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Spicer HBSM-0140 Service Manual

High voltage battery
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High Voltage Battery
Service Manual
HBSM-0140
February 2023

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  • Page 1 High Voltage Battery Service Manual HBSM-0140 February 2023...

  • Page 2: Table Of Contents

    Table of Content High Voltage Battery Safety Page • HV Battery Warnings, Cautions and Notes • Protective Equipment (PPE) • PPE Inspection • Work Area Precautions • Fire Instruction • Environment • Emergency Operation • After a Crash • Approaching & Vehicle Immobilization •...

  • Page 3: High Voltage Battery Safety

    High Voltage Safety 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.
  • Page 4 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.

  • Page 5: Protective Equipment (Ppe)

    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 •...

  • Page 6: Fire Instruction

    First Responder 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.

  • Page 7: After A Crash

    First Responder After a Crash or Impact Verify LCD screen for HV Isolation Issue. Turn off the vehicle key switch. Exit the vehicle. Turn off the LV disconnect switch if it can be safely accessed. Check for visible battery damage while maintaining a safe distance. Turn on procedure if no HV battery pack damage exists: 1.

  • Page 8: Approaching & Vehicle Immobilization

    First Responder Approaching the Vehicle and Immobilization • 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. •...

  • Page 9: Electric Vehicle Submersion

    First Responder 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.

  • Page 10: Service Instructions & Warnings

    Service Warnings 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.

  • Page 11: Hv Battery Charging

    HV Battery Charging HV Battery Charging Warning: Never spray liquid at high pressure towards the charging port while charging. Failure to follow these instructions can result in serious injury or damage to the vehicle, charging equipment or property. Caution: Make sure to use a designated charger when charging the HV battery. Using different types of chargers may have serious effect on the vehicle’s durability.

  • Page 12: Service Hv Shut Down

    HV Chassis Shut Down Procedure 3 Levels of Shutdown/De-Energization HV Chassis Shut Down Procedure Procedures Caution: Vehicle maintenance, other than routine operator maintenance should be performed by a Live High Voltage Components Shut Down certified, trained mechanic. Many maintenance procedures require special certification, training, and tools to be done safely.
  • Page 13 HV Chassis Shut Down Procedure Caution: Removing the Battery Pack MSDs DOES NOT De-Energize the Battery Packs. They remain charged and should be treated as hazardous if handled incorrectly. 12V Shutdown and LOTO Procedure Turn off vehicle and remove the key from the ignition.
  • Page 14 HV Chassis Shut Down Procedure GROUP “A” S-BOX MSD DE-ENERGIZING PROCEDURE Turn off vehicle and remove the key from the ignition. Locate the 12V/24V Master Disconnect Switchlocated on the right side behind the cabin. Create a six-foot or 2m barrier around the vehicle. Turn the switch to the off position and install a lockout tag and pad lock.
  • Page 15 HV Chassis Shut Down Procedure Wearing class 0 insulated gloves and leather protective gloves, Remove the MSDs (Manual Service Disconnect) from the S-BOX by compressing the buckle tab and rotating the handle 90 degrees. Warning: When required, wear the properly rated arc-rated shirt and pants or coveralls, face shield, and balaclava.
  • Page 16 HV Chassis Shut Down Procedure GROUP “B” HV BATTERY PACK MSD 18. Probe between (+ and -) Test Points 1, 2 and 3 busses with a Class IV multimeter to make sure the voltage DE-ENERGIZING PROCEDURE readings are less than < 5 Volts. Test Point # 1 Warning: To perform any service and maintenance operations involving High Voltage S-BOX, battery...
  • Page 17 HV Chassis Shut Down Procedure Secure the vehicle by placing wheel chucks under the 10. Wearing class 0 insulated gloves and leather front wheels to prevent vehicle from accidentally protective gloves, Remove the MSDs (Manual rolling. Service Disconnect) from the S-BOX by compressing the buckle tab and rotating the handle 90 degrees.
  • Page 18 HV Chassis Shut Down Procedure 14. For safety, the junction box has two “safety screws” 17. To ensure the meter is working properly, measure the voltage between the 12v battery terminals to that connects the cover to the box. These screws obtain a 12V DC reading.
  • Page 19 HV Chassis Shut Down Procedure 26. These MSD’s must be put into a lock out box. 22. Now locate the MSDs on the battery packs 27. A safety cover must be installed over the MSD outlet on the battery pack once an MSD is removed.
  • Page 20 HV Chassis Shut Down Procedure 30. Measure directly across the battery pack HV terminals (pack+/pack-), or if the s-box HV input connectors (batt+/batt-) are disconnected it can be measured across the HV plug terminals (cable side, not receptacle). Battery lug image with cover removed Test Points # 1, # 2 TP 1 (+) TP 1 (-)

  • Page 21: Electrification Vs. Ic Engine

    HV Battery Basics Why Elecrtification Over IC Engine? Electric vehicles (EV’s) have several differences from standard Internal Combustion Engine (ICE) vehicles. We will attempt to highlight the differences in how vehicles are managed: Driving Differences A typical IC engine is between 18% to 25% efficient in converting fuel energy to driving energy. About half the available energy from the fuel is dissipated as heat.
  • Page 22 HV Battery Basics Maximum Charge Rate ESS’s (Energy Storage Systems) typically get hotter while charging than while driving. This is due to the lack of resting time that would normally exist in a drive cycle. As we noted in the previous section, heat during charging needs to be controlled. DC charging equipment may be capable of higher power rate than the ESS can accept energy.
  • Page 23 HV Battery Basics Advised Operator Actions There are several things a vehicle operator can do to impact the ESS positively or negatively. Charger Selection – Chargers are classified as: Level 1 – 120V (1.2kW). DO NOT use Level 1 chargers on Commercial Vehicles. The vehicle system load may be greater than 1.2kW.

  • Page 24: Display And Instruments

    HV Battery Operation HV Battery Operation - Battery Display and Instruments Battery Cooling System Temperature Monitoring and Gauges With the drivetrain control switch in the "ON" position, a HV battery cooling system over temperature symbol with be illuminated on the dash cluster and/or the HMI screen depending on the chassis model. During operation, the temperature gauge should stay in the safety zone.
  • Page 25 Regenerative Braking System Telltale The regenerative braking system (RBS) telltale will activate when severe derating to the trucks regenerative braking system is occurring. The foundation brakes will still work without RBS function to allow continued driving without the retarder functionality.

  • Page 26: Measuring Hv Battery Pack Voltage

    HV Battery Pack Replacement Measure HV Battery Pack Voltages Warning: Even after shutdown procedure, some HV cables are “always live”. They must be handled by trained technicians wearing arc-flash rated PPE gear. Removal and installation MUST be completed in a specific order to prevent un-controlled high Voltage cables. 1.

  • Page 27: Measuring Replacement Pack Voltage

    HV Battery Cable Removal Measure Replacement Pack Voltages Even after shutdown procedure, HV battery packs are “always live”. They must be handled by trained Warning: technicians wearing arc-flash rated PPE gear. Removal and installation MUST be completed in a specific order to prevent un-controlled high Voltage cables.

  • Page 28: Charging Procedure

    HV Battery Charging HV Battery Charging After the battery packs are replaced, charge the packs to 100% and balance, as necessary. Caution: Make sure to use a designated charger when charging the HV battery. Using different types of chargers may have serious effect on the vehicle’s durability. Charging Procedure Turn off the vehicle and remove the ignition key.
  • Page 29 HV Battery Charging Verify Balance at Top of Charge Go to the HMI Screen: Turn on the vehicle with the ignition key. Using the HMI screen navigate to the diagnostics menu To access battery diagnostics, press the “Diagnostics” button on the HMI, then select the “HV” section. Energy Storage System status will be displayed along with other battery information.

  • Page 30: Hv Battery Maintenance

    HV Battery Maintenance HV Battery System Maintenance HV Battery Chiller Coolant Level Inspection 1. The fuild level should be between the MIN and MAX fill lines marked on the surge tank site glass. 2. Fill levels below the MIN fill line should be top off using the procedure below. HV Battery Chiller Coolant Change Instructions Dana recommends that a vacuum purge and refill tool be used to drain and refill the cooling system to insure the removal of air that may cause damage to the circulation pump.

  • Page 31: Lifting A Hv Battery Pack

    Lifting / Packaging Lifting / Packaging a HV Battery Pack or Box Assembly Important Note: Before lifting, moving and/or removing any HV battery box or pack you must have the proper fixturing to ensure that the HV battery pack stays within a flatness specification. The HV battery suppliers’...

  • Page 32: Packaging And Shipping Instructions

    Lifting / Packaging HV Battery Pack Packaging and Shipping Important Note : Never strap a HV battery pack to a conventional wood pallet. A HV battery pack must be supported from end to end on a surface that will not change the flatness during the shipping process. Always ship a HV battery pack in the shipping container supplied by the battery supplier when a HV battery is replaced.

  • Page 33: Recycling And Disposal

    Recycling and Disposal Recycling and Disposal Batteries should be labeled with at least one of the label images below. Do not send High Voltage batteries to a landfill. • It is recommended that depleted (end of life) batteries be fully discharged before recycling •...

  • Page 34: Hv Cable Removal 141Kwh

    HV Battery Removal THE NEGATIVE TERMINAL AND CABLE ARE HV Battery Cable Disconnect LIVE DURING DISASSEMBLY. Procedure for 141kwh HV Battery Configuration. 4. With a wrench or crows’ foot, back off the gland nut 1. Remove the 6 fasteners from the HV battery until loose on the cable.
  • Page 35 HV Battery Removal THE NEGATIVE TERMINAL AND CABLE 11. Now remove the terminal bolt holding the cable lug. You can now pull the cable from the terminal box. ARE LIVE DURING DISASSEMBLY. With a wrench or crows’ foot, back off the gland 12.
  • Page 36 HV Battery Removal Cover the removed cable lug with a LOTO lug cover. Then begin removing the opposite end of the cable. After BOTH ends are removed, the lug cover may be removed from the cable. Warning: At this point the cable should be de- energized on both ends.

  • Page 37: Hv Cable Removal 282Kwh

    HV Battery Removal THE NEGATIVE TERMINAL AND CABLE HV Battery Cable Disconnect ARE LIVE DURING DISASSEMBLY. Procedure for 282kwh HV Battery Configuration. With a wrench or crows’ foot, back off the gland nut until loose on the cable. Remove the Negative cable. Remove the 6 fasteners from the HV battery IMPORTANT NOTE:...
  • Page 38 HV Battery Removal THIRD CABLE CONNECTION to Remove - Battery #2 Negative Repeat for FOURTH CABLE CONNECTION to Remove - Battery #4 Negative Remove the four, Positive terminal box, cover Remove the four, NEGATIVE terminal box, cover fasteners and cover. fasteners and cover.
  • Page 39 HV Battery Removal FIFTH CABLE CONNECTION to Remove - Battery #2 Positive Repeat for SIXTH CABLE CONNECTION to Remove - Battery #4 Positive 12. Remove the four, Positive terminal box, High Voltage Battery Box cover fasteners and cover. Removal With the HV battery cables disconnected from the HV battery terminals, we can now disconnect the 12/24V connections to the HV batteries.
  • Page 40 HV Battery Removal The two coolant lines can now be disconnected from The bottom support rail bolts can now be the bottom HV battery. You will need to plug the inlet removed. and outlet of the bottom battery to reduce coolant loss.
  • Page 41 HV Battery Removal Remove the nut, washer, and nut. Add the 16. Slowly back away from the chassis with someone same thickness of shim and the gap between guiding the HV cables through the access frame of the string and the top of the center beam. the battery.

  • Page 42: Hv Battery Pack Removal

    If any chain is loose, free of tension, adjust the length before you lift the battery pack. Refer to Dana’s “HV Battery Important Note: Service Manual” (HBSM-0140) for packaging and shipping information.

  • Page 43: Hv Battery Pack Installation 41Kwh & 282Kwh

    HV Battery Installation High Voltage Battery Pack Installation The HV battery pack installation procedure will be different depending on the kilowatt hours of the vehicle. 141 kwh battery pack configuration will have one pack on each side of the vehicle. 209 kwh configuration will have one full pack on each side along with a half pack mounted on each side.

  • Page 44: Hv Battery Box Assembly Installation

    HV Battery Installation With all the bolts installed, they can be torqued to specification. Install the battery box cover. Slowly lower the cover over the battery packs. Align the slots in the back of the box to the three support brackets. With the side rails bolts just snug, lift the upper HV battery pack use the same procedure as the first.
  • Page 45 HV Battery Installation With a forklift, move the battery box assembly With all the mounting bolts installed, tighten the over the support rails. Take your time to align the back mount bolts first to pull the assembly flush assembly with the mounting holes in the support with the support bracket.

  • Page 46: Hv Cable Installation - Single Battery

    HV Battery Installation It’s important that damaged or faulty cables and/or cable Connect the HV cables next. Start by connecting ends are replaced with new, do not try to repair or the heater. modify. High voltage cable fasteners must be torqued to specification.
  • Page 47 HV Battery Installation Remove the terminal box cover from the Reinstall the terminal box cover and four NEGATIVE terminal. fasteners. Remember, the NEGATIVE HV battery terminal always stays “LIVE”. Push the cable end through the gland and align the lug with the terminal. Install the terminal bolt and torque to specification.

  • Page 48: Hv Cable Installation - In Series/Stacked Batteries

    HV Battery Installation HV Battery Cable Installation Procedure for In Series or Stacked Connections Reinstall the terminal box cover and four fasteners. Warning: The NEGATIVE HV battery terminal is always live. You must wear the proper PPE before you start this procedure. To install HV battery cables to an in-series or stacked HV battery system, we start with the BOTTOM, POSITIVE cable.
  • Page 49 HV Battery Installation You can how reinstall the gland nut and torque to specification. Important Note: To avoid cable damage, Do NOT use pliers to tighten the gland nut. Always use the proper tools. Next install the BOTTOM, NEGATIVE cable. Follow the same connection steps shown above.

  • Page 50: Warranty

    Warranty HV Battery Warranty Warranty Limitations of Liability Dana warrants that the battery systems shall be exempt of defects of material and workmanship for a period of six (6) years from the date of delivery. Warranty Exclusions • Damage or failure resulting from negligence, improper use (including use that would not be consistent with the User manual provided by Dana).
  • Page 51 Warranty • And all information and data, developed, prepared, or compiled by Dana shall remain the exclusive property of Dana and Client agrees to sign any document necessary or useful to relinquish any right of intellectual property arising from Dana’s products and services. Client agrees not to, directly or indirectly, in any way possible, engage in reverse engineering on Dana products.

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