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PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE
 
 
This vehicle has a high voltage circuit of 300 V <nominal value> (Depending on the remaining capacity of the battery, generate a maximum operating voltage of 336 V). If the vehicle is handled incorrectly, electric leakage or shock may result. Also, the service technicians/engineers who perform inspection and service related to the high-voltage circuit of the electric vehicles are obligated to observe national legal requirements.
 
 
 
INSPECTION/TEST OF PROTECTIVE EQUIPMENT, BLOTTER STORAGE
Check and store the protective equipment in accordance with national legal requirements.
 
 
PROTECTIVE EQUIPMENT (REFERENCE ONLY)
cautionUse protective equipment which complies with national legal requirements.
Protective equipmentNumber and nameSupersessionApplication
MB992640
Electric insulation helmet (with shield)
-
  • When you may contact with the exposed live wirings while handling the damaged vehicle
  • Alternatively, when you prevent the electric shock according to need
MB992645
Electric insulation jacket
-
  • When you may contact with the exposed live wirings while handling the damaged vehicle
  • Alternatively, when you prevent the electric shock according to need
MB992646
Electric insulation trousers
-
  • When you may contact with the exposed live wirings while handling the damaged vehicle
  • Alternatively, when you prevent the electric shock according to need
  1. MB992647
    Electric insulation glove (LL)
  2. MB992648
    Electric insulation glove (L)
  3. MB992649
    Electric insulation glove (M)
  4. MB992650
    Electric insulation glove (S)
-
  • Service plug removal and installation
  • Work on live wirings when there is a problem
  • When you may contact with the exposed live wirings while handling the damaged vehicle
  • Alternatively, when you prevent the electric shock according to need
  1. MB992651
    Electric insulation boots (24.0)
  2. MB992652
    Electric insulation boots (24.5)
  3. MB992653
    Electric insulation boots (25.0)
  4. MB992654
    Electric insulation boots (25.5)
  5. MB992655
    Electric insulation boots (26.0)
  6. MB992656
    Electric insulation boots (26.5)
  7. MB992657
    Electric insulation boots (27.0)
  8. MB992658
    Electric insulation boots (28.0)
-
  • When you may contact with the exposed live wirings while handling the damaged vehicle
  • Alternatively, when you prevent the electric shock according to need
 
 
 
 
TESTER AND SPECIAL TOOL
Be sure to use the tester and special tools specified in this manual.
 
 
 
HIGH-VOLTAGE COMPONENTS
The high-voltage components are described below. Also, wiring harness and connectors of high-voltage circuit are unified with a color of orange.
  • Main drive lithium-ion battery
  • Power drive unit (incorporating GCU [Generator Control Unit])
  • Rear electric motor control unit (REMCU)
  • Front motor assembly
  • Rear motor assembly
  • Generator
  • On board charger/DC-DC converter
  • Electric heater
  • Main drive lithium-ion battery cable
  • EV charging cable (Normal charger)
  • EV charging cable (Quick charger)
  • Service plug
  • Wiring harness and connector
 
 
 
SERVICE PRECAUTIONS
dangerWhen adjusting the high-voltage components, be sure to disconnect the service plug in order to shut off the high voltage. If the high voltage cannot be shut off after the following work, or if the high-voltage shut-off work is difficult because of the accidental damages, refer to .
Remove the service plug under the rear center seat according to the following procedure, which shuts off the high voltage to the high-voltage system. Also, when installing the service plug and the service lid, check the precautions (Refer to ).
 
 
Service plug and service lid removal steps
1. Prepare the service plug removal steps check sheet (Refer to ).
2. Turn off the power supply mode of the electric motor switch.
3.
warning
  • To avoid causing any trouble to the electric motor unit components, do not disconnect the 12V starter battery negative terminal for two minutes after turning off the power supply mode of the electric motor switch.
  • The voltage of the smoothing condenser in the inverter must be decreased thoroughly. Therefore, do not remove the service plug for 5 minutes after the negative terminal of the 12V starter battery is disconnected.
Disconnect the negative terminal of the 12V starter battery.
4. Remove the service lid cover.
5. Remove the service lid mounting nut, and then remove the service lid.
6.
danger
  • Wear the electric insulation gloves when pulling out the service plug.
  • Do not lift the lever of service plug by halve. It is dangerous because the current is supplied during the lifting operation. Be sure to remove the service plugs all at once.
warningThe voltage of the smoothing condenser in the inverter must be decreased thoroughly. Therefore, do not remove the service plug for 5 minutes after the negative terminal of the 12V starter battery is disconnected.
Lift the service plug lever.
7.
dangerAfter removing the service plug, insulate the plug installed part of the main drive lithium-ion battery securely.
Remove the service plug.
8.
dangerDuring inspection, wear the electric insulation gloves. If the high voltage cannot be shut off after the inspection, refer to .
When removing and installing each high-voltage part, be sure to perform the following inspection beforehand.
When the main drive lithium-ion battery is removed and installed
  • Remove the work-hole lids at the bottom of the main drive lithium-ion battery, and carry out the inspection as shown in the figure, using a high-voltage multimeter.
    noteFor how to remove and install the work-hole lids, refer to .
Normal voltage: Approximately 0 volt
When the other high-voltage parts are removed and installed
  • Remove the service lid on the top of the power drive unit in the engine compartment, and carry out the inspection as shown in the figure using a high-voltage multimeter.
    noteFor how to remove and install the service lid, refer to GROUP 54Db - Power Drive Unit .
Normal voltage: Approximately 0 volt
  • Remove the service lid on the top of the REMCU in the luggage compartment, and carry out the inspection as shown in the figure using a high-voltage multimeter.
    noteFor how to remove and install the service lid, refer to .
Normal voltage: Approximately 0 volt
 
 
 
SERVICE PLUG AND SERVICE LID INSTALLATION STEPS
dangerWear the electric insulation gloves when installing the service plug.
1.
cautionPull the service plug lever down until it clicks, because the interlock switch does not operate unless the service plug lever is pulled down properly.
Install the service plug.
2.
cautionIf the rubber boot around the service plug is released, water may enter the inside of the main drive lithium-ion battery, resulting in short-circuit. Therefore, check that the rubber boot is engaged with the body flange before installing the service lid.
The arrow on the service lid should face towards the front of the vehicle.
3. Tighten the service lid mounting nuts.
4.
cautionThe service lid cover mounting clip (two at the rear of the vehicle) is assembled with a packing to avoid water entry. When you install the service lid, make sure that this packing is not deformed or missing.
Install the service lid cover.
 
 
 
ACTION WHEN HIGH VOLTAGE CANNOT BE SHUT OFF
SPECIAL TOOL (REFERENCE ONLY)
ToolTool number and nameSupersessionApplication
MB992337
Electric insulation socket
-
cautionThis tool is the insulation tool which prevents the circuit of the equipment from shorting caused by tool dropping, etc. It does not isolate the operator from the equipment. When using this tool, be sure to wear the electric insulation gloves.
  • When shutoff of the high voltage is difficult, and the main drive lithium-ion battery cable and the EV charger cable (quick charging) connected to the main drive lithium-ion battery are removed
  • When shutoff of the high voltage is difficult, and the main drive lithium-ion battery cable and the motor (electric motor unit) cable connected to inverter are removed
  • Alternatively, when a short circuit of the equipment may be present with the damaged vehicle, etc.
dangerBe sure to wear the electric insulation gloves (special tool) during this work.
dangerBe sure to wear the electric insulation socket (MB992337) during this work.
When the high voltage remains even after the shut-off of the high voltage is performed, or when the high voltage shut-off work itself is difficult because of the accidental damages, perform the security according to the following procedure.
1. Remove the work-hole lid (Refer to ).
2.
Remove the six inner cable mounting bolts.
3. Remove the six outer cable mounting bolts.
4. Pull out the main drive lithium-ion battery cable <front and rear> and the EV charger cable (quick charging) from the main drive lithium-ion battery.
5. If steps 1 to 4 are difficult to perform or it is necessary to carry out any service work in the engine compartment or the electric motor unit compartment, disconnect the main drive lithium-ion battery cable at the power drive unit and the REMCU side (Refer to GROUP 54Db - Power Drive Unit <Power drive unit> and GROUP 54Db - REMCU <REMCU>).
 
 
 
ACTION WHEN HIGH-VOLTAGE SHUT-OFF SYSTEM IS OPERATED
A high-voltage shut-off system isolates high voltage in the event of a crash. When this system operates, diagnose the post-collision vehicles (Refer to GROUP 52B - Post-collision Diagnosis ). After the diagnosis, also erase the PHEV-ECU related DTC.
 
 
HIGH-VOLTAGE CONNECTOR REMOVAL STEPS
danger
  • When adjusting the high-voltage parts, remove the service plug.
  • When the lock of the connector is damaged, be sure to replace the wiring harness assembly.
cautionBe sure to release the lock of the connector with your hands, because use of a tool or others may damage the connector.
1. Slide the lock (A) towards the arrow direction to disengage it.
2. Depress the lock (B) and pull out the connector towards the arrow direction to its stop position.
3. Depress the lock (C) and disconnect the connector by pulling out it towards the arrow direction.