2016 FUSION HYBRID MKZ HYBRID FUSION …elvsolutions.org/wp-content/uploads/2015/08/2016_Fusion-MKZ_HEV...2016 FUSION HYBRID MKZ HYBRID ... for vehicle’s electric motor. ... servicing

FCS-21234-16

HIGH-VOLTAGE BATTERY REMOVAL GUIDE

2016FUSION HYBRID

MKZ HYBRIDFUSION ENERGI

FCS-21234-16 1 2015 Fusion/MKZ/Fusion Energi Battery Removal Guide

Table of Contents

FOREWORD .................................................................................................. Page 2

VIN Layout .............................................................................................Page 5

HYBRID VEHICLE IDENTIFICATION ............................................................ Page 3-4

HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES ........................ Page 6

HIGH-VOLTAGE WARNING DECALS ........................................................... Page 7

HYBRID COMPONENT LOCATION AND IDENTIFICATION ........................ Page 8-9

HIGH-VOLTAGE SERVICE DISCONNECT.................................................... Page 12

HIGH-VOLTAGE BATTERY PACK ................................................................ Pages 13-14

Follow Existing Training and Incident Commander Direction .........Page 15APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE ......................... Page 15

Approaching a Damaged Vehicle ........................................................Page 16If The High-Voltage Battery Case Has Been Ruptured ......................Page 17Moving Damaged Vehicles - Wrecker Drivers ....................................Page 17Special Note To Salvage Yards ...........................................................Page 17High Voltage System - Do Not Cut Zones ..........................................Page 18

DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES ........................................................................ Pages 19-20HIGH VOLTAGE BATTERY REMOVAL ........................................................ Pages 22-39SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS .................... Pages 40-41

ENERGI COMPONENT LOCATION AND IDENTIFICATION ........................ Pages 10-11

Fusion Hybrid .......................................................................................Page 12Fusion Energi ........................................................................................Page 13


FOREWORD The emergency response procedures for the Fusion Hybrid, MKZ Hybrid and Fusion Energi vehicles are similar to those for traditional gasoline-powered vehicles with the addition of special considerations for the high-voltage electric system components.

The Fusion Hybrid, MKZ Hybrid and Fusion Energi vehicles use a conventional gasoline engine in addition to an electric motor to power the vehicle.

• Gasolineisstoredinatraditionalfueltank.

• Electricityisstoredinahigh-voltagebatterypack.

The combination of a gasoline engine and electric motor provides for improved performance (V6 performance with a 4-cylinder engine and electric motor), reduced emissions and improved fuel economy. The Fusion Hybrid and MKZ Hybrid high-voltage systems are self contained, never needing to be plugged into an electrical outlet for recharging. The Fusion Energi high-voltage system can be plugged into an electric outlet for recharging to optimize the vehicle’s extended electrical range. Both vehicle systems incorporate a generator that charges the high-voltage battery during cruisingandbraking.

The information in this guide will allow response to emergencies involving the Fusion Hybrid, MKZ Hybrid and Fusion Energi vehicles to be as safe as non-hybrid vehicles.

The Fusion Hybrid, MKZ Hybrid and Fusion Energi vehicles have been designed with many safety features for your protection. These features help provide safe access to the vehicle under various conditions; however, when approaching a high-voltage vehicle in afire,rescueorrecoverysituation,alwaysfollowoneindustrystandardrule:

ALWAYS ASSUME THE VEHICLE’S HIGH-VOLTAGE SYSTEM IS POWERED UP !


NOTE:FusionEnergishown.

HYBRID VEHICLE IDENTIFICATION

•TheFusionHybridvehiclescaneasilybeidentifiedbythe“Hybrid”badgeslocatedon theleftandrightfrontdoors.Thereisa“Hybrid”nameplateonthetrunklid(located ontherighthandside)thatalsoincludesthegreenleaf/bluehighway“Hybrid”icon.

Hybrid/Energi nameplate and iconontrunklid.

Hybrid/Energi nameplate with Hybrid icon on front doors.

•TheFusionEnergivehiclescaneasilybeidentifiedbythe“Energi”badgeslocatedontheleftandrightdoors.Thereisa“Energi”nameplateonthetrunklid(locatedonthe lefthandside)thatalsoincludesthegreenleaf/bluehighway“Hybrid”icon.


HYBRID VEHICLE IDENTIFICATION - CONTINUED

•TheMKZHybridvehiclescaneasilybeidentifiedbythe“2.0H”badgelocatedonthe trunklid.

MKZHybrid“2.0H”nameplateontrunklid.


Fusion Hybrid FWD

VEHICLE

•The5th,6thand7thdigitsoftheVehicleIdentificationNumber(VIN)identifythe Hybrid vehicle line.

VIN POSITIONS 5, 6 and 7

P0L

L2LP0P

Fusion SE Full Hybrid MKZ Hybrid Full HybridFusion SE Energi Plug-in Hybrid

•TheFusionHybridandMKZHybridvehicleshaveauniqueengineappearancecoverwitharaised“HYBRID”(or“HYBRIDENERGI”forEnergivehicles)icon.

NOTE: Fusion/MKX Hybrid shown, Fusion Energi similar.

UniqueHybridengineappearancecover with raised lettering and icon

P0R Fusion Titanium Full HybridP0S FusionTitaniumEnergiPlugInHybrid


WARNING: ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH-VOLTAGE SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH-VOLTAGE ELECTRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH-VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HV SYSTEM AS DIRECTED BY THE FORD EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES

The following list describes certain features that have been incorporated into the Fusion Hybrid, MKZ Hybrid and Fusion Energi vehicles that allow for either simple or automatic shut off of the high-voltage electrical systems.

•High-VoltageFuse—Intheeventofahigh-voltageshortcircuit,thehigh-voltage fuse will open, disabling the high-voltage system.

•High-VoltageInterlockCircuit—Wheneverahigh-voltageconnectorisdisconnected,thehigh-voltageinterlockcircuitopensanddisablesthehigh-voltagesystem.

•IgnitionKeyintheOFFPosition—Anytimethe12-voltsystemisturnedoff(ignition lockcylinderisintheOFFposition),thehigh-voltagesystemisdisabled.

•High-VoltageServiceDisconnect—Wheneverthehigh-voltageservicedisconnect (locatedbehindtherearseatback)isremoved,thehigh-voltagesystemisdisabled.Foradditionalinformation,refertoPage10inthismanual.

•ThermalSensors—Intheeventthebatteryisexposedtoextremehotambient conditions and/or is being driven extremely aggressively with compromised cooling, power limits will be employed to prevent overheating. However, if the battery is in use and does become too hot, contactors will be opened and the vehicle will shut down. Insomeinstances,iftheignitionkeyisleftinthe“ON”position,thiscouldcausethe high-voltagebatterytemperaturetoexceed60°C(140°F);ifthistemperatureis reached, the thermal sensors located near the high-voltage battery will automatically disable the high-voltage battery.


HIGH-VOLTAGE WARNING DECALS

•OnHybridandEnergivehicles,WARNINGdecalsarelocatedoncomponentsinthe high-voltage system throughout the vehicle. Please see example below.


HYBRID COMPONENT LOCATION AND IDENTIFICATION

TheillustrationbelowanditsdefiningchartonPage9,providethelocation,descriptionand basic function of the Hybrid system components.

NOTE:Allhigh-voltagewiresandharnessesarewrappedinorange-coloredinsulation.

NOTE:FusionHybridshown,MKZHybridsimilar.

1

2

4

56

7

3


HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION1 High-VoltageBattery Approximately300- VoltsDC

• Liesflatinthetrunkarea, located behind the rear seat.

• Sealedlithiumbattery.

Provides high-voltage storage for vehicle’s electric motor.

2 12-VoltBattery • Locatedinthetrunkareaof the vehicle. • Typicalautomotive6-cell lead/acid design.

Provides 12-voltsforvehicleaccessories.

3 High-Voltage Service Disconnect

• Locatedbehindtherear seatback.• Orangerectanglewitha molded plastic handle, about 100mm(4in)inlength.

Provides means to disconnect high-voltage battery for safely servicing vehicle.

4 High-Voltage Wiring • Runsalongthevehicle’s floorpanfromthehigh-voltage battery to the Electronically ControlledContinuously VariableTransaxle(ECVT), totheDC-to-DCconverter andthentotheelectricA/C and heater units. • Allhigh-voltagewiringhas orange-colored insulation.

Provides physical connection between high-voltage battery and vehicle’s high-voltage equipment.

6 Electronically Controlled Continuously Variable Transaxle (ECVT)

•Transverse-mounteddesign, similar to the non-Hybrid Fusion MKZ vehicles.

Provides rotational force to the wheels for vehicle propulsion and transmits rotational force to the engine’s generator to recharge batteries.

5 TransmissionControlModule

•Locatedabovethe transmission.

Provides rotational force during ElectricalDriveModes.Gener-ates3-phaseAChigh-voltageelectricity via two cables to and from the traction motor and generator.

•Containscontrolling electronics for managing propulsion.

7 ElectricA/C Compressor

•Locatedinfrontofthe engine. • Has an orange high-voltage wire attached to it using an interlockconnector.

ProvideselectricA/Coperation; replacesthebeltdrivenA/Ccompressor.


TheillustrationbelowanditsdefiningchartonPage11providesthelocation, description and basic function of the Fusion Energi’s system components.

NOTE:Allhigh-voltagewiresandharnessesarewrappedinorange-coloredinsulation.

ENERGI COMPONENT LOCATION AND IDENTIFICATION

12

3

4

57

8

6

9


ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION

2 High-VoltageBattery Approximately300- VoltsDC

• Liesflatinthetrunkarea, located behind the rear seat.• Sealedlithiumbattery.

Provides high-voltage storage for vehicle’s electric motor.

3 12-VoltBattery • Locatedinthetrunkareaof the vehicle. • Typicalautomotive6-cell lead/acid design.

Provides 12-voltsforvehicleaccessories.

1 High-Voltage Service Disconnect

• Orangerectanglewitha molded plastic handle, about 100mm(4in)inlength.

Provides means to disconnect high-voltage battery for safely servicing vehicle.

4 High-Voltage Wiring • Runsalongthevehicle’s floorpanfromthehigh-voltage battery to the Electronically ControlledContinuously VariableTransaxle(ECVT), totheDC-to-DCconverter andthentotheelectricA/C and heater units.

Provides physical connection between high-voltage battery and vehicle’s high-voltage equipment.

7 Electronically Controlled Continuously Variable Transaxle (ECVT)

•Transverse-mounteddesign, similar to the non-Hybrid Fusion MKZ vehicles.

Provides rotational force to the wheels for vehicle propulsion and transmits rotational force to the engine’s generator to recharge batteries.

Provides110Vchargingoptiontothe high-voltage battery when the vehicle is not in operation .

8 ElectricA/C Compressor

•Locatedinfrontofthe engine. • Ithasanorangehigh-voltage wire attached to it using an interlockconnector.

ProvideselectricA/Coperation; replacesthebeltdrivenA/Ccompressor.

• Locatedbehindtherear seatback.

• Allhigh-voltagewiringhas orange-colored insulation.

5 ChargingPort •Locatedonthedriverside fender.

6 Transmission ControlModule

•Containscontrolling electronics for managing propulsion.

•Locatedabovethe transmission.

Provides rotational force during ElectricalDriveModes.Gener-ates3-phaseAChigh-voltageelectricity via two cables to and from the traction motor and generator.

9 ElectricHeater •Locatedintheengine compartment on the passenger side.

Provides passenger compart-ment with heat without the need to turn the engine on.


HIGH-VOLTAGE SERVICE DISCONNECT - FUSION HYBRID

NOTE: Ifpossible,releaseandremovethehigh-voltageservicedisconnect.

*

ROTATE THE LEVER TO HORIZONTAL.

PULL LEVER HANDLE OUTWARD TO DISENGAGE INTERLOCK.

REMOVAL INSTRUCTIONS

REMOVE THE HIGH-VOLTAGE SERVICE DISCONNECT.

NOTE: The Hybrid high-voltage servicedisconnect is located behind the rear seatback on the driver side. Fold the rear seatback down and remove the cover to access.

FUSION HYBRID VEHICLES

1

2

3

1

2

3

4

PULL THE LEVEL POSITION ASSURANCE(LPA) TAB TOWARD FRONT OF VEHICLE TO REMOVE.

4


WARNING: ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH-VOLTAGE SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH-VOLTAGE ELECTRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSON-AL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH-VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HV SYSTEM AS DIRECTED BY THE FORD EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

HIGH-VOLTAGE BATTERY PACK

HIGH-VOLTAGE SERVICE DISCONNECT - FUSION ENERGI

NOTE: Ifpossible,releaseandremovethehigh-voltageservicedisconnect.

ROTATE THE LEVER TO HORIZONTAL.

PULL LEVER HANDLE OUTWARD TO DISENGAGE INTERLOCK.

REMOVAL INSTRUCTIONS

NOTE: The Energi high-voltage servicedisconnect is located behind the rear seatback on the passenger side. Fold the rear seatback down and remove the cover to access.

1

FUSION ENERGI VEHICLES

2

3

4

1

2

3

4 REMOVE THE HIGH-VOLTAGE SERVICEDISCONNECT.

PULL LEVER POSITION ASSURANCE (LPA)TAB TOWARD FRONT OF VEHICLE TO REMOVE.


HIGH-VOLTAGE BATTERY PACK - CONTINUED

•Donotcutthehigh-voltagebatterycase.Donotpenetratethebatteriesorcasein any way.

•Thehigh-voltagebatteryislocatedintheforwardportionoftheluggage compartment.Thehigh-voltagebatteryliesflatjustbehindtherearseatbackunder the luggage compartment cargo cover.

•Removingthehigh-voltageservicedisconnectwilldisconnectthehigh-voltagefrom thevehicle.Thebatterypackwillremainliveanddangerous.

•Thetotalvoltageofthebatterypackisapproximately300-voltsDC.

•Thebatterycellscontainabaseelectrolyte,consistingoflithiumhexafluorophophate and organic solvents as the dominant active ingredient, that is absorbed in special polymericfilm.Theelectrolytewillnotleakfromthebatteryundermostconditions, however, if the battery is crushed, it is possible for a small amount of electrolyte to leak.

NOTICE:Thefollowingmustbefollowedwhenworkingwithadamagedbattery:

•Ifpossible,isolateandavoidcontactwithhigh-voltagevehiclecomponents.Ifcontact withthehigh-voltagesystemcannotbeavoided,PersonalProtectiveEquipment (PPE)suchasasplashshieldorsafetygoggles,gloves(latex,rubberorNitrile),an apronorovercoatandrubberbootsarerequiredwhenhandlingdamagedbatteries. Exposuretoelectrolytecouldcauseskinand/oreyeirritation/burns.Ifexposed,rinse withlargeamountsofwaterfor10-15minutes.

•Ifthebatteryisexposedtointenseheat(orotherabusiveconditions),itispossible thatflammablegasesandliquid(electrolyte)havebeenreleasedfromthecells.The gases include combustible hydrocarbons such as methane, toxic gases such as carbonmonoxide,andverysmallamountsofeye/skin/lungirritantssuchas hydrofluoricacidcouldbereleasedfromthebattery.Appropriateprecautionsshould betakentomakesuretheareaisproperlyventilated,suchasopeningthevehicle’s windowsordoors.FirstrespondersshouldwearPersonalProtectiveEquipment (PPE) and self contained breathing apparatus to safeguard against thermal, electrical,respiratoryandskin/eyehazards.

WARNING: FIRES IN CRASH-DAMAGED ELECTRIC VEHICLES MAY EMIT TOxIC OR COMBUSTIBLE GASSES. SMALL AMOUNTS OF EYE, SKIN OR LUNG IRRITANTS MAY BE PRESENT. WEAR PERSONAL PROTECTIVE EQUIPMENT (PPE) AND SELF-CONTAINED BREATHING APPARATUS WHEN WORKING IN CLOSE PROxIMITY OR IN A CONFINED AREA, SUCH AS A TUNNEL OR GARAGE. VENTILATE THE VEHICLE INTERIOR BY OPENING VEHICLE WINDOWS OR DOORS. VENTILATE THE WORKING AREA. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.


APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE

WARNING: ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH-VOLTAGE SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH-VOLTAGE ELECTRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH-VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HV SYSTEM AS DIRECTED BY THE FORD EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

WARNING: DAMAGED ELECTRIC VEHICLES SUBMERGED IN WATER PRESENT A POTENTIAL HIGH-VOLTAGE ELECTRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH-VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. DO NOT ATTEMPT TO ExTRACT THE VEHICLE UNTIL THE HIGH-VOLTAGE BATTERY HAS DISCHARGED INDICATED BY THE ABSENCE OF BUBBLING OR FIZZING. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

1. FOLLOW ExISTING TRAINING AND INCIDENT COMMANDER DIRECTION

•EmergencyrespondersshoulduseLARGE amountsofwateriffireispresentorsuspectedand,keepinginmindthatfirecanoccurforaconsiderableperiodafterthe crash, should proceed accordingly.

•ThisguideprovidesonlysupplementalinformationasitpertainstotheFusionHybrid, MKZ Hybrid and Fusion Energi vehicles. The same rules apply when approachinganypotentialhigh-voltagesituation.Alwaysfollowyourhigh-voltagesafetytraining. Someprecautionstotakeinahigh-voltagesituationinclude:

—Removealljewelry:Watches,necklacesandearrings.Removeany metalobjectsthatareconductorsofelectricity.

—WearthenecessaryPPEs:High-voltagerubbergloves,faceshield,insulated boots, protective raincoat and apron.

• Bringthefollowingequipment:

—ClassABCpowder-typefireextinguisher.

—Anonconductiveobject,about1.5m(5ft)long.Thiscanbeusedtosafely push someone away from the vehicle if they accidentally come in contact with high-voltage.


APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED

2. APPROACHING A DAMAGED VEHICLE

•Disablethehigh-voltageelectricalsystemusingasmanyofthefollowingstepsaspossible:

—Securethevehicle:PlacetheshiftleverintothePARKposition.Placethe ignitionintheOFFposition.Forvehiclesequippedwithpushbuttonstart, checkthatthevehiclereadylightisOFFtoverifythehigh-voltagesystemis disconnected.IfthevehiclereadylightisON,presstheStartbuttontoturn OFFtheignition.Blockthewheels,ifnecessary.

—Disconnectthenegativecablefromthe12-voltbattery.

—Ifpossible,removethehigh-voltageservicedisconnect(s).Foradditional information,refertopage12and13inthismanual.Iftheservicedisconnects cannot be removed, avoid the high-voltage system components, and wear all appropriatePPEasoutlinedonpage14ofthisguide.

•Ifthevehicleisonfire,useaClassABCpowder-typeextinguishertocontainandsmothertheflames.Ifwaterisbeingused, LARGE amountsofwaterwillberequiredtoextinguishtheflames.Afire-hydrantordedicatedfirehosecansupplytheneeded amount. Water can cause some degree of arcing/shorting across the cell and/or battery terminals; it can also react with the electrolyte from the cells to generate additionalcombustiblegasandotherby-productssuchashydrofluoricacid;however,thecoolingandsmotheringeffectsofflushingtheaffectedarticlewithlargeamountsofwaterand/orotherfiresuppressionmaterialisstillbeneficialforminimizingthe severity of the event.

•Ifthevehiclehasanyexposedcables,makesuretowearhigh-voltagerubberglovesandotherappropriatePPE.Donottouchanybrokenordamagedhigh-voltageorange cables. Treat severed cables as if they contain high-voltage.

•Ifthevehicleissubmergedinwater,varyingdegreesofarcing/shortingwithinthebatterywilltakeplace.Donottouchanyhigh-voltagecomponentsororangecables while extricating the occupant(s). Do not remove the vehicle until you are sure the high-voltagebatteryiscompletelydischarged.Asubmergedhigh-voltagebatterymayproduceafizzingorbubblingreactiontothewater.Iffizzingorbubblingisobserved,thehigh-voltagebatterywillbedischargedwhenthefizzingorbubblinghas completely stopped, however, still treat it as if it was not discharged.


APPROACHING A DAMAGED VEHICLE - CONTINUED

•Ifthevehicleisonfire,useaClassABCpowder-typeextinguishertocontainand smothertheflames.Ifwaterisbeingused, LARGE amountsofwaterwillberequiredtoextinguishtheflames.Afire-hydrantordedicatedfirehosecansupplytheneeded amount.•Ifthevehiclehasanyexposedcables,makesuretowearhigh-voltagerubberglovesandotherprotectiveclothing.Donottouchanybrokenordamagedhigh-voltage orange cables. Treat severed cables as if they contain high-voltage.•Ifthevehicleissubmergedinwater,donottouchanyhigh-voltagecomponentsor orange cables while extricating the occupant(s). Do not remove the vehicle until you aresurethehigh-voltagebatteryiscompletelydischarged.Asubmergedhigh-voltagebatterymayproduceafizzingorbubblingreactiontothewater.Thehigh-voltage batterywillbedischargedwhenthefizzingorbubblinghascompletelystopped, however, still treat it as if it was not discharged.

3. IF THE HIGH-VOLTAGE BATTERY CASE HAS BEEN RUPTURED

•Justlikeanyotherbattery,hosetheareadownwithLARGE amounts of water (ie. use a Fire Hose).

4. MOVING DAMAGED VEHICLES — WRECKER DRIVERS

•Ratherthanattempttodischargeapropulsionbattery,anemergencyresponder,tow truckoperator,orstoragefacilitymanagershouldcontactexpertsatthevehicle manufactureronthatsubject.•Ifpossible,removethehigh-voltageservicedisconnect.Foradditionalinformation, refertopage12and13inthismanual.•Bealert.Thereispotentialfordelayedfirewithdamagedlithium-ionbatteries.•CallanauthorizedFordDealerorvehiclemanufacturerrepresentative,ifnecessary, todetermineadditionalstepsthatyoushouldtaketosafelyrecoverortransportthe vehicle.•FollowtheguidelinesintheWreckerTowingManual.

—FrontTow:WheelLift(FWD) —RearTow:WheelLiftwithDolly(FWD) —Flatbed:FWDandAWD

5. SPECIAL NOTE TO SALVAGE YARDS

•Ifavehiclewithahigh-voltagebatteryistobescrapped,thehigh-voltagebatterymust be disposed of following all local, state/provincial and federal guidelines.•Operatorsoftowtrucksandvehiclestoragefacilitiesshouldensurethedamaged vehicleiskeptinanopenareainsteadofinsideagarageorotherenclosedbuilding.


APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED

•Ifpossible,removethehigh-voltagebatteryservicedisconnectbeforeattemptinganyextricationprocedure.Alwaysassumethehigh-voltagecablingandcomponentsare powered up.

•Ifoccupantextricationisnecessary,alwaysusecautionwhencuttingnearthe vehicle high voltage system components. Do not cut any of the high-voltage under vehicle or under hood cabling (all high-voltage cabling is orange in color). High- voltage cabling runs from the high-voltage batteries under the left hand side of the vehicletotheunderhoodcompartment.Refertothediagrambelowfornocutzones.


1. In the event of damage to or fire involving an Electric Vehicle (EV) or Hybrid Electric Vehicle (HEV).

•Alwaysassumethehigh-voltage(HV)batteryandassociatedcomponents are energized and fully charged.

•Exposedelectricalcomponents,wires,andHVbatteriespresentpotentialHVshockhazards.

•Venting/off-gassingHVbatteryvaporsarepotentiallytoxicandflammable.

•PhysicaldamagetothevehicleorHVbatterymayresultinimmediateor delayedreleaseoftoxicand/orflammablegasesandfire.

DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH-VOLTAGE BATTERIES (TOWING, RECOVERY OPERATORS AND VEHICLE STORAGE FACILITIES)

For questions contact Ford USA 1-800-392-3673 / Ford Canada 1-800-565-3673

2. Vehicle Shutdown and High-Voltage System Disabling

Identify Vehicle

• Determine if the vehicle is an electric or hybrid-electric vehicle, and if it is, advise your dispatch and all other responders that an electric or hybrid-electric vehicle is involved.

•Toidentifypotentialsymptomsofadamagedhigh-voltagesystem,contactan authorizedservicecenterorvehiclemanufacturerrepresentative.RefertotheVehicle OwnerManual,EmergencyPlacard(includedintheVehicleOwnerManual)and/or theEmergencyResponseGuideforappropriatecontactinformation.

• Ifyoudetectleakingfluids,sparks,smoke,flames,increasedtemperature,gurgling, popping or hissing noises from the HV battery compartment, ventilate the passenger area(i.e.,rolldownwindowsoropendoors)andcall911.

• Bealert.Thereisapotentialfordelayedfirewithdamagedlithium-ionbatteries.


DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH-VOLTAGE BATTERIES (TOWING, RECOVERY OPERATORS AND VEHICLE STORAGE FACILITIES) - CONTINUED

3. Recovering/Transporting Vehicle

•Callanauthorizedservicecenterorvehiclemanufacturerrepresentative, ifnecessary,todetermineadditionalstepsthatyoushouldtaketosafelyrecover or transport the vehicle. •Alwaysapproachthevehiclefromthesidestostayoutofpotentialtravelpath.It maybedifficulttodetermineifthevehicleisrunningduetolackofenginenoise.

•Refertovehiclemanual/recoveryguidetolocateproperattachment/connection points and transport method.

•Avoidcontactwithorangehigh-voltagecablingandareasidentifiedas high-voltageriskbywarninglabels.

4. Storing Vehicle

•For vehicles in the United States, notify Ford Motor Company 1-800-392-3673 (then follow the prompts on the voice response menu) or an authorized Ford Dealer as soon as possible as there may be additional steps necessary to secure, discharge, handle, and/or store the HV battery and vehicle.

• For vehicles in Canada, notify Ford Motor Company 1-800-565-3673 (then follow the prompts on the voice response menu), or an authorized Ford dealer as soon as possible. There may be additional steps necessary to secure, discharge, handle and/or store the HV battery and vehicle.

•Donotstoreaseverelydamagedvehiclewithalithium-ionbatteryinsidea structureorwithin50feetofanystructureorvehicle.

• Ensure that passenger and cargo compartments remain ventilated.

• Prior to placing and while located in storage area/tow lot, continue to inspect vehicleforleakingfluids,sparks,smoke,flames,gurglingorbubblingsounds fromtheHVbatteryandcall911ifanyofthesearedetected.

•Maintainclearaccesstostoredvehiclesformonitoringandemergencyresponse if needed.

Forspecificinformationandsafetypreparationregardingthehigh-voltagesystem,referto WWW.MOTORCRAFTSERVICE.COM,selectquickguidesfortheappropriatevehicle emergency response guide.


WARNING: ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH-VOLTAGE SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH-VOLTAGE ELEC-TRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH-VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH-VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN-CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

WARNING: DAMAGED ELECTRIC VEHICLES SUBMERGED IN WATER PRESENT A POTENTIAL HIGH VOLTAGE ELECTRICAL SHOCK HAZARD. ExERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. DO NOT ATTEMPT TO ExTRACT THE VEHICLE UNTIL THE HIGH VOLTAGE BATTERY HAS DISCHARGED INDICATED BY THE ABSENCE OF BUBBLING OR FIZZING. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

WARNING: ELECTRIC VEHICLES WITH DAMAGED HIGH VOLTAGE BATTERIES REQUIRE SPECIAL HANDLING PRECAUTIONS. INSPECT THE VEHICLE CAREFULLY FOR LEAKING BATTERY FLUIDS, SPARKS, FLAMES, AND GURGLING OR BUBBLING SOUNDS. CONTACT EMERGENCY SERVICES IMMEDIATELY IF ANY OF THESE PROBLEMS ARE OBSERVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A VEHICLE FIRE AND PERSONAL INjURY OR DEATH.

WARNING: FIRES IN CRASH-DAMAGED ELECTRIC VEHICLES MAY EMIT TOxIC OR COMBUSTIBLE GASSES. SMALL AMOUNTS OF EYE, SKIN OR LUNG IRRITANTS MAY BE PRESENT. WEAR PERSONAL PROTECTIVE EQUIPMENT (PPE) AND SELF-CONTAINED BREATHING APPARATUS WHEN WORKING IN CLOSE PROxIMITY OR IN A CONFINED AREA, SUCH AS A TUNNEL OR GARAGE. VENTILATE THE VEHICLE INTERIOR BY OPENING VEHICLE WINDOWS OR DOORS. VENTILATE THE WORKING AREA. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.


High Voltage Battery - Removal

WARNING: TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL WARNINGS AND SERVICE INSTRUCTIONS, INCLUDING INSTRUCTIONS TO DEPOWER THE SYSTEM. THE HIGH-VOLTAGE SYSTEM UTILIZES APPROxIMATELY 325 VOLTS DC, PROVIDED THROUGH HIGH-VOLTAGE CABLES TO ITS COMPONENTS AND MODULES. THE HIGH-VOLTAGE CABLES AND WIRING ARE IDENTIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLTAGE COMPO-NENTS ARE MARKED WITH HIGH-VOLTAGE WARNING LABELS WITH A HIGH-VOLTAGE SYMBOL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

2

1

1.DepowertheHigh-Voltage(HV)battery.RefertotheHVbatteryservicedisconnectprocedureonpage12and13.

NOTE:Wait5minutesaftertheservicedisconnectplugisremovedbeforecontinuing service. This allows any residual voltage in the HV system to dissipate.

NOTE: Fusion Energi shown, MKZ Hybrid and Fusion Hybrid similar.

2.Disconnectthe12Vbattery.

WARNING: REMOVING THE HIGH-VOLTAGE BATTERY SERVICE DISCONNECT DOES NOT DISSIPATE VOLTAGE INSIDE THE BATTERY, THE BATTERY PACK REMAINS LIVE AND DANGEROUS. CONTACT WITH THE HIGH-VOLTAGE BATTERY PACK INTERNALS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.


x2x2

4.Removetherearscufftrimpanel.

3.RemovetheHVbatterycarpet.


1

2

Fusion Energi only

6.ReleasethelatchandfoldtheRHrearbackrestdown.

x2

x2

x2

x2

x2

5.RemovetheRHandLHloadspacetrimpanels.


1

2

3

2

8.ReleasethelatchandremovetheRHbackrestfromthevehicle.

7.Ifequippedwithheatedseats,disconnecttheelectricalconnector.


10.Removethesafetybeltfastenerandpositionthebeltaside.

9.Removethesafetybeltlatchfastenerandpositionthelatchaside.


12.Ifequippedwithheatedseats,disconnecttheelectricalconnectors.

1

2

11.ReleasethelatchandfoldtheLHrearbackrestdown.


14.RemovethetrimpanelfromthefrontoftheHVbattery.

2

1

3

2

13.ReleasethelatchandremovetheLHbackrestfromthevehicle.


x3


16.RemovethewiringcoverfromtheHVbattery.

x6x6

All Vehicles

15.RemovethesixfastenersandtheLHandRHHVbatteryvents.


x22

x41

x22

x41

3

Fusion Energy only

18.RemovethefastenersandtheHVbatteryrearbrace.

1

2 x2


17.Disconnecttheelectricalconnectorsandwireharnessretainersfromthefrontofthe HV battery.


20.DisconnecttheHVbatterycoolingfanharnessretainer.

19.Removetheauxiliarychargeplugtoolboxfromthecargoarea.


x3x3

22.Disconnecttheelectricalconnectorsandwireharnessretainersfromtherearofthe HV battery.

x5x5

x2

21.RemovethefastenersandtheHVbatteryvent.


x2x2

24.DisconnecttheHVbatterycoolingfanelectricalconnector,removethetwo fasteners and remove the fan.

x2x2

x2

23.Disconnecttheventactuatorelectricalconnectorandwireharnessretainer. Removethefourfastenersandthevent.


x2x2

1

2

Fusion Hybrid and MKZ Hybrid only

26.DisconnecttheHVbatterycoolingfanelectricalconnectorandharnessretaining clip.Removethethreefastenersandremovethefan.

25.Removetheharnessretainerfromthefanventandpositiontheharnessaside. Removethefastenerandthevent.


x2

x2

x2

x2

Fusion Energy only

28.RemovethefourHVbatteryfasteners.

x3x3

x2

27.RemovethefiveHVbatteryfasteners.


x3x3

30.Removethethreefastenersandthesafetybeltlatch,thenremovetheseatlatch hookfastenerandtheseatlatchhook.

x2x2

29.DisconnecttheHVbatteryinletairtemperaturesensorelectricalconnectorand remove the wire harness retainers from the HV battery.


32.DisconnecttheRHandLHreardoorharnesselectricalconnector.

31.RemovetheRHandLHreardoorcheckfastener.


x2

34.PositiontwowoodblocksinfrontoftheHVbattery.Withthehelpofanassistant, slidethebatteryforwardontothewoodblocks.

x2

33.RemovethetwofastenersontheRHandLHreardoorhinge.Withthehelpofan assistant,removetheRHandLHreardoor.


x2

Fusion Hybrid and MKZ Hybrid only

36.Withthehelpofanassistant,removetheHVbattery.

303-F047303-F047

303-050

x2

303-050

x2

35.Usingafloorcrane,removetheHVbattery.


SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS

Ifavehiclewithahigh-voltagebatteryistobescrapped,thehigh-voltagebatterymustbe disposed of following all local, state/provincial and federal guidelines. TheFusionHybrid,MKZHybridandFusionEnergivehicles’Lithium-Ionhigh-voltagebatterypack(Li-IonHVB)isfullyrecyclableandshouldbeshippedtoapermittedrecyclingfacility.TheguidelinesbelowareforLi-IonHVBswhichhavebeenremovedfrom the vehicle and discharged.

General Packaging, Transport, and Recycling Guidelines

Oncethebatteryhasbeenremovedfromthevehicleanddischarged:

1. Storethebatterycomponentsinabuildingorundersheltersothatbatteriesare keptdryandnotexposedtohightemperatures.

2. Protect battery components from damage (e.g. crushed or punctured).3. Itisrecommendedtoaskaboutthespecificpackagingrequirementsforbattery

shipments to the recycler who will be receiving the battery components in order toavoidinappropriaterepacking/stackingofthebatteries.

4. Batteriesshouldbesortedbytype.Keepleadacidbatteries,NiMHbatteries,andLi-Ionbatteriesseparatedfromeachother(e.g.separatepalletsorstoragelocations).

5.Makesurethebatteryrecyclerisawareofthebatterytype.Li-ionbatteriescannotberecycledinthesamemannerasleadacidorNiMHbatteries.

ThoughFordMotorCompanymakesnorepresentationsorendorsements,therearecompaniesthathavethecapabilitytoaccept,consolidateandrecycleundamagedLi-IonHVBs,andafewarelistedbelow.Contacttheappropriatebatterymanufacturerforadditional information.

NorthAmericaBatteryRecyclers

KinsburskyBrothers,Inc.125E.CommercialStreetAnaheim,CA90804Phone:714-738-8516Fax:714-773-4830

RetrievTechnologies,Inc.125W.CommercialStreet#AAnaheim,CA92801Phone:855-4RETRIE(855-473-8743)Fax:714-278-9745


SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS - CONTINUED

Applicable Laws/Regulations

The following is a general explanation of certain applicable laws; however, these laws change from time to time, additional regulations are under development and Ford Motor Companymakesnorepresentationthatthisisacompletesummary.

PackagingandTransportTheU.S.DepartmentofTransportation(DOT)outlinespackagingandshippingrequirementsforLi-Ionbatteries.CertainexceptionsonpackagingandtransportationregulationsforlargeformatLi-Ionbatteriesmaybefoundin49CFR173.185(d)and(g).

Makesurethattheshippingpaperworkisfilledoutcorrectlyandthattheshipmentisproperly labeled per federal, state, and local laws and regulations. Ensure that you are complyingwithanyrecordkeepingrequirements.

Generally,underU.S.DOTregulations,Li-Ionbatteriesareconsideredadangerousgoodandregulatedashazardousmaterialswhentransported.Li-IonbatteriesareclassifiedasClass9hazardousmaterial.Onlycertifiedhazardousmaterialshippersshould offer transport of a hazardous material.

Batteries for recycling should be shipped by ground or vessel only. Do not ship batteries for recycling by air.

NOTE:Adamagedbattery(onethatisleakingelectrolytefromthebatterypack)mightneed to be shipped as a hazardous waste. Ifyouaretransportingadamagedbattery,utilize a company that specializes in hazardous waste transport and management. Ensure that you comply with all applicable hazardous waste management laws and regulations.

Recycling40CFR261statesthatmanufacturedarticlesthatyieldextractswhichexceedoneormoreoftheconcentrationlimitsofregulatedlistedconstituents,ormeetsthedefinitionofignitability,corrosivityorreactivityaredefinedashazardouswastesandmustbedisposed of in accordance with federal and state regulations. Since there are many variationsinthespecificchemistryofLi-Ionbatteries,additionalclassificationsmaybenecessarytodetermineifthebatteryisahazardouswaste.Itistheresponsibilityofthegeneratortomakethisdetermination.Generally,underfederalandstatelaw,sealed,Li-Ionbatteriesmaybeconsidereddrycellbatteriesandthereforemaybemanagedasauniversalwaste;damagedorleakingLi-Ionbatteriesmayberegulatedashazardouswaste under federal and state regulations.

Documents

2016 FUSION HYBRID MKZ HYBRID FUSION …elvsolutions.org/wp-content/uploads/2015/08/2016_Fusion-MKZ_HEV...2016 FUSION HYBRID MKZ HYBRID ... for vehicle’s electric motor. ... servicing