Electricdrivesystems -> 6.3 Packaging high-voltage batteries for Your Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021  
Replacement of lithium-ion high-voltage batteries - no measures  
necessary for high-voltage battery  
♦ The lithium-ion high-voltage battery can be stored in its origi‐  
nal packaging.  
♦ The removed lithium-ion high-voltage battery is placed in the  
original packaging and sent back in this way.  
♦ For transport within the workshop, suitable aids are required  
due to the heavy weight.  
Replacement of lithium-ion high-voltage batteries - measures  
necessary for high-voltage battery  
1 Classification of lithium-ion high-voltage battery with aid of  
test program according to following criteria  
♦ Thermal irregularities of lithium-ion high-voltage battery  
♦ Visible damage to lithium-ion high-voltage battery  
♦ Functional irregularities of lithium-ion high-voltage battery  
2 Storage of lithium-ion high-voltage batteries if one of the  
points from 1 applies.  
♦ Lithium-ion high-voltage battery stays in vehicle  
♦ Vehicle must be parked outside. Observe the following:  
♦ Park vehicle in safe area according to quarantine arrange‐  
ments ⇒ page 17  
If additional measures are necessary due to the classification of  
the lithium-ion high-voltage battery, the first step is an obligation  
to report or technical repair query in the DISS system. Product  
support will then decide which steps to take and, if necessary,  
will send out a specially trained representative.  
6.3  
Packaging high-voltage batteries  
⇒ h6.3.1 igh-voltage battery, e-up!”, page 34  
⇒ h6.3.2 igh-voltage battery, e-Golf”, page 42  
6.3.1  
Packaging high-voltage battery, e-up!  
Special tools and workshop equipment required  
♦ Workshop hoist -VAS 6100-  
34  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
♦ Support bracket -10 - 222 A-  
♦ Towing bracket -T10528-  
♦ Scissor-type assembly platform -VAS 6131 B-  
♦ Plate -VAS 6131/10-1-  
♦ Supplementary kit -VAS 6131/13-  
6. High-voltage battery  
35  
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High-voltage system - General information - Edition 02.2021  
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  
Preparing scissor-type assembly  
– Mount and align supports -1 to 4- on scissor-type assembly  
platform -VAS 6131 B-.  
36  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Front supports -1 and 2-:  
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 -3 and 4-:  
1 - Support -VAS 6131/13-2-  
2 - Knurled section -VAS 6131/10-5-  
3 - Taper -VAS 6131/10-4-  
4 - Plate -VAS 6131/13-4-  
Preparing support  
– Push support -T10528/1- -2- onto support bracket -10 - 222  
A- -1-.  
– Adjust support -T10528/1- -2- to -dimension a- and lock in  
position.  
6. High-voltage battery  
37  
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High-voltage system - General information - Edition 02.2021  
-Dimension a- = 515 mm  
– Hook support bracket -10 - 222 A- -1- with support -  
T10528/1- -2- onto workshop hoist -VAS 6100-.  
– Push two hooks -10 - 222 A /10- -3- onto first cross member  
-T10528/2- -2- as shown in illustration.  
– Push locking pins -T10528/3- into outer positions 6 -arrows-.  
– Push prepared cross member -T10528/2- in direction of  
-arrow- onto support bracket -10 - 222 A-.  
– End of cross member -T10528/2- must be flush -arrow-.  
– Lock cross member -T10528/2- in position.  
– Push two hooks -10 - 222 A /10- -1- onto second cross  
member -T10528/2- -2- as shown in illustration.  
– Push locking pins -T10528/3- into inner positions 2 -arrows-.  
– Push second prepared cross member -T10528/2- onto sup‐  
port bracket -10 - 222 A-.  
– Leave locking mechanism of cross member -T10528/2-  
loose.  
38  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
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.  
– Loosen securing bolts -arrows- with which high-voltage bat‐  
tery 1 -AX2- is secured in genuine part crate.  
– Remove nuts and washers.  
– Attach lifting eye bolts -T10528/5- to high-voltage battery 1  
-AX2- at positions shown -arrows-.  
– Move workshop hoist -VAS 6100- over high-voltage battery  
1 -AX2- with prepared support -T10528-.  
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- to lifting eye bolts -T10528/5-  
-arrows-.  
– Align second, still loose cross member -T10528/2- straight,  
and fix it in position.  
– Lift high-voltage battery 1 -AX2- out of genuine part crate in  
direction of -arrow- with cross member -T10528- -1-.  
6. High-voltage battery  
39  
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High-voltage system - General information - Edition 02.2021  
– Place high-voltage battery 1 -AX2- on top of genuine part  
crate cover.  
NOTICE  
Risk of damage to high-voltage battery 1 -AX2-.  
– Do not rest support -T10528- on high-voltage battery 1  
-AX2-.  
– Detach hook -10 - 222 A /10-.  
– Unscrew lifting eye bolts -T10528/5-.  
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.  
– Take high-voltage battery 1 -AX2- from scissor-type assem‐  
bly platform -VAS 6131 B-.  
– Lower high-voltage battery 1 -AX2- in genuine part crate.  
40  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Note  
Observe securing bolts -1-.  
– Guide all securing bolts -1- into corresponding holes.  
– Detach hook -10 - 222 A /10-.  
– Unscrew lifting eye bolts -T10528/5-.  
Note  
If any of the securing bolts fail to tighten, they will need to be  
counterheld.  
Ensure when tightening bolts that bottom battery shell is not  
distorted.  
– Start nuts with washers on 4 securing bolts in genuine part  
crate and tighten.  
Place new high-voltage battery 1 -AX2- from cover of genuine  
part crate on scissor-type assembly platform -VAS 6131 B- and  
install.  
– Take high-voltage battery 1 -AX2- off cover of genuine part  
crate.  
6. High-voltage battery  
41  
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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