Spicer HBSM-0140 User manual

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
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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.
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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.
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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.
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PPE