Check Housing Of Lithium-Ion Battery - AR47.70-P-0017-02A

Model all (CAR, smart) 

	Risk of fire  /risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning  caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death  due to voltage U >= 30 V AC and U >= 60 V DC.	No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
	Risk of death  when working on components and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live components and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
Notice	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
Notice	Notes on battery		AH54.10-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A

Model all (CAR, smart) 

Mechanical protective cover/housing damaged: B1a/b cracks or openings can be recognized on the housing 

1. Check lithium-ion battery for cracks and/or openings (arrows), e.g. caused by the breaking off of housing parts.

   If cracks or openings are detected, there is a danger of possible internal damage or possible ingress of foreign objects or fluids, which can lead to damage or short circuits in the lithium-ion battery,

   ↓

   Immediately make an emergency call under the respective location-specific and country-specific emergency call number and do not touch the high-voltage battery; vacate the danger zone.

   Courtesy of MERCEDES-BENZ USA

   Mechanical protective cover/housing damaged: B2a/b critical dent depths/deformation of the housing exceeded 

2. Check the housing of the lithium-ion battery incl. threaded connections, attaching parts, and, if applicable, attaching parts that are attached firmly to the housing for mechanical deformation.

   If any dents or deformations are detected, there is a potential danger of internal damage, which can lead to damage or short circuits in the lithium-ion battery.

   If there is a problem:

   ↓

   Perform operation steps 3 to 5.

3. Determine height of straightedge, scale ruler or contact angle as a point of origin at the non-deformed housing contour (arrow c).

   Commercially available devices/tools 

   Vernier caliper with a round measuring blade with a diameter of 1.5 mm

   Straightedge, ruler, or a contact angle

   For measuring the dent depths, it is important to measure the dent depths against a reference line (original, not deformed, housing contour) using suitable aids e.g. a straightedge, a ruler, or a contact angle.

   Courtesy of MERCEDES-BENZ USA

4. 1. If vehicles without a EB300, EB301, EB311, EB312, EB330, EB40x or EB42x high-voltage battery are tested.

      Check whether a dent depth (d) of 2 mm is exceeded.

      Dent depth (d) ≤ 2 mm: Transport approval Dent depth (d) > 2 mm: No transport approval

      If the maximum dent depth (d) prevents transport approval,

      ↓

      contact the responsible MPC/general representative.

   2. If vehicles with a EB300 or EB301 high-voltage battery are tested.

      Check whether the dent depth (d) exceeds the permissible limits in areas (A, B, C, D).

      If the maximum dent depth (d) prevents transport approval,

      ↓

      contact the responsible MPC/general representative.

   3. If vehicles with a EB311, EB312, EB330, EB40x or EB42x high-voltage battery are tested.

      Check whether dent depth (d) exceeds permissible limit values in areas (A, B, C, D, E).

      If the maximum dent depth (d) prevents transport approval,

      ↓

      contact the responsible MPC/general representative.

      Courtesy of MERCEDES-BENZ USA

      Permissible dent depths (d) for vehicles with EB300 or EB301 high-voltage battery 

      1. Evaluation according to B1, B3 and B4
      2. ≤ 2 mm
      3. ≤ 5 mm
      4. ≤ 10 mm If the permissible dent depth (d) in one area (A, B, C, D) is exceeded, no transport approval is granted.

      Courtesy of MERCEDES-BENZ USA

      Permissible dent depths (d) for vehicles with EB311, EB312 or EB330 high-voltage battery 

      1. ≤ 2 mm
      2. ≤ 2 mm
      3. ≤ 10 mm
      4. Evaluation according to B1, B3 and B4
      5. ≤ 3 mm If permissible dent depth (d) in one area (A, B, C, D, E) is exceeded, transport approval is not granted.

      Courtesy of MERCEDES-BENZ USA

      Permissible dent depths (d) for vehicles with EB40x or EB42x high-voltage battery 

      1. Evaluation according to B1, B3 and B4
      2. ≤ 50 mm
      3. ≤ 2 mm
      4. ≤ 5 mm
      5. ≤ 10 mm If permissible dent depth (d) in one area (A, B, C, D, E) is exceeded, transport approval is not granted.

      Courtesy of MERCEDES-BENZ USA

      Mechanical protective cover/housing damaged: B3 all dents/deformations must be recorded with the measured dent depths in the table 

5. Record all dents/deformations with location, type, and dent depths.

   Enter the lengths, widths, and depths of the dent depths. Record location of the dents/deformations in the drawing in the "analysis sheet for the transportability of high-voltage batteries form."

   Courtesy of MERCEDES-BENZ USA

   Mechanical protective cover/housing damaged: B4 Electrical connector and its surroundings damaged 

6. Check electrical contacts (plug, bushes, bolts, posts etc.) and check connections of the lithium-ion battery for damage (arrows).
7. 1. If an electrical contact (plugs, bushes, bolts, posts etc.) of the lithium-ion battery is damaged. Contact the responsible MPC/general representative and determine further safety precautions so that touching live parts is safely prevented.

      Courtesy of MERCEDES-BENZ USA

   2. If no electrical contact (plugs, bushes, bolts, posts etc.) of the lithium-ion battery is damaged. Cover contacts (plugs, bushes, bolts, posts etc.) with battery-specific cover caps so that touching is ruled out and ingress of objects and fluids is safely prevented.

      Mechanical protective cover/housing damaged: B5 pressure relief device triggered/open/damaged 

8. Check pressure relief device for integrity.

   If the pressure relief device is triggered or if the pressure relief device is open,

   ↓

   Check lithium-ion battery for electrolyte leakage.

   Check lithium-ion battery for electrolyte leakage 

9. Check lithium-ion battery for pungent odor caused by leaking electrolyte.

   Avoid direct skin contact with electrolyte that may have leaked.

   Electrolyte is volatile and has a pungent odor.

10. Wear personal protective equipment (PPE) or location/country-specific protective clothing when working with electrolyte.

    If a pungent odor is noticeable.

    Personal protective equipment for working with electrolyte consists of the following parts:

    Protective gloves (standard EN 60903.2012 class 0 (designation A (acid), A+H (acid + oil), or R (acid + oil + ozone))). Tightly fitting safety glasses, goggles, or face protection shield.

    Long-sleeved protective clothing.

    Respiratory protection - depending on the amount of electrolyte released and the intensity of the release.

11. Inspect housing of the lithiumion battery for signs of electrolyte leakage.

    Avoid direct skin contact with electrolyte that may have leaked.

    Electrolyte may have different colors depending on the reaction (from light/clear to dark/opaque). If the cell only has mechanical damage, the electrolyte is clear.

    If there is an electrolyte leakage:

    ↓

    Courtesy of MERCEDES-BENZ USA

    Evacuate danger zone and keep a safe distance.

    Ensure that working area is well ventilated.

    Wait for possible reaction of electrolyte (at least 20 min). Bind escaped electrolyte with an absorber (vermiculite) and transfer to containers designated for disposal. Clean components with shop towel and transfer shop towels to containers designated for disposal.

    If the prerequisites for removal are not met in the event of electrolyte leakage, make an emergency call to the respective location-specific and country-specific emergency call number immediately; do not touch high voltage battery and vacate danger zone.