2014
C-MAX HYBRID
C-MAX ENERGI
BATTERY REMOVAL GUIDE
FCS-21237-14
Table of Contents
FOREWORD .................................................................................................. Page 2
HYBRID VEHICLE IDENTIFICATION............................................................ Page 3
VIN Layout .............................................................................................Page 4
HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES ........................ Page 5
HIGH-VOLTAGE WARNING DECALS ........................................................... Page 6
HYBRID COMPONENT LOCATION AND IDENTIFICATION........................ Pages 7-9
ENERGI COMPONENT LOCATION AND IDENTIFICATION........................ Pages 10-12
HIGH-VOLTAGE SERVICE DISCONNECTS ................................................. Page 13
HIGH-VOLTAGE BATTERY PACK ................................................................ Pages 14-15
APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE ......................... Page 16
Follow Existing Training and Incident Commander Direction .........Page 16
Approaching a Damaged Vehicle ........................................................Page 17
If The High-Voltage Battery Case Has Been Ruptured......................Page 18
Moving Damaged Vehicles - Wrecker Drivers....................................Page 18
Special Note To Salvage Yards ...........................................................Page 18
High-Voltage System - Do Not Cut Zones ..........................................Page 19
DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY
ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH
HIGH VOLTAGE BATTERIES........................................................................ Pages 20-21
HIGH VOLTAGE BATTERY REMOVAL - HYBRID VEHICLE ....................... Pages 23-33
HIGH VOLTAGE BATTERY REMOVAL - ENERGI VEHICLE ....................... Pages 34-45
SPECIAL NOTE TO SALVAGE YARDS ........................................................ Pages 46-47
FCS-21237-14
C-Max Hybrid/Energi Battery Removal Guide
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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.
• 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 (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 incorporates a generator that recharges the high-voltage battery during cruising and
braking. 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
incorporates a generator that recharges the high-voltage battery during cruising and
braking.
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
under various conditions; however, when approaching a high-voltage vehicle in a fire,
rescue or recovery situation, always follow one industry standard rule:
ALWAYS ASSUME THE VEHICLE’S
HIGH-VOLTAGE SYSTEM IS POWERED UP !
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C-Max Hybrid/Energi Battery Removal Guide
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HYBRID VEHICLE IDENTIFICATION
• The C-Max Hybrid vehicles can easily be identified by the “Hybrid” badges
located on the left and right front doors. There is a “Hybrid” nameplate
on the trunk lid (located on the right hand side) that also includes the green
leaf/blue highway “Hybrid” icon.
• The C-Max Energi vehicles can easily be identified by the “Energi” badges
located on the left and right front doors. There is a “Energi” nameplate on
the trunk lid (located on the left hand side) that also includes the green
leaf/blue highway “Hybrid” icon.
Hybrid nameplate and icon
on trunk lid.
Hybrid/Energi nameplate
with Hybrid icon on front
doors.
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• The C-Max vehicle has a unique engine appearance cover with a
raised “HYBRID” icon on it.
Unique Hybrid engine appearance cover
with raised lettering and icon
NOTE: C-Max Hybrid shown, C-Max Energi similar.
• The 5th, 6th and 7th digits of the Vehicle Identification Number (VIN)
identify the Hybrid vehicle line.
VIN POSITIONS
5, 6 and 7
VEHICLE
P5A
Hybrid 5-door, SE
P5B
Hybrid 5-door, SEL
P5C
Energi 5-door, SEL (plug-in)
3 F A D P5A30AR100001
C-Max Hybrid FWD
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HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES
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.
The following list describes 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-Voltage Fuse — In the event of a high-voltage short circuit, the
high-voltage fuse will open, disabling the high-voltage system.
• High-Voltage Interlock Circuit — Whenever a high-voltage connector
is disconnected, the high-voltage interlock circuit opens and disables
the high-voltage system.
• Ignition Key/Button in the OFF Position — Any time the ignition is in
the OFF position, the high-voltage system is disabled.
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 highvoltage present in the system if the ignition is off.
• High-Voltage Service Disconnect — Whenever the high-voltage
service disconnect (located behind the rear seat fold) is removed, the
high-voltage system is disabled. For additional information, refer to
page 13 in this manual.
• Thermal Sensors — In the event the battery is exposed to extreme hot
ambient 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. In some instances, if the ignition
key is left in the “ON” position, this could cause the high-voltage battery
temperature to exceed 60°C (140°F); if this temperature is reached, the
thermal sensors located near the high-voltage battery will automatically
disable the high-voltage battery.
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C-Max Hybrid/Energi Battery Removal Guide
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HIGH-VOLTAGE WARNING DECALS
2U5A-14B218-CA
• On Hybrid vehicles, WARNING decals are located on components in the
high-voltage system throughout the vehicle. Please see example below.
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HYBRID COMPONENT LOCATION AND IDENTIFICATION
The illustration below and its defining chart on Pages 8 & 9, provide the location,
description and basic function of the Hybrid system components.
NOTE: All high-voltage wires and harnesses are wrapped in orange-colored insulation.
2
1
3
8
7
4
6
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C-Max Hybrid/Energi Battery Removal Guide
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7
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HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED
1
2
3
COMPONENT
LOCATION / DESCRIPTION
High-Voltage Battery • Lies flat in the trunk area,
behind the rear seat.
Approximately 300• Sealed lithium battery.
Volts DC
12-Volt Battery
(hidden from
graphic)
High-Voltage
Service Disconnect
•
5
6
High-Voltage Wiring
Provides high-voltage storage
for vehicle’s electric motor.
Located in the trunk area of
the vehicle.
Typical automotive 6-cell
lead/acid design.
Provides 12-volts for vehicle
accessories. Receives current
from the DC/DC converter (PIA
to the high-voltage battery) via a
pre-fuse box in the engine compartment which runs to the 12V
positive post.
Located behind the rear
seat back on the driver side.
Orange rectangle with a
molded plastic handle, about
100 mm (4 in) in length.
Provides means to disconnect
high-voltage battery for safely
servicing vehicle.
•
Runs along the vehicle’s
floorpan from the highvoltage battery to the Hybrid
Powertrain Control Module
(HPCM). The electric AC
compressor connects
directly to the HPCM.
Separate connections from
the HPCM are made to the
Electronically Controlled
Continuously Variable
Transaxle (ECVT).
Provides physical connection
between the high-voltage battery
and the vehicle’s high-voltage
equipment.
•
All high-voltage wiring has
orange-colored insulation.
•
•
•
4
FUNCTION
Electronically
Controlled
Continuously
Variable Transaxle
(ECVT)
• Transverse-mounted design
•
Contains the traction motor,
generator motor and hybrid
electronics.
Electric A/C
Compressor
•
Located in front of the
engine.
It has an orange highvoltage wire attached to it.
•
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C-Max Hybrid/Energi Battery Removal Guide
Provides rotational force to the
wheels for vehicle propulsion and
transmits rotational force to the
engine’s generator to recharge
batteries.
Provides electric A/C operation;
replaces the belt driven A/C compressor.
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HYBRID COMPONENT LOCATION AND IDENTIFICATION - CONTINUED
7
8
COMPONENT
Electric Water
Pump
LOCATION / DESCRIPTION
• Located in lower front of the
engine.
• It is an electric 12-volt pump.
Transmission Control • Located in front of the engine
Module
• Also referred to as the Hybrid
Powertrain Control Module.
• Contains controlling
electronics for managing
propulsion.
FCS-21237-14
C-Max Hybrid/Energi Battery Removal Guide
FUNCTION
Provides water pump operation
for the engine’s cooling system.
Replaces the belt driven water
pump.
Provides rotational force during
Electrical Drive Modes. Generates electricity for recharging the
high-voltage battery.
9
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ENERGI COMPONENT LOCATION AND IDENTIFICATION
The illustration below and its defining chart on Pages 11 & 12, provide the location,
description and basic function of the C-Max Energi’s system components.
NOTE: All high-voltage wires and harnesses are wrapped in orange-colored insulation.
1
2
3
11
10
9
4
5
6
8
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C-Max Hybrid/Energi Battery Removal Guide
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ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED
COMPONENT
LOCATION / DESCRIPTION
FUNCTION
Located behind the rear
seat back on the
passenger side.
• Orange rectangle with a
molded plastic handle, about
100 mm (4 in) in length.
• Located in the trunk area of
the vehicle.
• Typical automotive 6-cell
lead/acid design.
Provides means to disconnect
high-voltage battery for safely
servicing vehicle.
•
1
High-Voltage
Service Disconnect
2
12-Volt Battery
(hidden from
graphic)
3
High-Voltage Battery • Lies flat in the trunk area,
behind the rear seat.
Approximately 300Volts DC
• Sealed lithium battery.
Provides high-voltage storage
for the vehicle’s electric motor.
4
High-Voltage Wiring
Provides physical connection
between high-voltage battery
and vehicle’s high-voltage
equipment.
•
Runs along the vehicle’s
floorpan from the highvoltage battery to the Hybrid
Powertrain Control Module
(HPCM). The AC compressor connects directly to the
HPCM. Separate connections from the HPCM are
made to the Electronically
Controlled Continuously
Variable Transaxle (ECVT).
The PTC Heater connects
directly to the HV wiring on
the passenger side in the
engine compartment. Highvoltage wiring also connects
to the charge port.
•
All high-voltage wiring has
orange-colored insulation.
Provides 12-volts for vehicle
accessories. Receives current
from the DC/DC converter (PIA
to the high-voltage battery) via a
pre-fuse box in the engine compartment which runs to the 12V
positive post.
5
110V Convenience
Cord
•
Located under the front driver Provides 110V charging option to
side seat.
the high-voltage battery when the
vehicle is not in operation.
6
Charging Port
•
Located on the driver side
fender. It connects to the
high- voltage wiring in the
engine compartment.
It has an orange highvoltage wire attached to it
using an interlock connector.
•
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C-Max Hybrid/Energi Battery Removal Guide
Provides 110V or 220V charging
options from a Level II charging
station to the high-voltage battery
when the vehicle is not in operation.
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ENERGI COMPONENT LOCATION AND IDENTIFICATION - CONTINUED
COMPONENT
LOCATION / DESCRIPTION
Electronically
Controlled
Continuously
Variable Transaxle
(ECVT)
• Transverse-mounted design.
8
Electric A/C
Compressor
• Located in front of the
engine.
• It has an orange high-voltage
wire attached to it.
Provides electric A/C operation;
replaces the belt driven A/C compressor.
9
Electric Water
Pump
• Located in lower front of the
engine.
• It is an electric 12-volt pump.
Provides water pump operation
for the engine’s cooling system.
Replaces the belt driven water
pump.
10 Electric Heater
• Located in the engine
compartment on the
passenger side.
Provides passenger compartment with heat without the need
to turn the engine on.
11 Transmission
Control Module
• Located in front of the engine.
• Also referred to as the Hybrid
Powertrain Control Module.
Provides rotational force during
Electrical Drive Modes. Generates electricity for recharging the
high-voltage battery.
7
• Contains the traction motor,
generator motor and
connects to the Hybrid
Powertrain Control Module
which operates the motor
controls.
• Contains controlling
electronics for managing
propulsion.
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C-Max Hybrid/Energi Battery Removal Guide
FUNCTION
Provides rotational force to the
wheels for vehicle propulsion and
transmits rotational force to the
engine’s generator to recharge
batteries.
12
2014
HIGH-VOLTAGE SERVICE DISCONNECT - FUSION HYBRID
NOTE: If possible, release and remove the high-voltage service disconnect.
2014 LATE PRODUCTION
C-MAX HYBRID VEHICLES ONLY
ALL 2014 C-MAX
HYBRID VEHICLES
1
2
3
REMOVAL INSTRUCTIONS
1
PULL THE LEVEL POSITION ASSURANCE
(LPA) TAB TOWARD FRONT OF VEHICLE
TO REMOVE.
2
PULL LEVER HANDLE OUTWARD TO
DISENGAGE INTERLOCK.
3
ROTATE THE LEVER TO HORIZONTAL.
4
REMOVE THE HIGH-VOLTAGE SERVICE
DISCONNECT.
4
NOTE: The Hybrid high-voltage service
*
disconnect is located behind the rear seat
back on the driver side. Fold the rear seat
back down and remove the cover to access.
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HIGH-VOLTAGE SERVICE DISCONNECT - FUSION ENERGI
NOTE: If possible, release and remove the high-voltage service disconnect.
2014 LATE PRODUCTION
C-MAX ENERGI VEHICLES ONLY
ALL 2014 C-MAX
ENERGI VEHICLES
1
2
3
NOTE: The Energi high-voltage service
disconnect is located behind the rear seat
back on the passenger side. Fold the rear seat
back down and remove the cover to access.
REMOVAL INSTRUCTIONS
1
PULL LEVER POSITION ASSURANCE (LPA)
TAB TOWARD FRONT OF VEHICLE TO REMOVE.
2
PULL LEVER HANDLE OUTWARD TO
DISENGAGE INTERLOCK.
3
ROTATE THE LEVER TO HORIZONTAL.
4
REMOVE THE HIGH-VOLTAGE SERVICE
DISCONNECT.
4
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 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.
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HIGH-VOLTAGE BATTERY PACK - CONTINUED
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.
• Do not cut the high-voltage battery case. Do not penetrate the
batteries or case in any way.
• The high-voltage battery is located in the forward portion of the luggage
compartment. The high-voltage battery lies flat just behind the rear seat back
under the luggage compartment cargo cover.
• Removing the high-voltage service disconnect will disconnect the high-voltage
from the vehicle. The battery pack will remain live and dangerous.
• The total voltage of the battery pack is approximately 300-volts DC.
• The battery cells contain a base electrolyte, consisting of lithium
hexafluorophosphate and organic solvents as the dominant active ingredient,
that is absorbed in special polymeric film. The electrolyte will not leak from
the battery under most conditions, however, if the battery is crushed, it is
possible for a small amount of electrolyte to leak.
NOTICE: The following must be followed when working with a damaged battery:
• If possible, isolate and avoid contact with high-voltage vehicle components. If
contact with the high-voltage system cannot be avoided, Personal Protective
Equipment (PPE) such as splash shield or safety goggles, gloves (latex,
rubber or Nitrile), an apron or overcoat, and rubber boots are required when
handling damaged batteries. Exposure to electrolyte could cause skin and/or
eye irritation/burns. If exposed, rinse with large amounts of water for
10-15 minutes.
• If the battery is exposed to intense heat (or other abusive conditions), it is
possible that flammable gases and liquid (electrolyte) have been released
from the cells. The gases include combustible hydrocarbons such as
methane, toxic gases such as carbon monoxide, and very small amounts of
eye/skin/lung irritants such as hydrofluoric acid could be released from the
battery. Appropriate precautions should be taken to make sure the area is
properly ventilated, such as opening the vehicle’s windows or doors. First
responders should wear Personal Protective Equipment (PPE) and self
contained breathing apparatus to safeguard against thermal, electrical,
respiratory and skin/eye hazards.
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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
• Emergency responders should use LARGE amounts of water if fire is
present or suspected and, keeping in mind that fire can occur for a
considerable period after the crash, should proceed accordingly.
• This guide provides only supplemental information as it pertains to the
C-Max and C-Max Energi vehicles. The same rules apply when approaching
any potential high-voltage situation. Always follow your high-voltage safety
training. Some precautions to take in a high-voltage situation include:
—
Remove all jewelry: Watches, necklaces and earrings. Remove any
metal objects that are conductors of electricity.
—
Wear the necessary PPEs: High-voltage rubber gloves, face
shield, insulated boots, protective raincoat and apron.
• Bring the following equipment:
—
Class ABC powder-type fire extinguisher.
— A nonconductive object, about 1.5 m (5 ft) long. This can be used to safely
push someone away from the vehicle if they accidentally come in contact
with high-voltage.
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APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED
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.
Place the ignition in the OFF position to disconnect the high-voltage
system. Block the wheels, if necessary.
—
If possible, remove the high-voltage service disconnect(s). For
additional information, refer to page 13 in this manual. If the service
disconnects cannot be removed, avoid the high-voltage system
components and wear all appropriate PPE as outlined on page 15 of
this guide.
• If the vehicle is on fire, use a Class ABC powder-type extinguisher to contain
and smother the flames. If water is being used, LARGE amounts of water
will be required to extinguish the flames. A fire-hydrant or dedicated fire
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
other by-products such as hydrofluoric acid; however, the cooling and
smothering effects of flushing the affected article with large amounts of water
and/or other fire suppression material is still beneficial for minimizing the
severity of the event.
• If the vehicle has any exposed cables, make sure to wear high-voltage
rubber gloves and other appropriate PPE. Do not touch any broken or
damaged high-voltage orange cables. Treat severed cables as if they
contain high-voltage.
• If the vehicle is submerged in water, varying degrees of arcing/shorting
within the battery will take place. Do not touch any high-voltage components
or orange 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
reac tion to the water. If fizzing or bubbling is observed, the high-voltage
battery will be discharged when the fizzing or bubbling has completely
stopped, however, still treat it as if it was not discharged.
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APPROACHING A DAMAGED VEHICLE - CONTINUED
3. IF THE HIGH-VOLTAGE BATTERY CASE HAS BEEN RUPTURED
• Just like any other battery, hose the area down with LARGE amounts of
water (ie. use a Fire Hose).
4. MOVING DAMAGED VEHICLES — WRECKER DRIVERS
• Rather than attempt to discharge a propulsion battery, an emergency
responder, tow truck operator, or storage facility manager should contact
experts at the vehicle manufacturer on that subject.
• If possible, remove the high-voltage service disconnect. For additional
information, refer to page 13 in this manual.
• Be alert. There is potential for delayed fire with damaged lithium-ion
batteries.
• Call an authorized Ford Dealer or vehicle manufacturer representative, if
necessary, to determine additional steps that you should take to safely
recover or transport the vehicle.
• Follow the guidelines in the Wrecker Towing Manual.
—
Front Tow: Wheel Lift (FWD)
—
Flatbed: FWD
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.
• Operators of tow trucks and vehicle storage facilities should ensure the
damaged vehicle is kept in an open area instead of inside a garage or other
enclosed building.
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APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED
6. High Voltage System - Do Not Cut Zones
• If possible, remove the high-voltage battery service disconnect before
attempting any extrication procedure. Always assume the high-voltage
cabling and components are powered up.
• If occupant extrication is necessary, always use caution when cutting
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. Refer to the diagram below for no cut zones.
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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).
• Always assume the high-voltage (HV) battery and associated components
are energized and fully charged.
• Exposed electrical components, wires, and HV batteries present potential HV
shock hazards.
• Venting/off-gassing HV battery vapors are potentially toxic and flammable.
• Physical damage to the vehicle or HV battery may result in immediate or
delayed release of toxic and/or flammable gases and fire.
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
authorized service center or vehicle manufacturer representative. Refer to the
Vehicle Owner Manual, Emergency Placard (included in the Vehicle Owner
Manual) and/or the Emergency Response Guide for appropriate
contact information.
• If you detect leaking fluids, sparks, smoke, flames, increased temperature,
gurgling, popping or hissing noises from the HV battery compartment, ventilate
the passenger area (i.e., roll down windows or open doors) and call 911.
• Be alert. There is a potential for delayed fire with damaged lithium-ion batteries.
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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
• Call an authorized service center or vehicle manufacturer representative,
if necessary, to determine additional steps that you should take to safely recover
or transport the vehicle.
•
Always approach the vehicle from the sides to stay out of potential travel path. It
may be difficult to determine if the vehicle is running due to lack of engine noise.
• Refer to vehicle manual/recovery guide to locate proper attachment/connection
points and transport method.
• Avoid contact with orange high-voltage cabling and areas identified as
high-voltage risk by warning labels.
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
structure or within 50 feet of any structure or vehicle.
• Ensure that passenger and cargo compartments remain ventilated.
• Prior to placing and while located in storage area/tow lot, continue to inspect
vehicle for leaking fluids, sparks, smoke, flames, gurgling or bubbling sounds
from the HV battery and call 911 if any of these are detected.
• Maintain clear access to stored vehicles for monitoring and emergency response
if needed.
For specific information and safety preparation regarding the high- voltage
system, refer to WWW.MOTORCRAFTSERVICE.COM, select quick guides for
the appropriate vehicle emergency response guide.
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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.
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.
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.
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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 IDENTIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLTAGE 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.
1. Depower the high-voltage (HV) battery. Refer to high-voltage service disconnect
procedure on page 13.
NOTE: Wait 5 minutes after the service disconnect plug is removed before
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-voltage
inside the battery. The battery pack will remain live and dangerous.
2. Remove the cargo shade from the vehicle.
E153850
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3. Remove the cargo cover.
E153852
4. Remove the 12V battery cover.
5. Disconnect and isolate the 12V negative battery cable.
6. Remove the rear cargo trim.
2
x3
1
E153978
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7. Remove the 12V battery cover.
8. Disconnect and isolate the 12V negative battery cable.
9. Remove the rear cargo trim.
2
x3
1
E153978
10. Remove the rear trunk scuff.
x2
E153904
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11. Remove the LH rear door scuff.
x2
E154015
12. Remove the RH rear door scuff.
x2
E153910
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13. Disengage and position the LH loadfloor trim panel slightly away.
14. Disconnect the trim panel appropriately and remove.
1
x12
E154023
15. Disengage and position the RH loadfloor trim panel slightly away.
16. Disconnect the trim panel appropriately and remove.
x12
E153993
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17. Fold the rear seat back down.
18. Remove the upper high-voltage battery inlet ducts.
19. Remove the gap hider from the rear seat back.
x3
E153793
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20. Remove the top cover from the High-Voltage Battery.
x4
E153796
21. Return the rear seat back to the upright position.
22. Remove the rear seat cushions.
3
1
x2
x2
2
E153794
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23. Remove the rear seat backs.
x4
24. Disconnect the high-voltage battery wiring.
25. Remove the lower high-voltage battery air inlet ducts.
x2
x4
E153797
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26. Remove the high-voltage battery wiring cover.
27. Disconnect the high-voltage battery ground harness.
2
1
E153968
28. Disconnect the high-voltage battery wiring.
x2
x2
E153969
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29. Disconnect the 12V battery harness.
x5
E153200
30. Disconnect the wiring from the high-voltage battery cooling fan.
31. Remove the high-voltage battery cooling fan and air outlet duct.
x3
E153798
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32. Remove the fasteners securing the high-voltage battery.
x5
E153970
33. With the help of an assistant, remove the high-voltage battery through the
rear of the vehicle.
E153971
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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 IDENTIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLTAGE 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.
NOTE: Special Service Tools 303-F047 (Engine Lifting Bracket), 303-050
(Engine Lifting Bracket) and 300-OTC1819E (Floor Crane) are necessary
to remove the high-voltage battery.
1. Depower the high-voltage battery. Refer to high-voltage service disconnect procedure
on page 14.
NOTE: Wait 5 minutes after the service disconnect plug is removed before
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-voltage
inside the battery. The battery pack will remain live and dangerous.
2. Remove the cargo shade from the vehicle.
E153850
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3. Remove the cargo cover.
4. Remove the 12V battery cover.
5. Disconnect and isolate the 12V negative battery cable.
E153852
6. Remove the rear seat gap hider.
x3
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7. Remove the LH rear door scuff.
x2
E154015
8. Remove the RH rear door scuff.
x2
E153910
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9. Disengage and position the LH loadfloor trim panel slightly away.
10. Disconnect the trim panel appropriately and remove.
1
x12
E154023
11. Disengage and position the RH loadfloor trim panel slightly away.
12. Disconnect the trim panel appropriately and remove.
x12
E153993
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13. Fold the rear seat back down.
14. Remove the upper high-voltage battery inlet ducts.
15. Remove the top cover from the high-voltage battery.
x4
E153796
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16. Return the rear seat back to the upright position.
17. Remove the rear seat cushions.
3
1
x2
x2
2
E153794
18. Remove the rear seat backs.
x4
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19. Disconnect the high-voltage battery wiring.
20. Remove the lower high-voltage battery air inlet ducts.
x6
21. Remove the high-voltage battery wiring cover.
x3
E159092
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22. Disconnect the high-voltage battery ground.
23. Disconnect the high-voltage battery wiring.
x7
1
2
E159093
24. Remove the lower rear battery trim panel.
x4
x2
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x4
25. Remove the upper rear battery trim panel.
26. Remove the high-voltage battery rear outlet vent.
x2
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27. Disconnect the wiring from the high-voltage battery cooling fan.
28. Remove the high-voltage battery cooling fan and air outlet duct.
x2
29. Remove the high-voltage battery rear protector/guard.
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30. Disengage the wiring from the high-voltage battery.
31. Disconnect the 12V positive battery cable.
x5
32. Remove the fasteners securing the high-voltage battery.
x2
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NOTE: Special Service Tools 303-F047 (Engine Lifting Bracket), 303-050
(Engine Lifting Bracket) and 300-OTC1819E (Floor Crane) are necessary to
remove the high-voltage battery.
33. Install Special Service tools 303-F047 (Engine Lifting Bracket) and 303-050
(Engine Lifting Bracket) to the high-voltage battery securing fastener locations
(four corners of the high-voltage battery). Tighten the bracket fasteners to
55Nm (41 lbs.ft).
34. Connect Special Service tool 300-OTC1819E (Floor Crane) to the 303-F047
(Engine Lifting Bracket).With the help of an assistant, lift the high-voltage battery
and remove through the liftgate opening of the vehicle.
303-F047
303-050
x4
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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.
The C-max Hybrid and C-Max Energi vehicles’ Lithium-Ion high-voltage battery pack (LiIon HVB) is fully recyclable and should be shipped to a permitted recycling facility. The
guidelines below are for Li-Ion HVBs which have been removed from the vehicle and
discharged.
General Guidelines
Once the battery has been removed from the vehicle and discharged:
1. Store the battery’s components in a building or under shelter so that batteries are
kept dry and not exposed to high temperatures.
2. Protect battery’s components from being damaged (e.g. crushed or punctured).
3. It is recommended to ask about the specific packaging requirements for battery
shipments to the recycler who will be receiving the battery components in order
to avoid inappropriate repacking/stacking of the batteries.
4. Batteries should be sorted by type. Keep lead acid batteries, NiMH batteries,
and Li-Ion batteries separated from each other (e.g. separate pallets or storage
locations).
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
Company makes no representation that this is a complete summary.
Packaging and Transport
The U.S. Department of Transportation (DOT) outlines packaging and shipping
requirements for Li-Ion batteries. Certain exceptions on packaging and transportation
regulations for large format Li-Ion batteries may be found in 49CFR 173.185 (d) and (g).
Make sure that the shipping paperwork is filled out correctly and that the shipment is
properly labeled per federal, state, and local laws and regulations.
Check to make sure that you are complying with any record keeping requirements. Only
certified hazardous material shippers should offer transport of a hazardous material.
Generally, under U.S. DOT regulations, Li-Ion batteries are usually considered a
dangerous good and regulated as hazardous materials when transported. Li-Ion
batteries are classified as Class 9 hazardous material.
Batteries for recycling should be shipped by ground or vessel only. Do not ship batteries
for recycling by air.
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SPECIAL NOTE TO SALVAGE YARDS - CONTINUED
NOTE: A damaged battery (one that is leaking electrolyte from the battery pack)
might need to be shipped as a hazardous waste. Check your yellow pages (e.g.
waste, rubbish and garbage removal, recyclables, recycling) to locate a company that
specializes in transporting or managing hazardous wastes.
Recycling
40 CFR 261 states that manufactured articles that yield extracts which exceed one or
more of the concentration limits of regulated listed constituents, or meets the definition
of ignitability, corrosivity or reactivity are defined as hazardous wastes and must be
disposed of in accordance with federal and state regulations. Since there are many
variations in the specific chemistry of Li-Ion batteries, additional classifications may be
necessary and is the responsibility of the generator. Generally, under federal and state
law, sealed, Li-Ion batteries may be considered dry cell batteries and therefore may be
managed as a universal waste; damaged or leaking Li-Ion batteries may be regulated
as hazardous waste under federal and state regulations.
Though Ford Motor Company makes no representations or endorsements, there are
companies that have the capability to accept, consolidate and recycle Li-Ion HVBs,
and a few are listed below. Contact the appropriate battery manufacturer for additional
information.
North America Battery Recyclers
Kinsbursky Brothers, Inc.
125 E. Commercial
Anaheim, CA 92801
Phone: 714-738-8516
Fax: 714-773-4830
RETRIEV Technologies, Inc.
265 Quarry Road
Lancaster, OH 43130
Phone: 877-461-2345
Fax: 740-653-3240
RETRIEV Technologies, Inc.
9384 Highway 22A
P.O. Box 232
Trail, B.C. Canada V1R 4L5
Phone: 877-GOTOXCO (877) 468-6929
Fax: 250-367-9875
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