Volkswagen VAS 5581/5 User manual

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Operating manual
Diagnostic cable VAS 5581/5

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Revision Date Reason
V00 02.03.2021 First edition
Legal notice
Legal notice
Manufacturer CAR-connect GmbH
Am Egelingsberg 8
38542 Leiferde, Germany
Phone: [phone]
Fax: [phone]
[e-mail]
www.car-connect.cc
Reproduction Reproduction or reprinting, whether in whole or in part, always requires the written permission
of the manufacturer.
Copyright TRANSLATION OF THE ORIGINAL OPERATING MANUAL
All rights reserved.
All text, images and graphics are subject to copyright and other intellectual property laws.
Copyright 2020 CAR-connect GmbH.
Image sources Symbols for warnings, prohibitions, mandatory actions and standards are taken from publicly
accessible sources, such as the Internet. CAD product images and product photos are provided
by the manufacturer. Images showing the product in use are provided with a reference to the
source.

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Contents
Contents
LEGAL NOTICE 2
CONTENTS 3
INTRODUCTION 4
Preliminary information 4
Validity of the declaration of conformity 4
Manufacturer specifications 4
SAFETY 5
Warning levels 5
Important safety instructions 6
Intended use 7
Requirements for the target group 7
Duties of the operator 7
PRODUCT DESCRIPTION 8
Scope of delivery 8
Design 8
Symbols and connections 9
Wiring diagram 10
Technical data 10
OPERATION 11
Startup 11
Detaching the plug connections 13
Detaching the plug connection for the diagnostic cable (20-pin) 13
Cleaning 14
Storage 14
Disposal 14
Maintenance 14
HELP 15
Warranty 15
Customer service 15

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EN | Introduction
Introduction
Preliminary information
Read through this operating manual carefully before using the product.
The product is delivered with a USB stick containing the operating manual in various
languages. You can find the current version and additional languages on our homepage.
The operating manual is an essential part of the product and must be kept together with the
product. If you sell or transfer ownership of the product, the operating manual must be
handed over to the new operator.
In addition to this operating manual, you must observe all relevant regulations for
diagnostics or troubleshooting of intrinsically safe high-voltage systems in road vehicles. This
includes but is not limited to: instructions for the vehicle manufacturer’s diagnostics
systems, company-specific safety requirements and the state of the art for working with
high-voltage systems.
Validity of the declaration of conformity
The declaration of conformity applies to the product described in the operating manual. Any
changes, modifications or extensions shall void the declaration of conformity and the risk
assessment.
Manufacturer specifications
CAR-connect GmbH
Since its founding, our company has focused on groundbreaking solutions for
electromobility. CAR
-
connect develops and produces custom solutions for the automotive
industry, repair shops and special vehicle
fleets.
Our core business is developing and producing innovative high
-
voltage charging technology
for electric vehicles. Our portfolio also includes measurement and diagnostic technology for
the entire vehicle and battery analysis equipment.
With extensive
experience in software and hardware development, CAR-
connect is your
dependable partner at every production stage, from prototyping to series production.
CAR-connect GmbH – Experience, Expertise and Innovation – MADE IN GERMANY

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EN | Safety
Safety
This safety chapter provides information about the following:
•The warning levels contained in this operating manual
•Important safety instructions for the product
•Intended use of the product
•Requirements for the target group
This operating manual is only valid for the following product:
Item number
2210
0722
Designation
Diagnostic cable
VAS 5581/5
Warning levels
This chapter provides information about the warning levels used in this operating manual.
DANGER
Failure to observe the safety instructions WILL result in death or serious injury!
WARNING
Failure to observe with the safety instructions CAN result in death or serious injury!
CAUTION
Failure to observe the safety instructions CAN result in minor physical injury!
CAUTION
Failure to observe the safety instructions can lead to damage to the product!

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EN | Safety
Important safety instructions
This chapter contains the safety instructions that must be observed when handling the
product.
DANGER
Danger of fatal electric shock!
The electrical voltage in other systems is lethal and will cause death by electric shock!
•Do not use the product for measurements on utility power circuits!
•
Never attempt to power other devices with the product!
WARNING
Danger of fatal electric shock!
The electrical voltage in high-voltage systems is lethal and can cause death by electric
shock!
Liquids, condensation and high humidity can cause short circuits!
•Do not let the product come into contact with liquids!
•
Use the product only in dry and enclosed spaces!
WARNING
Danger of fatal electric shock!
The electrical voltage in the product is dangerous and can cause serious injury or death
from electric shock!
Defective and damaged products cannot guarantee protection against electrical voltage!
•Do not let the product come into contact with chemicals!
•Replace a defective or damaged product immediately!
•
Never attempt to repair or tamper with the product!

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EN | Safety
Intended use
Use the product only in accordance with this operating manual; otherwise the electrical
hazard protection provided by the product can no longer be guaranteed.
The product is used to adapt the VAS 5581/VAS 5581A high-voltage diagnostic box to the
vehicle-side plug connection specified by the vehicle manufacturer in the guided fault
finding. To do so, the product is connected to the battery management system for the high-
voltage battery.
The product may only be used on high-voltage systems that have been certifiably de-
energized.
The product is suitable for testing the high-voltage battery in the following vehicles:
•Volkswagen e-Golf (2014 model).
In this operating manual, vehicle manufacturers are exclusively defined as vehicle
manufacturers in the Volkswagen Group.
Any use beyond what is listed here is prohibited.
Requirements for the target group
Only qualified personnel may work with this product!
In this operating manual, qualified personnel is defined as personnel meeting all
requirements for working on high-voltage systems applicable in the country of operation, as
defined by:
•Regulations applicable in the country of operation
•Qualification according to DGUV 200-005 level 2 or higher, or equivalent
•Specifications from the vehicle manufacturer and/or the operator.
At all times while using the product, staff must wear the personal protective equipment
prescribed by the vehicle manufacturer for work on high-voltage systems.
Duties of the operator
The operator is responsible for ensuring that all staff working with the diagnostic cable
fulfills the requirements for the target group.
Furthermore, the operator is responsible for ensuring the following:
•The diagnostic cable is always in perfect working order.
•The regular inspection intervals for the diagnostic cable are observed and recorded.

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EN | Product description
Product description
Scope of delivery
Immediately check the condition of the product and the completeness of the delivery. If
anything is missing or defective, please contact the manufacturer immediately.
(1) Diagnostic cable
(2) USB stick with operating manual
Design
Product design:
(1) Plug for diagnostic box
(2) Ground clip
(3) Plug for battery management system

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EN | Product description
Symbols and connections
The following symbols are shown on the product:
Symbol Meaning
Caution:
Check the VAS number to ensure that you are using a suitable adapter cable.
Observe the operating manual!
The serial number is used in conjunction with the manufacturer part number to identify
the product.
The manufacturer part number is used in conjunction with the serial number to identify
the product.
The product complies with protection class II, meaning it has increased or double
insulation between active and accessible parts in accordance with VDE 0100, Part
410/412.1.
The disposal instruction prohibits disposal of the product with household waste. Always
dispose of the product in accordance with all local disposal regulations.
The CE marking certifies that the product complies with all applicable European
regulations and has been subjected to the prescribed conformity assessment procedure.
The seal of approval identifies the product as having been approved for use in workshops
and production facilities belonging to the vehicle manufacturer.

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EN | Product description
Wiring diagram
Technical data
Rated data Values
Manufacturer number 22100722
Maximum rated voltage
DC 14 V
Maximum rated current
5 A
Weight
~ 340 g
Cable length
~ 2020 mm/1450 mm
Ambient conditions Operation Storage Transportation
Temperature
5 °C to 40 °C
-20 °C to 60 °C
-20 °C to 60 °C
Elevation above sea level
Max. 2000 m
No limitation.
Humidity Max. 80 % up to 31° C,
decreasing linearly to
50 % at 40° C
Max. 85 %
Condensation not permitted. Maximum permissible relative humidity: 60 % in
environments with corrosive gas/air.

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EN | Operation
Operation
This chapter provides information about the following activities:
•Startup
•Detaching the plug connection
•Cleaning
•Storage
•Disposal
•Maintenance
WARNING
Danger of fatal electric shock!
The electrical voltage in high-voltage systems is lethal and can cause death by electric
shock!
•
Use the product only for the applications intended by the vehicle manufacturer!
CAUTION
Risk of damage!
Plug connections lock into place when attached.
•Unlock the plug connections before you detach them! (See chapter “Detaching the plug
connections”)
Startup
Observe the safety instructions.

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EN | Operation
Connect the ground clip to a conductive part of the vehicle body.
Connect the plug to the disconnected socket on the battery management system.
Lock the connection.
Connect the plug to the diagnostic box.
You can now perform measurements in accordance with the guided fault finding.

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EN | Operation
Detaching the plug connections
WARNING
Risk of explosion!
Product components may produce sparks and electric arcs.
•
Do not use the product in potentially explosive atmospheres!
Detaching the plug connection for the diagnostic cable (20-pin)
The plug connections have a bayonet locking mechanism. To detach a plug connection:
Twist the socket housing to unlock the connection.
Pull the plug connection apart.
The plug connection is now detached.

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EN | Operation
Cleaning
DANGER
Danger of fatal electric shock!
The electrical voltage in high-voltage systems is lethal and will cause death by electric
shock!
•
Disconnect the product from all power sources before cleaning the product!
Observe the safety instructions!
Use only a dry cloth to clean the product.
Storage
Store the product in a dry and dust-free location when not in use.
Disposal
Observe the safety instructions!
Always dispose of the product in accordance with all local disposal regulations.
Maintenance
Observe the safety instructions!
National and local requirements for regular testing must be observed!
Test the product for proper function at intervals of no more than 24 months.
Contact the manufacturer to have a professional function test performed.

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EN | Help
Help
Warranty
CAR-connect GmbH grants a warranty period of 24 months from the date of purchase. The
warranty is valid for demonstrable defects in functional material and workmanship.
Further information on the warranty conditions can be found in the terms and conditions on
the manufacturer’s website.
Customer service
Always include the serial number with any product queries. This number is found on the
product.
CAR-connect GmbH
Am Egelingsberg 8
38542 Leiferde, Germany
Phone: [phone] – 92197-0
Fax: [phone]
[e-mail]
www.car-connect.cc

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Volkswagen Aktiengesellschaft
K-GVO-LW
Group After Sales – Group Service
Literature and Systems
Repair Shop Equipment
PO box 011/4915
38442 Wolfsburg, Germany
For internal use only
Subject to technical changes
Edition 03 / 2021