Service Information: Handling high-voltage batteries after an accident with airbag and/or pyrofuse triggering

We would like to inform you that high-voltage batteries that were replaced due to an accident with airbag activation or triggered pyrofuse no longer need to be always interpreted as "not safe for transportation", but instead are assessed on transportability on the basis of the valid assessment report (through WIS for older model series, through XENTRY as of smart phase IV and 222 model refinement package). Before they are shipped, high-voltage batteries which have been replaced due to accident, and which are classified as safe for transportation based on the assessment criteria, must be clearly identified as an accident battery by means of an appropriate notice on the housing upper part.

Initial analysis:

At the vehicle inspection stage, the accident vehicle must be examined by qualified skilled personnel (retail battery specialists) for possible damage to the high-voltage battery:

 Visible mechanical damage to the high-voltage battery (if body deformation is visible at or around the high-voltage battery, the high-voltage battery must be removed if necessary using protective equipment)

 Electrolyte leakage (visible or smellable)

 Heat development (heat tinting)

 Coolant leakage or refrigerant leakage from battery housing

If one of the criteria is applicable, suitable measures must be implemented immediately by the skilled personnel.

See corresponding document in WIS: AH54.10-P-0001-01A

The vehicle must be parked up as follows:

1 Park vehicle in an open area at a sufficient distance (> 5 m) from other vehicles and buildings.

2 Remove ignition key; with KEYLESS-GO, remove transmitter from vehicle.

3 a) Vehicles with S7 (high-voltage disconnect device):

The HV disconnect device for deactivating the high-voltage on-board electrical system may only be disconnected or operated by qualified personnel (with product training). After deactivating the high voltage on-board electrical system the ground line for the 12 V battery has to be detached.

b) Vehicles without S7 (high-voltage disconnect device):

J14This affects the following models: 164, 212 (all right-hand drive vehicles and left-hand drive vehicles before YoM14 and vehicle model designation ###.195), 221, 451 phase II

The ground line for the 12 V battery has to be detached before deactivating the high voltage on-board electrical system!

The high-voltage on-board electrical system must be deactivated by qualified personnel (with product training), by disconnecting the high-voltage contacts. The high-voltage contacts may only be disconnected while wearing personal protective equipment (PPE).

4 The open area must be cordoned off to prevent it from being entered by unauthorized persons, and indicated by means of locally applicable warning signs which indicate the danger of the accident vehicle (high voltage), as well as the text "HV power disable not assured".

 If qualified personnel is not available out of office hours, Point 1, Point 2 and Point 4 must be conducted. As a precautionary measure in terms of fire protection and vehicle protection, the 12 V battery must also always be disconnected.

If a repair order has been issued for the vehicle, a visual inspection must first be performed for damage to the HV components and the 12-V on-board electrical system (bare lines, risk of short circuit) by qualified personnel (with product training).

If all HV components and lines have no external damage, the 12 V battery and the high-voltage disconnect device can be operated again or reconnected.

If this necessitates the connection of HV contacts, personal protective equipment (PPE) must be worn. This affects the following models: 164, 212, 221, 451 Phase II.

After an accident in which the pyrofuse was tripped (irreversible shutoff of the high-voltage on-board electrical system), the high-voltage battery must be replaced. For this, the power in the vehicle must be manually disabled by qualified personnel (training course T1192F "Manual power disable of high-voltage on-board electrical system and new high-voltage tests") in accordance with the process documented in WIS.

If further work on the vehicle is necessary, proceed according to the repair instructions. If the high-voltage battery cannot be removed using the conventional repair instructions, the responsible MPC must be contacted.

For the high-voltage battery to remain in the vehicle following an accident in which the pyrofuse did not trigger, the checks listed below must be performed as a minimum requirement after the repair work.

Function test:

 Read out fault memory in battery management system to detect safety-relevant faults and states (insulation resistance, proper operation of insulation monitor, proper operation of interlock, proper operation of contactors, max / min cell voltage, fuse triggering in the high-voltage battery).

 Carry out a charging sequence for the high-voltage battery, duration approx. 10 min ("Engine on" for hybrid vehicles or with the charging cable for plug-in hybrid and electric vehicles).

 Function check via state of charge (SOC) in instrument cluster (hybrid vehicle) or via the charging indicator box or the vehicle-mounted socket (electric vehicles & plug-in hybrids)

 Perform a test drive

If safety-relevant fault codes or malfunctions occur during these checks, the high-voltage battery must not remain in the vehicle and must be replaced. For model 242 ev, the fault codes listed in step (1) of the function test must be checked for plausibility via the instrument cluster. Likewise in the case of red fault messages, the high-voltage battery must not remain in the vehicle and must be replaced.

Specifications for shipment and identification of the high-voltage battery after an accident with airbag activation or triggered pyrofuse:

1 Ideally, transportability should be checked before the high-voltage battery is removed. The instructions from the vehicle manufacturer must be observed for each specific model series.

See corresponding document in WIS: OF54.10-P-3000-01** or as of smart phase IV and model series 222 facelift, the assessment report in XENTRY.

2 High-voltage batteries that were replaced after an accident with triggered pyrofuse must always be marked on the housing upper part with the notice "Lithium-ion battery from accident vehicle". For this purpose, the notice must be secured to the affected high-voltage battery using suitable tape so as to ensure that it cannot become detached.

In addition, when assessing transportability the criterion - "Was the vehicle in which the battery is installed involved in an accident in which the pyrofuse was triggered?" - must be answered with "YES".

3 Only transportable high-voltage batteries can be handed over to the return shipment process.

For technical questions about the high-voltage on-board electrical system, the respective responsible MPC should be contacted.

 Personal protective equipment (PPE) is intended to provide protection against potential hazards from electrical current when working on vehicles in which the condition of the high-voltage on-board electrical system cannot be clearly determined (e.g. accident vehicles).

The specified PPE can be found in AH00.00-Z-0300-01A.

Notice

If using the transportability assessment procedure in XENTRY, the notice is automatically printed out with the assessment report when "Was the vehicle involved in an accident in which the pyrofuse was triggered?" is selected; if the assessment is being carried out on older model series using the OF document from the WIS, the following certificate OF47.70-P-3000-01A must be printed out in German or English and attached to the top side of the high-voltage battery.

P54.10-3903-06

P54.10-3904-06