HV BATTERY RECOVERY INSPECTION

DTC Code DTC Name
RECOVERY INSPECTION

CAUTION / NOTICE / HINT

CAUTION:


  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  • Before returning the HV battery, make sure to perform a pre-return inspection.

  • Accidents such as electric shock may result if the HV battery is discharged improperly and disposed or abandoned.

    Therefore, make sure to return the HV battery through an authorized collection agent.

  • To reduce the risk of fire, HV battery must not be stored in an area where they will be exposed to fire or high temperatures.

  • If the temperature of the HV battery is high, leave it to cool down.

Tech Tips

In order to return the HV battery in a safe manner, it may be necessary to discharge it. The following pre-return inspection procedure can be used to determine whether or not it is necessary to discharge the HV battery the method that may be required.

PROCEDURE


  1. INSPECT FOR ELECTROLYTE LEAK

    CAUTION:

    Wear insulated gloves.


    1. B005YWB

      Position the HV battery as shown in the illustration and leave it for 5 minutes.

    2. Check that no electrolyte is leaking from the HV battery.

      OK
      There is no electrolyte leaking from the HV battery.

      CAUTION:


      • Perform this procedure in an area where the battery will not be exposed to fire.

      • Do not touch the HV battery, unless absolutely necessary, as electrolyte may be leaking.

      Note

      If there is an electrolyte leak, make sure to wear insulated gloves and goggles and clean it using a piece of cloth. Do not leave electrolyte-contaminated cloths unattended. Dispose of them according to law or local regulations.

      Result
      Proceed to
      OK
      NG

    NG

    DISCHARGING (WHEN USING THE SALT WATER SOLUTION)

    OK

  2. CHECK FOR DTCS


    1. Check the previously recorded DTCs which resulted in replacement of the HV battery.

      Result
      Result Proceed to
      DTC record not available. A
      The HV battery was replaced due to one of the DTCs listed in the following table. B
      The HV battery was replaced due to a reason other than the DTCs listed in the following table. C
      DTC No. Relevant Diagnosis
      P31AA-123 Hybrid Battery Cell High Voltage
      P31AB-123 Hybrid Battery Cell Low Voltage
      P31AC-123 Hybrid Battery Cell Extreme High Voltage
      P31B3-123 Hybrid Battery Voltage High
      P0AA6-612 Hybrid Battery Voltage System Isolation Fault

    B

    GO TO STEP 6 Click here

    C

    GO TO STEP 5 Click here

    A

  3. CHECK HV BATTERY VOLTAGE

    CAUTION:

    Wear insulated gloves.


    1. B005YKME01

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Condition Specified Condition
      f4-1(+) - Service plug grip connecting terminal A Power switch off Below 114.8 V
      g4-1(-) - Service plug grip connecting terminal B Power switch off Below 114.8 V

      CAUTION:

      Make sure not to cross the electrodes of an electrical tester measurement terminals.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 6 Click here

    OK

  4. INSULATION INSPECTION OF HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. B005ZG3E01
      Text in Illustration
      *a Insulation inspection area of the battery outer case

      Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f4-1(+) - Battery Outer Case Always 1 MΩ or higher
      g4-1(-) - Battery Outer Case Always 1 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 6 Click here

    OK

  5. HV BATTERY VISUAL CHECK

    CAUTION:

    Wear insulated gloves.


    1. Check that there is no deformation or discoloration of the HV battery.

      OK
      There is no deformation or discoloration of the HV battery.
      Result
      Proceed to
      OK
      NG

    OK

    RETURN HV BATTERY

    NG

  6. HV BATTERY CONNECTORS VISUAL CHECK

    CAUTION:

    Wear insulated gloves.


    1. Check that there are no deformations or abnormalities in the orange connectors connected to the battery smart unit.

      Tech Tips

      If any of the connectors are damaged, a Li-ion battery discharger will not be able to be connected to the HV battery. Soak the HV battery in a saltwater solution to discharge it.

      OK
      There are no deformations or abnormalities in the connectors.
      Result
      Proceed to
      OK
      NG

    OK

    DISCHARGING (WHEN USING THE LI-ION BATTERY DISCHARGER)

    NG

    DISCHARGING (WHEN USING THE SALT WATER SOLUTION)