PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE



This vehicle has a high-voltage (300 V) circuit. 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)


caution Use protective equipment which complies with national legal requirements.

Protective equipment
Number
Name
Use


MB992640

  1. MB992641
  2. MB992642
  3. MB992643
  4. MB992644
Electric insulation helmet (with shield)

  1. Helmet suspension
  2. Chin strap
  3. Visor
  4. Liner

  • 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

  1. MB992669
  2. MB992670
Electric insulation trousers

  1. Electric insulation trousers buckle
  2. Electric insulation trousers adjuster

  • 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
  2. MB992648
  3. MB992649
  4. MB992650


  1. Electric insulation glove (LL)
  2. Electric insulation glove (L)
  3. Electric insulation glove (M)
  4. 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
  2. MB992652
  3. MB992653
  4. MB992654
  5. MB992655
  6. MB992656
  7. MB992657
  8. MB992658


  1. Electric insulation boots (24.0)
  2. Electric insulation boots (24.5)
  3. Electric insulation boots (25.0)
  4. Electric insulation boots (25.5)
  5. Electric insulation boots (26.0)
  6. Electric insulation boots (26.5)
  7. Electric insulation boots (27.0)
  8. 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 colour of orange.




SERVICE PRECAUTIONS


danger When 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 centre 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


Prepare the service plug removal steps check sheet (Refer to ).
1.Turn off the power supply mode of the electric motor switch.
2.
warning
  • To avoid causing any trouble to the electric motor unit components, do not disconnect the auxiliary 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 auxiliary battery is disconnected.
Disconnect the negative terminal of the auxiliary battery.

3.Remove the service lid cover.

4.Remove the service lid mounting nut, and then remove the service lid.


5.
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.
warning 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 auxiliary battery is disconnected.
Lift the service plug lever.

6.
danger After removing the service plug, insulate the plug installed part of the drive battery securely.
Remove the service plug.
7.
danger During 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 drive battery is removed and installed


  • Remove the work-hole lids at the bottom of the drive battery, and carry out the inspection as shown in the figure, using a high-voltage multimeter.
    note For how to remove and install the work-hole lids, refer to .
Normal voltage: Approximately 0 V

When the other high-voltage parts are removed and installed
  • Remove the service lid on the top of the FPDU in the engine compartment, and carry out the inspection as shown in the figure using a high-voltage multimeter.
    note For how to remove and install the service lid, refer to .
Normal voltage: Approximately 0 V


  • Remove the service lid on the top of the RMCU in the luggage compartment, and carry out the inspection as shown in the figure using a high-voltage multimeter.
    note For how to remove and install the service lid, refer to .
Normal voltage: Approximately 0 V

SERVICE PLUG AND SERVICE LID INSTALLATION STEPS


danger Wear the electric insulation gloves when installing the service plug.

1.
caution Pull 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.
caution If the rubber boot around the service plug is released, water may enter the inside of the drive 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.
caution The 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


Tool
Number
Name
Use


MB992337
Electric insulation socket

  • When shutoff of the high voltage is difficult, and the drive battery cable and the EV charger cable (quick charging) connected to the drive battery are removed
  • When shutoff of the high voltage is difficult, and the drive 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.

danger Be sure to wear the electric insulation gloves (special tool) during this work.
danger Be 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 drive battery cable <front and rear> and the EV charger cable (quick charging) from the drive 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 drive battery cable at the FPDU and the RMCU side (Refer to <FPDU> and <RMCU>).

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. After the diagnosis, also erase the PHEV-ECU related diagnosis code.

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.
caution Be sure to release the lock of the connector with your hands, because use of a tool or others may damage the connector.

Unlock the connector by sliding the lock, and then remove it.

Unlock the connector by sliding the lock, and then remove it.