2015 C-MAX HYBRID C-MAX ENERGIelvsolutions.org/wp-content/uploads/2015/01/2015_C-Max_Battery...C-MAX HYBRID C-MAX ENERGI 2015. FCS-21237-15 1 2015 C-Max Hybrid/Energi Battery Removal

FCS-21237-15

BATTERY REMOVAL GUIDE

C-MAX HYBRIDC-MAX ENERGI

2015

FCS-21237-15 1 2015 C-Max Hybrid/Energi Battery Removal Guide

Table of Contents

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

VIN Layout .............................................................................................Page 4

HYBRID VEHICLE IDENTIFICATION ............................................................ Page 3

HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES ........................ Page 5

HIGH-VOLTAGE WARNING DECALS ........................................................... Page 6

HYBRID COMPONENT LOCATION AND IDENTIFICATION ........................ Pages 7-9

HIGH-VOLTAGE SERVICE DISCONNECTS ................................................. Page 13

HIGH-VOLTAGE BATTERY PACK ................................................................ Pages 14-15

Follow Existing Training and Incident Commander Direction .........Page 16

APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE ......................... Page 16

Approaching a Damaged Vehicle ........................................................Page 17

If The High-Voltage Battery Case Has Been Ruptured ......................Page 18Moving Damaged Vehicles - Wrecker Drivers ....................................Page 18Special Note To Salvage Yards ...........................................................Page 18High-Voltage System - Do Not Cut Zones ..........................................Page 19

DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITHHIGH VOLTAGE BATTERIES ........................................................................ Pages 20-21HIGH VOLTAGE BATTERY REMOVAL - HYBRID VEHICLE ....................... Pages 22-32HIGH VOLTAGE BATTERY REMOVAL - ENERGI VEHICLE ....................... Pages 33-44

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

SPECIAL NOTE TO SALVAGE YARDS ........................................................ Pages 45-46

C-Max Hybrid ........................................................................................Page 13C-Max Energi ........................................................................................Page 14


FOREWORD The emergency response procedures for the C-Max Hybrid and C-Max 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 C-Max Hybrid and C-Max 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 (2.0L with a 4-cylinder engine and electric motor), reduced emissions and improved fuel economy. The C-Max Hybrid high-voltage systems are self-contained, never needing to be plugged into an electrical outlet for recharging. The system incor-poratesageneratorthatrechargesthehigh-voltagebatteryduringcruisingandbrak-ing. The C-Max Energi’s high-voltage system can be plugged into an electric outlet for recharging to optimize the vehicle’s extended electrical range. The system also incorpo-ratesageneratorthatrechargesthehigh-voltagebatteryduringcruisingandbraking.

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

The C-Max Hybrid and C-Max Energi vehicles have been designed with many safety features for your protection. These features help provide safe access to the vehicle undervariousconditions;however,whenapproachingahigh-voltagevehicleinafire,rescue or recovery situation, always follow one industry standard rule:

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


HYBRID VEHICLE IDENTIFICATION

• TheC-MaxHybridvehiclescaneasilybeidentifiedbytheHybridbadges located on the left and right front doors. There is a Hybrid nameplate ontherighthandsideofthetrunklidthatalsoincludesthegreen leaf/blue highway Hybrid icon.

• TheC-MaxEnergivehiclescaneasilybeidentifiedbytheEnergibadges located on the left and right front doors. There is an Energi nameplate on thelefthandsideofthetrunklidthatalsoincludesthegreen leaf/blue highway Hybrid icon.

Hybrid name-plate and icon ontrunklid.

Hybrid/Energi nameplate with Hybrid icon on front doors.


C-Max Hybrid FWD

VEHICLE

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

VIN POSITIONS 5, 6 and 7

P5A

P5B

Hybrid5-door,SE

Hybrid5-door,SEL

• TheC-Maxvehiclehasauniqueengineappearancecoverwitha raisedHYBRIDicononit.

NOTE: C-Max Hybrid shown, C-Max Energi similar.

UniqueHybridengineappearancecover with raised lettering and icon

P5C Energi5-door,SEL(plug-in)

3 F A D P5A30AR100001


WARNING: ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH-VOLTAGE SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH-VOLTAGE (HV) 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 WATCH-ES AND RINGS. ISOLATE THE HIGH-VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE IN-STRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES

The following are certain features that have been incorporated into the C-Max Hybrid and C-Max Energi vehicles that allow for either simple or automatic shut off of the high-voltage electrical systems.

• High-VoltageFuse—Intheeventofahigh-voltageshortcircuit,the high-voltage fuse opens, disabling the high-voltage system.

• High-VoltageInterlockCircuit—Wheneverahigh-voltageconnector isdisconnected,thehigh-voltageinterlockcircuitopensanddisables the high-voltage system.

• IgnitionKey/ButtonintheOFFPosition—Anytimetheignitionisin theOFFposition,thehigh-voltagesystemisdisabled.

NOTE: If the vehicle is equipped with remote start, high-voltage may be present in the system if the ignition is off.

NOTE: ENERGI vehicles when plugged in for charging may have high- voltage present in the system if the ignition is off.

• High-VoltageServiceDisconnect—Wheneverthehigh-voltage service disconnect (located behind the rear seat fold) is removed, the high-voltage system is disabled. For additional information, refer to page13inthismanual.

• ThermalSensors—Intheeventthebatteryisexposedtoextremelyhot ambient conditions and/or is being driven aggressively with compromised cooling, power limits will be employed to prevent overheating. However, if the battery is in use and become too hot, contacts will openandthevehiclewillshutdown.Insomeinstances,iftheignition keyisleftintheONposition,thiscouldcausethehigh-voltagebattery temperaturetoexceed60°C(140°F):ifthistemperatureisreached,the thermal sensors located near the high-voltage battery automatically disable the high-voltage battery.


HIGH-VOLTAGE WARNING DECALS

• OnHybridvehicles,WARNINGdecalsarelocatedoncomponentsinthe high-voltagesystemthroughoutthevehicle.Seetheexamplebelow.


The following illustration provides the location, description and basic function of the Hy-brid system components.

NOTE:Allhigh-voltagewiresandharnessesarewrappedinorangeinsulation.

HYBRID COMPONENT LOCATION AND IDENTIFICATION

8

7

5

4

6

1

3

2


HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION1 High-voltagebattery approximately 300- (VoltsDC)

• Locatedinthetrunkarea, behind the rear seat.• Sealedlithiumbattery.

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

5 Electronically Controlled Continuously VariableTransaxle (ECVT)

•Transverse-mounteddesign• Containsthetractionmotor, generator motor and hybrid electronics.

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

6 ElectricA/C compressor

•Locatedinfrontofthe engine. • Ithasanorangehigh- voltage wire attached to it.

ProvideselectricA/Coperation; replacesthebeltdrivenA/Ccom-pressor.

3 High-voltage service disconnect

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

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

2 12-Voltbattery (hidden from graphic)

• Locatedinthetrunk.

• Typicalautomotive6-cell lead/acid design.

Provides 12-voltsforvehicleaccessories.ReceivescurrentfromtheDC/DCconverter(PIAto the high-voltage battery) via a pre-fuse box in the engine com-partmentwhichrunstothe12Vpositive post.

4 High-voltage wiring Provides the physical connection between the high-voltage battery and the vehicle’s high-voltage equipment.

• Allhigh-voltagewiringhas orange-colored insulation.

• Runsalongthevehicle’s floorpanfromthehigh- voltage battery to the Hybrid Powertrain Control Module (HPCM).TheelectricAC compressor connects directly to the HPCM. Separateconnectionsfrom the HPCM are made to the Electronically Controlled ContinuouslyVariable Transaxle(ECVT).


HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION7 Electricwater pump

•Locatedinlowerfrontofthe engine. • Itisanelectric12-voltpump.

Provides water pump operation for theengine’scoolingsystem.Re-places the belt driven water pump.

8 Transmission Control Module (TCM)

•Located in front of the engine

Provides rotational force during ElectricalDriveModes.Gener-ates electricity for recharging the high-voltage battery.

•Containscontrolling electronics for managing propulsion.

•AlsoreferredtoastheHybrid Powertrain Control Module (HPCM).


The following illustration provides the location, description and basic function of the C-Max Energi’s system components.

NOTE:Allhigh-voltagewiresandharnessesarewrappedinorangeinsulation.

ENERGI COMPONENT LOCATION AND IDENTIFICATION

9

7

5 4

8

11

1

10

2

3

6


ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION

3 High-voltage battery Approximately300- VoltsDC • Sealedlithiumbattery.

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

1 High-voltage service disconnect

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

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

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

• Locatedbehindtherear seatbackonthe passenger side.

• Allhigh-voltagewiringhas orange insulation.

6 Chargingport •Locatedonthedriverside fender.Itconnectstothe high-voltage wiring in the engine compartment.

2 12-Voltbattery (hidden from graphic)

• Locatedinthetrunkarea.

• Typicalautomotive6-cell lead/acid design.

Provides 12-voltsforvehicleaccessories.ReceivescurrentfromtheDC/DCconverter(PIAto the high-voltage battery) via a pre-fuse box in the engine com-partmentwhichrunstothe12Vpositive post.

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

5 110Vconvenience cord

•Locatedunderthefrontdriver side seat.

Provides110Vor220VchargingoptionsfromaLevelIIchargingstation to the high-voltage battery when the vehicle is not in opera-tion.• Ithasanorangehigh-

voltage wire attached to it usinganinterlockconnector.

• Runsalongthevehicle’s floorpanfromthehigh- voltage battery to the Hybrid Powertrain Control Module (HPCM).TheACcompres- sor connects directly to the HPCM.Separateconnec- tions from the HPCM are made to the Electronically Controlled Continuously VariableTransaxle(ECVT). The PTC heater connects directly to the high-voltage wiring on the passenger side in the engine compartment. High- volt age wiring also connects to the charge port.

• Locatedinthetrunkarea, behind the rear seat.


ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED

COMPONENT LOCATION / DESCRIPTION FUNCTION

11 Transmission Control Module (TCM)

•Locatedinfrontoftheengine.

Provides rotational force during ElectricalDriveModes.Gener-ates electricity for recharging the high-voltage battery.

•Containscontrolling electronics for managing propulsion.

10Electric heater •Locatedintheengine compartment on the passenger side.

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

9 Electric water pump

•Locatedinlowerfrontofthe engine. •Itisanelectric12-voltpump.

Provides water pump operation for the engine’s cooling system. Replacesthebeltdrivenwaterpump.

7 Electronically Controlled Continuously VariableTransaxle (ECVT)

•Transverse-mounteddesign. •Containsthetractionmotor, generator motor and connects to the Hybrid Powertrain Control Module (HPCM) which operates the motor controls.

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

8 ElectricA/C compressor

•Locatedinfrontofthe engine. •Ithasanorangehigh-voltage wire attached to it.

ProvideselectricA/Coperation; replacesthebeltdrivenA/Ccom-pressor.

•AlsoreferredtoastheHybrid Powertrain Control Module. (HPCM)


HIGH-VOLTAGE SERVICE DISCONNECT - C-Max Hybrid

*

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.

2015 C-MAX HYBRID VEHICLES ONLY

1

2

3

1

2

3

4

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

4

ALL 2015 C-MAXHYBRID VEHICLES

NOTE: Ifpossible,releaseandremovethehigh-voltageservicedisconnect.


HIGH-VOLTAGE SERVICE DISCONNECT - C-Max ENERGINOTE: Ifpossible,releaseandremovethehigh-voltageservicedisconnect.

HIGH-VOLTAGE BATTERY PACK

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 HIGH-VOLTAGE 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.

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.

ALL 2015 C-MAXENERGI VEHICLES

1

2015 C-MAX ENERGI VEHICLES ONLY

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.Donotpenetratethe batteries or case in any way.

•Thehigh-voltagebatteryislocatedintheforwardportionoftheluggage compartment.Thehigh-voltagebatteryliesflatjustbehindtherearseatback under the luggage compartment cargo cover.

•Removingthehigh-voltageservicedisconnectwilldisconnectthehigh-voltagefromthevehicle.Thebatterypackwillremainliveanddangerous.

•Thetotalvoltageofthebatterypackisapproximately300voltsDC.

•Thebatterycellscontainabaseelectrolyte,consistingoflithium hexafluorophosphateandorganicsolventsasthedominantactiveingredient, thatisabsorbedinspecialpolymericfilm.Theelectrolytewillnotleakfrom the battery under most conditions. However, if the battery is crushed, it is possibleforasmallamountofelectrolytetoleak.

NOTICE:Observethefollowingwhenworkingwithadamagedbattery:

•Ifpossible,isolateandavoidcontactwithhigh-voltagevehiclecomponents.If contact with the high-voltage system cannot be avoided, Personal Protective Equipment(PPE)suchassplashshieldorsafetygoggles,gloves(latex, rubberorNitrile),anapronorovercoat,andrubberbootsarerequiredwhen handlingdamagedbatteries.Exposuretoelectrolytecouldcauseskinand/or eyeirritation/burns.Ifexposed,rinsewithlargeamountsofwaterfor 10-15minutes.

•Ifthebatteryisexposedtointenseheat(orotherabusiveconditions),itis possiblethatflammablegasesandliquid(electrolyte)havebeenreleased from the cells. The gases include combustible hydrocarbons such as methane, toxic gases such as carbon monoxide, and very small amounts ofeye/skin/lungirritantssuchashydrofluoricacid.Appropriateprecautions shouldbetakentomakesuretheareaisproperlyventilatedsuchasopen ing the vehicle’s windows or doors. First responders should wear Personal ProtectiveEquipment(PPE)andself-containedbreathingapparatustosafe guardagainstthermal,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 HIGH-VOLTAGE 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 AS 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 amountsofwateriffireis presentorsuspectedand,keepinginmindthatfirecanoccurfora considerable period after the crash, should proceed accordingly.

• Thisguideprovidesonlysupplementalinformationasitpertainstothe C-Max and C-Max Energi vehicles. The same rules apply when approaching anypotentialhigh-voltagesituation.Alwaysfollowyourhigh-voltagesafety training.Someprecautionstotakeinahigh-voltagesituationinclude:

— Removealljewelry:Watches,necklacesandearrings.Removeany metalobjectsthatareconductorsofelectricity.

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

• Bringthefollowingequipment:

— ClassABCpowder-typefireextinguisher.

— Anon-conductiveobject,about5ft(1.5m)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-voltageelectricalsystemusingasmanyofthefollowing steps as possible:

— Securethevehicle:PlacetheshiftleverintothePARKposition. PlacetheignitionintheOFFpositiontodisconnectthehigh-voltage system.Blockthewheels,ifnecessary.

— Ifpossible,removethehigh-voltageservicedisconnect(s).For additional information, refer to the high-voltage service disconnect procedureinthisguide.Iftheservicedisconnectscannotberemoved, avoid the high-voltage system components and wear all appropriate PPE as outlined in this guide.

• Ifthevehicleisonfire,useaClassABCpowder-typeextinguishertocontain andsmothertheflames.Ifwaterisbeingused, LARGE amounts of water willberequiredtoextinguishtheflames.Afire-hydrantordedicatedfire hose can supply the needed 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 additional combustible gas and otherbyproductssuchashydrofluoricacid.However,thecoolingand smotheringeffectsofflushingtheaffectedarticlewithlargeamountsofwater and/orotherfiresuppressionmaterialisstillbeneficialforminimizingthe severity of the event.

• Ifthevehiclehasanyexposedcables,makesuretowearhigh-voltage rubberglovesandotherappropriatePPE.Donottouchanybrokenor damaged high-voltage orange cables. Treat severed cables as if they contain high-voltage.

• Ifthevehicleissubmergedinwater,varyingdegreesofarcing/shorting withinthebatterywilltakeplace.Donottouchanyhigh-voltagecomponents or orange cables while extricating the occupant(s). Do not remove the vehicle until you are sure the high-voltage battery is completely discharged. Asubmergedhigh-voltagebatterymayproduceafizzingorbubbling reactiontothewater.Iffizzingorbubblingisobserved,thehigh-voltage batterywillbedischargedwhenthefizzingorbubblinghascompletely stopped. However, you should still treat it as if it was not discharged.


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

4. MOVING DAMAGED VEHICLES — WRECKER DRIVERS

5. SPECIAL NOTE TO SALVAGE YARDS

APPROACHING A DAMAGED VEHICLE - CONTINUED

• UseafirehosetohosetheareadownwithLARGE amounts of waterjustlikeyouwouldanyotherbattery.

• Ifavehiclewithahigh-voltagebatteryistobescrapped,thehigh-voltage battery must be disposed of following all local, state/provincial and federal guidelines.

•Operatorsoftowtrucksandvehiclestoragefacilitiesshouldmakesurethe damagedvehicleiskeptinanopenareainsteadofinsideagarageorother enclosed building.

•Ratherthanattempttodischargeapropulsionbattery,anemergency responder,towtruckoperator,orstoragefacilitymanagershouldcontact the vehicle manufacturer. Ifpossible,removethehigh-voltageservicedis connect. For additional information, refer to the high voltage service disconnect procedure in this guide.

•Bealert.Thereispotentialfordelayedfirewithdamagedlithium-ion batteries.

•CallanauthorizedFordDealerorvehiclemanufacturerrepresentative,if necessary,todetermineadditionalstepsthatyoushouldtaketosafely recover or transport the vehicle.

• FollowtheguidelinesintheWreckerTowingManual.

— FrontTow:WheelLift(FWD)

— Flatbed:FWD


APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED

6. High Voltage System - Do Not Cut Zones

•Ifpossible,removethehigh-voltagebatteryservicedisconnectbefore attemptinganyextricationprocedure.Alwaysassumethehigh-voltage cabling and components are powered up.

•Ifoccupantextricationisnecessary,alwaysusecautionwhencutting near the 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 vehicle to the underhood compartment.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-voltagebatteryandassociatedcomponents are energized and fully charged.

•Exposedelectricalcomponents,wires,andhigh-voltagebatteriespresent potential 5ftshockhazards.

•Venting/off-gassinghigh-voltagebatteryvaporsarepotentiallytoxicand flammable.

•Physicaldamagetothevehicleorhigh-voltagebatterymayresultinimmediateordelayedreleaseoftoxicand/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 Owner’sManual,EmergencyPlacard(includedintheOwner’sManual)and/or theEmergencyResponseGuideforappropriatecontactinformation.

• Ifyoudetectleakingfluids,sparks,smoke,flames,increasedtemperature, gurgling, popping or hissing noises from the high-voltage battery compartment, ventilate the passenger area by rolling down windows or opening doors andcalling911.

• 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) - CONTINUED3. Recovering/Transporting Vehicle

•Callanauthorizedservicecenterorvehiclemanufacturerrepresentative, ifnecessary,todetermineadditionalstepsthatyoushouldtaketosafelyrecover or transport the vehicle.

•Alwaysapproachthevehiclefromthesidestostayoutofpotentialtravelpath.Itmaybedifficulttodetermineifthevehicleisrunningduetolackofenginenoise.

• 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.

• Do not store a severely damaged vehicle with a lithium-ion battery inside a structureorwithin50feetofanystructureorvehicle.

• Makesurethepassengerandcargocompartmentsremainventilated.

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

•Maintainclearaccesstostoredvehiclesformonitoringandemergencyresponse if needed.

Forspecificinformationandsafetypreparationregardingthehigh-voltage system, refer to WWW.MOTORCRAFTSERVICE.COM,selectquickguidesfor the appropriate vehicle emergency response guide.


High Voltage Battery Removal - HYBRID Vehicle

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 IDEN-TIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLT-AGE COMPONENTS 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.

E153850

1.Depowerthehigh-voltage(HV)battery.Refertohigh-voltageservicedisconnect procedureonpage13.

NOTE:Wait5minutesaftertheservicedisconnectplugisremovedbefore continuing service. This allows any residual voltage in the high-voltage system to dissipate.

NOTE: Depowering the high-voltage system does not dissipate the high-voltageinsidethebattery.Thebatterypackwillremainliveanddangerous.

2.Removethecargoshadefromthevehicle.


E153852

3.Removethecargocover.

E153978

x3 1

2

4.Removethe12Vbatterycover.

5.Disconnectandisolatethe12Vnegativebatterycable.

6.Removetherearcargotrim.


E153978

x3 1

2



9.Removetherearcargotrim.

10.Removethereartrunkscuff.

E153904

x2


11.RemovetheLHreardoorscuff.

12.RemovetheRHreardoorscuff.

E153910

x2

E154015

x2


13.DisengageandpositiontheLHloadfloortrimpanelslightlyaway.

14.Disconnectthetrimpanelappropriatelyandremove.

15.DisengageandpositiontheRHloadfloortrimpanelslightlyaway.


E154023

x12

1

E153993

x12


E153793

x3

17.Foldtherearseatbackdown.

18.Removetheupperhigh-voltagebatteryinletducts.

19.Removethegaphiderfromtherearseatback.


x2x21

x2x2

3

2

E153794

21.Returntherearseatbacktotheuprightposition.

22.Removetherearseatcushions.

E153796

x4

20.RemovethetopcoverfromtheHigh-VoltageBattery.


23.Removetherearseatbacks.

24. Disconnect the high-voltage battery wiring.

25.Removethelowerhigh-voltagebatteryairinletducts.

x4

x2

x4

x2

E153797

E154398

x4


1

2

E153968

26.Removethehigh-voltagebatterywiringcover.

27.Disconnectthehigh-voltagebatterygroundharness.


x2

x2

x2

x2

E153969


x5x5

E153200

30. Disconnect the wiring from the high-voltage battery cooling fan.

31.Removethehigh-voltagebatterycoolingfanandairoutletduct.

29.Disconnectthe12Vbatteryharness.

x3

E153798


x5x5

E153970

E153971x2

32.Removethefastenerssecuringthehigh-voltagebattery.

33. With the help of an assistant, remove the high-voltage battery through the rear of the vehicle.


High Voltage Battery Removal - ENERGI Vehicle 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 IDEN-TIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLT-AGE COMPONENTS 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.

E153850

NOTE:SpecialServiceTools303-F047(EngineLiftingBracket),303-050 (EngineLiftingBracket)and300-OTC1819E(FloorCrane)arenecessary to remove the high-voltage battery.

1.Depowerthehigh-voltagebattery.Refertohigh-voltageservicedisconnectprocedureonpage14.

NOTE: Wait5minutesaftertheservicedisconnectplugisremovedbefore continuing service. This allows any residual voltage in the high-voltage system to dissipate.

NOTE: Depowering the high-voltage system does not dissipate the high-voltageinsidethebattery.Thebatterypackwillremainliveanddangerous.

2.Removethecargoshadefromthevehicle.


E153852

3.Removethecargocover.



6.Removetherearseatgaphider.

E153793

x3


7.RemovetheLHreardoorscuff.

8.RemovetheRHreardoorscuff.

E153910

x2

E154015

x2


9.DisengageandpositiontheLHloadfloortrimpanelslightlyaway.


11.DisengageandpositiontheRHloadfloortrimpanelslightlyaway.


E154023

x12

1

E153993

x12


13.Foldtherearseatbackdown.

14.Removetheupperhigh-voltagebatteryinletducts.

E153796

x4

15.Removethetopcoverfromthehigh-voltagebattery.


x2x21

x2x2

3

2

E153794

16.Returntherearseatbacktotheuprightposition.

17.Removetherearseatcushions.

18.Removetherearseatbacks.

E154398

x4


19.Disconnectthehigh-voltagebatterywiring.

20.Removethelowerhigh-voltagebatteryairinletducts.

x6x6

E159091

21.Removethehigh-voltagebatterywiringcover.

x3x3

E159092


22. Disconnect the high-voltage battery ground.


x71

2

x7

E159093

24.Removethelowerrearbatterytrimpanel.

E159438

x2

x4


25.Removetheupperrearbatterytrimpanel.

x4x4E159431

26.Removethehigh-voltagebatteryrearoutletvent.

x2x4

x2x4

E159098


E159089

27.Disconnectthewiringfromthehigh-voltagebatterycoolingfan.

28.Removethehigh-voltagebatterycoolingfanandairoutletduct.

29.Removethehigh-voltagebatteryrearprotector/guard.

x2x2

E159094


30. Disengage the wiring from the high-voltage battery.

31.Disconnectthe12Vpositivebatterycable.

x5x5

E159095

32.Removethefastenerssecuringthehigh-voltagebattery.

x2x2

E159097


NOTE:SpecialServiceTools303-F047(EngineLiftingBracket),303-050 (EngineLiftingBracket)and300-OTC1819E(FloorCrane)arenecessaryto remove the high-voltage battery.

33.InstallSpecialServicetools303-F047(EngineLiftingBracket)and303-050 (EngineLiftingBracket)tothehigh-voltagebatterysecuringfastenerlocations (fourcornersofthehigh-voltagebattery).Tightenthebracketfastenersto 55Nm(41lbs.ft).

34.ConnectSpecialServicetool300-OTC1819E(FloorCrane)tothe303-F047 (EngineLiftingBracket).Withthehelpofanassistant,liftthehigh-voltagebattery and remove through the liftgate opening of the vehicle.

x4x4

E159099

303-F047

303-050


SPECIAL NOTE TO SALVAGE YARDSIfavehiclewithahigh-voltagebatteryistobescrapped,thehigh-voltagebatterymustbe disposed of following all local, state/provincial and federal guidelines.

TheC-MaxHybridandC-MaxEnergivehicles’Lithium-Ionhigh-voltagebatterypack(Li-IonHVB)isfullyrecyclableandshouldbeshippedtoapermittedrecyclingfacility.TheguidelinesbelowareforLi-IonHVBswhichhavebeenremovedfromthevehicleanddischarged. General Guidelines

Oncethebatteryhasbeenremovedfromthevehicleanddischarged:

1. Storethebattery’scomponentsinabuildingorundersheltersothatbatteriesarekeptdryandnotexposedtohightemperatures.

2. Protect battery’s components from being damaged (e.g. crushed or punctured).

3. Itisrecommendedtoaskaboutthespecificpackagingrequirementsforbatteryshipments to the recycler who will be receiving the battery components in ordertoavoidinappropriaterepacking/stackingofthebatteries.

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

Applicable Laws/RegulationsThe 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.

PackagingandTransport

TheU.S.DepartmentofTransportation(DOT)outlinespackagingandshippingrequirementsforLi-Ionbatteries.CertainexceptionsonpackagingandtransportationregulationsforlargeformatLi-Ionbatteriesmaybefoundin49 CFR173.185(d)and(g).

Makesurethattheshippingpaperworkisfilledoutcorrectlyandthattheshipmentisproperly labeled per federal, state, and local laws and regulations.

Checktomakesurethatyouarecomplyingwithanyrecordkeepingrequirements.Onlycertifiedhazardousmaterialshippersshouldoffertransportofahazardousmaterial.Generally,underU.S.DOTregulations,Li-Ionbatteriesareusuallyconsideredadangerousgoodandregulatedashazardousmaterialswhentransported.Li-IonbatteriesareclassifiedasClass9hazardousmaterial.

Batteriesforrecyclingshouldbeshippedbygroundorvesselonly.Donotshipbatteriesfor recycling by air.


SPECIAL NOTE TO SALVAGE YARDS - CONTINUED

NOTE:Adamagedbattery(onethatisleakingelectrolytefromthebatterypack)mightneedtobeshippedasahazardouswaste.Checkyouryellowpages(e.g.waste, rubbish and garbage removal, recyclables, recycling) to locate a company that specializes in transporting or managing hazardous wastes.

Recycling40CFR261statesthatmanufacturedarticlesthatyieldextractswhichexceedoneormoreoftheconcentrationlimitsofregulatedlistedconstituents,ormeetsthedefinitionofignitability,corrosivityorreactivityaredefinedashazardouswastesandmustbedisposedofinaccordancewithfederalandstateregulations.SincetherearemanyvariationsinthespecificchemistryofLi-Ionbatteries,additionalclassificationsmaybenecessaryandistheresponsibilityofthegenerator.Generally,underfederalandstatelaw,sealed,Li-Ionbatteriesmaybeconsidereddrycellbatteriesandthereforemaybemanagedasauniversalwaste;damagedorleakingLi-Ionbatteriesmayberegulatedas hazardous waste under federal and state regulations.

ThoughFordMotorCompanymakesnorepresentationsorendorsements,therearecompaniesthathavethecapabilitytoaccept,consolidateandrecycleLi-IonHVBs,and a few are listed below. Contact the appropriate battery manufacturer for additional information.

North America Battery Recyclers

Kinsbursky Brothers, Inc.125E.CommercialAnaheim,CA92801Phone:714-738-8516Fax:714-773-4830

RETRIEV Technologies, Inc.9384Highway22AP.O.Box232Trail,B.C.CanadaV1R4L5Phone:877-GOTOXCO(877)468-6929Fax:250-367-9875

Documents

2015 C-MAX HYBRID C-MAX ENERGIelvsolutions.org/wp-content/uploads/2015/01/2015_C-Max_Battery...C-MAX HYBRID C-MAX ENERGI 2015. FCS-21237-15 1 2015 C-Max Hybrid/Energi Battery Removal