Emergency Response Guide for the Mazda Tribute Hybrid

TRIBUTE HYBRID
EMERGENCY RESPONSE GUIDE
9999-95-ERG-08HEV
TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
CONTENTS
FOREWORD....................................................................................................................... - 1 TRIBUTE HYBRID VEHICLE IDENTIFICATION ............................................................... - 3 HIGH-VOLTAGE ELECTRICAL AND FUEL DISCONNECT FEATURES........................ - 5 HYBRID COMPONENT LOCATION AND IDENTIFICATION ........................................... - 6 HYBRID COMPONENT LOCATION.................................................................................. - 7 HIGH-VOLTAGE BATTERY PACK ................................................................................... - 8 APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE .......................................... - 10 NOTES.............................................................................................................................. - 12 -
FOREWORD
The emergency response procedure for the Tribute Hybrid vehicle is similar to
those for traditional gasoline-powered vehicles with the addition of special
considerations for the high-voltage electric system components.
The Tribute Hybrid vehicle uses a conventional gasoline engine in addition to an
electric motor to power the vehicle. The energy used to power the vehicle comes
from gasoline (used by the internal combustion engine) and electricity (used by the
electric motor).
• Gasoline is stored in a traditional fuel tank.
• Electricity is stored in a high-voltage battery pack.
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 high-voltage system is self
contained, never needing to be plugged into an electrical outlet for recharging. The
system incorporates a generator that recharges the batteries during cruising and
braking. For further information, the following website may be useful:
http://www.fordvehicles.com/escapehybrid/technology/.
The information in this guide will allow response to emergencies involving Tribute
Hybrid vehicles to be as safe as with conventional vehicles.
The Tribute Hybrid vehicle has been designed with many safety features for your
protection. These features help provide safe access to the vehicle under various
conditions. However, whenever approaching a high-voltage vehicle in a fire,
rescue or recovery situation, always follow one industry standard rule:
ALWAYS ASSUME THE VEHICLE HIGH-VOLTAGE
SYSTEM IS POWERED UP!!!
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TRIBUTE HYBRID VEHICLE IDENTIFICATION
•
The Tribute Hybrid vehicle can be easily identified by the Mazda “green leaf
globe” badges located on the left and right fenders. There is also a “Hybrid”
nameplate on the tailgate that also includes the “green leaf” icon.
•
The Tribute Hybrid vehicles have a unique left rear quarter glass that
incorporates the high-voltage traction battery air intake.
Green Leaf Globe
Badge on Fenders
Unique Left Rear
Quarter Glass
with Traction
Battery Air Intake
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Hybrid Nameplate
with Green Leaf
Globe Badge on
Tailgate
TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
•
The Tribute Hybrid vehicle has a unique engine appearance cover with
Mazda “Winged M” logo and HYBRID lettering.
•
The 5th, 6th and 7th digits of the vehicle identification number (VIN) identify
the hybrid vehicle line.
VIN POSITIONS
5, 6 & 7
U95
U96
VEHICLE
Tribute Hybrid — Front Wheel Drive (FWD)
Tribute Hybrid — All Wheel Drive (AWD)
SAMPLE VIN:
1FMYU95H35WA00001
Tribute Hybrid FWD
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TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
HIGH-VOLTAGE ELECTRICAL AND FUEL DISCONNECT
FEATURES
The following list describes certain features that have been incorporated into the
Hybrid vehicles that allow for either simple or automatic shutoff of the high-voltage
electrical and fuel systems.
•
•
•
•
•
•
•
Inertia Switch – Fuel Pump Shut-Off — The fuel pump shut-off inertia switch
is normally closed to allow vehicle operation. In the event of a collision or a
substantial physical jolt, the switch is designed to open automatically
shutting off electrical power to the fuel pump and the HV shut-off switch.
Inertia Switch – High-Voltage (HV) Shut-Off — The HV shut-off switch is
located behind the jack access panel in the cargo area on the passenger
side of the vehicle. In the event of a collision or a substantial physical jolt,
the switch is designed to open automatically disabling the HV system.
High-Voltage (HV) Fuse — In the event of a high current short circuit, the
HV fuse will open disabling the HV system.
High-Voltage (HV) Interlock Circuit — Whenever a high-voltage connector
is disconnected, the HV interlock circuit opens and disables the HV system.
Ignition Key in OFF Position — Anytime the ignition lock cylinder is in the
OFF position, the HV system is disabled.
High-Voltage Service Disconnect Switch — Whenever the high-voltage
service disconnect switch (located on top of the high-voltage battery in the
cargo area) is removed, the HV system is disabled. For additional
information, refer to Page 9 in this manual.
Thermal Sensors — In the event the ignition key is left in the ON position,
while the vehicle is parked and the HV battery temperature exceeds 60°C
(140°F), thermal sensors located near the HV battery will automatically
disconnect the HV battery.
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HYBRID COMPONENT LOCATION AND IDENTIFICATION
This chart provides the location, description and basic function of the hybrid
system components. Refer to the component location illustration on the following
page.
COMPONENT
1
High-Voltage
Shut-Off Switch
2
High-Voltage
Service Disconnect
Switch
3
High-Voltage
Battery
— 300+ Volts
4
High-Voltage Wiring
5
12-Volt Battery
6
Electronically
Controlled
Continuously
Variable Transaxle
(eCVT)
7
DC/DC Converter
8
Fuel Shut-Off
Inertia Switch
LOCATION / DESCRIPTION
FUNCTION
• Located in the jack stowage
compartment, passenger side in
the cargo area.
• Located on top of the HV battery,
passenger side in the cargo area
under carpet.
• Orange in color with molded plastic
handle, about 100 mm (4 inch) in
diameter.
• Located in the cargo area under
carpet.
• Sealed nickel-metal hydride.
• Runs along underside of vehicles
cab floor from HV battery to
electronically controlled
continuously variable transaxle
(eCVT) then to DC-to-DC
converter.
• All high-voltage wiring has
orange-colored insulation.
• Located under the hood on driver
side of the vehicle.
• Typical automotive 6-cell lead/acid
design.
• Transverse-mounted design
similar to the non-hybrid Tribute
vehicles.
• Contains the traction motor,
generator motor and hybrid
electronics.
Disconnects HV battery in the
event of a collision
• Located under the hood on the
passenger side forward of the strut
tower.
• Located behind the flip-up panel in
the passenger front foot well.
Provides means to disconnect
HV battery for safely servicing
vehicle.
Provides high-voltage storage
(300+ V) for vehicle propulsion
requirements.
Provides physical path for
high-voltage circuitry.
Provides 12-volt power for
vehicle accessories.
Provides delivery of power to
wheels for vehicle propulsion,
generates electricity to
recharge the batteries during
braking and coasting, and
contains certain hybrid
electronics.
Provides 12 volts of power to
charge the 12-volt battery and
run vehicle accessories.
Disables power supply to the
gasoline fuel pump and the HV
shut-off switch in the event of a
collision.
NOTE: All High-voltage wires and harnesses are wrapped in orange-colored insulation.
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TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
HYBRID COMPONENT LOCATION
•
Warning decals, as shown here, will be located on components included in
the high-voltage system.
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HIGH-VOLTAGE BATTERY PACK
The high-voltage battery pack is located in the rear of the vehicle underneath the
carpet.
•
•
•
•
•
•
The high-voltage battery pack consists of 50 battery modules.
Each module is comprised of 5 nickel-metal hydride (Ni-MH), 1.3-volt
batteries welded together.
Each battery within the module is similar in size and shape to a size D
flashlight battery and is sealed in a stainless steel case.
The total voltage of the battery pack is approximately 300 volts DC.
The battery case is designed to be water resistant.
The battery cells contain a base electrolyte (consisting of potassium
hydroxide as the dominant active ingredient) that is absorbed in a special
paper. The electrolyte will not leak from the battery under most conditions,
however, if the battery is crushed, it is possible for a small amount (drops) of
electrolyte to leak.
These warnings must be observed when working with a damaged battery:
1. Exposure to electrolyte could cause skin/eye irritation and or burns. If
exposed, rinse with large amounts of water until the soapy feel is gone.
Personal protective equipment (PPE) such as splash shield or safety
goggles, gloves (latex, rubber or Nitrile), an apron or overcoat suitable to
protect against alkaline and rubber boots are required when handling
damaged batteries. Fold-down helmet shields are not acceptable for
acid or alkaline spills.
2. If the battery is exposed to intense heat, it is possible that hydrogen could
be released from the battery. Appropriate precautions should be taken to
make sure the area is properly ventilated, such as, opening the lift gate and
vehicle doors and opening or removing the rear glass.
Note: The high-voltage service disconnect switch should be moved to the
service/shipping position if possible.
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High-Voltage
Battery Pack
High-Voltage Service
Disconnect Switch
High-Voltage Shut-Off
Switch Located Behind
Jack Access Panel
WARNING
•
Removing the high-voltage service disconnect switch disconnects
high voltage from the vehicle.
•
The individual cells inside the battery pack will still be charged.
•
Do not cut into the high-voltage battery case or penetrate the
batteries in any way.
High-Voltage Service Disconnect Switch Shown in LOCK position.
High-voltage system is STILL ACTIVE.
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Remove switch and place in SERVICE/SHIPPING position
to disconnect high-voltage system.
APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE
1. FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER DIRECTION
•
This guide provides only supplemental information as it pertains to the
Tribute Hybrid vehicle. The same rules apply when approaching any
potential high-voltage situation. Always follow your high-voltage safety
training. Some precautions to be taken in any high-voltage situation include:
− Remove all jewelry, watches, necklaces, earrings; etc. Metal objects are
conductors of electricity.
− Wear the necessary PPEs (high-voltage rubber gloves, face shield,
insulated boots, protective raincoat or apron).
− Bring the following equipment:
ƒ Class ABC powder-type fire extinguisher
ƒ A non-conductive object – about 1.5 meters (5 feet) long – used to
safely push someone away from the vehicle if they accidentally come
in contact with high voltage.
2. APPROACHING A DAMAGED VEHICLE
•
Disable the high-voltage electrical system using as many of the following
steps as possible:
− Secure the vehicle — place the shift lever into the PARK position.
Remove the ignition key. Block the wheels if necessary. Removing the
ignition key or turning it to the OFF position will disconnect the
high-voltage system.
− Disconnect the negative cable from the 12-volt battery – this will also
disconnect the high voltage.
− If possible, place the high-voltage service disconnect switch (see section
on Hybrid components for location) into the service position. To place in
the service position, turn counterclockwise and then lift out. Reinsert the
disconnect switch with the arrow aligned to the service/shipping position.
.SPECIAL NOTES:
•
If the vehicle is on fire, use a Class ABC powder-type extinguisher to contain
and smother the flames. Or, if water is used, large amounts are required
(e.g., from a fire hydrant).
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TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
•
•
If the vehicle has any exposed cables, make sure you are wearing insulated
gloves and other protective clothing. Do not touch any broken or damaged
orange cables. Treat severed lines as if they contain high voltage.
If the vehicle is submerged in water, do not touch any high-voltage
components or cables while extricating the occupant(s). Do not remove the
vehicle until you are sure the high-voltage battery is completely discharged.
A submerged high-voltage battery may produce a fizzing or bubbling
reaction. The high-voltage battery will be discharged when the fizzing or
bubbling has completely stopped.
3. IF THE HIGH-VOLTAGE BATTERY CASE HAS BEEN RUPTURED
•
Just like any other battery, hose the area down with large amounts of water.
4. MOVING DAMAGED VEHICLES — WRECKER DRIVERS
•
•
•
Turn the vehicle ignition key to the ACCESSORY position to release the
locking steering wheel.
If possible, remove the high-voltage service disconnect switch by turning it
counterclockwise and lifting out. Reinstall in the service/shipping position.
Follow the guidelines in the Wrecker Towing Manual.
— Front Tow: Wheel Lift with Dolly for 4WD and No Dolly for FWD
— Rear Tow: Wheel Lift with Dolly for All (FWD or 4WD)
— Flat bed: Front and Rear
5. SPECIAL NOTE TO SALVAGE YARDS
•
If a vehicle with a high-voltage battery is to be scrapped, the high-voltage
battery must be disposed of following all local, state/provincial and federal
guidelines.
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TRIBUTE HYBRID EMERGENCY RESPONSE GUIDE
NOTES
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