Volkswagen ID.4: Electric drive systems- Safety information and repair notes

Safety information

Observe safety information ⇒ Safety information and repair notes; Rep. gr. 00 ; Safety information .

Repair instructions

Observe repair instructions ⇒ Safety and repair instructions; Rep. gr. 00 ; Repair instructions .

Working on high-voltage vehicles

Employee qualification

Personal training profiles and focal points

Qualification Volkswagen/DGUV-I 209-093/ Scenario

EIP (person with electrical training)/Chapter 2/ Induction training for non-electrical work (< 60 VDC)

HVT (high-voltage technician)/ Chapter 3.1 b/ Working on inherently safe HV production vehicles

• Vehicles are deenergised exclusively with certification.
• Complete contact protection in place.

HVE level 1 (highvoltage expert)/Chapter 3.2 b/Working on not inherently safe HV production vehicles

• Vehicles are also de-energised without certification or there is no complete contact protection in place, e.g. in the event of an accident.

HVE level 2 (highvoltage expert)/ Chapter 3.3/Work on live accumulators

• Working on parts supplied with voltage, inevitably with no contact protection, for fault finding, component replacement, etc.

Qualifications and working for emergency service, authorised workshop and importer

De-energising high-voltage system

Listed in the Workshop Manual ⇒ Rep. gr. 00 ; Hazard rating of high-voltage system are all work measures for which the system must be de-energised.

• De-energise the system via Guided Functions with the aid of ⇒ Vehicle diagnostic tester.
• Fill in the test protocols for de-energisation. In the course of testing, the test protocols are printed out, filled in, signed and attached to the work order.

Re-energising high-voltage system

• Re-energise the system via Guided Functions with the aid of ⇒ Vehicle diagnostic tester.
• Fill in the test protocols for re-energisation. In the course of testing, the test protocols are printed out, filled in, signed and attached to the work order.

Workshop procedure for high-voltage vehicles

Important

• When a high-voltage vehicle is accepted at an authorised workshop, adhere to the workshop procedure for high-voltage vehicles.
• The workshop procedure for high-voltage systems is in the information medium of the manufacturer (Dealer Portal/ServiceNet) or the information medium of the importer.

Assessment of accident high-voltage vehicles

General information on assessment of accident vehicles

The quality of the documentation is important for assessment of the damage to the lower part of the battery housing. The recommended measures are orientated around the location and extent of damage:

• Paint repair
• Renewing lower part of battery housing
• Renewing components of high-voltage battery

Photographic documentation

Special tools and workshop equipment required

• Digital depth gauge - VAS 6087-
• Straightedge 500 mm - VAS 6075-

Procedure

• Carry out ⇒ "3.1.2 Classification of high-voltage batteries with aid of ODIS"
• Remove rear centre underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Roughly clean entire area.
• Draw around dent and damaged area with a marker.

Important

• The colour markings to be applied as follows for the photographic documentation must be made on the lower part of the battery housing. A drawing is not sufficient.
• The direction of travel must be identifiable on each photograph.
• If the lower part of the battery housing is damaged in more than one place, number the areas

• Mark damaged area -4- with adhesive strips -1- to -3-.

• Adhesive strips -1- for length and width of damaged area
• Adhesive strip -2- with "F->" for direction of travel
• Adhesive strip -3- indicating where damage is deepest

• Align camera parallel to lower part of battery housing -1-.
• For a better overview, photograph the entire lower part of the battery housing. If larger areas are affected, take several photographs.

• Hold straight edge 500 mm - VAS 6075- above dent.
• Use electric torch to backlight area.

• Measure depth of dent with digital depth gauge - VAS 6087- .
• Take picture of measurement.

Quarantine arrangements

Working on accident high-voltage vehicles

Important

• If a defective or accident high-voltage vehicle is delivered, inform high-voltage technician (HVT).
• Unload vehicles with high-voltage battery straight to a dedicated space.
• Authorised workshops should make immediate contact with the nearest high-voltage service partner or importer.
• Post a warning sign on the high-voltage vehicle reading "Warning! Hazardous voltage" - VAS 6649- or words to that effect. In the event of a quarantine, further signs will be necessary.
• Secure high-voltage vehicle to prevent unauthorised access.
• Protect severely accident-damaged vehicles and removed high-voltage batteries against rain and damp.

Arrangements for setting up quarantine area

The use of a sealed floor plate is recommended.

1. Warning sign "Danger from batteries" - VAS 6786-
2. Warning sign "Warning! Hazardous voltage" - VAS 6649-
3. Prohibition sign "No fire" - VAS 6882-
4. Prohibition sign "Access prohibited" - VAS 6881-
5. Isolated area inc. hazard warning signs
6. Outer safety zone
7. Suitable open area, e.g. parking space.

Procedure (continued)

Important

• Record complaints in DISS.
• Perform a visual inspection of the accident vehicle and appraise its hazard potential by means of the following assessment criteria.

Important

• Use temperature gauge - VAS 6886- to measure temperature.

Assessment criteria:

• Signs of fire
• Sparks, smoke or vapour
• Unusual noises inside the high-voltage battery, e.g.

  crackling or hissing.

• Pungent smell
• Fluid leak, suspected fluid in high-voltage battery system.
• Mechanical damage with exposed, accessible contacts/ conductors
• Accessibility of high-voltage battery for temperature measurements, e.g. due to missing or damaged body parts, surface temperature of high-voltage battery higher than 80ºC.

Meaning:

Important

• If at least one assessment criterion applies: beware of hazard Follow measure a)
• If none of the assessment criteria apply, proceed with b)

a) Observe the following measures in the event of "BEWARE! HAZARD": Keep a safe distance.

Observe high-voltage vehicle/high-voltage battery.

Have fire extinguishing equipment ready and at the first sign of fire immediately notify the fire service and evacuate the building.

Do not inhale smoke/gas. Wear mask.

If the high-voltage battery has suffered mechanical damage with exposed, accessible contacts/conductors, do not touch the vehicle or the high-voltage battery.

Quarantine high-voltage vehicle/high-voltage battery if possible.

a) Observe the following measures in the event of "BEWARE! HAZARD": Cordon off a large area and inform responsible party as per reporting procedure.

Use PPE.

b) If the accident-damaged high-voltage vehicle is deemed to be non-hazardous based on the assessment criteria, the following steps must be taken: ⇒ "3.1.2 Classification of high-voltage batteries with aid of ODIS"

Perform the work steps outside the buildings or in a suitable area if possible.

It may be necessary to repair the 12V onboard electrical system for a diagnosis.

Overhead view cameraHigh-voltage battery