Page 1 of 66 BMW Rescue manual Information for emergency service personnel January 2015 Foreword Essential information Medical aspects Technical aspects BMW Assist emergency call Response of the restraint and safety systems after an accident Notes for using emergency equipment Opening doors Opening doors Forcing dashboard forwards Forcing dashboard forwards Electric seat adjustment Securing vehicles Safety concepts and systems Identifica
Page 2 of 66 Front passenger airbag Side airbag ITS head airbag AITS head airbag Head airbag Knee airbag Safety mechanisms Belt tensioner - technical information Mechanical belt tensioner Pyrotechnic belt tensioner Pyrotechnic retractor tensioner / end fitting pretensioner Seat-integrated belt system Active head restraint Roll-over protection system Active engine compartment lid Body and materials Glazing Electrical system - ba
Page 3 of 66 2 Essential information 3 Rescue & Recovery 4 Towing Foreword One of the main priorities of the products developed and realised by BMW is optimum safety under all conditions. By taking an holistic view, the precisely-coordinated active and passive safety systems exceed the requirements set down by law. They also take into account the technical requirements for emergency crews.
Page 4 of 66 Visual inspection to see what restraint and safety systems are fitted Special features on the vehicle body which may influence the use of hydraulic emergency equipment BMW Assist emergency call BMW vehicles with an activated BMW Assist emergency call system and valid service contract can automatically or manually establish an emergency call.
Page 5 of 66 Example: Propping up vehicles The vehicles can be propped up from underneath the whole of the side sill. The precise position and number of prop points must be determined as a function of the situation in hand. Ideally, the mounting points for the jack should be used. Opening doors Version 1 Starting points for opening the doors on the A-pillar 1. Use the hydraulic emergency spreader to crush the front side panel.
Page 6 of 66 Starting points for opening the doors on the A-and/or B-pillar 1. Use the hydraulic emergency spreader to force the window frame apart. This produces a larger gap between the front door and B-pillar and/or between the front side panel and front door. 2. Use the emergency spreader to increase the gap at the same height as the hinges. The precise position of the hinges for each vehicle is drawn on the emergency services cards. 3.
Page 7 of 66 Danger of injury! Emergency equipment may slip or slide. Important! 1. Place material under the vehicle floor to prevent the base from caving in. 2. Carry out glass management (including cutting through the front windscreen horizontally in area 2 or 3 ). 3. Use hydraulic shears to cut off door at its hinges. 4. Use hydraulic shears to cut through the side sill 1 in front of the occupant towards the floor. 5.
Page 8 of 66 Danger of injury! Emergency equipment may slip or slide. Important! 1. Place material under the vehicle floor to prevent the base from caving in. 2. Carry out glass management (including cutting through the front windscreen horizontally in area 2 or 3 ). 3. Remove doors on both sides of vehicle. 4. Use hydraulic cutters to cut through both side sills 1 in front of the occupant towards the front end.
Page 9 of 66 Since the seats in vehicles with electric seat adjustment cannot be adjusted once the battery has been disconnected, under certain circumstances we would recommend disconnecting in the area marked. Securing vehicles Example: Possible ways of securing vehicles Chock Place chock in front of and behind the rear axle wheel on the side opposite that on which the vehicle will be raised. Ideally, the mounting points for the jack should be used.
Page 10 of 66 Secure the continuous loop to the rear or front by passing through the window openings and affix to a suitable counter support. Front and rear axles When securing the vehicle, always combine several axle components (axle support, wishbone, drive shaft).
Page 11 of 66 . Belt tensioners No identification The vehicles contain four kinds of systems for reducing belt slack: Mechanical belt tensioners Pyrotechnic belt tensioners Pyrotechnic retractor tensioners / end fitting pretensioners Seat-integrated belt system (SGS) . Active head restraints No identification The active head restraints are integrated into the driver's and front passenger seats. Active head restraints that have not been triggered require no special attention. .
Page 12 of 66 Triggered driver's airbag The driver's airbag is located in the steering wheel's impact absorber. Acceleration is recorded and evaluated by a sensor. If the triggering threshold is exceeded, the airbag control unit and/or the satellite responsible (= intelligent sensor) transmits an ignition voltage to the ignition squib which then triggers the airbag. The gas created by ignition escapes into the airbag which then unfolds in full.
Page 13 of 66 Side airbag not triggered The side airbags are located behind the side trim panel in the door in most BMW models. On some BMW models, as well as on all MINI models, the side airbags are located to the side, in the backrest of the driver's and front passenger seats. In the event of a side collision, the resulting lateral acceleration is recorded by sensors.
Page 14 of 66 AITS for front and rear seat passengers (triggered) The AITS head airbag is a head protection system like the ITS. Its advantage, however, lies in its curtain-like area protection. The AITS prevents the head and limbs from swinging back and forth. This means that the neck experiences lower shearing forces and there are fewer head injuries.
Page 15 of 66 Knee airbag on driver's and passenger's sides. In the event of a crash, when the driver or front passenger is not wearing a seat belt, the knee airbag will support their knees. This results in the upper body being shifted forwards in a controlled manner and being caught by the airbag. The knee airbag on the driver's side is located underneath the steering column behind a lid. The knee airbag on the passenger's side is located in the lid of the glove box behind a cover. .
Page 16 of 66 Seat-integrated belt system (SGS) All the systems have the same goal of reducing belt slack. This is the biomechanical load to which the human body is subjected after an accident. Mechanical belt tensioner On the mechanical belt tensioner, a mechanical sensor detects a crash and triggers the release of the tensioner energy via a switching mechanism. A force transfer element pulls the seat belt buckle obliquely downwards to tension the seat belt strap against the occupant's body.
Page 17 of 66 Pyrotechnic retractor tensioner . Pyrotechnic end fitting pretensioner . The pyrotechnic retractor tensioner reduces belt slack by creating friction in the seat belt guides, primarily in the shoulder region. Sensors and control electronics activate a pyrotechnic unit which starts the automatic shaft rotating through a wound cable. To eliminate the film spool effect, a clamping fixture holds the seat belt strap secure when the occupant moves forwards.
Page 18 of 66 In the seat-integrated belt system (SGS) all the belt elements, including the reversing points, are moved into the seats. In the event of a crash, all forces in vehicles without B-pillars are absorbed by the floor assembly. The head restraint and top belt reversing point also automatically adjust depending on the seat length adjustment. A top belt tensioner fitted on the top belt feed also restricts the amount by which the occupant moves forwards in the event of a crash.
Page 19 of 66 The active head restraints are integrated into the driver's and front passenger seats. Function In the event of a rear-end collision, the head is jolted to the rear because it becomes the most inactive part of the body due to the long distance to the head restraint. This jolt movement may result in cervical injuries (whiplash). To reduce the distance between the head and head restraint, the active head restraint swings forward to the head in the event of a rear-end collision.
Page 20 of 66 On models in the 6-Series (E64), the rollover sensor is located in one of the satellites. The rollover protection bars are retracted in the structure during normal operation. The rollover protection bars are pretensioned in the direction of extension by a spring and held by the lock on the actuator. . BMW 3-Series E93 and MINI Convertible R57 If the control electronics of the rollover protection controller detect an imminent rollover, the two actuators are triggered directly.
Page 21 of 66 1 Right engine compartment lid catch (with actuator) 2 Bowden cable 3 Right engine compartment lid hinge (with actuator) 4 Left engine compartment lid hinge (with actuator) 5 Left engine compartment lid catch (with actuator) 6 Optical fibres 7 Central sensor (acceleration) 8 Actuator (on engine compartment lid hinge) 9 Sensor (optical fibre) 10 Deformation structure . An optical fibre is integrated between the bumper support and impact absorber.
Page 22 of 66 optimised and therefore the safety of the occupants is increased. Modern heavy duty cutting equipment is mandatory for cutting the body; older hydraulic cutting tools could be overloaded. The heavy duty cutting equipment must be properly used by trained and qualified personnel. The optimum cutting point for each vehicle is drawn on the emergency services cards. . Materials The type and percentage proportion of each material differ for individual model ranges.
Page 23 of 66 . Safety battery terminal The safety battery terminal is fitted on the battery's positive terminal. The ignition squib of the safety battery terminal must not be crushed, cut through or heated! The safety battery terminal disconnects only the positive battery cable between the battery and starter motor/alternator. . Identification No identification .
Page 24 of 66 BMW Active E, E82, see 1-Series emergency services card. MINI E, see MINI E emergency services card. BMW eDrive, see emergency services card I01, I12 . For further detailed information on high-voltage technology, see rescue manual. Alternative engines Electric vehicles For detailed information on MINI E, see MINI E emergency services card. For detailed information on BMW Active E, see 1-Series emergency services card.
Page 25 of 66 The gas generator has been designed so that it will be triggered normally when exposed to fire if the surface temperature of the gas generator exceeds 200 °C. . Can water be used as an extinguishant? Yes. Any effective fire-extinguishing agent can be used, even in vehicles equipped with airbags. . Is it safe to inhale the air in the vehicle interior after airbag deployment? Yes. Chemical and medical analyses confirm that it is totally safe.
Page 26 of 66 BMW i - the safety of the eDrive is an essential element of all BMW i vehicles The safety of the eDrive is an essential element of product development. A variety of measures safeguard operating safety, including in the event of accidents. Fully insulated high-voltage system. Automatic safety cutout (disconnection) of the high-voltage battery in the event of an accident with airbag activation.
Page 27 of 66 Electric motor(s) and alternator(s) High-voltage component overview based on the example of the X6 ActiveHybrid E72: Item Explanation 1 Electrical machine electronics 2 Electrical refrigerant compressor 3 Active transmission with electric motors/alternators for full hybrid 4 High-voltage cables 5 High-voltage battery file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 28 of 66 High-voltage component overview based on the example of the 3 Series active hybrid 3 F30: Item Explanation 1 Electrical refrigerant compressor 2 Electric machine 3 Electrical machine electronics 4 High-voltage battery High-voltage safety With improper use, the high voltage in the high-voltage system may become a source of danger. The vehicle therefore has a comprehensive safety concept.
Page 29 of 66 High-voltage battery including high-voltage rescue separation point Example X6 Active HybridE72 Item 1 2 3 Explanation High-voltage battery High-voltage emergency separation point High-voltage cables . Example of a 3 Series active hybrid 3 F30: Item 1 2 3 Explanation High-voltage battery High-voltage emergency separation point Plug connection for high-voltage cable The high-voltage rescue separation point plays a crucial role in vehicle manufacturer safety concepts.
Page 30 of 66 In hybrid technology, electrical machine electronics are used to convert currents. The electrical machine electronics are called an inverter. It converts alternating current generated in the high-voltage alternator into direct current. As with all other high-voltage components, the inverter is not to be opened in any circumstances as high voltages are applied internally. Electric machine The electrical machine in the ActiveHybrid 5 is a permanently excited synchronous machine.
Page 31 of 66 High-voltage cables The high-voltage cables (1) connect the high-voltage components to each other, for example the high-voltage battery with the machine electronics or the machine electronics with the electrical machine. High-voltage cables can be identified by the orange coloured insulation (coating).
Page 32 of 66 First aid & recovery of vehicles with high-voltage systems according to the German Association of the Automotive Industry) FAQ (Frequently Asked Questions) . Structure 1. Investigation / vehicle identification 2. Danger by electrical shock 3. Danger from HV battery pack 4. Chemical danger 5. Thermal danger (fire) 6. Electrical charging infrastructure 7. Vehicles in water 8. Towing away, recovery, transport, BMW breakdown assistance and safekeeping 9.
Page 33 of 66 2.4 Is it possible for emergency service personnel to manually deactivate a HV system? Yes, electric or hybrid cars offer various ways of manually deactivating the HV system. Most vehicles are equipped with an additional switch-off device for the HV system, which can be used by emergency service personnel. These switch-off devices are called 12 volt separation points. These separation points can also be operated by non-specialists of HV to deactivate the HV system.
Page 34 of 66 6.1 What do I need to be aware of if an electric or hybrid HV vehicle connected to a charging station is involved in an accident? If possible, pull off the charging cable from the charging station/vehicle or switch off the charging station. The charging cable must always be disconnected from the vehicle. Visually check cables and connectors for possible damage before removing them.
Page 35 of 66 Country- and operator-specific tunnel regulations are to be observed. . 8.5 How should damaged electric or hybrid cars be parked and kept safe? For reasons of fire safety, electric or hybrid cars should be parked just like conventional vehicles in a closed-off area of an outdoor parking area with sufficient clearance to other vehicles, buildings and combustible objects. The vehicle should be marked accordingly.
Page 36 of 66 off. The high-voltage system (IT system) consists of two separate circuits (HV+, HV-), which are completely decoupled from the 12 V vehicle electrical system. The electrical GND (-) has no high-voltage potential. Only the housings of the components are connected to GND to allow potential compensation. In order to provoke electrical damage, a person needs to be in-between the positive and the negative HV circuit.
Page 37 of 66 A switched off high-voltage system can be identified via the Check Control message "High-voltage system deactivated" in the instrument cluster. Note: The display requires the 12 V battery to be connected and a terminal change (stop and start vehicle via start/stop button) to be carried out.
Page 38 of 66 Underneath the opening, the electrical machine electronics (1) and the electrical machine are located on the left handside while the range extender (2) is located on the right hand-side. 7. Disconnect high-voltage connector. Push locking at pole connector (1) of the high-voltage connector (2) and remove pole connector (1). Pull out locking (1) of the high-voltage connector (2) in direction of arrow until the limit position is reached.
Page 39 of 66 Pull off high-voltage connector (1) upwards. . 8. Measuring the de-energised state at the high-voltage connector. The disconnected high-voltage cable is directly linked to high-voltage battery. It is essential that the contacts are reached with the gauge tips when measuring. file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 40 of 66 In the next step, measurements can be taken from each of the contacts to the housing of the electrical machine electronics. The housings of all high-voltage components are connected via GND by means of potential compensation lines (aluminium drive module). If a high-voltage potential is present at the housing and/or at GND due to damage, it can be measured with this procedure. If no voltage is measured at any time, one can assume that the system is no source of danger. . 9.
Page 41 of 66 thermal response will take place. Monitoring the high-voltage battery with a thermographic camera is therefore recommended. Trapped persons can be rescued using suitable fire fighting equipment. The BMW I01 consists of a carbon fibre passenger cell based on an aluminium drive module. The carbon fibre are not combustible. However, since these fibres are held together by a special resin, the resin may catch fire in the event of high temperatures.
Page 42 of 66 however designed to be intrinsically safe on the inside. This includes, for example, an adequate touching protection. All high-voltage cables can be plugged in and are highlighted in orange. In case of a damaged high-voltage battery, a damaged touching protection needs to be assumed. In this very improbable case, electrical and thermal danger by the high-voltage battery need to be assumed. Adequate personal protective equipment is required.
Page 43 of 66 When lifting the vehicle, the areas surrounded by red colour may not be used as a supporting area (exception: after a fire) . Expert guide BMW I12 1 Introduction This guide is to be followed after a severe accident when the emergency service personnel is in doubt about the state of the high-voltage system. Always observe country-specific guidelines.
Page 44 of 66 emergency service personnel is to be assumed, a qualified electrical specialist needs to be consulted. In case of severe accidents with the risk of damage to the high-voltage battery being present, the high-voltage battery is automatically disconnected from the high-voltage system. Prior to any further work on the vehicle (e.g. repair, recycling), an inspection must be carried out by suitably qualified personnel, according to the BMW specification.
Page 45 of 66 High-voltage emergency separation point open. . 3.1.2 Determine voltage free status A switched off high-voltage system can be identified via the Check Control message "High-voltage system deactivated" in the instrument cluster. Note: The display requires the 12 V battery to be connected and a terminal change (stop and start vehicle via start/stop button) to be carried out. . 3.
Page 46 of 66 the high-voltage battery. When extinguishing the fire, audible processes can occur inside the high-voltage battery. This takes place in the safety valves of the battery cells. This process is no source of danger. These audible processes can also occur after extinguishing the fire. BGI/GUV-I 8677 governing electrical hazards at fires Observe the following safety distance when extinguishing 1 m - spray jet 5 m - full jet . 3.2.
Page 47 of 66 After recovery of the vehicle out of water the high-voltage system is to be switched-off by removing the high-voltage service disconnect and disconnecting the 12 V battery (negative terminal). In case of airbag deployment, the switch-off of the high-voltage system can be assumed. Touching high-voltage components and high-voltage cables is to be avoided. After recovery out of water: Observe vehicle thoroughly.
Page 48 of 66 The vehicle must not be pulled or towed. Transportation is possible exclusively on a truck. Any other variants of towing away a vehicle are forbidden. Pulling the vehicle out of the danger area is possible. Securing the vehicle via its wheels is recommended. When lifting the vehicle, the areas surrounded by red colour may not be used as a supporting area (exception: after a fire) .
Page 49 of 66 2 Essential information 2.1 Vehicle type The BMW 530Le is a PHEV. The abbreviation PHEV stands for "Plug-in Hybrid Electric Vehicle" – a motor vehicle with hybrid drive, the high-voltage battery of which can also be charged externally via the power grid. . 2.
Page 50 of 66 Installation position of high-voltage battery behind the rear seat bench . The high-voltage system is to be switched off by removing the small pole connector (HV interlock) (see chapter 3.1.2 point 8). . 3.1.2 Determine voltage free status A switched off high-voltage system can be identified via the Check Control message "High-voltage system deactivated" in the instrument cluster. file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 51 of 66 Note: The display requires the 12 V batteries to be connected and a terminal change (stop and start vehicle via start/stop button) to be carried out. If the de-energised state cannot be identified by means of the instrument cluster (no message), the state can be identified by a qualified electrical specialist with personal protective equipment via the following measurements. . Operations: 1. Switch off vehicle. Put vehicle in passive state via START-STOP button. 2.
Page 52 of 66 . 6. Disassemble the rear seat bench by the reaching underneath and pulling firmly. . 7. Disassemble the rear seat backrest Release the screw connections (Torx T50). file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 53 of 66 . - Detach the rear seat backrest by lifting. . The high-voltage battery is located behind the rear seat backrest. file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 54 of 66 . 8. Disconnect high-voltage connector Remove "HV interlock" (1) Pull out lock (2) in direction of arrow up to limit position Pull off high-voltage connector (3) . 9. Measure the de-energised state at the high-voltage connector The disconnected high-voltage cable is directly linked to high-voltage battery. It is essential that the contacts are reached with the gauge tips when measuring.
Page 55 of 66 housings of all high-voltage components are connected via GND by means of potential compensation lines. If a highvoltage potential is present at the housing and/or at GND due to damage, it can be measured with this procedure. If no voltage is measured at any time, one can assume that the system is no source of danger. . 10. Installing the high-voltage connector In order to rule out further improper treatment, install and lock the high-voltage connector again.
Page 56 of 66 Note: The high-voltage cables of the high-voltage battery can be identified by their considerably greater cross-section. If the insulation is melted due to the fire, only the copper lines can be identified. . 3.3 Vehicle in and under water After recovery of the vehicle out of water the high-voltage system is to be switched off by removing the high-voltage service disconnect and disconnecting the 12 V batteries (negative terminal).
Page 57 of 66 The vehicle must not be pulled or towed. Transportation is possible exclusively on a truck. Any other variants of towing away a vehicle are forbidden. Pulling the vehicle out of the danger area is possible. Securing the vehicle via its wheels is recommended. When lifting the vehicle, the areas surrounded by red colour may not be used as a supporting area (exception: after a fire) .
Page 58 of 66 This guide is to be followed after a severe accident when the emergency service personnel is in doubt about the state of the high-voltage system. Always observe country-specific guidelines. In case the intrinsic safety of the vehicle is suspected not to be present any longer and a dangerous situation for the emergency service personnel is to be assumed, a qualified electrical specialist needs to be consulted.
Page 59 of 66 If the high-voltage rescue separation point behind the trim panel cannot be accessed, the high-voltage system is switched off at the large high-voltage connector of the high-voltage battery (installation position below the luggage compartment floor cover). . The high-voltage system is to be switched off by removing the small pole connector (HV interlock) (see chapter 3.1.2 point 9). . 3.1.
Page 60 of 66 4. Remove the trim panel components. . After lifting the luggage compartment floor cover: Loosen expanding rivets (1) and screws (2), remove storage tray. Open right side trim panel (4). . 5. Disconnect 12 V battery at the negative terminal. . 6. Remove red connector lock (1) and pull apart plug connection of the high-voltage rescue separation point (2) (highvoltage service disconnect). file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 61 of 66 . 7. Disassemble luggage compartment floor cover: Raise front section, loosen Torx screws T50 (1), remove damper (2) and remove luggage compartment floor cover (3). . - Remove rear panel by lifting; the high-voltage connector (1) becomes visible. file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 62 of 66 . 8. Disconnect high-voltage connector Remove "HV interlock" (1) Pull out lock (2) in direction of arrow up to limit position Pull off high-voltage connector (3) . 9. Measure the de-energised state at the high-voltage connector The disconnected high-voltage cable is directly linked to high-voltage battery. It is essential that the contacts are reached with the gauge tips when measuring. file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
Page 63 of 66 . In the next step, the voltage of each of the two contacts to the housing of the electrical machine electronics is measured. The housings of all high-voltage components are connected via GND by means of potential compensation lines. If a highvoltage potential is present at the housing and/or at GND due to damage, it can be measured with this procedure. . If no voltage is measured at any time, one can assume that the system is no source of danger. . 10.
Page 64 of 66 . 3.2 Vehicle on fire In general, all statutory requirements relating to a conventional vehicle on fire are to be observed. No explosion will occur in the event of a reaction of the lithium ion high-voltage battery triggered by the fire. A quick thermal response will take place. Monitoring the high-voltage battery with a thermographic camera is therefore recommended. Trapped persons can be rescued using suitable fire fighting equipment.
Page 65 of 66 avoided. After recovery out of water: Observe vehicle thoroughly. Store vehicle outdoors with sufficient clearance to combustible material! Provide clear access for fire brigade. . 3.4 Split or separated high-voltage battery The voltage within the high-voltage battery cannot in principle be switched off. The high-voltage battery is, however, designed to be intrinsically safe on the inside. This includes, for example, an adequate touching protection.
Page 66 of 66 recommended. When lifting the vehicle, the areas surrounded by red colour may not be used as a supporting area (exception: after a fire) . © 2015 BMW AG Munich, Germany. Copying, reprinting or reproduction, even in excerpt form, the written permission of BMW AG Munich. 01/2015 file://C:\Users\QX54891\AppData\Local\Temp\14\DW_Temp_QX54891\VUL-REL-BM...
