Dongfeng Renault K-ZE Traction Battery and On-Board Charger Removal/Installation Safety Guide

Fault Background

The high-voltage service system for the Dongfeng Renault K-ZE EV (1691/1692 manual) is centered on "High-Voltage Lockout/Tagout (LOTO) + Two-Person Operation + Zero-Voltage Verification": before any traction battery operation, four steps must be completed: lock out the vehicle's high-voltage circuit → put the vehicle ECU to sleep → remove the service disconnect switch → disconnect the battery positive and negative cables; after removing the service disconnect switch, wait 5 minutes to ensure the high-voltage system is fully discharged. The entire process strictly requires: two-person operation, with at least one person holding an electrician's certificate and trained by the company/OEM; one person performs the removal/installation, the other observes and is ready to rescue; insulated protective equipment and insulated tools must have an insulation rating greater than 1000V, and must be inspected for damage or corrosion before wearing. Key torque values: battery pack mounting bolts 62 N·m, ground strap 8 N·m, charger mounting bolts and ground strap 14 N·m. This article is organized as a safe operation guide in the order of "battery removal/installation → battery transfer and storage → charger removal/installation".

Traction Battery Assembly Removal (11 Steps)

1. Read and understand the traction battery maintenance precautions, high-voltage system maintenance, and high-voltage electrical safety precautions;
2. Secure the vehicle;
3. Inspection: If the traction battery housing shows leakage or electrical leakage → stop work immediately, post warning signs, and notify the traction battery supplier;
4. Lock out the vehicle's high-voltage circuit (lockout/tagout);
5. Put the vehicle ECU to sleep;
6. Remove the service disconnect switch;
7. Disconnect the battery positive and negative cables — after disconnecting the negative cable, cover both the positive and negative terminals with a clean, insulated protective cover to avoid short circuits;
8. Traction battery insulation resistance test: >50 MΩ indicates good housing insulation; <50 MΩ indicates abnormal insulation → stop immediately, post warning signs, and notify the supplier; insulation testing must only be performed on de-energized circuits;
9. Remove the wheels → remove the traction battery protective plate;
10. Disconnect the traction battery cables (use insulated protective equipment and insulated tools throughout);
11. Disconnect the ground strap → remove the traction battery: one person lowers the lift platform cart, one person observes the area around the traction battery to prevent scratches or impacts; after removal, the battery or platform cart must be lowered to the lowest position.

Installation (reverse order): Before installing a new battery, wear full protective equipment, use a VAT tester to check and install the service disconnect switch cover → one person raises the platform, one person observes (note the size of the mounting bolts) → install the ground strap → install the traction battery cables — for both the signal harness connector (A) and the high-voltage cable connector, pull outward with a force ≤20 N while in the locked state to verify they "cannot be pulled out", after confirming proper insertion, rotate the locking tab in the arrow direction to re-insert to prevent poor contact from pulling back (do not pull on the wiring harness) → install the protective plate → install the wheels → install the service disconnect switch → unlock the vehicle's high-voltage circuit → install the battery positive and negative cables → clear DTCs and test drive (ensure the 12V battery voltage is above 10V during operation).

Service Disconnect Switch and Ground Strap Specifics

Service disconnect switch: Before wearing insulated protective equipment, inspect the equipment for damage or corrosion; replace if any is found; during service, wear high-voltage insulated safety suit/high-voltage insulated shoes/safety helmet/face shield/high-voltage insulated gloves; after removing the service disconnect switch, wait 5 minutes to ensure the high-voltage system is fully discharged; after installation, check that the service disconnect switch is securely locked.

Ground strap: No zero-voltage test is required for removal; mounting bolt torque 8 N·m; during installation, avoid installing the ground strap harness in reverse.

Traction Battery Transfer and Storage

• From packaging box to workbench: mobile crane with capacity greater than 1 ton; it is prohibited to move the crane and boom together, and prohibited to move the crane while lifting the traction battery upward;
• Storage: -10°C to 45°C, ventilated, clean, dry indoor area, avoid direct sunlight, keep at least 2 m away from heat sources; during storage, maintain remaining charge between 40% and 60%; never invert, lay on side, or stand upright, avoid mechanical shock or heavy pressure; never invert during transport or service;
• After transferring to the workbench, place a warning sign and cover with an insulating cover.

On-Board Charger Removal and Installation

Removal: Protect the front fender/front bumper/carpet (driver's side) → turn off the ignition switch, disconnect the battery negative cable → remove the service disconnect switch → cover the mounting hole with the traction battery service disconnect switch cover (E700101) to prevent metal debris from entering and causing circuit faults → unlock the locking clip at (A) of connector (1) by pushing backward, press the clip at (B) to release → unlock and disconnect connector (2) in the same manner → use a 10mm socket to remove the ground bolt (M6×12) → use an 8mm socket to remove the bracket bolts (M6×10) → use hose clamp pliers (BF0108A/B) to clamp the coolant hoses → use hose clamp removal pliers (BF0109) to remove the clamps and disconnect the coolant hoses (before disconnecting, move the connectors to a suitable position to prevent coolant from falling in; after disconnecting, wipe up any residual fluid around the hoses) → use an 8mm socket to remove the ground strap mounting bolt (M6×12) → use a 10mm socket to remove the mounting bolts (M8×25) ×2 → remove the charger.

Installation: Position the charger correctly → pre-tighten the M8×25 mounting bolts with a 10mm socket → tighten to 14 N·m (ground strap mounting bolt M6×12 with 8mm socket, 14 N·m) → align the coolant hoses to the ends, move the clamps to the installation position, remove the hose clamp pliers → install the bracket bolts M6×10 → push the connectors until they click into place and secure the locking clips → install the service disconnect switch → connect the battery negative cable → check the coolant level and add as necessary.

Insulation check (before installation): Insulation resistance tester (A60EV0104): connect the black test lead to the COM terminal, the red test lead to the insulation test terminal, and the other red test lead to the ground terminal and clamp to ground; select the 500V insulation test range; clamp the black test lead to the charger housing, and with the red test lead, measure the insulation resistance of the 4 electrical terminals of the 2 plugs to the housing — press the test button and hold for 2 seconds until the reading stabilizes, then read; normal reading >20 MΩ; if abnormal, do not install, find the cause or replace with a new part. Safety iron rule: do not touch the test lead tips with your hands; before measuring, confirm the object under test is de-energized and safely grounded; during measurement, keep one hand away from other objects (to reduce the chance of current passing through the chest/heart); stand on an insulating mat while measuring.

Safety Warnings

• This article is for technical reference. High-voltage service must be performed by qualified professional technicians (electrician's certificate + company training), two-person operation: one person performs the removal/installation, the other observes and is ready to rescue.
• High-voltage lockout/tagout, ECU sleep, service disconnect switch removal, negative cable disconnection, and 5-minute discharge wait are all mandatory steps; insulation testing must only be performed on de-energized circuits.
• If the housing leaks/electrically leaks, or insulation is <50 MΩ (battery housing) / <20 MΩ (charger terminals), stop work immediately, post warnings, and notify the supplier.
• Lifting and transfer: use a >1 ton mobile crane; never move the crane while lifting; never invert or lay the battery on its side; store at 40%–60% charge.

Service Insights

The K-ZE manual turns high-voltage safety into an executable sequence of actions. The three habits most worth learning are: "Lockout/tagout" is not just a slogan — lock out → sleep → remove service disconnect switch → disconnect negative cable, the order is fixed and each step leaves a trace; "5-minute discharge wait" is a hard timing requirement after removing the service disconnect switch, and many technicians skip it in a hurry; "A connector that cannot be pulled out with ≤20 N is properly seated" — using a quantitative pull force to verify connector locking is far more reliable than visual inspection. The insulation test posture also matters: one hand not touching other objects + standing on an insulating mat + pressing the test button and holding for 2 seconds to read a stable value — this is not formalism, but actual protection to reduce current passing through the chest. Finally, remember two easily overlooked details: the service disconnect switch hole must be covered with the cover (E700101) (metal debris entering the hole = circuit fault); the 12V battery voltage must be above 10V before clearing DTCs and test driving — low-voltage first, high-voltage second; if the order is reversed, problems will arise everywhere.

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【This article is for reference only】