Get Electricdrivesystems -> 6.3.2 Packaging high-voltage battery, e-Golf Guide for Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021

– Place high-voltage battery 1 -AX2- on scissor-type assembly

platform -VAS 6131 B-.

– Install high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-volt‐

age battery unit; Removing and installing high-voltage bat‐

tery 1AX2.

Close genuine part crate and prepare for transport

Note

If the sides have been removed, the bottom tabs of the sides

must be folded over again during assembly.

– Fit cover of genuine part crate and close using existing clips.

– Attach tensioning straps.

– Affix or check hazardous material label and package ID.

– Fill in and insert shipping documents.

Notes for transport preparation and hazardous material marking

(Europe)

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category

9 “Various hazardous substances and items” packaging

group 2”

6 - “Type label with UN number UN3480 for lithium-ion batter‐

ies”

6.3.2

Packaging high-voltage battery, e-Golf

Special tools and workshop equipment required

42

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

♦ Workshop hoist -VAS 6100-

♦ Support bracket -10 - 222 A-

♦ Hook -10-222A/10-, qty. 6

♦ Shackle -10-222A/12-, qty. 2

♦ Towing bracket -T10528-

♦ Locking pin -T10528/3-

♦ Lifting eye bolt -T10528/5-

♦ Supplement -T10528/7-/10-

6. High-voltage battery

43

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High-voltage system - General information - Edition 02.2021

♦ Scissor-type assembly platform -VAS 6131 B-

♦ Plate -VAS 6131/10-1-

♦ Supplementary kit -VAS 6131/13-

Overview of procedure

The procedure for packaging a lithium-ion high-voltage battery

for the e-up! is broken down into the following work steps:

A - Prepare scissor-type assembly platform and mounting tool

B - Place new high-voltage battery on cover of genuine part

crate

C - Remove high-voltage battery and place in genuine part

crate

D - Place new high-voltage battery from cover of genuine part

crate on scissor-type assembly platform and install

E - Close genuine part crate and prepare for transport

44

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

Preparing scissor-type assembly

– Mount and align supports -1 to 5- on scissor-type assembly

platform -VAS 6131 B-.

Front supports -3- and -4- for high-voltage battery 1 -AX2-:

1 - Support -VAS 6131/10-11-

2 - Knurled section -VAS 6131/10-5-

3 - Taper -VAS 6131/10-4-

4 - Plate -VAS 6131/10-1-

Rear supports -1-, -2- and -5- for high-voltage battery 1 -AX2-

1 - Support -VAS 6131/13-2-

6. High-voltage battery

45

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High-voltage system - General information - Edition 02.2021

2 - Knurled section -VAS 6131/10-5-

3 - Taper -VAS 6131/10-4-

4 - Plate -VAS 6131/10-1-

Preparing support

– Push support -T10528/10- -2- onto support bracket -10 - 222

A- -3-.

– Push on cross member -T10528/2- -1- on both ends, and

tighten fastening elements.

– Set support -T10528/10- -2- to specified dimension as

shown in illustration, and tighten fastening elements.

•

-Dimension a- = 515 mm

– Hook support bracket -10 - 222 A- with support -T10528/10-

onto workshop hoist -VAS 6100-.

– Push hooks -10 - 222 A /10- -2- onto cross members -

T10528/2- and support -T10528/10-, as shown in illustration.

46

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

Note

The two hooks on a cross member must be of the same length.

– Insert locking pin -T10528/3- -1- in holes, as shown in illus‐

tration:

♦ Cross member -T10528/2- at oblong hole: position 1

♦ Support -T10528/10- in centre: position 6

♦ Cross member -T10528/2- opposite to oblong hole: position

5

Place new high-voltage battery 1 -AX2- on cover of genuine

part crate.

– Open genuine part crate.

– Remove cover and place down on ground with top pointing

up so that cover can be reached with scissor-type assembly

platform -VAS 6131 B- and workshop hoist.

Note

♦ The new high-voltage battery 1 -AX2- is secured in the gen‐

uine part crate at 6 points with 2 nuts each.

♦ The middle nut is used for lifting.

– Do not remove threaded rods and nuts -arrow-.

6. High-voltage battery

47

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High-voltage system - General information - Edition 02.2021

Detailed view

1 - Upper nut (self-locking) on high-voltage battery

2 - Middle nut (used for lifting)

3 - High-voltage battery 1 -AX2-

4 - Genuine part crate

5 - Lower nut (self-locking) on genuine part crate

– Unscrew nuts -arrows-.

48

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

Secure lifting eye bolts -T10528/5- on high-voltage battery 1

-AX2-.

Note

Use washers.

– Install lifting eye bolts -T10528/5- at positions shown

-arrows-.

– Tighten lifting eye bolts -T10528/5- -1-.

Installing reinforcement struts

– Install reinforcement struts to high-voltage battery 1 -AX2-

-1- as shown in illustration. To do this, proceed as follows:

– Fit reinforcement strut -T10528/7/8- -2- and -3- on threaded

rods.

– Lightly tighten sleeves with inner thread -T10528/9- -4-.

6. High-voltage battery

49

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High-voltage system - General information - Edition 02.2021

– Screw nuts -arrow- onto threaded rods until flush. Cover of

genuine part crate would otherwise suffer damage.

– Attach shackles -10-222A/12- in holes of reinforcement

struts and secure.

Detailed view

1 - Sleeves with inner thread -T10528/9-

2 - Reinforcement strut -T10528/7/8-

3 - High-voltage battery 1 -AX2-

4 - Genuine part crate

5 - Middle nut

Secure cross member to high-voltage battery 1 -AX2-.

– Move workshop hoist -VAS 6100- -1- with prepared transport

device -T10528- -2- over high-voltage battery 1 -AX2- -3-.

NOTICE

Risk of damage to high-voltage battery 1 -AX2-.

– Do not rest support -T10528- on high-voltage battery 1

-AX2-.

– Attach hooks -10 - 222 A /10- in lifting eye bolts -T10528/5-.

– Straighten hooks -10 - 222 A /10- on front and rear cross

member -T10528/2- and fix in position.

50

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

– Attach hook -10 - 222 A /10- to support -T10528/10-.

– Turn hooks -10 - 222 A /10- in support -T10528/10- to ten‐

sion slightly.

– Raise high-voltage battery 1 -AX2- with workshop hoist -VAS

6100-.

– Place high-voltage battery 1 -AX2- using workshop hoist

-VAS 6100- on cover of genuine part crate.

– Remove lifting eye bolts -T10528/5- and reinforcement strut

-T10528/7/8-.

Remove high-voltage battery 1 -AX2- and place in genuine part

crate.

– Assess condition of old high-voltage battery 1 -AX2- in situ ⇒

page 30 .

– Remove high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-

voltage battery unit; Removing and installing high-voltage

battery 1AX2.

– Visually inspect high-voltage battery 1 -AX2- to ensure that it

is safe to transport.

In the next work step the reinforcement strut -T10528/7- and

reinforcement strut -T10528/8- are installed to high-voltage bat‐

tery 1 -AX2-.

The required components are provided as a kit along with the

new high-voltage battery 1 -AX2-.

The kit consists of the following:

♦ 6 threaded rods

♦ 6 washers

♦ 6 nuts

Detailed view

A

1 - Threaded rod

2 - Metal washer

3 - Large plastic washer

4 - Scissor-type assembly platform adapter

6. High-voltage battery

51

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High-voltage system - General information - Edition 02.2021

5 - Nut

6 - Metal washer

7 - Small plastic washer

B

1 - Reinforcement strut -T10528/7/8-

2 - Sleeves with inner thread -T10528/9-

Mount lifting eye bolts -T10528/5- as described above.

– Take up weight of high-voltage battery 1 -AX2- as described

above.

– Lower high-voltage battery 1 -AX2- in genuine part crate.

– Remove lifting eye bolts -T10528/5- and reinforcement strut

-T10528/7/8-.

– Screw in threaded rods until these protrude from base of

genuine part crate.

– Observe correct sequence of washers.

1 - Small metallic washer

2 - Large plastic washer

3 - High-voltage battery 1 -AX2-

4 - Small plastic washer

5 - Small metallic washer

6 - Genuine part crate

7 - Large, rectangular metallic washer

52

Rep. gr.93 - Electric drive systems

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High-voltage system - General information - Edition 02.2021

Note

Ensure when tightening nuts that bottom battery shell is not

distorted.

– Secure high-voltage battery 1 -AX2- in genuine part crate

from above and below with self-locking nuts.

Close genuine part crate and prepare for transport

Note

If the sides have been removed, the bottom tabs of the sides

must be folded over again during assembly.

– Fit cover of genuine part crate and close using existing clips.

– Attach tensioning straps.

– Affix or check hazardous material label and package ID.

– Fill in and insert shipping documents.

Notes for transport preparation and hazardous material marking

(Europe)

1 - “Protect against water”

2 - “Attention! Fragile”

3 - “This side up”

4 - “Maximum stacking load”

5 - “Hazardous material label: Hazardous material category

9 “Various hazardous substances and items” packaging

group 2”

6 - “Type label with UN number UN3480 for lithium-ion batter‐

ies”

6. High-voltage battery

53

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High-voltage system - General information - Edition 02.2021

6.4

Packaging critical high-voltage batter‐

ies with “Warning” status

⇒ c6.4.1 ritical high-voltage batteries with Warning status, mod‐

ule”, page 54

⇒ c6.4.2 ritical high-voltage batteries with Warning status, Golf

GTE / Passat GTE / Jetta Hybrid”, page 60

⇒ c6.4.3 ritical high-voltage batteries with Warning status, e-

Golf / e-up!”, page 70

6.4.1

Packaging critical high-voltage batter‐

ies with “Warning” status, module

DANGER

Danger to life from high voltage.

Severe or fatal injury from electric shock.

– Wear protective clothing against the thermal hazards of an

electric arc.

– Wear an insulated helmet with visor.

– Wear protective gloves.

– Wear safety shoes.

NOTICE

♦ Only after receiving induction training (for respective, certi‐

fied transport crate), at least one responsible high-voltage

expert (or higher qualification) or employees of Volkswa‐

gen AG who have received induction training.

♦ Hazardous material induction training also required.

♦ Lithium-ion high-voltage batteries and lithium-ion high-volt‐

age battery modules may only be packaged if they are

prepared for carriage. See carriage regulations D/BAM/

GGVSEB.

Described in this workshop manual are the packaging process‐

es of high-voltage batteries that are classed as critical with the

status “Warning”.

To determine whether and to what extent the lithium-ion high-

voltage battery poses a higher level of danger, it must be sub‐

ject to classification ⇒ page 26 .

54

Rep. gr.93 - Electric drive systems

Electricdrivesystems -> 6.3.2 Packaging high-voltage battery, e-Golf for Your Volkswagen Crafter Van Second Generation (2017-2025)

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