Special Service Tool

Tool Name / Number	Illustration	Description
Application guide 0K375 - CV210		Used for applying the high voltage battery gap filler
Application nozzle 0K375 - CV220
Application support 0K375 - CV230
Application dispenser gun 0K375 - CV300
TGF-NT300NL 600cc cartridge 09375 - GI220
Static mixer 09375 - GI230

   

Refer to the contact information below for special tools (09375 - CV210, CV220, CV230, CV300) for gap filler application.

– TOOL & TECH (overseas@toolntech.com)

Gap Filler Application

   

• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.

• When working on high voltage system or related components, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur.

• When working on high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.

   

Do not step on or apply a load when applying the gap filler. It may cause damage or transform when a load is applied.

1.Remove the Sub Battery Pack Assembly (Sub-BPA).(Refer to High Voltage Battery System - "Sub Battery Pack Assembly (Sub-BPA)")

2.Disconnect the all Cell Monitoring Unit (CMU) distributor connectors (A).

3.Separate the wiring (A) after removing the fasteners.

4.Separate the CMU (A) after removing the bolts.

Tightening torque1st : 8.8 N·m (0.9 kgf·m, 6.5 lb·ft)2nd : 10.8 N·m (1.1 kgf·m, 8.0 lb·ft)

5.Remove the remaining gap filler on the Sub-BPA downside surface and the lower case.

   

• Remove the residual gap filler as possible by hand and using an air blow gun.

• A few of the existing gap filler can remain on the surface. (It doesn't cause the serious performance problem)

• It may cause damage to the Sub-BPA downside surface or lower case when removing the gap filler by using the sharp tools like a blade.

6.Install the TGF-NT300NL 600cc cartridge (09375 - GI220) and application dispenser gun (0K375 - CV300).

   

• Be assemble all of the Special Service Tool (SST) by referencing the SST manual.

• Cut the static mixer (09375 - GI230) leaving the last layer of the static mixer as below.

7.Set to the 6 bar after installing the air hose (B) on the application dispenser gun (0K375 - CV300) (A).

   

When the pressure sets above the specification (6 bar), the TGF-NT300NL 600cc cartridge (09375 - GI220) is damaged.

8.Discard about the first 10 cm (3.94 in.) of the gap filler in order to removed the unmixed gap filler.

9.Install the application guide (0K375 - CV210) (A).

   

Check the IN and OUT direction of the nozzle when installing the application guide (0K375 - CV210).

10.Fix the application guide (0K375 - CV210) (A) by installing the fixing pins (B,C).

   

• The mounting location of the fixing pin is as below.

• Install the fixing pin (B) as it does not interfere with the applied surface.

11.Install the application dispenser gun (0K375 - CV300) (A) on the application guide (0K375 - CV210) (B).

12.Fix the application support (0K375 - CV230) handle (A) after adjusting it.

13.Release the rail by loosening the wing bolts (A).

14.Apply the gap filler equally after install the fixing pin (A) by pressing the trigger.

   

• Move the gap filer application guide after applying the gap filler enough without gap.

• 600 cc cartridge uses for 1 room and it will still have a little left after applying gap filler.

• Do not reuse the cartridge which is residual after applying.

15.Remove the trigger fixing pin (A) after completing the gap filler application.

16.Fix the rail by tightening the wing bolts (A).

17.Remove the gap filler application dispenser (0K375 - CV300) (A) from the gap filler guide (0K375 - CV210).

   

Remove the dispenser (0K375 - CV300), taking care not to damage the surface to which the gap filler is applied.

18.Remove the gap filler application guide (0K375 - CV210) (A) after removing the fixing pins (B,C).

   

Remove the gap filler application guide (0K375 - CV210) and fixing pins vertically, taking care not to damage the surface to which the gap filler is applied.

19.Clean the application nozzle (0K375 - CV220) and rail before the second application.

   

It may cause the bubbles if the residual gap filler is not removed completely.

20.Change the TGF-NT300NL 600cc cartridge(09375 - GI220).

21.Apply the gap filler in the same order as above.

22.Install in the reverse order of removal.

   

• Install the Sub Battery Pack Assembly (Sub-BPA) within 90 minutes and at room temperature [25°C (77°F)] before the gap filler is hardened.

• Be careful not to damage the surface to which the gap filler was applied, when installing the Cell Monitoring Unit (CMU).

• Install the Battery Module Assembly (BMA) to specified torque following the below orders.