2017 FUSION HYBRID MKZ HYBRID FUSION ENERGIelvsolutions.org/wp-content/uploads/2016/02/2017-Fusion-MKZ-HEV...fcs-21234-17 high-voltage battery removal guide 2017 fusion hybrid mkz

FCS-21234-17

HIGH-VOLTAGE BATTERY REMOVAL GUIDE

2017FUSION HYBRID

MKZ HYBRIDFUSION ENERGI

FCS-21234-17 1 2017 Fusion/MKZ/Fusion Energi Battery Removal 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 22-24HIGH VOLTAGE BATTERY REMOVAL ........................................................ Pages 25-44SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS .................... Pages 45-46

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

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


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

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


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 FUNCTION

1 High-voltage battery approximately300VoltsDC

Locatedinthecargoarea,behind the rear seat.

Sealed lithium battery.

Provides high-voltage storage for the vehicle’s 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 Runsalongthevehicle’sfloorpanfromthehigh-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 vehicle’s 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 engine’s 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.


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


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 vehicle’s electric motor.

3 12-Voltbattery Locatedinthetrunkarea.

Typical automotive 6-cell lead/acid design.

Provides12-voltsforvehi-cle accessories.

4 High-voltage wiring Runsalongthevehicle’sfloorpanfromthehigh-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 vehicle’s 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 engine’s generator to recharge batteries.



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.


HIGH-VOLTAGE SERVICE DISCONNECT - FUSION/MKZ HYBRID

1.PositiontheLHrearseatbackrestdown.

E157763

E157764

2.Removethehigh-voltagebatteryservicedisconnectcover.


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.


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


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

3.Removethehigh-voltageservicedisconnect:

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

1

2

3

E161375

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.


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.


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

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,andHVbatteriespresentpotentialHV shockhazards. •Venting/off-gassingHVbatteryvaporsarepotentiallytoxicandflammable. •PhysicaldamagetothevehicleorHVbatterymayresultinimmediateor delayedreleaseoftoxicand/orflammablegasesandfire.

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.

• To identify potential symptoms of a damaged high-voltage system, contact an authorizedservicecenterorvehiclemanufacturerrepresentative.Refertothe Vehicle OwnerManual,EmergencyPlacard(includedintheVehicleOwner Manual)and/ortheEmergencyResponseGuideforappropriatecontact information.

• 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,todetermineadditionalstepsthatyoushouldtaketosafely recover or transport the vehicle.

• Alwaysapproachthevehiclefromthesidestostayoutofpotentialtravelpath. Itmaybedifficulttodetermineifthevehicleisrunningduetolackofengine noise.

•Refertovehiclemanual/recoveryguidetolocateproperattachment/connection points and transport method.

• Avoidcontactwithorangehigh-voltagecablingandareasidentifiedas high-voltageriskbywarninglabels.

4. Storing Vehicles

•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. •Ensurethatpassengerandcargocompartmentsremainventilated.

•Priortoplacingandwhilelocatedinstoragearea/towlot,continuetoinspect vehicleforleakingfluids,sparks,smoke,flames,gurglingorbubblingsounds fromtheHVbatteryandcall911ifanyofthesearedetected.

•Maintainclearaccesstostoredvehiclesformonitoringandemergency response if needed.


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.

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


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.

1.DepowertheHigh-Voltage(HV)battery.RefertotheHVbatteryservicedisconnectprocedureonpages13-16.

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.Removethe12-voltbatterycoverlocatedontheLHloadspacetrimpanel.

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

E157008


4.Disconnectthe12Vbattery.

2

1

E184823

3. Position the positive battery post cover aside.


x2x2

6.Removetherearscufftrimpanel.

x4x4

E162229

5.Positionthecarpetaside,removethefourbatterycoverretainers(FusionEnergi only) and remove the HV battery cover.


E161078

1 1

2

3

Fusion Energi only

8.Removetherearseatcushion. 1.Releasethelockingtabs. 2.Positiontherearseatcushionupward. 3.Ifequippedwithheatedseats,disconnecttheelectricalconnector.

x2

x2

x2

x2

x2

7.RemovetheRHandLHloadspacetrimpanels.


1

2

9.ReleasethelatchandfoldtheRHrearbackrestdown.

10.Ifequippedwithheatedseats,disconnecttheelectricalconnector.


1

2

3

2

11.ReleasethelatchandremovetheRHbackrestfromthevehicle.

12.Removethesafetybeltlatchfastenerandpositionthelatchaside.


13.Removethesafetybeltfastenerandpositionthebeltaside.

1

2

14.ReleasethelatchandfoldtheLHrearbackrestdown.


15.Ifequippedwithheatedseats,disconnecttheelectricalconnectors.

2

1

3

2

16.ReleasethelatchandremovetheLHbackrestfromthevehicle.


17.RemovethetrimpanelfromthefrontoftheHVbattery.

x6x6

All Vehicles


18.RemovethesixfastenersandtheLHandRHHVbatteryvents.


x3


19.RemovethewiringcoverfromtheHVbattery.

1

2 x2


20.Disconnecttheelectricalconnectorsandwireharnessretainersfromthefrontofthe HV battery.


x22

x41

x22

x41

3

Fusion Energy only

21.RemovethefastenersandtheHVbatteryrearbrace.

22.Removetheauxiliarychargeplugtoolboxfromthecargoarea.


23.DisconnecttheHVbatterycoolingfanharnessretainer.

x5x5

x2

24.RemovethefastenersandtheHVbatteryvent.


x3x3

25.Disconnecttheelectricalconnectorsandwireharnessretainersfromtherearofthe HV battery.

x2x2

x2

26.Disconnecttheventactuatorelectricalconnectorandwireharnessretainer. Removethefourfastenersandthevent.


x2x2

27.DisconnecttheHVbatterycoolingfanelectricalconnector,removethetwo fasteners and remove the fan.

28.Removetheharnessretainerfromthefanventandpositiontheharnessaside. Removethefastenerandthevent.


x2x2

1

2

Fusion Hybrid and MKZ Hybrid only

29.DisconnecttheHVbatterycoolingfanelectricalconnectorandharnessretaining clip.Removethethreefastenersandremovethefan.

x3x3

x2

30.RemovethefiveHVbatteryfasteners.


x2

x2

x2

x2

Fusion Energy only

31.RemovethefourHVbatteryfasteners.

x2x2

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


x3x3

33.Removethethreefastenersandthesafetybeltlatch,thenremovetheseatlatch hookfastenerandtheseatlatchhook.

34.RemovetheRHandLHreardoorcheckfastener.


35.DisconnecttheRHandLHreardoorharnesselectricalconnector.

x2

36.RemovethetwofastenersontheRHandLHreardoorhinge.Withthehelpofan assistant,removetheRHandLHreardoor.


x2

37.PositiontwowoodblocksinfrontoftheHVbattery.Withthehelpofanassistant, slidethebatteryforwardontothewoodblocks.

303-F047303-F047

303-050

x2

303-050

x2

38.Usingafloorcrane,removetheHVbattery.


x2

Fusion Hybrid and MKZ Hybrid only

39.Withthehelpofanassistant,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. Storethebatterycomponentsinabuildingorundersheltersothatbatteriesarekeptdryandnotexposedtohightemperatures.

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 ordertoavoidinappropriaterepacking/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.CommercialStreet Anaheim,CA92801 Phone:714-738-8516 Fax: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

2017 FUSION HYBRID MKZ HYBRID FUSION ENERGIelvsolutions.org/wp-content/uploads/2016/02/2017-Fusion-MKZ-HEV...fcs-21234-17 high-voltage battery removal guide 2017 fusion hybrid mkz