NHTSA ID Number: 10161665
Manufacturer Communication Number: Email_batt_hand
TSB/Document Date: 2019-07-08
Summary
Audi Battery Handling & Logistics Guide
VWoA Compliance
From:
Sent:
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Audi Communications
Thursday, June 20, 2019 6:30 AM
VWoA Compliance
Dealer Communication: Audi Battery Handling & Logistics Guide
Dealer Communication
To: DP, GM, Parts, Sales, Service, Warranty
From: Audi After Sales, Audi
ONE
Audi Battery Handling & Logistics Guide
Dear Dealer Partners,
The U.S. market introduction of the Audi e-tron represents a pivotal moment for the Audi brand as we
begin to sell and service our first all-electric vehicle. The high-voltage battery in an electric vehicle
requires modifications to existing service and repair processes. Evaluating and handling the high-voltage
battery in an Audi e-tron requires specific technical training and adherence to new procedures.
To provide clarity and guidance on these procedures, Audi of America has compiled the Audi Battery
Handling and Logistics Guide. This Guide houses complete details on high-voltage battery evaluation,
battery handling instructions, and battery logistics.
The following topics are addressed in the Guide:
›
›
›
›
›
›
Dealership personnel qualified to handle high-voltage vehicles
Workshop safety standards and procedures
Quarantine dimensions and temporary battery storage guidelines
Safe battery handling practices
Processes for inspecting and repairing a high-voltage vehicle
Packing and shipping high-voltage battery modules
Please read through this Guide to ensure your dealership practices are aligned with the recommended
processes and procedures. In the Appendix of the Guide, you will find specific contacts to reach out to
should you have questions regarding a particular topic.
For more dealer communications, visit the Communications page on iAudi.
Audi of America | 2200 Ferdinand Porsche Drive, Herndon, VA 20171
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1
Audi Battery
Handling and
Logistics Guide
The Audi Battery Handling and Logistics Guide provides detailed information
on the safety standards and inspection processes that must be followed
when handling and servicing a high-voltage battery.
01
02
03
04
05
06
07
08
Dealership Personnel
1.1 High-Voltage Technician
1.2 High-Voltage Expert
1.3 Electrically Instructed Person
1.4 Repair Responsibilities
1.5 Training
Workshop Safety
2.1 Workshop Lifts
2.2 Workshop Tools
2.3 Forlifts
2.4 Fire Suppression
Workshop Procedures & Reporting
3.1 Workshop Procedure Plan
3.2 Collision Reporting Requirements
3.3 Battery Classification Test
Quarantine Dimensions & Temporary Battery Storage
4.1 Quarantine Area
4.2 Temporary Battery Storage
Battery Handling
5.1 Equipment Needed
5.2 Unloading a Battery from a Transport Vehicle
5.3 Packing a Used Battery in a New Battery’s Shipping Container
5.4 Removing a Used Battery from a Dealership or Collision Center
Battery Inspection & High-voltage Vehicle Repair
6.1 Inspecting & Replacing a Non-Critical Battery
6.2 Inspecting a Battery in a Faulty or Accident-damaged High-voltage Vehicle
6.3 Repairing a Vehicle with a “Normal” Battery
6.4 Removing a Battery Classified as “Warning/May be critical”
6.5 Immediate Responses to a “Danger” Battery
Packaging & Shipments
7.1 Battery Replacement Tool Kit
7.2 Non-Critical Battery Packaging
7.3 Critical Battery Packaging
7.4 Non-Critical Battery Shipment – Battery Under Warranty
7.5 Critical Battery Shipment
Appendix
8.1 Contacts
8.2 Helpful Links
8.3 Warning Labels
Dealership
Personnel
The handling and servicing of high voltage batteries requires specialized training by designated Audi dealership technicians
who have achieved either HVT or HVE designations.
1.1 High Voltage Technician (HVT)
>> Any disconnection of the car from the battery, and its reconnection, must be performed by an HVT.
>> The HVT is qualified to perform the battery classification test.
>> See section 1.4 for specific repairs an HVT can perform.
1.2 High Voltage Expert (HVE)
>> The HVE is the most highly-trained person for performing work on high-voltage components.
>> In addition to battery repairs, HVEs support dealerships in handling of “Warning” and “Danger” classified batteries.
>> See section1.4 for specific repairs an HVE can perform.
>> If your dealership does not have an HVE onsite, and one is needed, follow the steps below:
>> Open a case in the Technical Assistance Center (TAC) – access TAC through iAudi.
>> Contact your local Technical Field Manager (TFM).
1.3 Electrically Instructed Person (EIP)
>> An electrically instructed person is permitted to perform specific repair work on high-voltage vehicles, such as changing
tires or replacing the wipers.
>> An EIP cannot repair high-voltage components. Any EIP performing work on a high-voltage vehicle must be instructed
and supervised by a HVT.
1.4 Repair Responsibilities – HVE v. HVT
Repair
HVT
HVE
High-voltage systems (power electronics, on-board charger)
X
X
Battery management controller (BMC)
X
X
Battery junction box (BJB)
X
X
Cell module
X
Cell module controller (CMC)
X
1.5 Training
>> For additional information regarding the training that dealership personnel are required to complete to repair or service
vehicles with high-voltage batteries, please visit the Audi Academy, accessed through iAudi.
>> Specific course numbers can be found in Section 8.2.
Workshop
Safety
This section provides an overview of the safety protocols to adhere to when handling a high-voltage battery, the equipment
and tools needed for servicing and repair, and the best practices for fire suppression.
Electric vehicles require specialized workshop equipment and tools for both common maintenance tasks and heavy repairs,
such as battery removal and battery module replacement. The following minimum standards were established to ensure
safe, proper handling of Audi EVs and high voltage batteries.
2.1 Workshop Lifts
> At least one lift must have unobstructed clearance between superstructure posts of at least 67”. Clearance of 70” is
recommended.
> Lift capacity must be 8,000 lbs. or greater.
2.2 Workshop Tools
Audi e-Mobility Tooling — AT-377 Tool Package
A3
e-tron
HVT and General Repair
T 10358
Bracket
T 40155
Retaining strap
T 10408+ /1-/5
T 40258
High-voltage release tool
T 40259
Battery removal eyes
T 40262
Service disconnect lock
T 40409
Key for coolant expansion tank
T 40430
VAS 5581
High-voltage diagnostics box
2 items
Audi
e-tron
HVT and General Repair (cont.)
VAS 5581/8
Adaptor cable
VAS 611009
Diagnostic adaptor for high-voltage charging system
VAS 6558A
High-voltage test adaptor
VAS 6558/1A
High-voltage test adaptor
VAS 6558A/9-6
High-voltage test adaptor
VAS 6558/14A
High-voltage test adaptor
VAS 6558/15
High-voltage test adaptor
VAS 6558/18A
High-voltage test adaptor
VAS 6558A/23
High-voltage test adaptor
VAS 6558A/28
Earth cable
VAS 6558A/29
High-voltage test adaptor
VAS 6558A30
High-voltage test adaptor
VAS 6606/10
Test adaptor
VAS 6649
Sign — flash
VAS 6650A
Sign — switch
VAS 681001
USB adaptor for e-tron charging system
VAS 691007
Shackle
3 pieces
VAS 691009
Shackle
2 pieces
VAS 691013
Lifting eye, M8
4 pieces
VAS 691015
Lifting eye, M10
2 pieces
VAS 6911/3A
Test connector set
VAS 6911/4
Leak-tight connector
VAS 6911/10
Rubber bung
VAS 6946
Test instrument adaptors/DSO
TBD
Personal protective clothing
PHEV protective clothing is not sufficient
Audi e-Mobility Battery Repair — US & CA
3409
Trim removal wedge
T 10341
Guide pin
T 10542A
Adaptor
T 10543
Suspension device
T 10544
Contact protection
A3
e-tron
Audi
e-tron
A3
e-tron
Audi
e-tron
2 pieces
2 pieces
A3
e-tron
Audi e-Mobility Battery Repair — US & CA (cont.)
T 40417
Leak-tight connector
2 pieces
T 40418
Leak-tight connector
3 pieces
T 40420
Cover
T 40421
Contact protection
T 40422
T 40424
Module remover
VAG 1561A
Cutter
VAS 611013
Pressure sensor
VAS 6648
Pneumatic gun, 18 bar
VAS 6762
High-voltage tool set
VAS 6762/44
Insulating mat
VAS 6762/48
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
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TSB/Document ID: Email_batt_hand
Replacement Service Bulletin Number:
MFR Communication Date: 2019-06-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:12V/24V/48V BATTERY
MFR Component System:
MFR Component Subsystem:
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