End caps

VAS 6786

Batter warning notice

VAS 6845

Scraper set

VAS 6881

Warning sign

VAS 6886

Warning sign (danger from batteries)

VAS 6883/1(A)

Torque wrench, 5-25 Nm

VAS 6884

High-voltage barrier tape

VAS 6900/1

Blade

VAS 9600/2

Scraper

VAS 6900/3

Scraper

VAS 6900/6

Lever

VAS 691003A

High-voltage tool set, TORX

VAS 691003/19

High-voltage socket, TORX

VAS 691005

Cooling system tester for high-voltage batteries

VAS 691005/9

Guide sleeve

VAS 6911/15

Rubber plugs

VAS 852015

Plastic wedge set

VAS 891005

2- Component cartridge gun

Audi
e-tron

Audi e-Mobility Tooling Importer Owned Battery — Lifting Module Balancing — US & CA
T 40416

Battery limit stop (BEV)

VAS 501009

Fork-lift cross beam with chains

VAS 501011

Sling chain

VAS 6910

Module blanacer

VAS 6910/12A

Wiring harness

VAS
6910/17/1&/2

Wiring harness

A3
e-tron

Audi
e-tron

4 pieces

4 pieces

2.3 Forklifts
>> Forklifts are required to move a high-voltage battery. If your
dealership does not have a forklift, you must either rent, lease or
purchase a forklift. The forklift must have a minimum lifting capacity
of 3,500 lbs. Contact Tony Russo for additional details.
>> Tony Russo – Parts Program Specialist, Audi of America.
>> [email protected] // (703) 364-7491.
>> Options for obtaining a forklift:
1. Rent a forklift from a local equipment rental company. It is
recommended to call a local equipment rental company a minimum
of three days before the forklift is needed to place an order.
2. Lease or purchase a forklift through Audi After Sales’ partnership
with Doosan through Valley Industrial.
>> For a lease or purchase, contact Jim Hammond at Valley
Industrial. Identify yourself as an authorized user.
>> [email protected] // (330) 506-2896.
>> Any individual operating a forklift must complete a training program prior to operating the forklift. Dealerships should
ensure compliance with OSHA standards, including 29 CFR § 1910.178.
2.4 Fire Suppression
>> Before starting and during repairs, there should be a pathway that remains clear to the outside of the building that is the
shortest route possible to the designated quarantine area.
>> Do not house batteries near fuel tanks in the workshop.
>> A Class B fire extinguisher should be present in the near vicinity.
>> A standard ABC or BC dry chemical fire extinguisher should be used. Class B is the classification given to flammable
liquids. Lithium-ion batteries contain liquid electrolytes that provide a conductive pathway, so the batteries receive a
Class B fire classification.

Workshop
Procedures

Workshop procedure for high voltage vehicles
Electrically Instructed Person (EIP)

Start

3.1 Workshop Procedure
Plan for High-Voltage
Vehicles
>> The following process
flow chart should be
followed upon the
arrival of a highvoltage vehicle at the
workshop. Use the
workshop procedure
plan to determine
when an issue with a
high-voltage vehicle
needs to be escalated
to an HVT or HVE.
>> The Workshop
Procedure Plan can
be accessed online
through ServiceNet.

Visual inspection and diagnostics on vehicle, HV
system/high-voltage battery
Park vehicle in
quarantine area

Is there smoke? Fire?

Vehicle/HV battery
Quarantine procedure
steps in ElsaPro.
Performed by HVT or
HVE.

NO
Is it necessary to
classify HV battery?

Call Fire Department
Has fluid entered HV battery?
Is HV battery damaged or
modified in any way?

YES

YES
Classification of HV battery

NO
YES

Mark vehicle
as
"high-voltage vehicle".

Classification of HV
battery

HV Quarantine required

NO
YES

1.

Has airbag or belt
tensioner deployed?

De-energise vehicle

NO

Ignition on

Secure against restarting

Secure against restarting

3.

NO

YES

NO
Is vehicle de-energ.?

Is vehicle de-energized

Is HV warning lamp in
instrument cluster on?

YES

NO

YES

Service literature: Is
it necessary to deenergise vehicle?

YES

Visual inspection of the HV
components and cables in work
area

Switch off and
secure
high-vol. sys.

Repair HV components

If necessary, remove
high-voltage battery,
pack it and render it
transportable

NO

NO

YES

Ignition off

Visual inspection
of the HV
components and
cables in work
area OK?

De-energise vehicle

2.
Certified
de-energisation

This section provides an
overview of the different
processes and procedures
that are used when
servicing and repairing a
high-voltage vehicle.
Specific use cases for
when to perform these
procedures are outlined
in Section 6.

High-voltage
expert (HVE)

High-voltage technician (HVT) with
product technician

Repair HV component de-energised or shockproofed?

NO

NO

YES
Remove and repair HV components as
instructed in Workshop Manual

YES

Maintenance and
repair of
conventional
components
as per service
literature

Install high-voltage
components in vehicle

Replace the HV
components / carry
out repairs in
vicinity of HV
components as per
service literature

Remove HV
components and
repair as per service
literature

Restart the high-voltage
system

End
Assign EIP, responsibility stays with HVT Assigned
HVE / transfer responsibility

Assign HVT and transfer responsibility

3.2 Reporting Requirements for a Vehicle in a Collision
In an instance where a high-voltage vehicle has been involved in an
accident and the customer makes contact with the dealership, the
customer should be instructed to bring the vehicle to the nearest
Audi Certified Collision Center.
>> The standard reporting requirements for a vehicle that has been in
a collision must be followed for a high-voltage vehicle.
>> These reporting requirements are found in the brochure included
with the high-voltage vehicle, as is standard with all Audi vehicles.
3.3 Battery Classification Test
The battery classification test is used to determine whether or not the
high-voltage battery is in a critical or non-critical state. The procedure
for the battery classification test can be found on ODIS.
>> The battery classification test examines the battery from three
dimensions:
>> Visual Inspection: is there any visual damage to the lithium-ion
battery?
>> Diagnostic Inspection: are there any functional abnormalities of
the lithium-ion battery?
>> Thermal Inspection: are there any thermal abnormalities on the
lithium-ion battery?
>> The results of the test classify the battery into one of three
categories:
>> Normal (non-critical): there is no functional damage to the
battery.
>> Warning (may be critical): there is damage to the battery and
the battery may react.
>> Danger (critical): the damaged battery is already reacting.

Determining Battery State Classifications
Normal

Warning/May Be Critical

Danger

Visual Inspection

No mechanical damage or
loss of fluids.

There is mechanical
damage, leakage of fluids
and a penetrative smell.

There is smoke, vapor or
fire coming from the
battery.

Diagnostic Inspection

Battery can be diagnosed
and there are no critical
entries in the fault
memory.

The battery cannot be
diagnosed or there are
critical entries in the fault
memory.

Do not attempt a
diagnostic inspection if
there is smoke, vapor or
fire coming from the
battery.

Thermal Inspection

The temperature is within
the tolerance range.

The temperature is within
the tolerance range after
degassing or the
temperature exceeds the
tolerance temporarily.

The temperature exceeds
the tolerance range.

Quarantine
Dimensions &
Temporary Battery
Handling

This section provides an overview of the recommended dimensions for a quarantine zone and outlines best practices for
temporarily storing a high-voltage battery.
4.1 Recommended Quarantine Area
>> The following guidelines designate an area as a quarantine zone. Any battery classified as “Warning” or “Danger” must
be moved in to the quarantine area, if safely possible. The process for removing a “Warning” or “Danger” battery must be
coordinated by an HVE.