Electric Drive Systems: Service Precautions
NOTICE FOR EV SYSTEM
1. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
CAUTION: This vehicle has a high-voltage EV battery system that operates at 277.5 V. Be sure to follow the instructions to handle the system correctly. Failure to do so may result in serious injury or electrocution.
a. Technicians must undergo special training to be able to service and inspect the high-voltage system.
b. All high-voltage wire harnesses and connectors are colored orange. The EV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
c. When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
d. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug grip to prevent electrocution. Carry the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
e. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
f. Remove the service plug grip.
CAUTION: After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.
HINT: Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
NOTICE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
g. Install the service plug grip.
NOTICE:
- Before connecting the service plug grip, check again to make sure that no parts or tools have been left behind, and that high voltage terminals are properly tightened and connectors are properly connected.
- Connect the auxiliary battery on the same day of installing the service plug grip to allow the battery cell voltage equalization function of the battery smart unit to operate. - After folding down the grip 90°, firmly slide the grip until a click sound can be heard.
h. When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
i. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
j. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
k. Bolts and nuts for high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
l. Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
m. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
n. When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.
o. When installing EV control system components such as the EV battery, make sure that the polarity of all connections is correct.
2. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT
CAUTION: This vehicle has a high-voltage EV battery system that operates at 277.5 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the EV battery. Be sure to follow the instructions to handle the system correctly. Failure to do so may result in serious injury or electrocution.
a. Items to be prepared for the accident site
- Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))
- Soap
- ABC fire extinguisher (effective against both oil flames and electrical flames)
- A shop towel or piece of cloth (for wiping off the electrolyte)
- Insulating tape (for insulating cables)
- Electrical tester
b. Actions to be taken at the accident site
CAUTION:
- Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
- If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.
- Visually check the EV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.
- The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.
- Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.
- If the vehicle is immersed in water, do not touch any high-voltage components or cables including service plug grips. This is to prevent a shock hazard. Work on the vehicle only after the vehicle has been pulled out of the water.
- In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.
- If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.
- If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.
1. Check the vicinity of the EV battery for any leakage of the electrolyte.
CAUTION: Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.
2. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.
CAUTION: Be sure to wear insulated gloves, goggles and safety shoes.
3. Turn the power switch off.
HINT: If the power switch cannot be turned off, remove the IG2 fuse from the No. 1 motor compartment relay block. Confirm that the READY indicator light is off.
4. Disconnect the cable from the negative (-) auxiliary battery terminal.
5. Wear insulated gloves, and then remove the service plug grip.
NOTICE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
c. Moving the damaged vehicle
If any of the following conditions is met, tow the vehicle away using a tow truck.
NOTICE: When towing the vehicle, refer to the "PRECAUTIONS FOR TOWING FRONT WHEEL DRIVE VEHICLES".
- One or more of the high-voltage components and cables are damaged.
- Components related to driving, the transaxle, or the EV battery system are damaged.
- The master warning light is on.
- The READY indicator light does not come on when attempting to turn the power switch on (READY).
CAUTION: Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) auxiliary battery terminal and remove the service plug grip.
NOTICE: Perform the procedure below if the master warning light turns on, or there are abnormal noises, unusual smells, or strong vibrations while driving:
1. Park the vehicle in a safe place.
2. Apply the parking brake, and then move the shift lever to P.
3. Turn the power switch off, and disconnect the cable from the negative (-) auxiliary battery terminal.
4. Remove the service plug grip while wearing insulated gloves.
d. Actions required after moving the damaged vehicle
1. Procedure
If there is liquid on the floor, it could be organic electrolyte containing carbonic acid esters. Wipe the liquid away while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.
e. Items to be prepared (when repairing a damaged vehicle)
- Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))
- Soap
- ABC fire extinguisher (effective against both oil flames and electrical flames)
- A shop towel or piece of cloth (for wiping off the electrolyte)
- Insulating tape (for insulating cables)
- Electrical tester
f. Precautions to be observed when servicing a damaged vehicle
CAUTION:
- Always follow instructions to ensure safety.
- Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
- Visually check the EV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.
- The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.
- Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.
- In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.
- If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.
- If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.
1. Wear insulated or rubber gloves, goggles, and safety shoes.
2. Check the EV battery and immediate area for any electrolyte leakage.
CAUTION: Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.
3. Do not touch any bare cables that could be high voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.
4. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
CAUTION: Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
5. Turn the power switch off.
HINT: If the power switch cannot be turned off, remove the IG2 fuse from the No. 1 motor compartment relay block. Confirm that the READY indicator light is off.
6. Disconnect the cable from the negative (-) auxiliary battery terminal.
7. Wear insulated gloves, and then remove the service plug.
NOTICE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
g. Precautions to be taken when disposing of an EV battery
1. When disposing of an EV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the EV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.
CAUTION:
- Before returning the EV battery, make sure to perform recovery inspection.
- Accidents such as electric shock may result if the EV battery is disposed of improperly or abandoned. Therefore, make sure to return all EV batteries through an authorized collection agent.
- To reduce the risk of fire, the EV battery must not be stored in an area where it will be exposed to fire or high temperatures.
h. Precautions to be observed when towing
1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.
CAUTION: Towing the damaged vehicle with its front wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.
i. Towing with the 4 wheels on the ground
CAUTION:
- If the vehicle needs to be towed using a rope with all 4 wheels on the ground, do not exceed 30 km/h (19 mph) and tow only for a short distance and then have the vehicle towed by a truck.
- Turn the power switch on (IG), move the shift lever to N and confirm that neutral (N) has been selected.
- Make sure not to turn the power switch off while the vehicle is being towed. Park (P) may be selected, which while being towed can result in damage or an accident.
- If any abnormality is present in the damaged vehicle while towing, stop towing immediately.
3. PRECAUTIONS FOR TOWING FRONT WHEEL DRIVE VEHICLES
a. Use one of the following methods to tow the vehicle.
b. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).
NOTICE: Do not use any towing method other than those shown above.
c. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s).
This should only be attempted on hard surfaced roads for short distances below 30 km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.
NOTICE: If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with the front wheels on the ground, the transaxle may be damaged.
1. Emergency towing procedure
1. Turn the power switch on (IG).
2. Depress the brake pedal and move the transaxle shift lever to N.
3. Release the parking brake.
4. Release the brake pedal slowly.
NOTICE:
- Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.
- If the EV control system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.
- Do not turn off the power switch. Turning off the power switch may result in engagement of the parking lock, resulting in a hazardous situation or accident.
d. The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.
1. Do not tow the vehicle facing rearward with the front wheels on the ground.
NOTICE:
- If the vehicle is towed facing rearward with the front wheels on the ground, the drivetrain may overheat and be damaged.
- In addition, if the vehicle is equipped with the VSC system, the system may apply the brakes to the rotating wheels.
2. Do not use a sling-type towing method either from the front or rear.
NOTICE: If a sling-type tow truck is used, damage may occur to the vehicle body.