Spicer HBSM-0140 Manuel utilisateur

High Voltage Battery

Service Manual

HBSM-0140

February 2023

High Voltage Battery Safety Page

•HV Battery Warnings, Cautions and Notes 2-3

•Protective Equipment (PPE) 4

•PPE Inspection 4

•Work Area Precautions 4

•Fire Instruction 5

•Environment 5

•Emergency Operation 5

•After a Crash 6

•Approaching & Vehicle Immobilization 7

•Electric Vehicle Submersion 8

Service Instructions & Warnings

•Service Warnings 9

•Welding Instructions 9

•HV Battery Charging 10

•Service HV Shut Down 11-19

HV Battery System Operation

•Electrification vs. IC Engine 20

•Information to the Driver 20

•HV Battery Basics 20-22

•Display and Instruments 23-24

•Measuring HV Battery Pack Voltage 25

•Measuring Replacement Pack Voltage 26

•Charging Procedure 27-28

HV Battery Maintenance

•HV Battery Maintenance 29

HV Battery Pack Lifting, Packaging and Shipping

•Lifting a HV Battery Pack 30

•Packaging and Shipping Instructions 31

Recycling and Disposal

•Instructions 32

HV Battery Replacement

•HV Cable Removal 141kwh 33-35

•HV Cable Removal 282kwh 36-38

•HV Battery Box Assembly Removal 33-40

•HV Battery Pack Removal 41

•HV Battery Pack Installation 41kwh & 282kwh 42-43

•HV Battery Box Assembly Installation 43-45

•HV Cable Installation –Single Battery 45-46

•HV Cable Installation –In Series/Stacked Batteries 47-48

Warranty

•Warranty Statement 49

•Warranty Exclusion 50

Table of Content

High Voltage Battery Safety

This manual should be read thoroughly before servicing any HV battery systems to insure that operating

and safety requirements are understood.

The DC-DC converter uses energy from the high voltage battery to power auxiliary components such as the

audio system, supplemental restraint system, headlights, power steering, and windshield wipers.

The HV battery pack provides power to the traction motor that moves the vehicle. The vehicle must be

plugged to charge the HV battery pack. The vehicle system can extend the vehicle range through

regenerative braking. Regenerative braking converts braking power into electricity that is stored in the HV

battery pack while the vehicle is decelerating or driven downhill.

Caution: To prevent damage to the lithium-ion battery:

•Do not expose the vehicle to extreme ambient temperatures for extended periods.

•Do not store the vehicle in temperatures below - 13°F (- 25°C) for more than 7 days.

•Do not leave the vehicle for more than 14 days where the lithium-ion battery charge gauge

reaches 5% state of charge.

•Do not use the lithium-ion battery for any other purpose.

NOTE: If the outside temperature is − 13 °F (− 25 °C) or less, the HV battery pack may freeze, and

it cannot be charged or provide power to run the vehicle. Move the vehicle to a warmer location.

The capacity of the HV battery pack to hold a charge will decrease with heat, calendar time and energy

throughput. Ambient heating is the factor that owners can affect the most. As the battery pack ages and

capacity decreases the driving range will decrease. This is normal, expected, and not indicative of any

defect in your HV battery. Testing have estimated that battery capacity willbeapproximately 80% of original

capacity after six years, this is only an estimate, and this percentage may vary (and could be significantly

lower)dependingonindividualvehicleandHVbattery pack usage. The HV battery pack has limited-service

life. When the battery pack reaches a specific level, the EV system warning light will illuminate.

High Voltage Safety

Safety Alerts

Please read and follow all safety alerts in this manual. They are for your protection and information. The

alerts can also help you avoid injury to yourself and your passengers. The alerts can also help prevent

costly damage to the vehicle. Safety alerts are highlighted by safety alert symbols and signal words

such as "WARNING", "CAUTION", or "NOTE". Do not ignore any of these alerts.

Warnings

The safety message following this symbol and word provides a warning against operating

procedures which could cause injury or even death. Failure to follow these warnings could also

cause equipment or property damage. The alert will identify a hazard, how to avoid it, and the

probable consequence of not avoiding the hazard.

Cautions

The safety alert following this symbol and word provides a caution against operating procedures

which could cause equipment or property damage. The alert will identify a hazard, how to avoid

it, and the probable consequence if ignored.

Notes

The alert following this symbol and word provides important information that is not safety related

but should be followed. The alert will highlight things that may not be obvious and is useful to

your efficient operation of the vehicle.

Warnings and Safety Regulations

WARNING: To prevent damage to the vehicle, for your safety, and for

bystanders’ safety, the following warning and safety regulations must be strictly

observed.

Read the instructions and warnings on the labels on all components. Failure to follow these

warnings could cause equipment damage, property damage, injury, and death. The

instructions and warnings are for your health and safety.

Modifications to the HV Battery

Modifying your vehicle could make it unsafe. Some modifications could affect your vehicle's

electrical system, stability, or other important functions. For no reason should the electric

powertrain be modified. Modification to any of Dana’s components will void your warranty.

Modifications to the electric chassis could cause death or personal injury.

Warning: Connecting to an unapproved CAN bus may trigger CAN fault codes. The

manufacturer will not warrant failures or damage caused to the CAN bus components

when the failure or damage is a result of improper connections to the CAN bus.

High Voltage Safety

Personal Protection Equipment

Ensure that an approved PPE equipment is available to anyone working on the vehicle.

•High Voltage Insulated glasses or face shields

•High Voltage (rubber) gloves with protective (leather) outer gloves

•Insulated tools for use on high Voltage equipment

•Insulating equipment covers (to prevent unintended contact with covered surfaces)

•Insulating bags (t capture hazardous material if necessary

PPE Inspection

Users of PPE must check all protective wear for deterioration or damage before beginning work. Do

not use any damaged PPE items

•Insulated gloves should be inspected for scratches, holes, or tears

•Insulated rubber sheet should be inspected for scratches, holes, or tears

Work Area Precautions

•Work area should be indoors. Work must be protected from rain, snow, or other substances. Ideal

conditions include air conditioning to prevent condensation from forming as a result of high humidity

•Work area floor must be dry. Do not allow rain soaked or snow-covered vehicles to enter the work

area.

•Work area must be free of airborne contaminants such as metal powders or grinding debris.

•Work area must be free of free of debris or foreign material. If necessary, use curtains, cones or

safety tape to mark cleared area. (at least 6 feet)

•Display appropriate warning sign in the work area.

PPE

Fire Extinguisher

•Ensure that an approved fire extinguisher is well secured under the driver’s seat, within

the driver's reach and easily accessible for first responders.

•Routinely check the fire extinguisher according to its manufacturer’s instructions.

•If the fire extinguisher has been used, it must be replaced with a new fire extinguisher or

refilled before the truck can be returned to service.

•Use type A, B, or C extinguisher. DO NOT use type D fire extinguisher on battery fires.

Fire Instructions:

During a fire, certain plastic seals can produce gases which with water form a corrosive

acid. Do not touch any fluid on the vehicle.

1. Contact firefighters.

2. Create a safety perimeter of at least 6 feet around the vehicle.

3. If possible, follow HV SHUTDOWN PROCEDURE

Environment

Pollution is a serious threat to the environment. To keep pollution to a minimum, the

following rules should be observed:

Do not dump used oil, lubricants, hydraulic fluid or coolants in drains, in sewers, in

landfills or on the ground. This is illegal. These fluids should be returned to the

designated authority or appropriate chemical waste collection company for recycling or

destruction. All used fluids should be stored separately.

Service the vehicle regularly according to the instructions and recommendations in this

manual. If component service intervals are not provided in this manual, check the truck

manufacturer’s operator’s manual.

Emergency Operation

•Proper techniques and standard protocols are essential for safety during an emergency operation

involving an electric vehicle (EV).

•Shut down procedures will vary between OEM’s and even vehicle models.

•Because EV’s can move with little or no sound, conventional methods of determining if a vehicle can be

moved under its own power will be difficult to do. Making assumptions that the vehicle is not powered

up can be dangerous.

•Always be prepared to deal with hazardous conditions when working with EV’s by wearing the proper

safely equipment. Cutting corners may put you in the hospital or worse.

First Responder

After a Crash or Impact

1. Verify LCD screen for HV Isolation Issue.

2. Turn off the vehicle key switch.

3. Exit the vehicle.

4. Turn off the LV disconnect switch if it can be safely accessed.

5. Check for visible battery damage while maintaining a safe distance.

Turn on procedure if no HV battery pack damage exists:

1. Turn the LV disconnect switch back to ON.

2. Turn the key to the START position.

Safety procedures if the HV battery pack is damaged.

1. Contact firefighters.

2. Create a safety perimeter of at least 2 meters around the vehicle.

3. Move to an area upwind and far enough away from the accident site to avoid breathing any

hazardous smoke or gases.

Note: Always assume that the HV battery packs could be damaged after an accident and have it

inspected by a service technician.

Warning: High Voltage (HV) Shutdown

The high voltage system on any vehicle has no parts that an owner or unauthorized service

technician can service. Under no circumstances should you attempt to perform any HV battery repair.

First Responder

•Until proven otherwise, ALWAYS ASSUME ALL HIGH VOLTAGE COMPONENTS ARE ENERGIZED

•Electric Vehicles are quiet. DO NOT ASSUME THE VEHICLE IS UN-POWERED.

•Always approach at a 45-degree angle to avoid being hit if the vehicle unexpectedly moves.

•Physical damage to HV batteries pack may result in the release of harmful or flammable gases.

•To prevent gas buildup the passenger's compartment must be ventilated by opening the doors, rolling

down the windows or breaking the glass.

•Block (chock) the front and back of at least one of the wheels

•Engage the parking brake

Disabling the Electric Commercial Vehicle

•If the ignition switch is accessible, turn it to the “OFF” position

•Turn the Lockout Tagout Switch to the “OFF” position.

Commercial high voltage battery boxes are designed to protect the batteries in case of a crash. If the HV

battery pack is damaged, the following should be considered.

•Lithium-ion battery materials can be toxic and/or flammable.

•Ventilation is required to prevent buildup of flammable or toxic gasses.

•Lithium-ion batteries are considered “dry-cell” so any leakage would be minimal.

•Some HV batteries packs have cooling and heating systems that use coolant like a standard

vehicle’s radiator. This fluid does not create a hazard.

•Do not handle any damaged battery components at any time after an accident.

•Be aware of any odors or irritation to the eyes, nose, throat, or skin.

•When a damaged HV battery pack is identified, look for sparks, smoke, flames, bubbling or

gurgling sounds that may cause a fire.

•In case any electrolyte does leak, spray “HF Acid Eater” onto surface. Wipe up with absorbent

paper towel. Place paper towels into plastic bag or pail with spill residue. Place sealed bags in

“universal” waste storage for proper disposal.

Approaching the Vehicle and Immobilization

First Responder

HV Battery Damage (Breaches)

Recommended Fire Suppression Procedures

•Use NFPA compliant firefighting PPE and SCBA.

•Class A, B, or C extinguishers may be used.

•DO NOT USE CLASS D extinguishers on battery fire. These contain metal powders that can short

circuit batteries or terminals.

•Because of the time and water requirement to extinguish a battery fire, it may be best to let it burn itself

out.

•Do not force open the battery box to apply an extinguishing agent Do not penetrate body panels with

extraction tools. You may contact a HV cable.

Warning: There are HV cables that are always energized, always assume that HV cables can

cause personal injury or even death. Never attempt to cut a HV cable for any reason.

•When the vehicle is approachable, follow the vehicle shutdown procedure.

•Keep all nonessential personal upwind of the fire. Gasses may be corrosive or toxic.

•Always treat the vehicle as energized when performing post fire handling.

Electric vehicles that are partially or completely submerged will not energize the water causing a threat of

shock. Electrified vehicles are designed with ground faults circuit interrupters and other AC protection to

eliminate this hazard.

Warning: Never remove a service discontent from a submerged vehicle.

Although the water is not energized, there is still a shock hazard if you contact any of the

exposed HV cables.

Standard Procedures for Handling vehicles in water are:

•Follow the shutdown procedure in this owner’s manual.

•If the shutdown procedure cannot be performed with the vehicle submerged, contact Dana before

removing the vehicle from the water.

First Responder

Electric Vehicle Submersion

Service Instructions & Warnings

High Voltage (HV) System

Note: The high voltage battery on this vehicle has no components that require service by the

user. Do not try to repair high voltage battery components, cables, or connectors. All high

voltage cables are colored orange for easy identification.

Note: If a collision occurs, do not touch any high voltage cables, connectors, or components.

Note: In the unlikely event of a fire, immediately contact your local fire emergency responders.

Warning: Do not touch or attempt to remove any orange colored high voltage cables,

connectors, or components.

Warning: The high voltage battery has no parts that an owner or unauthorized service

technician can service. Under no circumstances should you open or tamper with the battery or

other HV components. Always contact a certified service dealer.

Caution: The HV battery requires no owner maintenance. If you get a battery check light,

contact a PACCAR service dealer.

Warning: Repair of HV components or the HV battery is very dangerous and could cause

severe burns and electric shock. Never remove or disassemble any HV components in this

vehicle. Dana recommends that all inspections and repairs be conducted by an authorized and

trained service dealer.

Warning: DO NOT cut into or remove any of the orange high voltage cables. Refer to the OEM

specific location of chassis mounted component.

Warning: DO NOT cut into or open any electric motors, the DC/DC converter, HV inverters, HV

chargers, HV battery packs or controllers. These components are non-serviceable and should

only be replaced if service is required

Welding

Caution: Dana’s warranty does not cover damage to electrical components

caused by any type of welding. Electrical components closer than 12” from the

welding site must be removed from the vehicle.

Warning: Prior to performing any maintenance on the electric vehicle, always perform the HV

voltage shutdown procedure.

Warning: High Voltage Shutdown

The high voltage system on this vehicle has no parts that an owner or unauthorized service

technician can service. Under no circumstances should you attempt to perform any part of this

procedure. This procedure should only be performed by a trained and certified service provider.

Service Warnings

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