Component Integration Requirements - Bosch e-GoKart PowerTrain Young Star Manual

5 | Overall Integration Requirements of e-GoKart System Components into the Superior Vehicle Context
5.3.1 Vehicle Control Unit VCU MS 40
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# At assembly or disassembly of the wiring harness to or from the interfaces of the BOSCH
MOTORSPORT e-GoKart System, the used tightening torque shall not exceed the max-
imum allowed torque, according to VDA specification.
# The screw connection for assembly shall be designed by the CUSTOMER so that an
autonomous loosening is not possible over the whole lifetime of the BOSCH MOTORS-
PORT e-GoKart System.
# The design of the screw connection shall be aligned between BOSCH MOTORSPORT
and the CUSTOMER.
# Assembly or disassembly is only permitted without applied 48 V voltage. To avoid unin-
tended autonomous power-up of the system, the 12 V battery shall be disconnected (ter-
minal 30). In order to reach this condition during assembly, the 12 V battery shall be con-
nected at the very end (terminal 30).
# Connection of the (partly screwed) power contacts (terminal 40, terminal 41) and com-
munication connector (terminal 30, CANH, CANL, terminal 30C) is only allowed to be con-
ducted in currentless and voltageless condition.
# Dismounting and removal of the wiring harness of the BOSCH MOTORSPORT e-GoKart
System shall only be carried out by authorized and trained staff.
# Before dismounting the wiring harness, the key signal (terminal 15) shall to be switched
off and a potential overshoot time shall be considered. To avoid unintended autonomous
power-up of the system, the 12 V battery shall be disconnected (terminal 30).
# Screws shall only be mounted into clean screw threads of the BOSCH MOTORSPORT e-
GoKart System components. Before mounting the wiring harness, the respective compon-
ent screw threads shall be checked for cleanliness.
# Unused pins in any connector shall be sealed.
# BOSCH MOTORSPORT components require longitudinally watertight cables, to avoid
propagation due to capillary effect. This means that all customer connectors and wires
must be sealed in order to avoid trapped water within cables and connectors.
# Mating connectors (plugs, cable shoes) of the wiring harness shall be sealed, so that wa-
ter intrusion into the connector is avoided.
# Electric interfaces shall not be exposed to mechanical forces or torques except for
mounting forces. Therefore a flexible cable connection is required.
# All electric interfaces of the BOSCH MOTORSPORT e-GoKart System shall be located in
the vehicle such that electrical connections are not permanently exposed to water.
# For connecting the battery only BOSCH MOTORSPORT -approved cable lugs, screws,
and washers shall be used. BOSCH MOTORSPORT specification concerning the screw con-
nection must be strictly observed. Excessive or insufficient tightening torque as well as
forgotten washers might lead to elevated contact resistances. Danger of overheating and
fire!
# Do not use any other combination of screw, cable lug, and washers. Do not leave out
the washers. Do not mount more than one cable lug onto a single battery terminal.

5.3 Component Integration Requirements

The VCU MS 40 is designed for mounting at the vehicle chassis. In the BOSCH MOTORS-
PORT e-GoKart it should be fixed on the HV-box.
e-GoKart_Powertrain__Young_Star__Manual Bosch Motorsport