Audi Battery Handling and Logistics Guide

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VWoA Compliance
From: Audi Communications
Sent: Thursday, June 20, 2019 6:30 AM
To: VWoA Compliance
Subject: 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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Sent by audicommunications@audi.com
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.
Dealership Personnel
1.1 High-Voltage Technician
1.2 High-Voltage Expert
1.3 Electrically Instructed Person
1.4 Repair Responsibilities
1.5 Training
01
Workshop Safety
2.1 Workshop Lifts
2.2 Workshop Tools
2.3 Forlifts
2.4 Fire Suppression
02
Workshop Procedures & Reporting
3.1 Workshop Procedure Plan
3.2 Collision Reporting Requirements
3.3 Battery Classification Test
03
Quarantine Dimensions & Temporary Battery Storage
4.1 Quarantine Area
4.2 Temporary Battery Storage
04
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
05
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
06
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
07
Appendix
8.1 Contacts
8.2 Helpful Links
8.3 Warning Labels
08
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.
Dealership
Personnel
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.
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
1.4 Repair Responsibilities – HVE v. HVT
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.
HVT and General Repair
A3
e-tron
Audi
e-tron
T 10358 Bracket
T 40155 Retaining strap 2 items
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
2.2 Workshop Tools
Audi e-Mobility Tooling — AT-377 Tool Package
HVT and General Repair (cont.)
A3
e-tron
Audi
e-tron
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 2 pieces
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 2 pieces
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
A3
e-tron
Audi
e-tron
3409 Trim removal wedge
T 10341 Guide pin
T 10542A Adaptor
T 10543 Suspension device
T 10544 Contact protection
Audi e-Mobility Battery Repair — US & CA (cont.)
A3
e-tron
Audi
e-tron
T 40417 Leak-tight connector 2 pieces
T 40418 Leak-tight connector 3 pieces
T 40420 Cover
T 40421 Contact protection
T 40422 Seal
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 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-Mobility Tooling Importer Owned Battery — Lifting Module Balancing — US & CA
A3
e-tron
Audi
e-tron
T 40416 Battery limit stop (BEV) 4 pieces
VAS 501009 Fork-lift cross beam with chains
VAS 501011 Sling chain 4 pieces
VAS 6910 Module blanacer
VAS 6910/12A Wiring harness
VAS
6910/17/1&/2
Wiring harness
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.
>> Anthony.Russo@audi.com // (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.
>> jhammond@valleyindustrialtrucks.com // (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
Electrically Instructed Person (EIP) High-voltage
expert (HVE)
Start
Classification of HV battery
Visual inspection of the HV
components and cables in work
area
Replace the HV
components / carry
out repairs in
vicinity of HV
components as per
service literature Restart the high-voltage
system
Switch off and
secure
high-vol. sys.
Secure against restarting
Workshop procedure for high voltage vehicles
Remove HV
components and
repair as per service
literature
Visual inspection and diagnostics on vehicle, HV
system/high-voltage battery
Install high-voltage
Maintenance and components in vehicle
repair of
conventional
components
as per service
literature
Mark vehicle
as
“high-voltage vehicle”.
Is there smoke? Fire?
Call Fire Department
Has fluid entered HV battery?
Is HV battery damaged or
modified in any way?
Service literature: Is
it necessary to deenergise
vehicle?
Visual inspection
of the HV
components and
cables in work
area OK?
NO
NO
YES
YES
NO
NO
YES
YES
YES
NO
NO
YES
NO
Certified
de-energisation
1.
2.
3.
High-voltage technician (HVT) with
product technician
NO
Classification of HV
battery
Repair HV component –
de-energised or shockproofed?
Remove and repair HV components as
instructed in Workshop Manual
YES
NO
End
YES
YES
Is it necessary to
classify HV battery?
YES
NO
De-energise vehicle
Park vehicle in
quarantine area
Secure against restarting
Is vehicle de-energ.?
De-energise vehicle
If necessary, remove
high-voltage battery,
pack it and render it
transportable
YES
NO
Assign EIP, responsibility stays with HVT Assigned
HVE / transfer responsibility
Assign HVT and transfer responsibility
Vehicle/HV battery
Quarantine procedure
steps in ElsaPro.
Performed by HVT or
HVE.
Repair HV components
Is vehicle de-energized
Has airbag or belt
tensioner deployed?
Is HV warning lamp in
instrument cluster on?
Ignition on
Ignition off
HV Quarantine required
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.
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.
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.
Determining Battery State Classifications
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.
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.
Quarantine Zone Guidelines
1. Park the vehicle outside, as far away as reasonably possible from the building and other established structures, with the
following safe distance dimensions (see diagram below for a visual outline):
> Minimum unobstructed vehicle parking area (shown as yellow and black box around vehicle): 16 ft. x 8 ft.
> Minimum safety distance between parking area and surrounding buildings, etc.: 16 ft.
2. The surface area must be sealed for vehicles involved in a collision or a drip tray must be placed under the vehicle where
the battery is located.
3. The vehicle must be covered with a waterproof tarp.
4. The vehicle must be secured from unauthorized access and marked with the designated warning labels (see warning
labels in Section 8.3).
(VAS 6881) (VAS 6882)
(VAS 6649) (VAS 6786)
4.2 Temporary Battery Handling & Storage
>> Non-critical, high-voltage batteries can be
temporarily stored with less restrictions than
the quarantine zone recommended for critical
batteries. Note that high-voltage batteries
should only be stored temporarily for repair
purposes and should not be stockpiled at the
dealership.
>> To ensure that storage of a high-voltage vehicle
does not create a hazard, follow the storage
instructions specified in the safety data sheet
(SDS) for the particular battery, in addition
to the temporary storage guidelines outlined
below.
>> Li-ion batteries are subject to OSHA’s Hazard
Communication Standard, which means that
Audi has an SDS for each Li-ion battery in its
vehicles.
>> Use the online EH&S system to access Audi
SDSs.
>> Access EH&S through the following
platforms:
>> Access Audi – App Links – Parts –
Safety Data Sheets.
>> Parts on Command – Safety Data
Sheets.
>> When performing service on a high-voltage
vehicle, pull the SDS for the relevant part
number and follow any handling and storage
instructions provided. More information on
servicing a high-voltage vehicle can be found in
Section 6.
>> At a minimum, the following guidelines must
be followed for the temporary storage of highvoltage
batteries.
Temporary Storage Guidelines:
1. Mark the battery storage area with the
appropriate warning labels. See the labels in
Section 8.3.
2. Do not store the battery out in the open or in
areas where repairs are being performed.
3. Protect the battery from mechanical and
thermal exposure.
4. Store the battery in an area not accessible to
other technicians or customers.
5. Store the battery at ground level.
6. The storage area should be adequately
ventilated.
7. A Class B fire extinguisher should be present
in the near vicinity.
>> Dealerships should ensure compliance with
OSHA’s Material Handling and Storage
regulation 29 C.F.R. § 1910.176(b).
Battery
Handling
Reference this section for detailed instructions on moving and handling a high-voltage vehicle and its battery upon arrival at
the dealership.
5.1 Equipment Needed
Forlifts
>> Forklifts are required to move a high-voltage battery. Before a battery is delivered to the dealership, ensure you have a
forklift. If your dealership does not have a forklift, you must either rent, lease or purchase a forklift. See Section 2.1 for
complete details on obtaining and operating a forklift.
Battery Replacement Tool Kit
>> When a replacement battery is ordered through VWGoA Parts Logistics, the tools required to prepare the replacement
high-voltage battery for installation will be kitted and shipped with the replacement high-voltage battery. This process
will take place automatically and there is no need to contact the Audi Tools and Equipment Program to request this tool
kit.
>> Prior to shipping, you will be contacted by the High-Voltage Battery Distribution Center to complete a Mandatory Loaner
Agreement.
>> NOTE: This agreement must be filled out and returned to the High-Voltage Battery Distribution Center before shipping
of the high-voltage battery can take place. The use of these tools, as outlined in ELSA, is critical in avoiding serious
damage to the high-voltage battery. Instructions and return FAX number will be provided by the High-Voltage Battery
Distribution Center at that time.
>> There is no cost for return shipping of this tool kit. Return shipping labels and instructions will be provided inside the tool
kit shipping container.
Unload
the new high-voltage
battery from the truck
Remove
the old high-voltage battery
using the scissor-type
assembly platform
“Park”
the old high-voltage
battery on the floor using
the forklift truck of the
lifting strap
Prepare
by placing the new
high-voltage battery on
the scissor-type assembly
platform
Install
the new high-voltage
battery in the car
Pack
the old high-voltage
battery
Load
the old high-voltage
battery into the truck
1. 2. 3. 4. 5. 6. 7.
5.2 Unloading a Battery from the Transport Vehicle
1. Upon the battery’s arrival to the dealership, use the forklift to move the shipping container out of the transport vehicle.
2. Use the forklift to transport the battery in its shipping container to the designated temporary storage area within the
workshop.
>> This process is outlined in the flow diagram below.
5.3 Packing an Old Battery in the New Battery’s Shipping Container
1. Unbolt the battery from the vehicle and lower it onto the transmission table. Follow the removal procedure outlined in
group 93 in the repair manual found on ElsaPro.
> Remove the transmission table and the old battery from underneath the vehicle.
2. Use the battery lifting kit to connect the battery to the forklift.
> The battery lifting kit will be delivered with the new battery’s shipping container. See Section 5.1 for more details on
the battery lifting kit.
3. Forklift the old battery off the transmission table and place it on floor.
> Remove the battery lifting kit from the old battery.
4. Connect the battery lifting kit to the new battery and forklift the new battery to the transmission table, then remove the
lifting kit from the battery.
5. Connect the battery lifting kit to the old battery and forklift the old battery into the shipping container the new battery
arrived in.
6. Store the old battery, now packed in the shipping container, in the designated temporary storage area until the battery is
picked up.
5.4 Removing an Old Battery from the Dealership or Collision Center
1. Upon the arrival of the transport vehicle, use the forklift to carry the battery in its shipping container from the temporary
storage area to the transport vehicle.
2. Load the battery into the vehicle using the forklift.
3. Ship the battery lifting kit that arrived with the new battery with the battery container.
Battery Inspection &
High-voltage
Vehicle Repair
This section provides a process flow to follow when inspecting both a non-critical battery and a high-voltage vehicle that is
faulty or accident-damaged. Note that during the launch period all instructions will be given through TAC.
6.1 Process for Inspecting & Replacing a Non-Critical Battery
In the event an e-tron is undergoing normal inspection and a non-critical repair is identified that will require removal and
replacement of the battery, the following steps must be taken to ensure safe battery handling and temporary storage:
1. Report the repair to the Technical Assistance Center and submit the warranty claim per the normal operating procedures.
>> The HV battery classification test must be performed for all battery replacements. See ELSA repair manual.
>> TSB 2049384 must be followed by the technician along with the attachment found in the TSB, which should be filled
out and completed.
>> This protocol will go into effect when the launch period has ended.
>> The HV battery must remain in the vehicle until the replacement part(s) is available to complete the repair.
>> The TAC will inform you if the battery will be needed for analysis or if the HV battery can be recycled.
2. The TAC must release the high-voltage battery part.
>> A TFM can release a HV battery if TAC is unavailable.
>> The dealer must provide the part number required for release.
>> Use the standard process for supplying replacement parts through ETKA, which can be accessed through iAudi.
3. Before the battery is delivered to the dealership, ensure you have a forklift.
>> If your dealership does not have a forklift, you must pursue one of the options outlined in Section 2.2.
4. When the new battery is delivered to the dealership, adhere to the guidelines for temporarily storing a high-voltage
battery.
>> Note that high-voltage batteries should only be stored temporarily for repair purposes and should not be stockpiled at
the dealership.
>> For complete details on temporary storage, see Section 4.2.
Temporary Storage Guidelines:
1. Mark the battery storage area with the appropriate warning labels. See the labels in Section 8.3.
2. Do not store the battery out in the open or in areas where repairs are being performed.
3. Protect the battery from mechanical and thermal exposure.
4. Store the battery in an area not accessible to other technicians or customers.
5. Store the battery at ground level.
6. The storage area should be adequately ventilated.
7. A Class B fire extinguisher should be present in the near vicinity.
5. The HVT removes the existing battery from the vehicle and places it in the original packaging for the new battery.
>> If the battery will not be immediately shipped, follow the temporary storage guidelines.
>> When performing service on a high-voltage vehicle, pull the SDS for the relevant part number and follow any handling
and storage instructions provided.
>> Use the online EH&S system to access Audi SDSs.
6. After completing the battery replacement, submit the warranty claim.
>> The TAC will notify the technician through the TAC case if the battery is needed for analysis or can be recycled.
>> Based off whether or not the battery is needed for analysis, follow either Step 7 or Step 8 below.
7. If the non-critical battery is REQUIRED for analysis, it will appear in the Warranty Parts Portal under the “Requested” tab.
>> Follow the same Warranty Return process that you would for any other HAZMAT warranty parts.
>> Shipping instructions will be provided when the claim is submitted and approved for payment.
>> You will receive a shipping label to ship the battery.
>> Ship the used battery in the new battery’s shipping container. See Sections 7.2 and 7.4 for more details.
8. If the non-critical battery is NOT NEEDED for analysis, it will appear in the Warranty Parts Portal under the “Core/Scrap”
tab.
>> Dealer contacts Retriev Technologies at (714) 318 – 7731 to obtain a recycling quote.
>> Dealer is responsible for proper marking and shipping of the battery to Retriev.
>> Ship the used battery in the new battery’s shipping container. See Sections 7.2 and 7.4 for more details.
>> Dealers will be reimbursed for the cost of shipping batteries. The dealer must contact Audi Warranty for claim coding
instructions for battery shipping costs.
>> Audi Warranty: (866) 667-2834
6.2 Process for Inspecting a Faulty or Accident-Damaged High-voltage Vehicle
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 car to the body shop. The following steps must be taken to ensure
safe battery handling.
1. Ensure the HVT is onsite for the arrival of a faulty or accident-damaged vehicle.
2. Follow the Workshop Procedure Plan.
>> Outlined in Section 3.1.
3. Follow the reporting protocol and perform the battery classification test.
>> Conduct the regular reporting requirements for a vehicle in a collision, outlined in Section 3.3.
>> The HVT performs the battery classification test.
4. The results of the battery classification test will determine the appropriate next step, detailed in Sections 6.3 – 6.5.
6.3 Process for Repairing an Accident-Damaged High-voltage Vehicle with a Battery
Classified as “Normal”
If a high-voltage vehicle needs a repair, and the battery is classified as “Normal”, the
vehicle can be removed from the quarantine zone and the below steps must be followed to
repair the vehicle.
1. Determine if the battery will need to be de-energized to perform the necessary repairs.
>> The high-voltage system must be de-energized to perform the following work:
>> Welding, grinding or cutting work near high-voltage components.
>> Any repair where ELSA or ODIS instructs to de-energize the HV system.
2. If the vehicle DOES NOT need to be de-energized, repair the e-tron at the body shop.
3. If the vehicle DOES need to be de-energized, the HVT can do one of the following:
>> The high-voltage battery must be de-energized according to the Guided Fault
Finding routine. The Guided Fault Finding routine can be found in ODIS under the
Special Functions tab.
1. De-energize the battery at the dealership before sending the vehicle to the body
shop.
2. Travel to the body shop to perform the de-energization.
4. If the battery needs to be de-energized, determine if the battery will also need to be
removed from the vehicle.
>> If the battery DOES NOT need to be removed, the HVT will re-energize the battery at
the dealership or collision center after the repairs are completed.
>> If the battery DOES need to be removed, the HVT can do one of the following:
1. The HVT can remove the battery at the dealership and send the battery and the
vehicle to the body shop for repair. Both components will then be returned to the
dealership, where the HVT will re-install and re-energize the battery. This is the
AoA-preferred method.
2. The HVT can travel to the body shop to remove the battery. When repairs are
completed, the HVT will return to the collision center to re-install and reenergize
the battery.
6.4 Process for Removing a Battery Classified as “Warning/May be critical”
If a high-voltage vehicle is faulty or accident-damaged, and the battery is classified as “Warning/May be critical”, follow the
below steps to safely remove the battery from the vehicle.
1. Upon the battery receiving a “Warning/May be critical” classification, do not immediately attempt to remove the battery
from the vehicle.
2. Notify an HVE of the “Warning/May be critical” classification.
>> Open a case with the Technical Assistance Center (TAC). See Section 8.2 for how to access TAC.
>> The quarantine will be started and the instructions will be given through the TAC case.
>> The TAC will verify the classification and, if verified as damaged and/or in a possible critical state, the case will be
escalated to your area EFK certified TFM.
>> Contact your local Technical Field Manager (TFM). See Section 8.2 for details on contacting a TFM.
3. The TFM must contact the Technical Assistance Center to obtain a shipping container for any critical modules that will
need to be removed from the battery.
>> Technical Assistance Center: 1 (800) 388-2834
>> See Section 7 for additional information on packaging and shipments.
>> Please note: a full e-tron battery will never be shipped if it has been classified as “critical”.
>> In an instance where a battery is classified as “critical”, the critical modules will be removed, and the remainder of
the battery will be re-assembled and shipped as a non-critical battery.
>> Shipment of the re-assembled, non-critical battery will follow the shipment steps outlined in Section 7.2.
4. Observe the battery in the vehicle for (5) days, following the below observation protocol.
>> Observation of the battery requires regularly checking the temperature of the battery.
>> During the launch period, the protocol for battery temperature monitoring will be handled on a case by case basis
via TAC.
>> In the event that TAC is unavailable to provide a step by step protocol, contact Uwe Dingeldey for specific
instructions.
>> Uwe Dingeldey – Product Support Engineer, Audi of America
>> Uwe.dingeldey@audi.com // (248) 754 – 6192
>> In the event that TAC or Uwe Dingeldey is unavailable, call the area TFM for instructions on observing the battery.
5. Regularly inform the HVE on the battery’s condition.
6. Repeat the (5) day observation routine until the battery condition remains constant.
7. Once the battery condition is constant, schedule an HVE visit to the dealership.
8. The HVE will:
>> Transport the vehicle from the quarantine area into the workshop.
>> Disassemble the battery and remove the critical module(s).
>> Pack the critical module(s) in the recycling or transport box(es) previously ordered via the Technical Assistance Center.
>> Arrange for proper shipping of the removed modules through Retriev Technologies.
>> The remainder of the battery will be reassembled and shipped via the steps outlined Section 6.3.
6.5 Immediate Response Actions for a Battery Classified as “Danger”
If a high-voltage vehicle is faulty or accident-damaged, and the battery is classified as “Danger”, immediately follow the
below steps.
1. Call the local fire department immediately.
2. If safely possible, quarantine the vehicle.
Packaging &
Shipments
Packing and shipping a complete battery pack or battery module requires special evaluation and care. Batteries
classified as “Normal” or “Warning” can be shipped under certain circumstances. A battery classified as “Danger” cannot
be transported.
7.1 Battery Replacement Tool Kit
>> When a replacement battery is ordered through VWGoA Parts Logistics, the tools required to prepare the replacement
high-voltage battery for installation will be kitted and shipped with the replacement high-voltage battery. This process
will take place automatically, and there is no need to contact the Audi Tools and Equipment Program to request this tool
kit.
>> Prior to shipping, you will be contacted by the High-Voltage Battery Distribution Center to complete a Mandatory Loaner
Agreement.
>> NOTE: This agreement must be filled out and returned to the High-Voltage Battery Distribution Center before shipping
of the high-voltage battery can take place. The use of these tools, as outlined in ELSA, is critical in avoiding serious
damage to the high-voltage battery. Instructions and return FAX number will be provided by the High-Voltage Battery
Distribution Center at that time.
>> There is no cost for return shipping of this tool kit. Return shipping labels and instructions will be provided inside the tool
kit shipping container.
7.2 Non-Critical Battery Packaging
>> If a non-critical, high-voltage battery needs replacement:
>> The packaging for the new high-voltage battery can be reused for the non-critical battery being removed.
>> If a module in a non-critical, high-voltage battery needs replacement:
>> The packaging for the new high-voltage module can be reused for the non-critical module being removed.
7.3 Critical Battery Packaging
>> If a critical battery needs to be removed from the vehicle:
>> Contact the Technical Assistance Center to obtain a critical shipping container.
>> 1 (800) 388-2834
>> The HVE is qualified to package the vehicle in the transport box.
7.4 Non-Critical Battery Shipping – Battery under Warranty
>> After completion of battery repairs or replacement, submit the warranty claim.
1. If the non-critical battery is REQUIRED for analysis, it will appear in the Warranty Parts Portal
under the “Requested” tab.
>> Follow the Warranty Return process that is standard for any other HAZMAT warranty parts.
>> Shipping instructions will be provided when the claim is submitted and approved for
payment.
>> The dealer will receive a supplier label to ship the battery.
2. If the non-critical battery is NOT NEEDED for analysis, it will appear in the Warranty Parts Portal
under the “Core/Scrap” tab.
>> Dealer contacts Retriev Technologies at (714) 318 – 7731 to obtain a recycling quote.
>> Dealer is responsible for proper marking and shipping of the battery to Retriev.
>> Dealers will be reimbursed for the cost of shipping batteries. The dealer must contact Audi
Warranty for claim coding instructions for battery shipping costs.
>> Audi Warranty: (866) 667-2834
7.5 Critical Battery Shipping
>> A full e-tron battery will never be shipped if it has been classified as “critical”.
>> In an instance where a battery is classified as “critical”, the critical modules will be removed,
and the remainder of the battery will be re-assembled and shipped as a non-critical battery.
>> Shipment of the critical modules follows the steps outlined in Section 7.3.
>> Shipment of the re-assembled, non-critical battery follows the steps outlined in Section 7.2.
Appendix
8.1 Contacts
>> Forklifts
>> To lease & purchase:
>> Jim Hammond at Valley Industrial
>> jhammond@valleyindustrialtrucks.com // (330) 506-2896
>> General questions:
>> Tony Russo – Parts Program Specialist, Audi of America
>> Anthony.Russo@audi.com // (703) 364-7491
>> Battery Shipment
>> Retriev Technologies
>> Andrew Wood
>> (714) 318 – 7731
>> info@evbattmgmt.com
>> Audi Warranty
>> Claim coding instructions for battery shipping costs
>> (866) 677-2834
>> Technical Support
>> Technical Assistance Center
>> 1 (800) 388-2834
>> Battery Observation Protocols
>> TAC
>> If TAC is unavailable:
>> Uwe Dingeldey – Product Support Engineer, Audi of America
>> Uwe.dingeldey@audi.com // (248) 754 – 6192
>> Download Safety Data Sheets through EH&S
>> Access Audi – App Links – Parts – Safety Data Sheets
>> Parts on Command – Safety Data Sheets
>> Technical Field Managers
>> Dealers can contact their direct Technical Field Managers as
needed for technical process questions.
>> VWGoA Parts Logistics
>> Obtain a Critical Shipping Container:
>> Technical Assistance Center: 1 (800) 388-2834
8.2 Helpful Links
>> Technical Assistance
Center: Access Audi –
Service – ElsaPro – Technical
Assistance Icon
Available through iAudi:
>> ElsaPro
>> ETKA
>> Warranty Parts Portal
>> ServiceNet
8.3 Audi Academy HV Training
Courses
> 670154 Audi Hybrid Aware
> 990442 2016 Audi
A3 Sportback e-tron
Introduction (3 day)
> 990592 2019 Audi e-tron
quattro and HVE
> 970192 Audi High Voltage
Technician (HVT)
> 970292 Audi High Voltage
Expert (HVE)
8.4 Warning & Prohibition Labels

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