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Hioki DT4261 Manual
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Hioki DT4261 Manual

Hioki DT4261 Manual

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EV MAINTENANCE
TEST TOOL
Read carefully before use.
Keep for future reference.
When using the instrument for
the first time
Dec. 2023 Revised edition 1
C0213A961-01
EV Maintenance Manual
Contents
p.8
p.9
p.10
HIOKI C0213A961-01
p.18
p.24
p.27
EN
[600653781]

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Summary of Contents for Hioki DT4261

  • Page 1: Table Of Contents

    Verifying That There Is No Voltage p.18   Performing Equipotential Bonding Precautions for Use p.24   Testing Preparing for Measurement Performing Insulation Resistance p.27  p.10  Testing (IR4059, RM3548) Dec. 2023 Revised edition 1 [600653781] C0213A961-01 HIOKI C0213A961-01...
  • Page 2 HIOKI C0213A961-01...
  • Page 3 Introduction Introduction Thank you for choosing Hioki’s EV Maintenance Test Tool. To ensure your ability to make full use of the product, please handle this documentation carefully and store it for future reference. The following documentations are available for reference:...
  • Page 4 For more information about instrument options, please review the applicable Instruction Manual. If you wish to purchase an option, please contact your authorized Hioki distributor or reseller. Optional equipment is subject to change with no advance notice. Check Hioki’s website for the latest information. Model...
  • Page 5 For more information about disconnecting and restoring an EV’s high-voltage bus and related safety precautions, please consult the service manual from the vehicle’s manufacturer or contact the vehicle’s manufacturer. HIOKI C0213A961-01...
  • Page 6 (p.  1 3) battery FT3701-20 Verify absence of any voltage (p.  1 8) (DC voltage measurement) DT4261 Disconnect the high-voltage bus cables from the vehicle Wait for any residual charge to discharge Verify absence of any voltage (p.  2 0)
  • Page 7 Perform equipotential bonding test (p.  2 4) (low-resistance measurement) RM3548 Perform insulation resistance test (p.  2 7) (insulation resistance measurement) IR4059 Verify absence of any voltage (p.  2 2) (DC voltage measurement) DT4261 Restore the high voltage Complete work HIOKI C0213A961-01...

  • Page 8: Safety Information

    Before using any of the instruments described in this manual, review its Instruction Manual and the service manual published by the vehicle’s manufacturer. Work that involves handling high-voltage components should be performed only by qualified personnel who have received specialized training. HIOKI C0213A961-01...

  • Page 9: Precautions For Use

    Checking safety before use Inspect the instrument prior to use to ensure there are no faults or damage and verify proper operation. If you find any damage, contact your Hioki distributor. HIOKI C0213A961-01...

  • Page 10: Preparing For Measurement (Ir4059, Rm3548)

    If hanging the instrument from your neck You can attach the neck strap to an instrument so that you can hang it from your neck. The strap can be attached as follows: (The strap attaches at four points.) RM3548 IR4059 HIOKI C0213A961-01...
  • Page 11 If hanging the instrument from the chassis Route the neck strap through two Z5020 Magnetic Straps. Then attach the neck strap to the RM3548 Resistance Meter or IR4059 Insulation Tester. (The strap attaches at two points.) RM3548 IR4059 HIOKI C0213A961-01...
  • Page 12 Preparing for Measurement (IR4059, RM3548) Affix the magnets so as to position the instrument as desired. (Example with IR4059) HIOKI C0213A961-01...
  • Page 13 Failure to do so could cause electric shock. For more information, refer to the vehicle manufacturer’s service manual. If a test indicates an anomaly, halt work. „ Failure to do so could cause electric shock. For more information, refer to the vehicle manufacturer’s service manual. HIOKI C0213A961-01...
  • Page 14 (p.  1 8); equipotential bonding testing, for example to verify that locations where electricity could flow, such as the vehicle’s chassis, are at the same potential (p.  2 4); and insulation resistance testing to verify that there are no insulation defects (p.  2 7). HIOKI C0213A961-01...
  • Page 15 Preparing to Repair or Inspect the Vehicle (Disconnecting the Vehicle’s High-voltage Bus) Measurement locations (example) High-voltage bus Chassis Traction battery High-voltage Inverter, motor, etc. bus cables The high-voltage bus consists of electrical circuitry that operates at a high voltage, including the connection system for REESS charging. HIOKI C0213A961-01...
  • Page 16 For more information about how to use the FT3701-20, see the FT3701-20’s Instruction Manual. FT3701-20 Using the DT4261, verify that there is no voltage across locations with which your hands might come into contact when disconnecting high-voltage bus cables and the vehicle’s chassis ground.
  • Page 17 Preparing to Repair or Inspect the Vehicle (Disconnecting the Vehicle’s High-voltage Bus) Using the DT4261, verify that there is no voltage between the high-voltage bus cable terminals and the vehicle’s chassis ground. (p.  2 0) Once you’ve verified that there is no voltage, the process of disconnecting the vehicle’s high-voltage bus is complete.

  • Page 18: Verifying That There Is No Voltage

    EV. Before reconnecting the high-voltage To verify that the high-voltage bus cables bus cables between the traction can be safely connected after repairing or battery and inverter inspecting the EV. HIOKI C0213A961-01...
  • Page 19 Before disconnecting the high-voltage bus cables After disconnecting the high-voltage bus, test locations with which your hands could come into contact when disconnecting the high-voltage bus cables. For more information about how to use the DT4261, see the DT4261’s Instruction Manual. You will need:...
  • Page 20 The discharge time varies from manufacturer to manufacturer. For more information, refer to the vehicle manufacturer’s service manual. For more information about how to use the DT4261, see the DT4261’s Instruction Manual. Once the high-voltage bus has discharged, verify that there is no voltage.
  • Page 21 Verifying That There Is No Voltage You will need: DT4261 Digital Multimeter, L9300 Test Lead (included with the DT4261), and protective gear Put on the protective gear. Select LoZ V with the DT4261’s rotary switch. Connect the test leads to the DT4261.
  • Page 22 The table lists example measurement locations. Since the inverter side of the bus includes diodes, switch the DT4261’s polarity when performing the test. For more information about how to use the DT4261, see the DT4261’s Instruction Manual.
  • Page 23 Verifying That There Is No Voltage You will need: DT4261 Digital Multimeter, L9300 Test Lead (included with the DT4261), and protective gear Put on the protective gear. Select LoZ V with the DT4261’s rotary switch. Connect the test leads to the DT4261.

  • Page 24: Performing Equipotential Bonding Testing

    For more information, refer to the vehicle manufacturer’s service manual. (To measure a resistance of 0.1 Ω or less at a measurement current of 200 mA or greater, set the RM3548’s measurement range to 300 mA.) Connect the test leads to each measurement location. HIOKI C0213A961-01...
  • Page 25 Verify that each measured value is less than 0.1 Ω and that there are no significant discrepancies between measurement locations. Black Between connected component terminals RM3548 Between connected components Example: Between connected components HIOKI C0213A961-01...
  • Page 26 • There is a significant difference the resistance value of the connected components. between the resistance value of the connecting components’ terminals and the resistance value of the connected components. HIOKI C0213A961-01...

  • Page 27: Performing Insulation Resistance

    Inverter side High-voltage bus cable Chassis ground (GND) positive electrode (+) High-voltage bus cable Chassis ground (GND) negative electrode (−) Chassis ground (GND) High-voltage bus cable positive electrode (+) Chassis ground (GND) High-voltage bus cable negative electrode (−) HIOKI C0213A961-01...
  • Page 28 Press the MEASURE key. Once the display stabilizes, check the value. Select the OFF position with the MEASURE key while leaving the test leads connected to the measurement locations. HIOKI C0213A961-01...
  • Page 29 Verify that the measured value is greater than the insulation resistance value specified by the vehicle manufacturer. Inverter side Traction battery side Black 4, 7, 9 4, 7, 9 IR4059 Example: Inverter-side high-voltage bus cable negative electrode and chassis ground (GND) HIOKI C0213A961-01...
  • Page 30 Reconnect the service plug. Re-energize the vehicle’s high-voltage bus. For more information about how to re-energize the vehicle’s high- voltage bus, see the vehicle manufacturer’s service manual. Specifications For more information about an instrument’s specifications, refer to its Instruction Manual. HIOKI C0213A961-01...
  • Page 31 HV components HV connectors damages or contamination DTCs All potential equalization (bonding) cables Battery temperature °C Other Instrument information Model Serial number Other Infrared Thermometer FT3701-20 Resistance Meter RM3548 Insulation Tester IR4059 Digital Multimeter DT4261 2-pole voltmeter Other equipment HIOKI C0213A961-01...
  • Page 32 Between (+) HV- and (-) GND Inverter side Between (+) HV+ and (-) GND Inverter side Between (+) HV- and (-) GND Inverter side Between (+) HV+ and (-) GND Inverter side Between (+) HV- and (-) GND Memo HIOKI C0213A961-01...
  • Page 33 Between (+) HV- and (-) GND Inverter side Between (+) HV+ and (-) GND Inverter side Between (+) HV- and (-) GND Inverter side Between (+) GND and (-) HV+ Inverter side Between (+) GND and (-) HV- Memo HIOKI C0213A961-01...
  • Page 34 Appendix Memo HIOKI C0213A961-01...
  • Page 35 HIOKI C0213A961-01...
  • Page 36 HIOKI C0213A961-01...

This manual is also suitable for:

Ft3701-20Ir4059