HV BATTERY DISCHARGING


  1. DISCHARGING (WHEN USING THE LI-ION BATTERY DISCHARGER)

    Note

    Make sure to observe the following points when using the Li-ion battery discharger.


    • Set it in a secure, flat place.

    • Set it in a dry place protected from dust and water.

    • Set it in a position where illumination of the LED indicators can be observed.

    • Do not block the ventilation holes or cooling fans.


    1. Select Li-ion battery connection cables


      1. A0040CB

        Confirm the type of the Li-ion battery connection cable as indicated by the tag shown in the illustration. (Type: TM4216-21)

    2. Install Li-ion battery connection cable


      1. A00430N

        Set the Li-ion battery discharger as shown in the illustration.

      2. A00406VE01
        Text in Illustration
        *1 Connector A

        Connect the Li-ion battery connection cable connector (A) to the Li-ion battery discharger connector (A).

        Note

        Make sure that the connector is connected securely.

      3. A0043U3E01
        Text in Illustration
        *1 Connector B

        Connect the Li-ion battery connection cable connector (B) to the Li-ion battery discharger connector (B).

        Note

        Make sure that the connector is connected securely.

      4. A004492

        Set the Li-ion battery discharger as shown in the illustration.

        Tech Tips

        The Li-ion battery discharger is set on its side so that the ventilation holes will not be blocked.

    3. Connect Li-ion battery connection cable

      CAUTION:

      Wear insulated gloves.


      1. A0040MZ

        Disconnect the 4 high-voltage connectors (orange) from the battery smart unit.

      2. A00425C

        Connect the Li-ion battery connection cable connector (orange) to the 4 high-voltage connectors (orange) of the HV battery.

      3. A0042EV

        Confirm that all of the LED indicators are illuminated as shown in the following table.

        CAUTION:

        If all of the LED indicators of the Li-ion battery discharger listed in the following table are not illuminated, discharge using the Li-ion battery discharger cannot be performed on the HV battery. Make sure to soak the HV battery in a saltwater solution to complete discharging.

        LED Indicator Illumination Status (When discharge has started normally)
        LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status LED Indicator No. LED Indicator Illumination Status
        1 Illuminated 2 Illuminated 3 Illuminated
        4 Illuminated 5 Illuminated 6 Illuminated
        7 Illuminated 8 Illuminated 9 Illuminated
        10 Illuminated 11 Illuminated 12 Illuminated
        13 Illuminated 14 Illuminated 15 Not illuminated
        16 Not illuminated 17 Not illuminated 18 Not illuminated
        19 Not illuminated 20 Not illuminated 21 Not illuminated
        22 Not illuminated 23 Not illuminated 24 Not illuminated
        25 Illuminated 26 Illuminated 27 Illuminated
        28 Illuminated 29 Illuminated 30 Illuminated
        31 Illuminated 32 Illuminated 33 Illuminated
        34 Illuminated 35 Illuminated 36 Illuminated
        37 Illuminated 38 Illuminated 39 Not illuminated
        40 Not illuminated 41 Not illuminated 42 Not illuminated
        43 Not illuminated 44 Not illuminated 45 Not illuminated
        46 Illuminated 47 Illuminated 48 Illuminated
        49 Illuminated 50 Illuminated 51 Illuminated
        52 Illuminated 53 Illuminated 54 Illuminated
        55 Illuminated 56 Illuminated 57 Illuminated
        58 Illuminated 59 Illuminated 60 Not illuminated
        61 Not illuminated 62 Illuminated 63 Illuminated
        64 Illuminated 65 Illuminated 66 Illuminated
        67 Illuminated 68 Illuminated 69 Illuminated
        70 Illuminated 71 Illuminated 72 Illuminated
        73 Illuminated 74 Illuminated 75 Illuminated

      4. Confirm that the cooling fans operate.

        A0041TRE01
        Text in Illustration
        *1 Cooling Fans

        Tech Tips


        • To discharge the HV battery completely, continue discharging for at least 1 hour after the LED indicators have turned off.

        • Discharge of a fully charged HV battery will complete within 20 hours (including 1 hour waiting time after the LED indicators have turned off).

    4. Confirm discharge completion


      1. Confirm that all of the LED indicators of the Li-ion battery discharger have turned off.

      2. Continue to discharge the battery for 1 hour after all of the LED indicators of the Li-ion battery discharger have turned off.

    5. Disconnect Li-ion battery connection cable

      CAUTION:

      Wear insulated gloves.


      1. A00418Q

        Disconnect the Li-ion battery connection cable connector (orange) from the 4 high-voltage connectors (orange) of the HV battery.

        Note

        Make sure to install a shorting connector within 1 minute of disconnecting the Li-ion battery connection cable, as the HV battery voltage may recover unexpectedly.

    6. Install shorting connector

      CAUTION:

      Wear insulated gloves.


      1. A00447WE01
        Text in Illustration
        *1 Shorting Connector

        Connect the shorting connector to the 4 high-voltage connectors (orange) of the HV battery.

        Note

        Make sure to install a shorting connector within 1 minute of disconnecting the Li-ion battery connection cable, as the HV battery voltage may recover unexpectedly.

    7. Remove Li-ion battery connection cable


      1. A0042G1

        Set the Li-ion battery discharger as shown in the illustration.

      2. A0041VEE01
        Text in Illustration
        *1 Connector B

        Disconnect the Li-ion battery connection cable connector (B) from the Li-ion battery discharger connector (B).

      3. A0042M9E01
        Text in Illustration
        *1 Connector A

        Disconnect the Li-ion battery connection cable connector (A) from the Li-ion battery discharger connector (A).

  2. DISCHARGING (WHEN USING THE SALT WATER SOLUTION)

    Note


    • When discharging using saltwater solution, first add a measured amount of water to the container, and then add the concentrated saltwater solution.

    • Calculate the saltwater concentration based on the measured volume of water in the container so that a 1% saltwater solution will be made after adding the concentrated saltwater solution to the water in the container where HV battery is set.


    1. Prepare HV battery

      CAUTION:

      Wear insulated gloves.

      Note


      • Perform discharging in a well-ventilated area.

      • Perform discharging in a dry area protected from rain.


      1. A00434Y

        Remove the 2 bolts.

      2. A0041KY

        Install the 2 engine hangers (12281-28010) with the 2 bolts as shown in the illustration.

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }
      3. A00441YE01
        Text in Illustration
        *1 Hook

        Set the 2 hooks and 2 straps as shown in the illustration.

      4. A004106E02
        Text in Illustration
        *a Example
        *b Container (A)

        Using a suitable adaptor such as straps, set the HV battery in the container (A).

        CAUTION:

        To prevent any accidents or injuries due to the weight of the HV battery, follow all specified procedures and be careful to balance the HV battery when setting it in the container.

      5. Remove the 2 hooks and 2 straps.

      6. Remove the 2 bolts and 2 engine hangers (12281-28010).

    2. Prepare to discharge (Add water to container)

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      1. A0042B2E01
        Text in Illustration
        *a Example
        *b Container (B)

        Measure the water capacity of the container (B).

        Tech Tips

        Water capacity of the container (B) is assumed as X (liter).

      2. A0041XTE01
        Text in Illustration
        *a Example
        *b Water Surface
        *c Container (A)
        *d Container (B)

        Using the container (B), add water to the container (A) until the HV battery is completely submerged.

        Note

        Make sure to record the times the container (B) was filled with water to add water to the container (A).

      3. Using the following formula, calculate the amount of water added to the container (A).

        Amount of water added to the container (A)
        Y (liter) = Water capacity of the container (B) x Number of times the container (B) was filled with water to submerge the HV battery

        Tech Tips

        Amount of water added to the container (A) is assumed as Y (liter).

    3. Prepare saltwater solution


      1. A0040A7E01
        Text in Illustration
        *a Example
        *b Container (B)

        While measuring the amount of water, fill about half of the container (B) with water.

        Tech Tips

        Amount of water added to the container (B) is assumed as Z (liter).

      2. Calculate the amount of salt to be added to the container (A) so that a 1% salt water solution will be made.

        Amount of Salt
        Amount of salt (kg) = (Y (liter) + Z (liter)) x 0.01
      3. A0042H7E01
        Text in Illustration
        *a Example
        *b Container (B)

        Add the calculated amount of salt to the container (B) and stir it thoroughly.

    4. Add saltwater solution

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      1. A0042IY

        Add the concentrated saltwater solution to the container (A).

    5. Discharge


      1. Leave the HV battery as is for 24 hours or more until discharge is complete.

        CAUTION:


        • Do not place a lid on the container.

        • Make sure to leave the HV battery and container as is for 24 hours or more.

        • Display a warning sign to inform others that discharge is being performed.

    6. Confirm discharge completion

      CAUTION:

      Be sure to wear insulated gloves and protective goggles.


      1. Check that bubbles are not forming in the container.

        Note

        If bubbles are forming, discharge may not be completed yet. Do not place a lid on the container.

    7. Display a warning sign such as ''DO NOT TOUCH! (DISCHARGE BEING PERFORMED) to inform others. Make a copy of the warning sign and place it near the HV battery being discharged.

      A0040J4