2017 FUSION HYBRID MKZ HYBRID FUSION FUSION HYBRID MKZ HYBRID FUSION ENERGI. ... directly to the HPCM.…

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  • FCS-15129-17

    EMERGENCY RESPONSE GUIDE

    2017FUSION HYBRID

    MKZ HYBRIDFUSION ENERGI

  • FCS-15129-17 1 2017 Fusion/MKZ Hybrid Emergency Response Guide

    Table of Contents

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

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

    HYBRID VEHICLE IDENTIFICATION ............................................................ Pages 3-4

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

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

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

    HIGH-VOLTAGE SERVICE DISCONNECT.................................................... Page 13

    HIGH-VOLTAGE BATTERY PACK ................................................................ Pages 16-17

    Follow Existing Training and Incident Commander Direction .........Page 18APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE ......................... Pages 18-21

    Approaching a Damaged Vehicle ........................................................Page 19If The High-Voltage Battery Case Has Been Ruptured ......................Page 20Moving Damaged Vehicles - Wrecker Drivers ....................................Page 20Special Note To Salvage Yards ...........................................................Page 20High Voltage System - Do Not Cut Zones ..........................................Page 21

    DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES ........................................................................ Pages 22-24

    ENERGI COMPONENT LOCATION AND IDENTIFICATION ........................ Pages 10-12

    Fusion Hybrid .......................................................................................Pages 13-14Fusion Energi ........................................................................................Pages 15-16

  • FCS-15129-17 2 2017 Fusion/MKZ Hybrid Emergency Response Guide

    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 vehicles 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 VEHICLES HIGH-VOLTAGE SYSTEM IS POWERED UP !

  • FCS-15129-17 3 2017 Fusion/MKZ Hybrid Emergency Response Guide

    NOTE:FusionEnergishown.

    HYBRID VEHICLE IDENTIFICATION

    TheFusionHybridvehiclescaneasilybeidentifiedbytheHybridbadgeslocatedon theleftandrightfrontdoors.ThereisaHybridnameplateonthetrunklid(located ontherighthandside)thatalsoincludesthegreenleaf/bluehighwayHybridicon.

    Hybrid/Energi nameplate and iconontrunklid.

    Hybrid/Energi nameplate with Hybrid icon on front doors.

    TheFusionEnergivehiclescaneasilybeidentifiedbytheEnergibadgeslocatedontheleftandrightdoors.ThereisaEnerginameplateonthetrunklid(locatedonthe lefthandside)thatalsoincludesthegreenleaf/bluehighwayHybridicon.

  • FCS-15129-17 4 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HYBRID VEHICLE IDENTIFICATION - CONTINUED

    TheMKZHybridvehiclescaneasilybeidentifiedbythe2.0Hbadgelocatedonthe trunklid.

    MKZHybrid2.0Hnameplateontrunklid.

  • FCS-15129-17 5 2017 Fusion/MKZ Hybrid Emergency Response Guide

    Fusion Hybrid FWD

    TheFusionHybridandMKZHybridvehicleshaveauniqueengineappearancecoverwitharaisedHYBRID(orHYBRIDENERGIforEnergivehicles)icon.

    UniqueHybridengineappearancecover with raised lettering and icon

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

    The5th,6thand7thdigitsoftheVehicleIdentificationNumber(VIN)identifytheHybrid vehicle line.

    VIN POSITIONS5, 6 and 7 VEHICLE

    P0L Fusion SE Full HybridL2L MKZ Hybrid Full HybridP0P Fusion SE Energi Plug-in HybridP0R Fusion Titanium Full HybridP0S FusionTitaniumEnergiPlugInHybrid

  • FCS-15129-17 6 2017 Fusion/MKZ Hybrid Emergency Response Guide

    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-VoltageFuseIntheeventofahigh-voltageshortcircuit,thehigh-voltage fuse will open, disabling the high-voltage system.

    High-VoltageInterlockCircuitWheneverahigh-voltageconnectorisdisconnected,thehigh-voltageinterlockcircuitopensanddisablesthehigh-voltagesystem.

    IgnitionKeyintheOFFPositionAnytimethe12-voltsystemisturnedoff(ignition lockcylinderisintheOFFposition),thehigh-voltagesystemisdisabled.

    High-VoltageServiceDisconnectWheneverthehigh-voltageservicedisconnect (locatedbehindtherearseatback)isremoved,thehigh-voltagesystemisdisabled.Foradditionalinformation,refertoPage10inthismanual.

    ThermalSensorsIntheeventthebatteryisexposedtoextremehotambient 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,iftheignitionkeyisleftintheONposition,thiscouldcausethe high-voltagebatterytemperaturetoexceed60C(140F);ifthistemperatureis reached, the thermal sensors located near the high-voltage battery will automatically disable the high-voltage battery.

  • FCS-15129-17 7 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HIGH-VOLTAGE WARNING DECALS

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

  • FCS-15129-17 8 2017 Fusion/MKZ Hybrid Emergency Response Guide

    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

  • FCS-15129-17 9 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

    COMPONENT LOCATION / DESCRIPTION FUNCTION

    1 High-voltage battery approximately300VoltsDC

    Locatedinthecargoarea,behind the rear seat.

    Sealed lithium battery.

    Provides high-voltage storage for the vehicles electric motor.

    2 12-Voltbattery Locatedinthetrunkarea.

    Typical automotive 6-cell lead/acid design.

    Provides12-voltsforvehi-cle accessories.

    3 High-voltage service disconnect

    Locatedbehindtherearseatbackrest.

    Orangerectanglewithamolded plastic handle, about100mm(4in)inlength.

    Provides means to dis-connect the high-voltage battery for safely servic-ing the vehicle.

    4 High-voltage wiring Runsalongthevehiclesfloorpanfromthehigh-volt-age battery to the Hybrid PowertrainControlMod-ule(HPCM).TheelectricA/CcompressorconnectsdirectlytotheHPCM.Separate connections from theHPCMaremadetotheElectronicallyControlledContinuouslyVariableTransaxle(ECVT).

    Provides the physical connection between the high-voltage battery and the vehicles high-voltage equipment.

    5 TransmissionControlModule

    Locatedabovethetrans-mission.

    Containscontrollingelectronics for managing propulsion.

    Provides rotational force during Electrical DriveModes.Generates3-phaseAChigh-voltageelectricity via two cables to and from the traction motor and generator.

    6 ElectronicallyCon-trolledContinuouslyVariable Transaxle (ECVT)

    Transverse-mounted de-sign, similar to the non-Hy-brid Fusion MKZ vehicles.

    Provides rotational force to the wheels for vehicle propulsion and transmits rotational force to the engines generator to recharge batteries.

    7 ElectricA/CCompressor

    Locatedinfrontofthe engine.

    Has an orange high-volt-age wire attached to it us-inganinterlockconnector.

    ProvideselectricA/Cop-eration; replaces the belt drivenA/Ccompressor.

  • FCS-15129-17 10 2017 Fusion/MKZ Hybrid Emergency Response Guide

    TheillustrationbelowanditsdefiningchartonPage11providesthelocation, description and basic function of the Fusion Energis system components.

    NOTE:Allhigh-voltagewiresandharnessesarewrappedinorange-coloredinsulation.

    ENERGI COMPONENT LOCATION AND IDENTIFICATION

    12

    3

    4

    57

    8

    6

    9

  • FCS-15129-17 11 2017 Fusion/MKZ Hybrid Emergency Response Guide

    ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

    COMPONENT LOCATION / DESCRIPTION FUNCTION

    1 High-voltage service disconnect

    Locatedbehindtherearseatbackrest.

    Orangerectanglewithamolded plastic handle, about100mm(4in)inlength.

    Provides means to dis-connect the high-voltage battery for safely servic-ing the vehicle.

    2 High-voltage battery approximately300VoltsDC

    Locatedinthecargoarea,behind the rear seat.

    Sealed lithium battery.

    Provides high-voltage storage for the vehicles electric motor.

    3 12-Voltbattery Locatedinthetrunkarea.

    Typical automotive 6-cell lead/acid design.

    Provides12-voltsforvehi-cle accessories.

    4 High-voltage wiring Runsalongthevehiclesfloorpanfromthehigh-volt-age battery to the Hybrid PowertrainControlMod-ule(HPCM).TheelectricA/CcompressorconnectsdirectlytotheHPCM.Separate connections from theHPCMaremadetotheElectronicallyControlledContinuouslyVariableTransaxle(ECVT).

    Provides the physical connection between the high-voltage battery and the vehicles high-voltage equipment.

    5 Chargingport Locatedonthedriversidefender.Itconnectstothehigh-voltage wiring in the engine compartment.

    Ithasanorangehigh-volt-age wire attached to it us-inganinterlockconnector.

    Provides110Vor220Vcharging options from a LevelIIchargingstationto the high-voltage battery when the vehicle is not in operation.

    6 TransmissionControlModule

    Locatedabovethetrans-mission.

    Containscontrollingelectronics for managing propulsion.

    Provides rotational force during Electrical DriveModes.Generates3-phaseAChigh-voltageelectricity via two cables to and from the traction motor and generator.

    7 ElectronicallyCon-trolledContinuouslyVariable Transaxle (ECVT)

    Transverse-mounted de-sign, similar to the non-Hy-brid Fusion MKZ vehicles.

    Provides rotational force to the wheels for vehicle propulsion and transmits rotational force to the engines generator to recharge batteries.

  • FCS-15129-17 12 2017 Fusion/MKZ Hybrid Emergency Response Guide

    COMPONENT LOCATION / DESCRIPTION FUNCTION

    8 ElectricA/CCompressor

    Locatedinfrontoftheengine.

    Ithasanorangehigh-volt-age wire attached to it us-inganinterlockconnector.

    ProvideselectricA/Cop-eration; replaces the belt drivenA/Ccompressor.

    9 Electric Heater Locatedintheenginecom-partment on the passenger side.

    Provides passenger compartment with heat without the need to turn the engine on.

  • FCS-15129-17 13 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HIGH-VOLTAGE SERVICE DISCONNECT - FUSION/MKZ HYBRID

    1.PositiontheLHrearseatbackrestdown.

    E157763

    E157764

    2.Removethehigh-voltagebatteryservicedisconnectcover.

  • FCS-15129-17 14 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HIGH-VOLTAGE SERVICE DISCONNECT (CONTINUED) - FUSION/MKZ HYBRID

    3.Pulltoremovethehigh-voltagebatteryservicedisconnectinterlockcover.

    E171591

    E157765

    1

    2

    3

    4.Removethehigh-voltageservicedisconnect:

    1.PulltheLeverPositionAssurance(LPA)tabtowardthefrontofvehicleto remove. 2.Pulltheleverhandleoutwardtodisengagetheinterlock. 3.Rotatethelevertohorizontalandremovethebatteryhigh-voltageservice disconnect.

  • FCS-15129-17 15 2017 Fusion/MKZ Hybrid Emergency Response Guide

    HIGH-VOLTAGE SERVICE DISCONNECT - FUSION ENERGI

    1.Positiontherearseatbackrestdownandremovethehigh-voltagebatteryservice disconnect cover.

    WARNING: THE HIGH-VOLTAGE SYSTEM MAY RETAIN A DANGEROUS LEVEL OF VOLTAGE FOR A SHORT TIME AFTER THE SERVICE DISCONNECT HAS BEEN REMOVED. WAIT 5 MINUTES FOR THE VOLTAGE TO DISSIPATE BEFORE BEGINNING SERVICE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

    E171592

    2.Pulltoremovethehigh-voltagebatteryservicedisconnectinterlockcover.E161374

    x2

  • FCS-15129-17 16 2017 Fusion/MKZ Hybrid Emergency Response Guide

    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 META...

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