Electrical - EV Battery Replacement Equipment Info.
12-062January 31, 2013
Applies To:
2013 Fit EV - ALL
Fit EV Battery Replacement Equipment
(Supersedes 12-062, dated September 14, 2012, to revise the information marked by asterisks.)
REVISION SUMMARY
*Under GENERAL INFORMATION, the special equipment kit return time was changed.*
INTRODUCTION
The Fit EV battery replacement equipment loan kit is ordered automatically when you place an order fora Fit EV lithium ion battery assembly.
NOTE:
Due to the cost and limited quantity of applicable vehicles, we have made this kit in an effort to prevent a financial burden unto the dealer and this kit is not available for purchase.
American Honda will contact your dealership to confirm the delivery date, time, and additional requirements for the battery assembly and special equipment kit.
The battery tool kit crate weighs about 2,000 lb. and is up to 90 inches long and 48 inches wide. It is extremely important to stage the tool kit crate near the vehicle.
A forklift is required to load and unload the crate, and will be provided if necessary.
Place the Fit EV battery Equipment on a flat even surface. Also, it is important that you do not store or allow either crate to be exposed to moisture as it can damage the material of both crates.
This service bulletin explains the preparation for the use, and return of the Fit EV battery and the Fit EV battery replacement equipment.
For ordering, returns and warranty information, see S/B 12-061, Fit EV Battery Exchange Program, and PIB A12-0009, Lithium Battery Exchange Program.
GENERAL INFORMATION
Only authorized Fit EV dealers may order the replacement lithium ion battery and the EV battery replacement equipment loan kit. The replacement lithium ion battery and the EV battery replacement equipment loan kit will be delivered on a dedicated Honda truck with no other parts.
A loan fee of $800.00 will be applied to your order. The vehicle must be ready for service when the battery and special tool kit arrive at your dealership.
If the special equipment kit or crate is physically damaged, your warranty claim will be debited and your dealership will be issued a core charge of $16,000.00 and/or you will be assessed a repair or replacement fee by AHM Service Operations.
*If the special kit is not received back at American Honda within 15 calendar days, your warranty claim will be debited and your dealership will be issued a core loss charge of $16,000.00.*
TOOL INFORMATION
EV Battery Replacement Equipment Loan Kit:
T/N O7EVBATOOLKIT-02
UNLOADING THE EQUIPMENT CRATE
NOTE:
The following operation should be performed by two people.
1. Remove and discard the green security tag located on the right side latch of the crate.
2. Unlatch the three latches on each side of the crate in the order shown.
NOTE:
Unlatch the top latch last.
3. With the help of an assistant, slowly lower the ramp.
4. Remove the four small ramps enclosed in the document holder attached to the right side of the crate interior wall.
5. Unlatch the top and bottom tie-downs securing the hoist.
6. Rotate the brace locks to clear brace # 1. Repeat on the opposite side. Then, secure brace #1 upright on the right side of the crate with the attached wall chain.
7. Carefully remove the hoist from the crate.
8. Rotate the brace locks to clear brace #2 and #3. Then, secure both braces upright on the right side of the crate with the attached wall chain.
9. Unlatch the tie-down securing the power lift table, and remove it.
10. Carefully roll the power lift table out of the crate.
NOTE:
The lift table is equipped with two rotation locking casters located on the opposite side of the end marked with an arrow. Unloading the power lift table may require locking or unlocking these casters.
11. Unlatch the wall tie-down from the battery fixture. Then slightly lift up on the battery fixture to remove it from the channel. Shift the battery fixture left or right to remove it from the crate.
12. Retrieve the four 7-1/2" stands from the top shelf for staging the old battery with fixture when it's removed from the vehicle.
SETTING UP THE HOIST
1. Remove the detent pin from each hoist leg.
2. Lower the legs and insert the detent pin into the forward pin hole.
3. Remove the rubber bungee cord securing the chain to the hoist.
4. Extend the boom on the hoist to the preset length marker (fifth hole position).
NOTE:
The hoist chain length should be used at the fifth chain link marked.
5. Place the battery fixture onto the power lift table as shown. The front of the table (marked with an arrow) should match the front fixture (marked on both left and right fixture attachments).
UNLOADING THE BATTERY CRATE
NOTE:
All crate packaging will be reused. Store it out of the way to avoid damage.
1. Remove the four straps from the crate lid.
2. Remove and save the four corner foam pieces, then remove the crate lid.
3. Remove the four side walls by sliding them up.
4. Remove the center wall support beams.
5. Remove the two bolts from each corner securing the battery fixture.
6. Align the hoist to the center of the battery fixture marked by the arrow on the side of the fixture.
NOTE:
If the arrow is missing, use the raised rectangular section on the battery case for a center reference point.
7. Remove the small ramps from the document holder in the equipment crate, and place them on each inner and outer portion of the battery crate beam as shown.
8. Move the hoist underneath the battery crate to the alignment arrow as shown.
9. Attach the lifting sling hooks to the battery fixture eye bolts on each corner.
NOTE:
Make sure the stitching on the sling is on the same side of the end of the battery as shown.
10. With the help of an assistant, lift the battery about 8" above the crate floor. Then slowly rotate the battery as shown to clear the crate ends.
11. With an assistant stabilizing the battery, slowly back out the hoist with the battery and fixture attached.
NOTE:
Make sure not to hit the battery crate walls while removing the battery.
12. Using an extension cord, plug in the power lift table and lower it completely.
13. Raise the battery with the fixture high enough for the power lift table to roll underneath it. With the help of an assistant, rotate the battery so that the rear of the battery is towards the hoist.
14. Roll the power lift table inward until the arrow on the power lift table aligns with the arrow on the hoist leg. Then lower the battery and fixture onto the power lift table while an assistant aligns it to the lift tables alignment fixture.
NOTE:
Make sure the two fixtures are interlocked before disconnecting the sling.
LOADING THE OLD BATTERY INTO THE CRATE
NOTE:
The battery fixture used to remove the old battery from the vehicle will be placed into the battery crate with the removed battery. The battery fixture from the new replacement battery will be loaded into the equipment loan kit crate.
1. Position the hoist at the rear of the battery (identified by the cooling fans) as shown.
2. Attach the hoist sling to the fixture eyebolts.
3. Raise the battery and remove the stands.
4. Move the battery to the side of the battery crate, center the hoist to the crate. Position the ramps on the inner and outer portion of the battery crate lower beam.
5. Raise the battery and fixture high enough to clear the crate.
6. With the help of an assistant, hold the battery and fixture at the angle shown (rear first) then push the hoist under the crate until the battery and fixture are in the center of the crate.
7. Rotate the battery and fixture to align the front of the battery to the front of the crate, marked (FR).
8. With the help of an assistant, guide the battery into position onto the four red marks as the battery is lowered. Then fully lower the battery and fixture into the four red marks.
9. Once all of the brackets are in place and the bolts are started, disconnect the lifting slings. Torque the eight bolts to (38 lb-ft).
10. Reinstall the two crate center wall support beams using the bolts. Torque the bolts to (38 lb-ft).
11. Reinstall the crate side walls, and the foam post cut-outs. Secure the battery crate lid using the four removed straps.
RELOADING THE EQUIPMENT CRATE
1. Load the battery fixture with the smaller end downward and the arrow pointing up as shown. Secure the fixture into place using the tie-down. Make sure not to overtighten it.
2. Load the power lift table with the front end (with arrow) on the right side.
3. Strap the power lift table down using the tie down as shown. Make sure not to overtighten it.
4. Lower brace # 3 into the slot of the crate. If the brace does not move into the slotted position, make sure that it is all the way forward against the fixed floor brace of the battery fixture, and/or recheck the orientation as noted in step 2. Rotate the brace lock to the closed position.
5. Lower brace # 2 into the slotted position. Rotate both brace locks to the closed position.
6. Load the hoist into the crate. Move brace # 1 into the downward position locking the hoist into position. Turn the brace lock to secure it.
7. Strap the hoist between the leg and the upward post area using the attached tie-down as shown. Make sure not to overtighten the straps.
8. Use the crate top tie down to secure the legs. Make sure not to overtighten it.
9. Place the four 7-1/2" stands back into the storage shelf in the crate.
10. Secure the chain and lifting strap to the hoist as shown.
11. Place the four small ramps back into the document holder.
PREPARING THE FORMS (TO BE DONE BY THE PARTS MANAGER)
1. Remove the bill of lading and yellow security tag on the left side of the crate.
2. Fill out the bill of lading:
^ Fill in your information on the top portion.
^ Sign on the Shippers Signature line.
^ Make 2 copies.
^ Give the original and one copy to the CEVA driver when they pick up the used battery crates.
^ File one copy in your dealerships hazardous material shipping file.
3. You will need to print out two separate Core Return Update Acknowledgement documents. First, print out the one for the battery:
^ From the iN main menu, select PARTS.
^ Select Returns and Surplus.
^ Select Core Returns.
^ Select Cores with VIN, then Submit, to view the Core Returns Acknowledgement screen.
^ You will see two order reference numbers associated with the VIN of the vehicle you're working on. Select the one for the battery.
^ Enter the serial number from the core, then select Submit.
^ Review the form, then print out a copy by selecting the printer icon.
4. Print out the Core Return Update Acknowledgement document for the special equipment kit:
^ From the Core Returns Acknowledgement screen, select the order reference number for the equipment kit.
^ Enter the crate serial number (located on a label affixed to the outside of the equipment crate), then select Submit.
^ Review the form, then print out a copy by selecting the printer icon.
5. Place the equipment Core Return Update Acknowledgement in the outside document holder of the special equipment crate.
NOTE:
If either the battery core or the special equipment kit is sent back without the proper forms, your warranty claim will be debited.
6. Place the battery order form and the battery Core Return Update Acknowledgement in the outside document holder of the battery crate.
7. Install the yellow security tag to the right side large lower latch as shown.
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