassis Ground: _________________________________Vdc
Use the insulation meter set to 500V to measure and record the resistance between the following
points:
o Traction Battery (-) to Chassis Ground: _________________________________Ω
o Traction Battery (+) to Chassis Ground: ________________________________Ω
5) Open the battery pack contactors, disable the 12V wakeup signal, and stop Fisker Service Tool. Remove
the LV connector and the chassis ground connection from the pack.
6) ____ Remove the MSD.
7) ____ Drain the coolant from the pack and purge the cooling system using house air (5 minutes at 15 psi).
24 Loss of Isolation Detection Process
8) ____ Perform a pressure test on the coolant system. The pack should maintain 30 psi of pressure for 10
minutes. Leave the pressure test fixture attached to the pack during the remainder of the test. Periodically
monitor the pressure reading on the pressure gauge.
9) ____ Remove the battery pack cover.
10) ____ Perform a visual inspection of the battery pack (bus bars/wires, fluid in pack, etc). Record any
issues:
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
11) ____ Label the battery modules with location tags per Figure 1.
12) ____ Re-install the MSD.
13) ____ Reconnect the LV connector and chassis ground connection to the battery pack, start Fisker Service
Tool, and re-enable the 12V wakeup signal. Verify that the isolation issue is still present in the pack:
Close the battery pack contactors.
Record the Current Sense Module (CSM) isolation measurement: ______________________Ω
Record the batter pack voltage: ________________________________________________Vdc
Record any Diagnostic Trouble Codes (DTCs): ______________________________________
14) ____ Use Fisker Service Tool to disable the CSM isolation measurements.
Use the DMM to measure the DC voltages between the following points:
o Traction Battery(-) to Chassis Ground: ___________________________________Vdc
o Traction Battery(+) to Chassis Ground: ___________________________________Vdc
Use the insulation meter set to 500V to measure the resistance between the following points:
o Traction Battery (-) to Chassis Ground: _____________________________________Ω
o Traction Battery (+) to Chassis Ground: ____________________________________Ω
15) ____ Open the pack contactors, disable the 12V wakeup signal, and stop Fisker Service Tool. Remove
the LV connector and the chassis ground connection from the pack.
16) ____ Remove the MSD.
17) ____ Disconnect the CSM HVBATT_NEG connection (RADSOK) and remove the high voltage sense
connector from the CSM. Perform the following measurements:
Use the insulation meter set to 500V to measure the resistance between the following points:
o Traction Battery (-) to Chassis Ground: ____________________________________Ω
o Traction Battery (+) to Chassis Ground: ___________________________________Ω
Note: This step confirms the isolation fault is not due to the CSM
25 General Overview
18) ____ Use the insulation meter set to 500V to measure and record the measurements in “Table A”
Table A
Fluke Insulation tester @ 500V Interconnect Location

Resistance MΩ
setting, MSD removed
Negative Side of MSD if <550MΩ
No interconnects disconnected Module 7P
Removed connection from: Module 7N-6P
Removed connection from: Module1N
Positive Side of MSD if <550MΩ
No interconnects disconnected Module 8N
Removed connection from: Module 8P-9N
Removed connection from Module 15P
26 General Overview
19) ____ With the suspect Module(s) electrically isolated from the neighboring Module(s) use the insulation
meter set at 500V and the DMM to measure and record the following measurements:
Table B
Resistance Module
Measurement Points MΩ Voltage Location Module S/N
Module Negative Terminal
to Chassis Ground
Module Positive to Chassis
Ground

to Chassis Ground
Ground

to Chassis Ground
Ground
Note: This step confirms the location of the isolation fault with this Module
20) ____ Remove the Module (s) for further analysis

Remove module.
Tag the module with pack serial number.
Include the module’s location in the pack.
21) ____ Store all the Fisker Service Tool data and test notes on the lab drive. Return the completed form to
A123 Systems.
27 General Overview
Figure 1 - Fisker Pack Module Configuration
28 Loss of Isolation Detection Process

First Steps – Preparation For Battery Pack Repair
General Information
Perform these “First Steps” procedures first, before beginning ANY repair procedures on the Battery Pack.
First Steps Explained

Step 1 – Remove and Store Manual Service Disconnect (MSD) (verify MSD is removed and securely
stored). Refer to Step 1 - Verify Manual Service Disconnect (MSD) Removal.
Step 2 – Remove Battery Cover. Refer to Step 2 - Battery Cover Removal.
Step 3 – Break-Down Battery Pack (disable Battery Pack’s full voltage potential). Refer to Step 3 - Battery
Pack High Voltage (HV) Break-Down Procedure.
· Always use safe practices when performing repair procedures.

· Refer to Safety Information for further details.
29 First Steps – Preparation For Battery Pack Repair

Step 1 - Verify Manual Service Disconnect (MSD) Removal
Description
The Manual Service Disconnect (MSD) is located in the Electronics Wing of the Battery Pack. The MSD is used to
disconnect the battery high voltage during any Battery Pack inspection, maintenance and repair. Always use insulating
Personal Protective Equipment (PPE) when removing and installing the MSD.
The Manual Service Disconnect (MSD) must be removed from the Battery Pack before servicing
the Battery Pack. Refer to Manual Service Disconnect (MSD) Warning in Safety Information for further details.
1. Manual Service Disconnect (MSD)
Safety Information


MSD Verification Procedure
1) Verify the MSD is removed from the MSD Receptacle (1) and stored in a secure area away from the
Battery Pack.
Note: If the MSD is not removed, perform the MSD removal procedure. Refer to MSD Removal
Procedure for details.
MSD Removal Procedure
· The Manual Service Disconnect (MSD) must only be removed while wearing the proper
Personal Protective Equipment (PPE).
· Refer to Manual Service Disconnect (MSD) Danger in Safety Information for
further details.
Note: The MSD (1) is latched to the MSD Receptacle with primary and secondary connector locks. The
MSD locking handle (2) is used to control the locking mechanism.

1) Using a suitable tool (1), release the primary MSD lock by depressing the lock tab.
2) Rotate the MSD locking handle (1) upward to the secondary lock position (approximately 45 degrees).
3) Using a suitable tool (1), release the secondary MSD lock by depressing the lock tab.

4) Rotate the MSD locking handle (1) upward to its fully upright position (approximately 90 degrees).
5) Using the MSD locking handle, remove the MSD from the MSD Receptacle and store in a secure area
away from the Battery Pack.

Step 2 - Battery Cover Removal
Description
The Battery Cover protects against environmental intrusion and provides support to the tray assembly upon
which the battery components are built. In order to reduce damage to the Battery Tray, the Battery Pack should
be placed on a flat surface before removing the Battery Cover.
1. Battery Cover
Safety Information


Hardware and Tools
Battery Cover
Replace Reapply
Fastener Tool Torque
Quantity During Loctite
Description Required Specification
Service (Blue 242)
Battery Cover Mounting Screws 3mm Hex Head
(M5 X 8 Button Head Socket w/Loctite®) 44 No Yes 3 Nm (26 in-lbs)
Driver
MSD Receptacle Screws 4mm Hex Head
(M6 X 12 Flanged Head w/Loctite®) 4 No Yes 6 Nm (53 in-lbs)
Driver
Removal
The Manual Service Disconnect (MSD) must be removed from the Battery Pack before servicing
the Battery Pack. Refer to Manual Service Disconnect (MSD) Warning in Safety Information for further details.
1) Remove the Battery Cover screws (1).
2) Remove the four screws (1) from the MSD receptacle assembly.

3) Lift the Battery Cover from the battery tray.
Note: Two people are required to lift the battery cover.
4) Break-Down the Battery Pack. Refer to Step 3 - Battery Pack High Voltage (HV) Break-Down Procedure.
· Once the Battery Cover is removed, immediately proceed to Step 3 - Battery Pack
High Voltage (HV) Break-Down Procedure.

Step 3 - Battery Pack High Voltage (HV) Break-Down Procedure
Description
The process for reducing the Battery Pack voltage potential must be made before performing ANY service
procedures on the Battery Pack. Removing the three series braided jumper connections allows the Battery Pack
to be serviced at a safe voltage level.
1. 30mm Flat Braided Jumpers
Safety Information

Hardware and Tools
Battery Pack Break-Down Procedure
Replace Reapply
Service (Blue 242)
Driver
Driver
30mm Flat Braided Jumper Bolts T30 Torx Head
(M6 X 12 Pan Head) 12 Yes N/A 12 Nm (106 in-lbs)
Driver
2.5mm Flat Washers 6 No - - -
(2.5mm Thick)

Break-Down Procedure
· The Battery Pack is at its FULL voltage potential.

· Refer to Battery Pack Voltage Potential Danger in Safety Information for
further details.
1) Using an insulated tool, remove the three 30mm Flat Braided Jumpers attached to the RH side of the
Battery Pack.
Note: While removing the Jumpers, observe the location and placement of the flat washers on each
fastener. The location of the flat washers is important during reassembly.
Note: Removing the three 30mm Flat Braided Jumpers disables the battery and allows the Battery Pack
to be serviced at a safe voltage level.

Electronics Wing Repair Procedures
Electronics Wing General Information
Description
The Electronics Wing of the Battery Pack houses the following components:
1. Current Sense Module (CSM)
2. Manual Service Disconnect (MSD) Receptacle
3. Generator Inverter HV Connector
4. Motors Inverter HV Connector
5. Battery Control Module (BCM)
6. Electrical Distribution Module (EDM)
39 Electronics Wing Repair Procedures

Description
The Battery Control Module (BCM) is located in the electronics wing of the Battery Pack. This is used to control
all low voltage and high voltage circuits throughout the Battery Pack. The BCM is replaced as a complete
assembly; there are no serviceable components in the BCM.
1. Battery Control Module (BCM)
Safety Information
· Electronic modules are sensitive to Electrostatic Discharge (ESD).

· If exposed to high voltage charges, damage can result.
· Refer to Electrostatic Discharge (ESD) Caution for further details.
40 Battery Control Module (BCM)

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
BCM Mounting Screws 4mm Hex Head
(M6 X 30 Button Head w/Loctite®) 4 No Yes 6 Nm (53 in-lbs)
Driver
HV Flexible Busbar and Cable Inspection
· Inspect the HV Flexible Busbars and Cable contact points.

· Refer to HVIL Contact Point Integrity Caution in Safety Information.
Inspect the HV cable connections for signs of arching (1),

evidenced by the following conditions:
Discoloration from heat (indicating a loose connection)
Hot spots or corrosion
Discolored or melted insulation (indicating a high
temperature area)
Note: Replace any suspect HV Busbar(s) or Cable(s) as necessary.
Preparing Battery Pack For Repair

Refer to First Steps – Preparation For Battery Pack Repair prior to performing any repair procedures.
The following procedures MUST be performed before performing any repairs on the Battery Pack:
1) Remove and securely store the Manual Service Disconnect (MSD). Refer to Step 1 - Verify Manual
Service Disconnect (MSD) Removal.
2) Remove the Battery Cover. Refer to Step 2 - Battery Cover Removal.

Removal
1) Remove the four BCM mounting screws (1).
2) Lift the BCM from its mounting brackets.

3) Disconnect the BCM electrical connector by sliding the BCM red connector lock (1) and unlock the BCM
electrical connector (2).
4) Depress the BCM electrical connector lock tab (1).

5) Rotate the BCM electrical connector (1) and remove the electrical connector from the BCM.

Installation
· Fasteners requiring replacement or thread locker are identified in repair procedures.

· Always replace any Battery Pack fasteners with new fasteners where indicated.
· Refer to Fastener Caution in Safety Information for further details.
1) Connect the BCM electrical connector by inserting the BCM electrical connector (1) into the BCM and
rotate the electrical connector into the locked position.
2) Slide the BCM red connector lock into the locked position (1), and lock the BCM connector (2).
Note: Press the red lock tab to lock the connector in place.

3) Position the BCM on the mounting brackets.
Note: Ensure the wiring harness (1) is properly routed during assembly. Do not allow the wiring harness
to be pinched under the BCM.
4) Install the four BCM mounting screws (1).

Tighten: BCM mounting screws to 6 Nm (53 in-lbs).
5) Reflash the Battery Pack firmware.

Note: After replacing the BCM the Battery Pack firmware must be reflashed.

Preparing Battery Pack For Return To Service
Refer to Final Assembly – Reconnect and Reassemble Battery Pack to complete the Battery Pack repair.
The following procedures MUST be performed before returning the Battery Pack to service:
1) Inspect the Battery Cover Seal. Refer to Step 1 – Battery Cover Seal (O-Ring) Inspection.
2) Reconnect the Battery Pack. Refer to Step 2 – Battery Pack High Voltage (HV) Reconnect Procedure.
· Reconnecting the Battery Pack will cause the Battery Pack to be at its full
voltage potential.
· Refer to Battery Pack Reconnect Danger for further details.
3) Install the Battery Cover. Refer to Step 3 – Battery Cover Installation.

Description
The Electrical Distribution Module (EDM) is located in the electronics wing of the Battery Pack. The EDM houses
the Charge, Positive and Negative Contactors. The BCM signals the EDM to close contactors and controls all high
voltage circuits throughout the Battery Pack. The EDM is replaced as a complete assembly; there are no
serviceable components in the EDM.
1. Electrical Distribution Module (EDM)

(shown with EDM covered removed)
Safety Information

47 Electrical Distribution Module (EDM)

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
EDM HV Positive Cable Screw T30 Internal Torx
(M6 X 12 Pan Head w/Scotch Grip) 1 Yes N/A 12 Nm (106 in-lbs)
Driver
EDM Cover Mounting Nuts 4 Yes N/A 7mm Hex Socket 2 Nm (17 in-lbs)
(M4 Nylon Lock)
EDM Mounting Screws 4mm Hex Head
Driver
EDM Ground Stud Nut 1 Yes N/A 7mm Hex Socket 2 Nm (17 in-lbs)
(M4 Nylon Lock)
RADSoK® Busbar Mounting Nut 1 Yes N/A 13mm Hex Socket 10 Nm (89 in-lbs)
(M8 Hex Nut, Wedge Ramp Lock)
EDM Contactor Nuts (Large) 3 No N/A 10 Nm (89 in-lbs)
EDM Contactor Nuts (Small) 6 No N/A 6 Nm (53 in-lbs)


temperature area)

Refer to First Steps – Preparation For Battery Pack Repair prior to performing any Removal procedures.

Removal
1) Remove the Battery Control Module (BCM). Refer to Battery Control Module (BCM).
2) Remove the positive HV cable clamp from the EDM cover (1).
3) Remove the positive HV cable mounting screw (1).
4) Remove the low voltage wiring harness clamps from the EDM cover (1).

5) Remove the four EDM cover mounting nuts (1) from the EDM cover.
6) Remove the EDM cover.
7) Remove all wiring connected to the contactors.

Note: Before removing any wiring, mark all wires and observe the component location and the wiring
orientation prior to removal.
8) Remove the RADSoK® busbar mounting nut (1) from the contactor.

9) Remove the RADSoK® busbar (1) from the HV post on the Current Sense Module (CSM).
10) Remove the HV Ground (1) from the EDM baseplate.
11) Remove the four EDM mounting screws (1) from the mounting brackets.

12) Remove EDM (1) from its mounting brackets (2).

Installation

1) Install the EDM to the mounting brackets and install the EDM mounting screws (1).
Tighten: EDM mounting screws to 6 Nm (53 in-lbs).
2) Carefully slide the RADSoK® busbar (1) onto the HV post of the CSM and push the busbar down onto the
contactor terminal.
3) Install the necessary wiring to the contactor terminal.

4) Install the RADSoK® busbar mounting nut (1) to the contactor.
Tighten: RADSoK® busbar mounting nut to 10 Nm (89 in-lbs).
5) Install the HV Ground (1) to the EDM baseplate.

Tighten: HV Ground to 2 Nm (17 in-lbs).
6) Install all necessary wiring connected to contactors (see figure below).

Note: Carefully re-route and connect all previously disconnected wiring.


1. CHG BATT NEG JUMPER 16. MAIN POS BUS TERMINAL

2. CHG NEG BATT TERMINAL 17. PRE-CHARGE RESISTOR LEAD
3. CHG NEG BUS TERMINAL 18. HV BUS POS SENSE
4. CHG BUS NEG CABLE 19. HV BATT POS SENSE
5. CHG NEG SENSE 20. HV BATT POS JUMPER
6. CHG POS BATT TERMINAL 21. PRECHG BATT TERMINAL
7. CHG POS BUS TERMINAL 22. PRECHG RES TERMINAL
8. CHG BUS POS CABLE 23. PRE-CHARGE RESISTOR LEAD
9. CHG POS SENSE 24. HV BUS NEG SENSE
10. LEM POS BUSBAR 25. MAIN NEG BUS TERMINAL
11. MAIN POS BATT TERMINAL 26. HV BUS NEG CABLE
12. AUX POS CABLE 27. AUX NEG CABLE
13. AUX POS CABLE 28. AUX NEG CABLE
14. AUX POS CABLE 29. CSM to EDM BUSBAR
15. HV BUS POS BUSBAR 30. MAIN NEG BATT TERMINAL

7) Install the 6 small EDM contactor wiring harness ring terminal nuts.
Tighten: EDM ring terminal nuts to 6 Nm (53 in-lbs).
8) Install the 3 large EDM contactor wiring harness ring terminal nuts.
Tighten: EDM ring terminal nuts to 10 Nm (89 in-lbs).
9) Install the EDM cover onto the mounting studs.

10) Install the EDM cover mounting nuts (1).
Tighten: EDM cover mounting nuts to 2 Nm (17 in-lbs).
11) Install the low voltage wiring harness clamps (1) to the EDM cover.

12) Install the HV positive cable mounting screw (1).

Tighten: HV positive cable mounting screw to 12 Nm (106 in-lbs).
13) Install the HV positive cable clamp (1) to the EDM cover.
14) Install the Battery Control Module (BCM). Refer to Battery Control Module (BCM).

voltage potential.

Description
The Current Sense Module (CSM) is located in the electronics wing of the Battery Pack. The CSM monitors input
and output current of the high voltage bus circuits. The CSM reports current flow rate data to the Battery
Control Module (BCM). The BCM monitors the CSM for current fault reporting and can disable high voltage
between the Battery Pack and vehicle or charging system when a fault occurs. The CSM also has the ability to
interrupt the Heartbeat signal going to the BCM, in turn disrupting high voltage output from the Battery Pack.
The CSM is replaced as a complete assembly; there are no serviceable components in the CSM.
1. Current Sense Module (CSM)
Safety Information


61 Current Sense Module (CSM)

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
Driver
Driver
CSM Mounting Screws 4mm Hex Head
Driver


temperature area)



Removal
2) Remove the HV positive cable clamp (1) from the Electrical Distribution Module (EDM) cover.
3) Remove the HV positive cable mounting screw (1) from the EDM.
4) Remove the low voltage wiring harness clamps (1) from the EDM cover.

5) Remove the four EDM mounting screws (1) from the EDM mounting brackets.
6) Lift the EDM and carefully remove the RADSoK® busbar (1) from the HV post on the Current Sense
Module (CSM).

7) Position the EDM (1) aside.
Cut the HV cable tie straps as necessary to prevent damage to the EDM or the HV
cables.
Note: Use a suitable method to hold the EDM in place while removing the CSM.
8) Remove the Module 1 HV cable clamp from the battery tray.

Note: Pull the cable clamp (1) straight up to remove.

9) Simultaneously slide the Module 1 HV cable and the RADSoK® busbar (1) off the CSM post.
The Module 1 HV cable has a 125 Volt potential. Refer to Module 1 HV Cable Warning in
Safety Information.
10) After cable removal, thoroughly insulate the cable end (1) to prevent an accidental short circuit.
The Module 1 HV cable has a 125 Volt potential. Thoroughly insulate the cable end to
prevent an accidental short circuit. Refer to Module 1 HV Cable Warning in Safety Information.

11) Disconnect the CSM HV Sense Harness electrical connector by sliding the CSM HV Sense Harness red
connector lock (1) and unlock the CSM HV Sense Harness electrical connector (2).
12) Depress the CSM HV Sense Harness electrical connector lock tab (1).
13) Rotate the CSM HV Sense Harness electrical connector (1) and remove the electrical connector from the
CSM.

14) Disconnect the CSM LV electrical connector by sliding the CSM LV red connector lock (1) upward and
unlock the CSM LV electrical connector (2).
15) Depress the CSM LV electrical connector lock tab (1) and remove the electrical connector.
16) Remove the four CSM mounting screws (1) and remove the CSM.

Installation

1) Install the CSM to the mounting brackets and install the four CSM mounting screws (1).
Tighten: CSM mounting screws to 6 Nm (53 in-lbs).
2) Connect the CSM HV Sense Harness electrical connector by inserting the CSM HV Sense Harness
electrical connector (1) into the CSM and rotate the electrical connector into the locked position.
3) Slide the CSM HV Sense Harness red connector lock into the locked position (1).
Note: Press the red lock tab to lock the CSM HV Sense Harness connector (2) in place.

4) Connect the CSM LV electrical connector by inserting the CSM LV electrical connector (1) into the CSM
and confirm the electrical connector is in the locked position.
5) Slide the CSM LV red connector lock into the locked position (1).
Note: Press the red lock tab to lock the connector in place.
Connector Check: Push/Pull the connector to confirm positive connector engagement.
6) Remove the temporary insulation from the Module 1 HV cable and the RADSok® busbar.
7) Simultaneously slide the 1 HV cable and the RADSoK® busbar (1) onto the CSM post.
The Module 1 HV cable has a 125 Volt potential. Refer to Module 1 HV Cable Warning in
Safety Information.

8) Install the Module 1 HV cable clamp (1) to the battery tray.
9) Carefully slide the RADSoK® busbar (1) onto the HV post of the CSM and push the EDM down onto the
EDM mounting brackets.
10) Install the EDM to the mounting brackets and install the four EDM mounting screws (1) to the mounting
brackets.
Tighten: EDM mounting screws to 6 Nm (53 in-lbs).
Note: Install, as necessary, the HV cable tie straps that were cut while positioning the EDM aside during
removal.

11) Install the low voltage wiring harness clamps (1) to the EDM cover.
12) Install the HV cable mounting screw.

Tighten: HV positive cable mounting screw to 12 Nm (106 in-lbs).
13) Install the HV positive cable clamp (1) to the EDM cover.
Note: After replacing the CSM the Battery Pack firmware must be reflashed.

voltage potential.

Fuse 20A and Fuse 30A (600 Volt)
Description
The 20 Amp and 30 Amp (600V) power fuses are located on the underside of the electronics wing of the Battery
Pack in the Fuse Panel. The fuses can be replaced individually as needed.
1. Power Fuses (20A and 30A)
Safety Information

75 Fuse 20A and Fuse 30A (600 Volt)

Battery Pack Fuse Identification and Amperage Ratings
1. A/C Compressor Fuse (30A) 3. PTC Heater Fuse (30A)

(Littelfuse 30A-Part No. 0HEV030.SXC) (Littelfuse 30A-Part No. 0HEV030.SXC)
2. 12V DC/DC Auxiliary Power Module Fuse (30A) 4. Charger Fuse (20A)
(Littelfuse 30A-Part No. 0HEV030.SXC (Littelfuse 20A-Part No. 0HEV020.SXC)

Hardware and Tools
Fuse Panel Cover
Replace Reapply
Service (Blue 242)
Fuse Panel Cover Screws T20 Internal Torx
(M4 X 10 Button Head) 4 No Yes 1.5 Nm (13 in-lbs)
Driver

The following procedure MUST be performed before performing any repairs on the Battery Pack:
Removal
1) Verify the Manual Service Disconnect (MSD) is removed.
2) Remove the four screws (1) securing the Fuse Panel Cover.
3) Remove the Fuse Panel Cover.
4) Remove the secondary fuse covers (1).

Note: Grasp the center grip area of the secondary fuse covers to remove.

5) Remove the defective fuse.
Note: The fuses snap into the Fuse Panel locking tabs.

Installation

1) Install the replacement fuse.
Always replace a blown fuse with the proper amperage replacement fuse. Refer to
Replacement Fuse Caution in Safety Information.
2) Install the Fuse Panel Cover O-Ring seal (1) to the Fuse Panel.

3) Install the Secondary Fuse Covers (1) to the Fuse Panel.
4) Install the Fuse Panel Cover.

Note: ·Ensure the Fuse Panel Cover O-Ring seal is properly located before installing the cover.
·The Fuse Panel Cover is indexed (1) for proper alignment to the battery tray.
5) Install the four screws (1) securing the Fuse Panel Cover.
Tighten: Fuse Panel Cover screws to 1.5 Nm (13 in-lbs).

Fuse Panel
Description
The Fuse Panel and Secondary Fuse Covers are located on the underside of the electronics wing of the Battery
Pack.
1. Fuse Panel
Safety Information


81 Fuse Panel
Hardware and Tools
Fuse Panel
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
Fuse Panel Cover Screws T20 Internal Torx
(M4 X 10 Button Head) 4 No Yes 1.5 Nm (13 in-lbs)
Driver
Fuse Panel Mounting Screws T25 Internal Torx
Driver
Ring Terminal Screws #2 Cross Head
(#10-32 UNF Screw) 8 No No 6 Nm (53 in-lbs)
Driver


temperature area)

82 Fuse Panel
Removal
2) Disconnect the Fuse Panel wiring harness from the harness clips.
3) Remove the wiring harness clamp (1) from the battery tray.
4) Remove the four screws (1) securing the Fuse Panel Cover.
5) Remove the Fuse Panel Cover.
6) Remove the secondary fuse covers (1).

Note: Grasp the center grip area of the secondary fuse covers to remove.
83 Fuse Panel
7) Remove the eight wiring harness screws (1) from the Fuse Panel.
8) Pull the wiring harness ring terminals out from the Fuse Panel.
Note: Before removing any wiring, mark all wires and observe the location and the wiring orientation
prior to removal.
9) Remove the four Fuse Panel mounting screws (1) from the battery tray.
10) Disconnect the Fuse Panel HVIL electrical connector (1).

11) Remove the Fuse Panel from the battery tray.
84 Fuse Panel
Installation

1) Install the Fuse Panel to the battery tray.
Note: Align the Fuse Panel to the battery tray using index tab (1).
2) Install the four Fuse Panel mounting screws (1).

Tighten: Fuse Panel mounting screws to 2 Nm (17 in-lbs).
3) Connect the Fuse Panel HVIL electrical connector (1).
85 Fuse Panel
4) Insert the wiring harness ring terminals into the Fuse Panel (see figure below).
Note: Carefully connect all previously disconnected wiring.
1. HVA280 CHG POS 9. FUSE PANEL ACC OUT

2. FUSE PANEL CHG OUT 10. HVA280 ACC POS
3. FUSE PANEL CHG IN 11. FUSE PANEL ACC IN
4. CHG CABLE BUS POS 12. AUX POS CABLE
5. FUSE PANEL APM OUT 13. AUX POS CABLE
6. HVA280 APM POS 14. FUSE PANEL PTC IN
7. FUSE PANEL PTC OUT 15. AUX POS CABLE
8. HVA280 PTC POS 16. FUSE PANEL APM IN
86 Fuse Panel
5) Install the eight wiring harness screws (1) to the Fuse Panel.
Tighten: Ring terminal screws to 6 Nm (53 in-lbs).
6) Install the Fuse Panel Cover O-Ring (1) to the Fuse Panel.
87 Fuse Panel
7) Install the Secondary Fuse Covers (1) to the Fuse Panel.

Note: The secondary fuse covers are cosmetic only. The battery pack will operate properly without the
secondary fuse covers.
8) Install the Fuse Panel Cover.

Note: ·Ensure the Fuse Panel Cover O-Ring seal is properly located before installing the cover.
·The Fuse Panel Cover is indexed (1) for proper alignment to the battery tray.
88 Fuse Panel
9) Install the Fuse Panel Cover and four screws (1).

Tighten: Fuse Panel Cover screws to 1.5 Nm (13 in-lbs).
10) Connect the wiring harness to the harness clips.

11) Install the wiring harness clamp (1) to the battery tray.
89 Fuse Panel
voltage potential.
90 Fuse Panel
Manual Service Disconnect (MSD) Receptacle Assembly
Description
The Manual Service Disconnect (MSD) Receptacle Assembly is located in the electronics wing of the Battery
Pack. The MSD is used to control all high voltage circuits throughout the Battery Pack. The MSD splits the Battery
Pack between Battery Modules M7 and M8. Removing the MSD further improves safety by rendering the BCM
unable to close the contactors.
1. Manual Service Disconnect (MSD) Receptacle Assembly
Safety Information

91 Manual Service Disconnect (MSD) Receptacle Assembly

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
HV Cable Mounting Nuts 2 No N/A 10mm Hex Socket 9 Nm (80 in-lbs)
(M6 Hex Flange)


temperature area)


Removal
1) Rotate the MSD receptacle assembly (1) in order to access the bottom.
2) Remove the MSD High Voltage Inter-Lock (HVIL) electrical connector (1).
3) Remove the HV cable nuts (1) from the MSD receptacle assembly.
Note: Mark all cables/wires and observe the component location and the wiring orientation prior to
removal.

Installation

1) Install the HV cables and wiring to the MSD assembly.

Tighten: HV cable nuts (1) to 9 Nm (80 in-lbs).
Note: Connect all cables/wires to the proper component location as noted prior to removal.
2) Install the MSD HVIL electrical connector (1).

voltage potential.

Description
The Generator Inverter HV Connector is located in the electronics wing of the Battery Pack.
1. Generator Inverter HV Connector
Safety Information


96 Generator Inverter HV Connector

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
Driver
(M4 Nylon Lock)
Driver
(M4 Nylon Lock)
RADSoK® Busbar Mounting Nut 1 Yes N/A 13mm Hex Socket 10 Nm (89 in-lbs)
Generator Inverter Mounting 4mm Hex Head
Screws/Nuts 4 No Yes 6 Nm (53 in-lbs)
Driver
(M5 X 6 Button Head Socket w/Loctite®)
Generator Inverter Ground T20 Internal Torx
Screw 1 No Yes 2 Nm (17 in-lbs)
Driver


temperature area)


Removal
1) Remove the Solid Negative Busbar (1) mounting screws.
2) Remove the Solid Negative Busbar connecting Generator Inverter HV Connector and Motors Inverter HV
Connector.
3) Remove the HV cable tie strap (1) from the cable routing channel.
4) Lift the HV cables out of the cable routing channel and position the cables aside.
5) Remove the two cable routing channel mounting screws (1).

6) Remove the HV cable mounting screw (1) from Generator Inverter HV Connector.
7) Remove the Solid Positive Busbar mounting screw.

8) Remove the Solid Positive Busbar (1) connecting Generator Inverter HV Connector and Motors Inverter
HV Connector.
9) Remove the Generator Inverter HV Connector ground wire (1).
10) Remove the four Generator Inverter HV Connector mounting screws and nuts from the battery tray.
11) Carefully lower the Generator Inverter HV Connector down and out of the battery tray.

Installation

1) Install the Generator Inverter HV Connector to the battery tray using four screws and nuts.
Tighten: Generator Inverter HV Connector mounting screws to 6 Nm (53 in-lbs).
2) Install the Generator Inverter HV Connector ground wire (1).
Tighten: Generator Inverter HV Connector ground screw to 2 Nm (17 in-lbs).
3) Install the lower Solid Positive Busbar (1) connecting Generator Inverter HV Connector and Motors
Inverter HV Connector.
Tighten: Solid Positive Busbar screw to 12 Nm (106 in-lbs).
4) Install the HV cable/Solid Positive Busbar mounting screw (1) to the Solid Positive Busbar and the
Generator Inverter HV Connector.
Tighten: HV cable/Solid Positive Busbar screw to 12 Nm (106 in-lbs).

5) Install the cable routing channel (1) to the battery tray.

Tighten: Cable routing channel screws to 6 Nm (53 in-lbs).
6) Reposition the HV cables into the cable routing channel.

7) Install the HV cable tie strap (1) to the cable routing channel.
8) Install the Solid Negative Busbar (1) connecting Generator Inverter HV Connector and Motors Inverter
HV Connector.
Tighten: Solid Negative Busbar screw to 12 Nm (106 in-lbs).

voltage potential.

Description
The Motors Inverter HV Connector is located in the electronics wing of the Battery Pack.
1. Motors Inverter HV Connector
Safety Information

104 Motors Inverter HV Connector

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
Driver
(M4 Nylon Lock)
Driver
(M4 Nylon Lock)
RADSoK® Busbar Mounting Nut 1 No N/A 13mm Hex Socket 10 Nm (89 in-lbs)
Motors Inverter Mounting 4mm Hex Head
Screws/Nuts 4 No Yes 6 Nm (53 in-lbs)
Driver
Motors Inverter Ground Screw T20 Internal Torx
Driver


temperature area)



Removal
2) Remove the BCM rear mounting bracket screws (1) and rear bracket.
3) Remove the Solid Negative Busbar (1) mounting screws.

4) Remove the Solid Negative Busbar connecting Generator Inverter HV Connector and Motors Inverter HV
Connector.
5) Remove the HV cable tie strap (1) from the cable routing channel.

6) Lift the HV cables out of the cable routing channel and position the cables aside.
7) Remove the two cable routing channel mounting screws.
8) Remove the HV cable mounting screw (1) from Generator Inverter HV Connector.
9) Remove the Solid Positive Busbar mounting screw.

10) Remove the Solid Positive Busbar (1) connecting Generator Inverter HV Connector and Motors Inverter
HV Connector.

11) Remove the four Motors Inverter HV Connector mounting screws and nuts from the battery tray.
12) Remove the Motors Inverter HV Connector ground wire (1).
13) Carefully lower the Motors Inverter HV Connector down and out of the battery tray.

Installation

1) Install the Motors Inverter HV Connector to the battery tray using four screws and nuts.
Tighten: Motors Inverter HV Connector mounting screws to 6 Nm (53 in-lbs).
2) Install the Motors Inverter HV Connector ground wire (1).
Tighten: Motors Inverter HV Connector ground screw to 2 Nm (17 in-lbs).
3) Install the Solid Positive Busbar (1) connecting Generator Inverter HV Connector and Motors Inverter HV
Connector.
Tighten: Solid Positive Busbar screw to 12 Nm (106 in-lbs).
4) Install the HV cable/Solid Positive Busbar mounting screw (1) to the lower Flexcable and the Generator
Inverter HV Connector.
Tighten: HV cable/Solid Positive Busbar screw to 12 Nm (106 in-lbs).

5) Install the cable routing channel to the battery tray.
Tighten: Cable routing channel screws to 6 Nm (53 in-lbs).
6) Reposition the HV cables into the cable routing channel.

7) Install the HV cable tie strap (1) to the cable routing channel.
8) Install the Solid Negative Busbar (1) connecting Generator Inverter HV Connector and Motors Inverter
HV Connector.
Tighten: Solid Negative Busbar screw to 12 Nm (106 in-lbs).

9) Install the BCM rear mounting bracket and screws (1).
Tighten: BCM rear mounting bracket screws to 6 Nm (53 in-lbs).


voltage potential.

Battery Module Repair Procedures
Battery Module General Information
Description
The A123 Battery Modules use the patented Nanophosphate® cell technology, which delivers high power,
excellent safety, and long life. The high-performance cells are incorporated into the Battery Modules which
serve as the building blocks for the advanced energy storage systems.
The Battery Pack (Battery Module portion) contains the following components:
15 Separate Battery Modules each equipped with Monitor and Balance Board (MBB)
21 Cells in each Battery Module (7 in series, 3 in parallel, 7S3P)
Cold Plate
Various Flexible Busbars and High Voltage (HV) Cables
114 Battery Module Repair Procedures

Thermal Gap Pad Replacement
Description
The Thermal Gap Pads provide thermal conductivity between the Battery Modules and the Cold Plate in the
battery bank area of the Battery Pack.
1. Thermal Gap Pads (Battery Modules M2, 3. Thermal Gap Pad (Battery Module M3)
M4, M7, M8, M11, M12, M15)
2. Cold Plate Assembly 4. Thermal Gap Pads (Battery Modules
M1, M5, M6, M9, M10, M13, M14)
115 Thermal Gap Pad Replacement

Installation
1) Install a new Thermal Gap Pad to the Battery Module (see below for specific orientation).
Carefully install the Thermal Gap Pad. Refer to Thermal Gap Pad Caution in Safety
Information.
Upper Horizontal Battery Module (typical)
Thermal Gap Pad Placement (1)
Lower Horizontal Battery Module (typical)

M3 Vertical Battery Module

116 Thermal Gap Pad Replacement

Flat Washer Location/Identification
Description
The Battery Pack’s HV Flexible Busbars, 30mm Braided Jumpers, and 61mm Braided Jumpers are designed to use
selected flat washers at specific locations. The flat washers are used along with M6 x 12 pan head screws. The
Battery Pack uses both “thick” and “thin” flat washers.
The following diagrams indicate the location and type of washers required:
Battery Pack RH Side Flat Washer Location
A. One Thin Washer B. One Thick Washer C. One Thick & One Thin Washer
Battery Pack LH Side Flat Washer Location
A. One Thin Washer B. One Thick Washer C. One Thick & One Thin Washer
117 Flat Washer Location/Identification

Battery Module Bushings
Description
Each Battery Module is equipped with specialized bushings. There are (4) metal bushings and (4) metal/plastic
bushings for each Battery Module.
The following diagram indicates the location and type of bushings installed:
Battery Pack RH Side Bushing Location
A. Metal Bushings B. Metal/Plastic Bushings
Battery Pack LH Side Bushing Location
A. Metal Bushings B. Metal/Plastic Bushings
118 Battery Module Bushings

Removal
Metal Bushings
1) Using a 12mm tap (1), gently thread the tap into the bushing and pull the bushing out of the Battery
Module.
Note: Twist and pull the tap to remove the metal bushing.
Metal/Plastic Bushings
1) The metal/plastic bushings (1) are a loose fit, and removed by hand.

Installation
Metal Bushings
1) Lightly tap the metal bushings into the Battery Module.
Note: Use a plastic hammer (1) to install the metal bushings.
Plastic Bushings
1) To install the metal/plastic bushings (1), insert the bushings into the Battery Module by hand.

Module Hold Down Bolt Removal With Stripped Cage Nut
Removal
1) Follow the direction of the module through bolt.
2) Locate the area in the aluminum baseplate where the module through bolt intersects the baseplate.
3) Remove the rope seal from the baseplate to avoid damage to the rope seal.
4) Drill a 5.0mm hole in the baseplate at the location where the bolt intersects the baseplate.
Note: Center the drilling location within the width of the baseplate.
5) Tap the hole using a M6x1.0 drill tap.

6) Drive a M6x1.0 screw into the hole until it bottoms into the cage nut and prevents the nut from
spinning.
7) Remove the module through bolt.
Note: Be certain to ensure that the through bolt reaches proper torque during reassembly.
121 Module Hold Down Bolt Removal With Stripped Cage Nut
Battery Modules M2 and M4 through M13
Description
Battery Modules M2 and M4 through M13 are located in the battery bank of the Battery Pack.
Battery Bank - RH Side
Battery Bank - LH Side
Safety Information

122 Battery Modules M2 and M4 through M13

Hardware and Tools
Battery Module(s)
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
2.5mm Flat Washers 6 No N/A - -
(2.5mm Thick)
Battery Module Through Bolts 15mm Hex Head
(M10 X 360 Flanged Hex Head) 28 No Yes 35 Nm (25 ft-lbs)
Socket


temperature area)


Removal
1) Remove the HV Flexible Busbar (1) or Flat Braided 61mm Jumpers as necessary from the LH side or RH
side of the Battery Module.
Note: While removing the HV Flexible Busbar, observe the location and placement of the flat washers on
each fastener. The location of the flat washers is important during reassembly.
2) Disconnect the Battery Module electrical connector (1).
3) Remove the Battery Module through bolts (1) from the restriction plate.

4) Loosen the adjacent Battery Module through bolts.
5) Using an appropriate tool, slightly rock the Battery Module to loosen the bond between the Cold Plate
and the adjacent Battery Modules.
6) Using consistent pressure, carefully push the Battery Module out of the Battery Pack.
Note: Push the module out in the same direction as the heat sink fins.
7) Remove the Battery Module Bushings from the Battery Module. Refer to Battery Module Bushings for
removal instructions.

Installation

1) Install the new Battery Module in the reverse order of removal.

Note: Transfer all Battery Module Bushings to the replacement Battery Module. Refer to Battery
Module Bushings for installation instructions.
Note: After replacing the MBB the Battery Pack firmware must be reflashed.
Note:
Always install new Thermal Gap Pads when replacing Battery Modules. Refer to Thermal Gap Pad
Replacement.
Always install the new Battery Module in the same direction that the original Battery Module was
removed.
Never push or exert any pressure on the MBB circuit board.
Inspect ALL HVIL contact points for signs of discoloration, hot spots or corrosion.
Replace all Battery Pack fasteners as required during reassembly. Always use the correct part number
for the application.
Install all flat washers in the proper location. Refer to Flat Washer Location/Identification.
· All flat washers MUST be installed in the proper location.

· Refer to Flat Washer Location Caution in Safety Information for further details.


voltage potential.

Battery Module M1
Description
Battery Module M1 is located in the battery bank of the Battery Pack.
1. Battery Module M1
Safety Information

128 Battery Module M1

Hardware and Tools
Battery Module M1
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)
Socket


temperature area)


Removal
1) Remove Battery Module M5 (1). Refer to Battery Modules M2 and M4 through M13.
Note: Battery Module M5 must be removed prior to removing Battery Module M1.
2) Remove Battery Module M5 Flat Braided 61mm Jumpers (located on the LH and RH side of the Battery
Module).
Note: While removing the Jumpers, observe the location and placement of the flat washers on each
3) Disconnect Battery Module M5 electrical connector (1).
4) Remove the four Battery Module M5 through bolts (1) from the restriction plate.

8) Disconnect the electrical connector (1) from Battery Module M1.

9) Remove Battery Module M1 HV cable (1) (front of Battery Module).

10) Remove Battery Module M1 Flat Braided 61mm Jumper (1) (RH side of Battery Module).
Note: While removing the Jumper, observe the location and placement of the flat washers on each
11) Remove Battery Module M1 four through bolts (1) from the restriction plate.

13) Slide Battery Module M1 over to the previously occupied space for Battery Module M5.

14) Using consistent pressure, push the Battery Module out of the Battery Pack from the RH side of the
Battery Pack.

Installation


Note:
Replacement.
removed.



voltage potential.

Battery Module M3
Description
Battery Module M3 is located in the rear most position of the battery bank of the Battery Pack.
1. Battery Module M3
Safety Information


Hardware and Tools
Battery Module M3
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)
Socket
Battery Module Through Bolts 8.0 Internal Hex
(M10 X 202 Allen Head) 2 No Yes 35 Nm (25 ft-lbs)
Head Socket


temperature area)


Removal
1) Remove the HV Flexible Busbar (1) from the LH side of Battery Module M3.
2) Remove the HV Flexible Busbar (1) from the RH side of Battery Module M3.
3) Disconnect Battery Module M3 electrical connector (1).

4) Remove the two Battery Module through bolts (1) from the restriction plate.
5) Remove the two Battery Module mounting bolts (2).
Note: The Battery Module mounting bolts are recessed internal hex bolts.


Installation


Note:
Replacement.
removed.
·All flat washers MUST be installed in the proper location.

·Refer to Flat Washer Location Caution in Safety Information for further details.


voltage potential.

Description
Battery Modules M14 and M15 are located in the front most positions of the battery bank of the Battery Pack.
1. Battery Module M15 2. Battery Module M14
Safety Information

142 Battery Modules M14 and M15

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)
Socket


temperature area)


Removal
1) Remove the Flat Braided 61mm Jumper (1) from the LH side of the Battery Module.
Note: While removing the Jumper, observe the location and placement of the flat washers on each
2) Remove the HV Flexible Busbar (1) from the RH side of Battery Module.
3) Disconnect the Battery Module electrical connector (1).

4) Remove the Coolant Temperature Sensor (2) and electrical connector (1) from the cooling tube (3).
Note: The Coolant Temperature Sensor must be reinstalled on the cooling tube after replacing the
Battery Module.
5) Remove the Battery Module through bolts (1) from the restriction plate.
6) Remove the ground strap nut (2) and the ground strap.


Installation


Note: Transfer all Battery Module Bushings to the replacement Battery Module. Refer to Battery Module
Bushings for installation instructions.
Note:
Replacement.
removed.
Install the Coolant Temperature Sensor and electrical connector on the cooling tube using tie straps.



voltage potential.

Description
The Cooling Ports Assembly is located in the front of the Battery Pack. The Cooling Ports Assembly is connected
to the Cold Plate, which is located horizontally between the upper and lower rows of the Battery Modules. The
Cooling Ports Assembly provides an external connection to the captive battery cooling system, thereby allowing
coolant to circulate through the Cold Plate to cool the Battery Pack.
1. Cooling Ports Assembly
Safety Information

148 Cooling Ports Assembly

Hardware and Tools
Replace Reapply
Service (Blue 242)
Driver
Driver
Cooling Ports Mounting Screws 3mm Hex Head
Driver
Cooling Ports Hose Clamps 4 No N/A Hose Clamp Pliers N/A
(4 Spring Clamps)


temperature area)


Removal
1) Remove the three Cooling Ports Assembly mounting screws (1).
Note: Inspect hoses and clamps and replace if necessary.
2) Compress the hose clamp springs (1) and move the clamps to the center of the hose.
3) Remove the Cooling Ports Assembly from the Cold Plate.

Installation

1) Compress the hose clamp springs and install the Cooling Ports Assembly onto the Cold Plate.
Note: When installing the hose clamps, ensure the clamps are installed past the cooling pipe retention
bead on the Cooling Ports Assembly and the Cold Plate.
When installing the hose clamps (1), ensure the clamps are installed in the correct
position (see figure) to avoid interference with the Battery cover.
Clamp tabs on the inboard hose (2) almost touching the outlet hose.
Clamp tabs on the outlet hose (3) perpendicular to the bottom of the tray.
2) Verify that a straight-edge (1) lined up with the tray ramp (2) has no contact with the inboard clamps (3).

3) Install the three Cooling Ports Assembly mounting screws (1).

Tighten: Cooling Ports Assembly mounting screws to 4 Nm (35 in-lbs).
4) Pressure test the Battery Pack cooling system.
Note: Install the necessary test equipment in order to pressure test the Cooling Ports Assembly
and Cold Plate.
Pressure Test Specification: Test cooling system by holding pressure at 30 psi for two minutes. There
should be zero loss in pressure. Any loss of pressure indicates a leak in the system.

voltage potential.

Description
The Coolant Temperature Sensor is mounted in contact with the Cold Plate at the front of the Battery Bank. The
Coolant Temperature Sensor reports the temperature of the Battery Pack coolant to the Battery Control Module
(BCM).
1. Coolant Temperature Sensor Electrical 2. Coolant Temperature Sensor

Connector
154 Coolant Temperature Sensor

Safety Information

Hardware and Tools

Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)


temperature area)


Removal
1) Remove the Coolant Temperature Sensor electrical connector from the cooling tube.
2) Remove the tie strap (1) retaining the Coolant Temperature Sensor to the Cold Plate.
3) Disconnect the Coolant Temperature Sensor electrical connector (1).
4) Slide the Coolant Temperature Sensor off of the retaining bracket.

Installation

1) Slide the Coolant Temperature Sensor onto the retaining bracket.

2) Connect the Coolant Temperature Sensor electrical connector (1).
3) Attach a tie strap (1) retaining the Coolant Temperature Sensor to the Cold Plate.



Flat Braided Jumpers – 30mm Length (Typical)
Description
The 30mm Flat Braided Jumpers are located in the battery bank area of the Battery Pack.

Torque: 12 Nm (106 in-lbs)
Safety Information
Defective 30mm Jumper Example

A burned HV jumper will experience the same appearance as a burned HV cable (see below).
Example of a burned HV cable
159 Flat Braided Jumpers – 30mm Length (Typical)

Flat Braided Jumpers – 61mm Length (Typical)
Description
The 61mm Flat Braided Jumpers are located in the battery bank area of the Battery Pack.

Torque: 12 Nm (106 in-lbs)
Safety Information

Defective 61mm Jumper Example

A burned HV jumper will experience the same appearance as a burned HV cable (see below).
Example of a burned HV cable

Monitor and Balance Board (MBB) (Typical)
Description
The Monitor and Balance Boards (MBB) are located in the battery bank area of the Battery Pack. Each Battery
Module is equipped with an MBB. Each MBB monitors the individual cells within its respective Battery Module.
1. Monitor and Balance Board (MBB)
Safety Information

162 Monitor and Balance Board (MBB) (Typical)

Hardware and Tools
Monitor and Balance Board (MBB)
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)
Monitor and Balance Board T15 Torx Head
Cover Screws 4 No No 2.65 Nm (20 in-lbs)
Driver
(Pan Head)
Monitor and Balance Board T15 Torx Head
Screws 4 No No 2.65 Nm (20 in-lbs)
Driver
(Pan Head)


temperature area)


Removal
1) Remove the four screws (1) from the Monitor and Balance Board cover.
2) Carefully pull the cover loose and remove the cover from the battery module.
3) Remove the four Monitor and Balance Board mounting screws (1).
4) Carefully rotate the circuit board away from the battery module in order to gain access to the electrical
connectors.
5) Disconnect the Cell Sense electrical connector (1).
6) Disconnect the Low Voltage Communication electrical connector (2) and remove the Monitor and
Balance Board.

Installation

1) Connect the Cell Sense electrical connector (1).

2) Connect the Low Voltage Communication electrical connector (2).
3) Install the four Monitor and Balance Board mounting screws (1).
Tighten: Monitor and Balance Board screws to 2.65 Nm (20 in-lbs).

4) Install the Monitor and Balance Board cover.
Tighten: Monitor and Balance Board cover screws (1) to 2.65 Nm (20 in-lbs).



voltage potential.

Flexible Busbar (Typical)
Description
The Flexible Busbars are located in the battery bank area of the Battery Pack.
Flexible Busbar Part Numbers
Part Number – Description – Quantity

1. 404147-221 – Flexible Busbar High Voltage Module 11 POS to Module 12 NEG – Qty 1
2. 404147-225 – Flexible Busbar High Voltage Module 4 NEG to Module 3 POS – Qty 1
3. 404147-222 – Flexible Busbar High Voltage Module 7 POS to MSD – Qty 1
4. 404147-224 – Flexible Busbar High Voltage Module 8 NEG to MSD – Qty 1
5. 404147-223 – Flexible Busbar High Voltage Module 15 POS to HV BAT POS EDM – Qty 1
6. 404147-236 – Flexible Busbar High Voltage Module 3 NEG to Module 2 POS – Qty 1
7. 405780-3G01 – Solid Copper Busbar High Voltage HV CONN BUS NEG – Qty 1
8. 405780-3H01 – Solid Copper Busbar High Voltage HV CONN BUS POS – Qty 1
9. 404040-061 – Jumper Flat Braid 61mm Long 50mm 2 Holes – Qty 7
10. 403097-030 – Jumper Flat Braid 30mm Long 50mm 2 Holes – Qty 3
169 Flexible Busbar (Typical)

Safety Information

Hardware and Tools
Flexible Busbars
Replace Reapply
Service (Blue 242)
Driver
Driver
Flexible Busbar Bolts T30 Torx Head
Driver
(2.5mm Thick)


temperature area)


Removal
1) Remove the mounting screws (1) to the Battery Module for the defective Flexible Busbar.
Note: While removing the defective Flexible Busbar, observe the location and placement of the flat
washers on each fastener. The location of the flat washers is important during reassembly.
2) Identify the Flexible Busbar connection (1) that requires replacement.

Note: There are many Flexible Busbar connection joints used throughout the Battery Pack.

3) Using a utility knife (1), carefully cut a slice in the shrink tubing.
Note: Use caution not to cut into the HV cables while cutting the shrink tubing.
4) Separate the shrink tubing (1) and remove the shrink tubing from the HV cable and Flexible Busbar
connection.
5) Remove the HV cable/Flexible Busbar connecting bolt (1).

Installation
1) Place the Flexible Busbar onto the Battery Pack.
2) Properly route the Flexible Busbar and confirm all insulators (1) are in place.
Note: Inspect the insulators for any tears, burns, arcing or loose fit. Replace any damaged insulators as
necessary.
3) Remove the Flexible Busbar cable clamp (1) (if applicable).

Note: The cable clamp must be removed in order to slide the heat shrink tubing over the HV cable.

4) Slide a piece of shrink tubing (1) over the HV cable.

Note: To ensure proper insulation, only use A123 approved shrink tubing.
5) Install the HV cable/Flexible Busbar connecting bolt (1).

Tighten: HV cable/Flexible Busbar connecting bolt to 12 N·m (106 in-lbs).
6) Slide the shrink tubing (1) over the HV cable and the Flexible Busbar connection.

7) Heat the shrink tubing using a heat gun (1).
8) Verify the shrink tubing (1) is tightly shrunk to the HV cable and the Flexible Busbar connection.
9) Install the Flexible Busbar cable clamp (if applicable).
Note: To prevent any interference with the Battery Cover, position the HV cable/Flexible Busbar
connection away from the Battery Cover.
10) Install all flat washers in the proper location. Refer to Flat Washer Location/Identification.


11) Install the Flexible Busbar mounting screws (1) to the Battery Module.
Tighten: Flexible Busbar mounting screws to 12 N·m (106 in-lbs).


voltage potential.

Final Assembly – Reconnect and Reassemble Battery Pack
General Information
Perform these “Final Assembly” procedures to ready the Battery Pack for return to service.
Final Assembly Explained

Step 1 – Inspect the Battery Cover Seal (O-Ring). Refer to Step 1 – Battery Cover Seal (O-Ring) Inspection.
Step 2 – Reconnect the Battery Pack. Refer to Step 2 – Battery Pack High Voltage (HV) Reconnect
Procedure.
Step 3 – Install the Battery Cover. Refer to Step 3 – Battery Cover Installation.
·Always use safe practices when performing repair procedures.

·Refer to Safety Information for further details.
178 Final Assembly – Reconnect and Reassemble Battery Pack

Step 1 – Battery Cover Seal (O-Ring) Inspection
Description
The Battery Cover Seal (O-Ring) is located around the perimeter of the Battery Pack. The battery case has a
continuous groove that the Battery Cover Seal fits in. The Battery Cover is fastened to the battery case to form a
tight seal.
1. Battery Cover Seal (O-Ring)
Safety Information


Inspection
1) Inspect the Battery Cover seal for any signs of wear or damage.
2) If the seal requires replacement, proceed to the Removal procedure to replace the seal.
Removal
1) Remove the Battery Cover Seal (1) from the battery tray by pulling it from the groove.
Installation
1) Use a vacuum cleaner and thoroughly clean the Battery Cover sealing surface of any foreign matter
which would prevent a tight seal.
2) Install the Battery Cover Seal into the Battery Tray groove.
Note: Do not stretch the seal during installation; simply place the seal into the groove.

Note: Be sure the seal does not fall out of the seal groove.
3) Install the Battery Cover Seal (1) around the entire Battery Tray.

Step 2 – Battery Pack High Voltage (HV) Reconnect Procedure
Description
The Battery Pack MUST be “Reconnected” prior to installing the Battery Cover. Installing the three 30mm Flat
Braided Jumpers will reconnect the Battery Pack, thereby bringing the Battery Pack to its FULL voltage potential.
Safety Information


Hardware and Tools

Battery Pack Reconnect
Replace Reapply
Service (Blue 242)
Driver
Driver
Driver
(2.5mm Thick)
Secure High Voltage Connections with Anti-Friction Tape

1) Tape bottom left HV connection.
2) Tape bottom right HV connection.

3) Tuck right HV connection under module and away from inside of the battery cover.
4) Tie strap the taped HV connection into place so it will not contact the inside of the battery cover.
Reconnect Procedure

1) Install all flat washers in the proper location. Refer to Flat Washer Location/Identification.


2) Install the three 30mm Flat Braided Jumpers (1) attached to the RH side of the Battery Pack.
Tighten: 30mm Flat Braided Jumper mounting bolts to 12 Nm (106 in-lbs).
voltage potential.
· Refer to Battery Pack Reconnect Danger in Safety Information.

Step 3 – Battery Cover Installation
Description
The Battery Cover protects against environmental intrusion and provides support to the tray assembly upon
which the battery components are built.
1. Battery Cover
Safety Information


Hardware and Tools
Battery Cover
Replace Reapply
Service (Blue 242)
Driver
Driver
Installation

1) Use a vacuum cleaner and thoroughly clean the Battery Cover sealing surface of any foreign matter
which would prevent a tight seal.
2) Verify the Battery Cover Seal is located in the proper location on the Battery Tray.
3) Carefully place the Battery Cover onto the battery tray.
Note: Two people are required to lift the battery cover.
4) Carefully align the Battery Cover holes (1) with the Battery Tray.
Note: The Battery Cover and Battery Tray holes must align.

5) Using an alignment tool (1), align the Battery Cover holes with the Battery Tray.
6) Install the four screws (1) to the Manual Service Disconnect (MSD) receptacle assembly.
Tighten: Manual Service Disconnect (MSD) mounting screws to 6 Nm (53 in-lbs).
7) Install the Battery Cover screws (1).

Tighten: Battery Cover mounting screws to 3 Nm (26 in-lbs).

Battery Cover Insert Repair
Part One — Removing the Damaged Insert
1) Drill the brass out of the damaged insert using a ¼ inch drill bit.
Note: Drill straight. Do not drill at an angle.
2) Remove the head of the brass insert from the slot using a flat bladed tool.
21
3) Drill through the metal and partially into the composite with a /64 inch drill bit.
Do not drill completely through the cover. Drill only as far as needed to properly
seat the new insert.

4) Twist a screw partway into the new insert and seat the new insert into the newly prepared insert hole.
5) Verify the new insert seats properly.

6) Pull the new insert out of the hole using the screw as a handle.
Note: Leave the screw in the insert.
Part Two — Insert Installation

1) Clean the newly prepared insert hole to remove dust and debris.
2) Mix the epoxy on a clean and disposable surface such as a piece of cardboard or thick paper.
Note: Use the epoxy from the insert repair kit. Squeeze out enough epoxy to cover a space about the
size of a dime. Mix the epoxy thoroughly.
3) Coat the new insert equally on all sides with the epoxy.
Note: Hold onto the screw so the epoxy does not coat your hands.
4) Push the new insert into the hole until it seats firmly.
Do not disturb the insert for a minimum of six minutes to allow the epoxy to cure.

Part Three — Insert Installation Final Steps

1) Remove the installation screw from the new insert and discard.
2) Remove excess epoxy by scraping with a flat bladed tool.
3) Insert new screw into the cover and torque to 3 Nm (26 in-lbs).
Note: If specified torque is achieved, the repair is finished. If the specified torque is not achieved,
repeat the repair procedure as necessary until specified torque is achieved.

Specifications
All specifications are based on the latest information available at the time of publication.
Battery Pack General Specifications

Fisker Battery Pack Specifications
Pack Weight 275 kg
Capacity 58.5 Ah
Voltage Nominal 347 VDC
Energy 19.7 kWh
Pack Series Elements 105
Pack Total Cells 315
Coolant 50/50 DEX-COOL® / Deionized Water

Fisker Battery Module – Common Elements
Cells in Parallel 3
Cells in Series 7
Total Cells per module 21
Modules in Pack 15
Battery Pack Fuse Specifications

Fisker Battery Pack – Fuse Identification
Fuse Identification Amperage
AC Compressor Fuse 30 Amp
PTC Heater Fuse 30 Amp
12V DC/DC Auxiliary Power Module Fuse 30 Amp
Charger Fuse 20 Amp
192 Specifications
Battery Pack Fastener Specifications
Fastener Torque/Reuse Specifications
Fastener Replace During Torque
Quantity
Description Service Specification
Battery Cover Mounting Screws 44 No 3 Nm (26 in-lbs)
Battery Module Through Bolts 28 No 35 Nm (25 ft-lbs)
BCM Mounting Screws 4 No 6 Nm (53 in-lbs)
BCM Rear Mounting Bracket Screws 2 No 6 Nm (53 in-lbs)
HV Cable to MSD Nuts 2 No 9 Nm (80 in-lbs)
Cold Plate Ground 1 No 6 Nm (53 in-lbs)
Cooling Ports Mounting Screws 3 No 4 Nm (35 in-lbs)
CSM Mounting Screws 4 No 6 Nm (53 in-lbs)
EDM HV Positive Cable Screw 1 Yes 12 Nm (106 in-lbs)
EDM Contactor Nuts (Large) 3 No 10 Nm (89 in-lbs)
EDM Contactor Nuts (Small) 6 No 6 Nm (53 in-lbs)
EDM Cover Mounting Nuts 4 Yes 2 Nm (17 in-lbs)
EDM Mounting Screws 4 No 6 Nm (53 in-lbs)
EDM Ground Stud Nut 1 Yes 2 Nm (17 in-lbs)
Flexible Busbar Bolts 12 Yes 12 Nm (106 in-lbs)
Fuse Panel Cover Screws 4 No 1.5 Nm (13 in-lbs)
Fuse Panel Mounting Screws 4 No 2 Nm (17 in-lbs)
Generator Inverter Mounting Screws (HVIC) 4 No 6 Nm (53 in-lbs)
Generator Inverter Ground Screw (HVIC) 1 No 2 Nm (17 in-lbs)
MSD Receptacle Screws 4 No 6 Nm (53 in-lbs)
Monitor and Balance Board Cover Screws 4 No 2.65 Nm (20 in-lbs)
Monitor and Balance Board Screws 4 No 2.65 Nm (20 in-lbs)
Motors Inverter Mounting Screws (HVIC) 4 No 6 Nm (53 in-lbs)
Motors Inverter Ground Screw (HVIC) 1 No 2 Nm (17 in-lbs)
RADSoK® Busbar Mounting Nut 1 No 10 Nm (89 in-lbs)
Restriction Plate Ground 1 No 6 Nm (53 in-lbs)
Ring Terminal Screws 8 No 6 Nm (53 in-lbs)
30mm Flat Braided Jumper Bolts 12 Yes 12 Nm (106 in-lbs)
61mm Braided Jumper Bolts 42 Yes 12 Nm (106 in-lbs)
193 Specifications
194 Specifications
(c) A123 Systems, Inc

All rights reserved
Part No. 404025-998
195

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FISKER K1 BATTERY PACK REPAIR MANUAL

Fisker K1 Battery Pack

Repair Manual PDF Format Information

Repair Procedure Step-by-Step Views

1 How To Use This Repair Manual

The Safety Information section contains information on the following topics:

First Steps–Preparation For Battery Pack Repair

2 How To Use This Repair Manual

Battery Bank Repair Procedures

Final Assembly–Preparing Battery Pack For Return To Service

3 How To Use This Repair Manual

Battery Pack Common Acronyms

4 How To Use This Repair Manual

Important Safety Information Contained In This Manual

Danger, Warning and Caution Statement Definitions

Battery Pack High Voltage Danger

Personal Protective Equipment (PPE) Danger

The high-voltage battery contains high-voltage components and wiring. High-voltage

Battery Pack Break-Down Danger

Battery Pack Reconnect Danger

Battery Pack Voltage Danger

Manual Service Disconnect (MSD) Danger

Buffer Zone Danger

Manual Service Disconnect (MSD) Warning

Module 1 HV Cable Warning

HVIL Contact Point Integrity Caution

Battery Pack Lifting Caution

Replacement Fuse Caution

Thermal Gap Pad Caution

Flat Washer Location Caution

Electrostatic Discharge (ESD) Caution

Insulated Shoes (rated for up to 1000 Volts)

Face Shield or Safety Glasses

Work Area Preparation

Work Area Must Be Indoors

Work Area Must Be Free Of Foreign Materials

Work Area Must Remain Dry

Work Area Size Requirements

1. Battery Module M1 6. Battery Module M6 11. Battery Module M11

The Battery Pack contains the following components:

15 Separate Battery Modules (with Monitor and Balance Board (MBB))

Battery Pack Serial Number Location

2) Tighten the four eye bolt nuts (1).

Battery Bank - LH Side

Battery Module Cell Specifications

Battery Module Description/Service Part Numbers

Electronic Module Identification & Bar Code Location (1)

1. A/C Compressor Fuse (30A) 3. PTC Heater Fuse (30A)

·Fasteners requiring replacement or fasteners requiring thread locker are identified in

Fasteners Included With Service Parts

Pack and Meter Information

PACK NUMBER: ______________________________________________________________________

6) ____ Remove the MSD.

9) ____ Remove the battery pack cover.

12) ____ Re-install the MSD.

16) ____ Remove the MSD.

Fluke Insulation tester @ 500V Interconnect Location

Module Negative Terminal

Module Negative Terminal

20) ____ Remove the Module (s) for further analysis

Figure 1 - Fisker Pack Module Configuration

28 Loss of Isolation Detection Process

First Steps – Preparation For Battery Pack Repair

First Steps Explained