Toyota Li-ion Battery System

Product Data Sheet with Safe Handling

www.toyota-forklifts.eu
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| TOYOTA MATERIAL HANDLING
 TOYOTA LI-ION BATTERY SYSTEM |
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1. GENERAL DESCRIPTION ..................................................................................................................4

IDENTIFICATION OF PRODUCT AND COMPANY..............................................................................................4
TOYOTA IN-HOUSE LI-ION BATTERY SAFETY FEATURES ..................................................................................... 6
Basic description of safety and installed redundancy......................................................................................... 6
2 example cases of how the system acts................................................................................................................ 6
Li-ion Battery System configuration......................................................................................................................... 7

2. CHEMICAL INFORMATION ..............................................................................................................8

HAZARDS IDENTIFICATION .............................................................................................................................................. 8
Classification of the substance or mixture.............................................................................................................. 8
Label elements................................................................................................................................................................. 8
Other hazards.................................................................................................................................................................... 8
Substances......................................................................................................................................................................... 9
Mixtures.............................................................................................................................................................................. 9
PHYSICAL AND CHEMICAL PROPERTIES ..................................................................................................................10
TOXICOLOGICAL INFORMATION AND REACTIVITY ................................................................................................11
A SAMPLE OF DIFFERENT BATTERY COMPOSITIONS .........................................................................................12

3. ENVIRONMENT ..................................................................................................................................... 13
ECOLOGICAL INFORMATION ..........................................................................................................................................13
DISPOSAL CONSIDERATIONS ........................................................................................................................................13

4. HANDLING AND STORAGE ..........................................................................................................14

HANDLING AND STORAGE ..............................................................................................................................................14
EXPOSURE CONTROLS/PERSONAL PROTECTION ................................................................................................14
STABILITY ..............................................................................................................................................................................15
Cold Store operations...................................................................................................................................................15

5. SAFETY MANAGEMENT ................................................................................................................ 16

FIRST-AID MEASURES .....................................................................................................................................................16
Description of first-aid measures.............................................................................................................................16
FIREFIGHTING MEASURES .............................................................................................................................................16
Smoke from the battery..............................................................................................................................................16
Battery or charger on fire............................................................................................................................................17
ACCIDENTAL RELEASE MEASURE ...............................................................................................................................17
SAFETY PRECAUTIONS AND RECOMMENDATIONS FOR CHARGING AREAS ..............................................18

6. CERTIFICATION ..................................................................................................................................... 20
CERTIFICATE OF CONFORMITY .....................................................................................................................................20
TEST & CERTIFICATION ...................................................................................................................................................20
NORMS & REGULATIONS FOR ELECTRIC TRUCKS ................................................................................................21

7. TRANSPORTATION ............................................................................................................................ 22
TRANSPORT INFORMATION ..........................................................................................................................................22
REGULATORY INFORMATION ........................................................................................................................................22

8. OTHER INFORMATION ................................................................................................................... 23

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IDENTIFICATION OF PRODUCT
AND COMPANY

TOYOTA IN-HOUSE LI-ION BATTERY SYSTEM

Toyota Material Handling Manufacturing Italy Spa

Via Persicetana Vecchia, 10
40132 Bologna (Italy)
Tel: +39 051 205 411

Toyota Material Handling Manufacturing Sweden AB

Svarvargatan 8,
595 81 Mjölby (Sweden)
Tel: +46 142 860 00
Fax: +46 142 863 02
 TOYOTA LI-ION BATTERY SYSTEM |
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As a solid, manufactured article, exposure to hazardous ingredients is not

expected with normal use. This battery is an article pursuant to REACH
regulation 1907/2006/EC and, as such, does not require the publication of
a safety data sheet. The information contained in this Product Data Sheet
contains valuable information critical to the safe handling and proper use
of the product.
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TOYOTA IN-HOUSE LI-ION BATTERY

SAFETY FEATURES

BASIC DESCRIPTION OF SAFETY AND INSTALLED REDUNDANCY

• Cell level
• Safety devices in the top cap assembly of our chosen cylindrical cell can prevent a cell
from thermal runaway or explosion in the abusive environment, including overcharging
and external short circuit.

• Module level
• Special assembly pattern with a safety distance to prevent a chain reaction between
cells resulting from a hazardous situation.
• Each module has a control unit for monitoring and management of the complete
module including the cell voltage and temperature.

• Battery system level

• Redundant Battery Management System (BMS) monitoring and managing all the
modules and interface to the truck and chargers, protecting the battery system from
abuse.
With the constant monitoring of the battery system any situation outside normal
operating parameters (i.e. higher or lower temperature, or higher or lower voltage) will
generate error codes according to different escalations and take action by for example
switching off certain truck parameters to prevent hazardous situations. This could for
example be by reducing current during charging.
• Mechanical protection to prevent penetration, shock and vibration.

2 EXAMPLE CASES OF HOW THE SYSTEM ACTS

• Case 1
The mechanical protection of the battery system is penetrated
(e.g. forks through the battery)
See page 16 - Firefighting measures

• Case 2
Truck on fire
See page 16 - Firefighting measures
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LI-ION BATTERY SYSTEM CONFIGURATION

TYPICAL BATTERY CONFIGURATIONS

24 volt Modules type #

Total cells Total voltage
battery in Ah Modules

50 Ah 50 1
105 Ah 105 7 252 25,9
150 Ah 150 7 364 25,9
210 Ah 210 7 504 25,9
300 Ah 150 14 728 25,9
420 Ah** 210 14 1008 25,9
630 Ah** 210 21 1512 25,9
840 Ah** 210 28 2016 25,9

48 volt
battery
210Ah* 210 13 936 48,1
300 Ah* 150 26 1352 48,1
420 Ah* 210 26 1872 48,1
300 Ah** 150 28 1456 51,8
420 Ah** 210 28 2016 51,8
630 Ah* 210 39 2808 48,1

80 volt
battery
420Ah** 210 44 3168 81,4
630 Ah** 210 66 4752 81,4
840 Ah** 210 88 6336 81,4

*Warehouse trucks
**Counterbalance trucks
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HAZARDS
IDENTIFICATION

CLASSIFICATION OF THE SUBSTANCE OR MIXTURE

No risks occur during normal use of lithium-ion batteries when handled in accordance with the
operator manual supplied with the truck.

However, if exposed to fire, subject to mechanical shock, disintegration or incorrectly connected

/ charged, the hazardous substances of the battery can be released, resulting in a risk of fire or
significant discharge.

LABEL ELEMENTS

In accordance with the EU batteries directive and current national legislation, lithium-ion
batteries must be labeled with a crossed bin with ISO’s return / recovery symbol.

OTHER HAZARDS

None identified.

BATTERY MODULE SUBSTANCES

As a solid, manufactured article, exposure to hazardous ingredients is not expected during

normal use.
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NOTE: There are variants with different contents. See mixtures below

A. Mixtures If the battery module has any of these symbols on the top lid:

Including NMC-cells.

Classification according
Max. percentage
CAS-No. Chemical name/Name to Regulation (EC)
of BRIX weight
No 1278/2008 (CLP)
N/A Lithium Nickel Manganese Cobalt Oxide Not classified 40
N/A Silicon Oxide Not classified 4
7782-42-5 Graphite Not classified 21
24937-79-9 Poly Vinylidene Flouride Not classified 2
N/A Electrolyte Not classified 12
21324-40-3 Lithium Hexaflourophosphate(1-) Not classified 2
25929-04-8 PC (Polycarbonate) Not classified 4
24936-68-3 PC (Polycarbonate) Not classified 9
115-86-6 Phosphoric acid ester Not classified 2
9003-56-9 ABS (Acrylonitrile Butadiene Styrene) Not classified 6

B. Mixtures If the battery module has any of these symbols on the top lid:

Including NCA-cells.

Classification according
Max. percentage
CAS-No. Chemical name/Name to Regulation (EC)
of BRIX weight
No 1278/2008 (CLP)
12325-84-7 Lithium Nickel Oxide Not classified 27
7782-42-5 Graphite Not classified 23
7439-89-6 Iron Not classified 16
7440-50-8 Copper Not classified 12
24936-68-3 PC (Polycarbonate) Not classified 9
ABS (Acrylonitrile
9003-56-9 Not classified 6
Butadiene Styrene)
12190-79-3 Cobalt lithium dioxide Not classified 4
Flam. Liq. 2, H225
554-12-1 Methyl propanoate 4
Acute Tox. 4, H332
Pyr. Sol. 1, H250
7429-90-5 Aluminium 4
Water-react. 2, H261
25929-04-8 PC (Polycarbonate) Not classified 4
21324-40-3 lithium hexafluorophosphate(1-) Not classified 2
4-Fluoro-1,
114435-02-8 Not classified 2
3-dioxolan-2-one
616-38-6 Dimethyl carbonate Flam. Liq. 2, H225 2
9002-88-4 Polyethylene Not classified 2
115-86-6 Phosphoric acid ester Not classified 2
- Polypropene + halogen free flame retardant Not classified 2
Skin Sens. 1, H317 Carc. 2,
7440-02-0 Nickel H351 STOT RE 1, H372 1
Aquatic Chronic 3, H412
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PHYSICAL AND CHEMICAL

PROPERTIES

The following applies to electrolyte leaks

Proper actions Use general ventilation or spot extraction to keep exposure below
hygiene limits. Avoid direct contact with the electrolyte. Emergency
shower and eye shower should be available in the workplace.
Respiratory protection In case of insufficient ventilation, use respiratory protection adapted
for the specific conditions of use.
Skin / body protection Use chemical-resistant gloves. Use full protective clothing and
chemical-resistant apron.
Eye protection Wear safety glasses.

Information on basic physical and chemical properties

The battery consists of an outer cover of which the lid and the cover are made
of polypropylene plastic.

Form Solid
Colour Various
Odour Odourless
pH value Not applicable
Flash point Not applicable
Lower explosion limit Not applicable
Vapour pressure Not applicable
Density Not applicable
Water solubility Insoluble
Ignition temperature Not applicable
 TOYOTA LI-ION BATTERY SYSTEM |
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TOXICOLOGICAL
INFORMATION

If appropriately handled and in accordance with the general hygienic rules, no health
hazards have become known.
However, the product contains substances that are considered to be hazardous to health.

Information on toxicological effects

Acute toxicity LD50 oral > 2000 mg/kg or more
Irritating nature Irritative to skin and eyes
Mutagen Not applicable
Chronic effects of overexposure Not applicable
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A SAMPLE OF DIFFERENT
BATTERY COMPOSITIONS

RRE 420Ah
Content of Lithium-Ion Battery, weight %
Steel - 90,1%
Cell components* - 9,4%
Electrical components - 0,3%
Copper - 0,13%
Plastic - 0,01%
* Content of cell components; LiNiCoAIO2, carbon, PVDF,
AI foil, Cu foil, electrolyte, laminated AI foil

SWE Medium 105Ah

Content of Lithium-Ion Battery, weight %
Steel - 90,1%
Cell components* - 7,9%
Electrical components - 1,8%
Copper - 0,12%
Plastic - 0,04%
* Content of cell components; LiNiCoAIO2, carbon, PVDF,
AI foil, Cu foil, electrolyte, laminated AI foil

LWE Medium 105Ah

Content of Lithium-Ion Battery, weight %
Steel - 62,0%
Cell components* - 31,2%
Electrical components - 6,2%
Copper - 0,58%
Plastic - 0,04%
* Content of cell components; LiNiCoAIO2, carbon, PVDF,
AI foil, Cu foil, electrolyte, laminated AI foil

SWE Large 210Ah

Content of Lithium-Ion Battery, weight %
Steel - 86,2%
Cell components* - 11,7%
Electrical components - 1,8%
Copper - 0,18%
Plastic - 0,01%
* Content of cell components; LiNiCoAIO2, carbon,
PVDF, AI foil, Cu foil, electrolyte, laminated AI foil.
Contents on other battery types on request.
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ECOLOGICAL
INFORMATION

Ecological injuries are not known or expected under normal use. There is no mercury (Hg),
cadmium (Cd) or lead (Pb) in the battery.

DISPOSAL
CONSIDERATIONS

Waste treatment methods

Batteries should be handled as hazardous waste and shall be recycled in special facilities
approved for the purpose. Spent lithium-ion batteries (EWC 16 06 01) are subject to
regulation of the EU Battery Directive (2006/66/EC) and its adoption into national
legislation on the composition and end-of-life management of batteries. Suggested waste
code 16 06 05 (EWC code). Cleaned packaging material is recycled in accordance with
national regulations.
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HANDLING
AND STORAGE

Precautions for safe handling

• Avoid short circuit.
• Avoid reverse polarity (incorrect connection) during installation.
• Keep the battery dry.
• Do not expose the battery to strong oxidising agents.
• Do not damage or remove the battery cover.
• Keep away from open flames, hot surfaces and sources of ignition.
• Do not solder directly on the battery.
• Do not damage or deform the battery.
• Protect the poles from mechanical impact.
• Use only manufacturer-intended charger.

Recommendations for safe storage, including any incompatibilities

• Do not store the batteries in dusty areas and avoid water, acid and oxidising agents.
• Store indoors, between 0°C and +25°C in a dry environment, air humidity below 60%,
battery SOC 50-75%. Optimum temperature is just below 20°C.”
• Avoid direct sunlight, high temperature and high humidity.
• Keep in closed original container to prevent short circuit.
• Check charging level every three month.

EXPOSURE CONTROLS/
PERSONAL PROTECTION

Control parameters
Not specified. During normal charging and discharging no release of any hazardous
substances occur.

Exposure controls
During normal charging and discharging no release of any hazardous substances occur.
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STABILITY
AND REACTIVITY

Reactivity
Not expected to be reactive. In case of leakage, the electrolyte reacts with water.

Chemical stability
Stable under normal conditions of use and storage.

Possibility of hazardous reactions

No dangerous reactions are known.

Conditions to avoid
• Short circuit.
• Mechanical impact that can cause deformation.
• Temperature above 85°C.
• Direct sunlight.
• High humidity.

Incompatible materials
• Electrically conductive material.
• Water.
• Strong oxidising agents.
• Strong acids.

Hazardous decomposition products

No decomposition occurs during storage and use as instructed.
In case of fire and open cells, there is the possibility of hydrofluoric acid and carbon
monoxide release.

COLD STORE OPERATIONS

If the vehicle is converted for Cold Store use, it is possible to work in cold store areas for a
limited time with our standard Li-ion batteries.
For continuous cold store operations the battery need to be ordered with the “heating”
option. The battery will then keep itself warm by internal heating elements.
The heated batteries can be charged in cold store but the charger must be kept warm by an
optional housing or placed outside.
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FIRST-AID
MEASURES

DESCRIPTION OF FIRST-AID MEASURES

The following first-aid measures are required only in case of exposure to interior battery
components after damage of the external battery casing. Undamaged, closed cells do not
represent a danger to the health.

EXPOSURE ACTION
After inhalation Ensure of fresh air. Seek medical attention.
After contact with skin Wash off immediately with plenty of water. Remove all
contaminated clothing. If skin irritation persists, consult
a physician.
After contact with eyes Rinse immediately with plenty of water, also under the eyelids,
for at least 15 minutes. Seek medical treatment by eye specialist.
After ingestion Drink plenty of water. Call a physician immediately.

FIREFIGHTING
MEASURES

If you discover fire or smoke coming from the truck while driving, switch off the truck and
step away from the danger area.

If you discover fire or smoke while charging the truck, switch off the charging unit or
disconnect it and step away from the danger area.

SMOKE FROM THE BATTERY

Important countermeasures:
• Bring the vehicle outside if possible
• Cool down the battery thermal leakage, water is ok to use
• Avoid inhaling the smoke
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BATTERY OR CHARGER ON FIRE

Following these steps:

1. Vacate the room
2. Call the fire brigade
3. Cut the main power to the charger and disconnect the battery charger plug
4. Start the firefighting according to the recommendations below

• Use an AVD (Aqueous Vermiculite Solution) Li-Ion extinguisher aimed directly at the fire
• When the battery fire is extinguished, keep cooling down the battery with water until
the fire brigade arrives
• If the fire is started in an enclosed space, it could be extinguished through an automatic
fire sprinkleror manual controlled sprinkler system.

ACCIDENTAL RELEASE
MEASURE

This information is relevant only if the battery is broken and the contents are released.

Personal precautions, protective equipment and emergency procedures

Use personal protective clothing. Avoid contact with skin, eyes and clothing.
Avoid breathing fume and gas.

Environmental precautions
Do not discharge into the drains/surface waters/groundwater.

Methods and material for containment and cleaning up

Take up mechanically and send for disposal. The solids are put in a container.

Handling of broken batteries

In any case of malfunctioning or damage to the battery, park the machine in a safe place
and contact Toyota service responsible.

See section 3 page 13 for Exposure controls/personal protection and section 4 page 14 for
Disposal considerations.
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SAFETY PRECAUTIONS AND

RECOMMENDATIONS FOR CHARGING AREAS

The site owner is responsible for the installation and precautions around the charging
areas for Lithium-Ion batteries. Always check with your insurance company for specific
requirements or if any local regulations apply to trucks with Li-ion batteries.
Toyota always recommend to make a local risk assessment of the installation to meet the
local directives regarding electrical high-power equipment for industrial use.
As the Toyota Lithium-Ion batteries don’t emit any gas during the charging process, the
charging areas can be placed anywhere in the building without mechanical ventilation,
following our recommendations below.

Note: The high-power Li-Ion chargers might emit a lot of heat during their normal operation.

General recommendations for selecting the area and precautions for charging
Li-Ion batteries:
Installation
• Select an area without heavy traffic or install barrier protections for the vehicles put on
charge
• Don’t place the charger in a small closed room without any air circulation
• Dusty areas or premises with high humidity should be avoided as charging areas
• The floor, walls and ceiling must be made of fire safe material
• The chargers should be steady mounted on the wall at >1500 mm height from the floor,
>300 mm from the ceiling and with a space of >200 mm to the next charger
• Remove all flammable material around the chargers
• The charger must be possible to unplug from the mains or disconnected by an all-pole
power switch

Handle & Care

• Check that the charger plug is fully inserted to the battery and locked when charging
• Handle the charging plug and cable with care, never drop them on the floor or pull the
cable too hard
• Make regularly inspections on cables and sockets, replace at any signs of wear
• If the charger gets any mechanical damages, disconnect mains plug and repair before
use
• Put up the Toyota Safety Poster with user-instructions about safe Li-ion charging

Fire precautions
• Fire extinguisher of type AVD/10kg should be mounted accessible near the charging
area
• Equip the charging area with a smoke & fire detection alarm
• Preferable also install a water tap & hose close to the charging area
• If possible install an automatic fire sprinkler system if the charging takes place during
unmanned hours

Read carefully the instructions in the Operator’s Manual for the vehicle and charger
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CHARGING INFORMATION

During the charging process the Li-ion battery controls charger and the power supply.
The battery BMS secures that the charger is switched off at any malfunctions or high
temperatures.
The recommended temperature range for charging Li-ion trucks is between 0 to +30 C.
Between 0 to +5 C the charging speed is reduced.

DPL chargers
As standard our Li-ion chargers are as standard prepared with a feature called
DPL(Dynamic Power Limitation). The function is used to control the power distribution for
a fleet of chargers. Limitations of the total power from the mains can be managed as well
as the charging current for each charger according to defined charging priorities of the truck
fleet.
Normally the DPL feature is very useful for a large number of vehicles that should be
charged during a break and the power supply from grid is limited.

Toyota charging connector

The new Toyota Li-ion charging connector, replacing the former twist-in connector has a
number of benefits:
• The electrical safety switch system secures that the power is cut before disconnected
– no risk for sparks
• LED-indications on plug indicates the charging process
• Ergonomic shape ensures smooth handling for frequently use
• Easy disconnection via release button
• Dust-protected and durable design
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CERTIFICATE
OF CONFORMITY

The Battery System is a part of the truck CE marking according to the applicable regulations

TEST &
CERTIFICATION

Toyota Li-ion batteries are assembled along our production line in our factory according
Toyota’s Quality and TPS standards.

The Li-ion modules are IP54 certified.

Several safety and redundancy systems are installed to ensure highest safety levels can
be achieved E.g double temp. and voltage measurement on the cells, modules and the
complete battery. If something is wrong down to cell level, the battery is shut down.Each
battery cell has an overtemperature valve that releases the pressure if the cell becomes
overheated. All cells are arranged with a small space in-between, to prevent a chain-
reaction if one cell gets overheated.

Multiples tests are made in our risk assessments:

• Vibrations, Water , Fire, Altitude drop, shocks, short circuits, overcharge, over discharge,
collisions and durability

TMH li-ion battery system meets or exceeds regulation requirements.

With the “EC Declaration of Conformity” that is provided with each truck, Toyota takes full
responsibility of the products and declares that they meet or exceed all requirements of
the applicable EU Directives.

Other documentation from the Technical File are considered as confidential and must not
be disclosed externally.
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NORMS &
REGULATIONS

• MD 2006/42/EC (machine directive) issued in 2006 (EU)

• EMC 2014/30/EU (electromagnetic compatability) (EU)
• ANSI ITSDF_B56.1-2012 (US)

Certificate Status
IEC 62619 Fulfilled
UN 38.3 7th Ed. Fulfilled
EN 1175 Fulfilled
IEC 62620 Fulfilled
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TRANSPORT
INFORMATION

The battery is always transported as part of the truck. Standard accessories and
documentation are included. Check that the delivery is complete and not damaged. Report
any damage directly to the carrier. Replacement or separate battery components should
only be transported in coordination with our dedicated service following the mandatory
rules about packaging, labelling and documents which apply for each transport method.

UN UN PROPER TRANSPORT PACKING

NUMBER SHIPPING NAME HAZARD CLASS(ES) GROUP
ADR/RID UN3480 Lithium-ion batteries 9 188, 230, 310, 636, P903a, P903b
IMDG UN3480 Lithium-ion batteries 9 188, 230, 310, P903
IATA/ICAO UN3480 Lithium-ion batteries 9 A88, A99, A154, A164, P965, P966,
P967, P968, P969, P970
IMDG UN3171 Lithium-ion batteries 9 Battery in truck

Recommendations for safe transportation of Li-ion trucks

If possible reduce the Li-ion battery charging level to <50% before road transports. The risk
in case of an accident will be reduced in relation to the stored energy level.
The ambient temperature range during transportation should be within -40°C to +60°C. If
the battery temperature is below 0°C after transportation, it’s recommended to store the
vehicle in indoor temperature to acclimatise the battery before normal use.
If the vehicle is used with a battery temperature between -25 to 0°C an error code is
displayed. The truck performance and functions are limited to protect the cold battery. The
error code will disappear when the battery is warm again.
Below -25°C the machine can’t be started.

Special precautions for user

Not applicable.

Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code

Not applicable.
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REGULATORY
INFORMATION

Safety, health and environmental regulations/legislation specific for the substance

or mixture
In accordance with the EU Battery Directive and the respective national legislation, lithium
ion batteries have to be marked by a crossed-out dust bin. Lithium-ion batteries are
regulated by the EU Battery Directive (2006/66 / EC) and its implementations in national
legislation on the composition and management of end-of-life batteries.

OTHER
INFORMATION

The information describes the safety requirements for the product(s) and is based on the
present level of our knowledge. Data of all sections do not necessarily refer to the use and
the regular handling of the product (always refer to the operators manual for adequate
product use). This data does not constitute a guarantee for the characteristics of the
product(s) as defined by the legal warranty regulations.
The data for the hazardous ingredients were taken respectively from the last version of the
sub-contractor’s safety data sheet.
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