CHANGSHA J & W ELECTRONICS CORP. LTD

     1614 HONGFEI BUILDING No. 123  yanshan street furong district  bayi road changsha hunan

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HP144V Battery Pack Assembly Manual

This manual is suitable for TOYOTA Prius C battery replacement guidance.

1. Please open the box #1 #2 #3 individually and find the components in following list

2. The combination of modules

The 10pcs modules should be combined successively according to serial number which marked on the module. The module and hoop should be installed in the correct position as shown in the following figure.

3. To ensure the insulating performance in all the contact between modules and fixed brackets, 4 pieces fixed brackets should be wrapped with insulating tape.

4. The installation of module

4.1 The positive pole and negative pole of module should be installed at correct direction as shown in following figure. Install the module #10 firstly, then fix the bottom of module with #M5 nut as a basement.

4.2 

Install the temperature probe on the module: 01, 06 and 10 top buttons, and fixing the wire harness. Installation method of temperature probe : surround the battery module with white plastic and buckle gromet.

4.3 Before the bottom screws of module are tightened, the plastic splints on both sides need to be loosened suitably to facilitate the adjustment o  f the bottom screws hole. After the bottom screws are all screwed in, fix the plastic splints on both sides , and finally tighten the bottom bolts.

5. The installation of the connector copper bar and voltage collection wire

5.1 Install the connector copper bar and voltage collection wire synchronously(Note: Bronze screw torque 5~6N • m).

5.2 Immobilize the voltage collection wire into wiring harness groove.

5.3 

Install the voltage collection wire into wiring harness groove on the other side.

6. Install the wiring harness of positive pole, the wiring harness of negative pole and safety wiring harness .

6.1 Install voltage collection wire #V4 insurance terminal of the original insurance connector (If the installed position of insurance connector is different from the original one, please set the insurance collection wire

according to the red circle in the follow picture.

6.2 Install the positive connector wire and the voltage collection wire harness #V11 . Note: The main positive wire harness of sample is in the form of a wire harness, will be optimized to connector copper bar in the future.

6.3 Install negative connector wire and the voltage collection wire harness #V01. Note:the main negative connection wiring harness adopts

the original vehicle wiring harness, but the bent portion of the original vehicle wiring harness must be flattened to ensure that the connection terminal position is closely connected with the main negative of battery.

7. The installation of cover plate.

7.1 Install the cover plate #, the cover plate needs to wrap the voltage

collection wiring harness(.  

7.2 Install the main positive and negative insutating cover for insulating protect