INFINITI QX60 HYBRID 2014 Dismantling Guide

2. Basic High Voltage Information
2-1 Battery Information
The QX60 HYBRID utilizes two batteries in order to supply both high and low voltage.
2-1.1 12V Battery• The QX60 HYBRID contains a conventional lead-acid 12volt battery.
• The 12V battery is located in the front of the vehicle on the left side of the engine compartment, under a trim cover.
• The 12V battery is charged by the Li-ion battery through the DC/DC converter.
: Vehicle front
2-1.2 Li-ion Battery • The QX60 HYBRID contains a Li-ion high voltage battery.
• The high voltage battery is mounted in the cargo areaunder the 3rd row seating, enclosed in a metal case
and concealed by trim cover.
• The high voltage battery stores approximately 144 volts DC.
• A vent hose is provided to exhaust gasses outside the vehicle if necessary.
• Air vents (A) are located on the cargo area trim panels for battery cooling.
The high voltage battery supplies power to the following: • High voltage harnesses
• DC/DC converter
• Traction motor inverter
• Traction motor
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2-2 High Voltage-Related and 12V-Related Component Locations andDescriptions
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NOTE:
Components with white number in black background are high voltage components.
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No. Component Location Description DC/DC Converter Cargo area floor
(mounted right of
Li-ion battery) The DC/DC converter reduces the voltage of
the Li-ion battery to provide power to the 12V
battery in order to operate the vehicle’s electric
components (headlights, audio system, etc.) .
Service Plug Cargo area floor
(inside storage bin
behind access door) This is used to disable the high voltage system.
Lithium-ion (Li-ion)Battery Cargo area floor
(under 3rd row
seating floor trim) The Li-ion battery stores and outputs DC
power (Maximum voltage 144V) needed to
propel the vehicle.
Traction Motor Engine compart-
ment (built-into thetransmission) Converts three-phase alternating current (AC)
power to drive power (torque) which propels
the vehicle.
Traction MotorInverter Engine compart-
ment (front driverside) Converts the DC power stored in the Li-ion
battery to three-phase AC power and controls
motor torque (revolution) by regulating the
motor current. The inverter has a built in high
voltage capacitor.
12V Battery Engine compart-
ment (front driverside) A lead-acid battery that supplies power to the
low voltage devices.
High Voltage Har-ness Cargo area (on
Li-ion battery) ,
under floor, enginecompartment Orange-colored power cables carry high DC
voltage between each of the high voltage com-ponents.
2-3 Li-ion Battery Pack Specifications
Li-ion Battery Specifications
Li-ion battery voltage 144V
Number of Li-ion battery modules in the pack 3 modules (40 cells)
Li-ion battery module voltage 48V each
Li-ion battery dimensions 36.31 x 22.07 x 6.52 in. (922.3 x 560.5 x 165.6 mm)
Li-ion battery weight 62.4 lbs (28.3 kg)
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2-4 High Voltage Safety Measures
Circuit insulation The high voltage positive (+) and negative (-) circuits are insulatedfrom the metal chassis.
Reducing the risk of electrocution The high voltage components and harnesses have insulated cases or orange-colored coverings which provide insulation and easy identification.
The high voltage battery case is electrically connected to the vehicle ground.
This connection helps protect the vehicle occupants and vehicle dismantlers
from high voltage electrical shock.
Identification The high voltage components are labeled “WARNING” similar to label shown below. All high voltage harnesses are coated in orange.
2-4.1 Warning Label
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2-5 High Voltage Safety System
The high voltage safety system is intended to help keep vehicle occupants and emergency responders safe
from high voltage electricity.• A high voltage fuse provides short circuit protection inside the high voltage battery.
• The high voltage safety system is insulated from the metal chassis.
• Positive and negative high voltage power cables are connected to the high voltage battery and arecontrolled by normally open system main relays (SMR1 and SMR2) . When the vehicle is shut off,
the relays stop electrical flow from leaving the high voltage battery. However, it can take
approximately ten (10) minutes for the high voltage capacitor to fully discharge.
• The high voltage system and high voltage capacitor may remain powered for up to
approximately 10 minutes after the vehicle is shut off. Personal Protective Equipment
(PPE) must always be worn when touching or working on high voltage components
to avoid risk of electrical shock and severe personal injury or death.
• The high voltage battery retains high voltage at all times. PPE must always be worn when touching or working on high voltage components to avoid risk of electrical shock and
severe personal injury or death.
• A ground fault monitor continuously monitors for high voltage leakage to the metal chassis while the vehicle is running. If a malfunction is detected, the HPCM (hybrid powertrain control module) will
illuminate the hybrid system warning lamp
in the instrument cluster.
Cargo Area
Junction Box Li-ion Battery
System main relay 1
Service Plug (With Fuse)
System main relay 2
Transmission
Traction Motor Traction
Motor Inverter
(With built in high
voltage capacitor) DC/DC
Converter
HPCM
(Hybrid Powertrain Control Module)
Engine Compartment
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• The high voltage battery relays (SMR1 and SMR2) will automatically open to stop the electrical flowin a front, side or certain rear collisions that are sufficient enough to activate the supplemental
restraint system (SRS) .
2-6 High Voltage Circuit Shut-Off System
This vehicle is equipped with a system to shut off the current from the Li-ion battery by the following methods:
Service plug Positioned in the right rear area of the Li-ion battery, this plug shuts off the output of high voltage when manually removed.
System main relays
(located in the high voltagebattery) Controlled by the ignition switch, these relays are powered by the 12V sys-
tem and shut off high voltage from the Li-ion battery.
Emergency shut-off sys-tem In the case of a collision (front and side collisions in which the air bags are
deployed, certain rear collisions) or certain system malfunctions this system
is designed to shut off the high voltage from the Li-ion battery.
2-7 Preventing Electrical Shock 1. If it is necessary to touch any of the high voltage harnesses or components, always wearappropriate Personal Protective Equipment (PPE) [refer to
3-1 Preparation Items (DG–18)].
Shut off the high voltage system by referring to
3-4.1 High Voltage System Shut-Down
Procedure (DG–21)
.
2. To avoid the risk of electrocution, NEVER touch the inside of the Li-ion battery with bare hands after shutting off the high voltage system. The Li-ion battery maintains charge even though the
high voltage system is shut down. PPE must always be worn when touching or working on high
voltage components.
3. Cover damaged high voltage components with insulated tape.
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3. Preparation for Dismantling
•Failure to properly shut down the high voltage electrical system before the
Dismantling Procedures are performed will result in serious injury or death from
electrical shock. To prevent serious injury or death, NEVER touch high voltage
harnesses or components without always wearing appropriate Personal Protective
Equipment (PPE) . PPE must always be worn when touching or working on high
voltage components.
•
If it is necessary to touch any of the high voltage harnesses or components you
must always wear appropriate PPE to avoid electrical shock. PPE must always be worn
when touching or working on high voltage components. Shut down the high voltage
system by following the steps outlined in
3-4.1 High Voltage System Shut-Down
Procedure (DG–21)
. Wait approximately ten (10) minutes for complete discharge of the
high voltage capacitor after the high voltage system has been shut down.
• NEVER assume the QX60 HYBRID is shut OFF simply because it is quiet.
• If it becomes necessary for the dismantler to leave the vehicle, place a “DANGER” sign [for example, refer to
5. Storing the Vehicle (DG–39)] on the vehicle to alert other people
that the vehicle contains a high voltage battery.
• If the READY
indicator is ON the high voltage system is active.
• If possible, be sure to check the READY
indicator on the instrument cluster and
verify that the READY
indicator is OFF and the high voltage system is stopped.
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3-1 Preparation Items
Preparation Items Specification Purpose
PPE (personal protective equipment):
Insulated gloves
Up to 1,000V For protection from high voltage electri-
cal shock
Insulated shoes
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Safety shield
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Wrenches
Size:10mm To remove the 12V battery terminal bolt.
Solvent resistant protec-
tion gloves
Solvent resistant
protection shoes –
To utilize in the event of a Li-ion battery
electrolytic solution leak.
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Absorbent pad The same pad used for internal com- bustion engine fluids can be used. To absorb any Li-ion battery electrolytic
solution leakage.
Standard fire fightingequipment Standard fire fighting equipment.
Depending on type of fire (vehicle or
battery) use standard fire fighting
equipment (water or extinguisher) . To extinguish a fire.
Insulated tape Insulating To cover any damaged harnesses to
protect from and prevent electrical
shock. Tape should cover all bare or
damaged wire.
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3-2 Personal Protective Equipment (PPE) and Insulated Tools
3-2.1 Personal Protective Equipment (PPE) Protective Wear Control
Perform an inspection of the Personal Protective Equipment (PPE) items before beginning work. Do not use
any damaged PPE items.
3-2.2 Daily Inspection
This inspection is performed before and after use. The worker who will be using the items should perform
the inspection and check for deterioration and damage.• Insulated rubber gloves should be inspected for scratches, holes and tears. (Visual check and airleakage test)
• Insulated safety boots should be inspected for holes, damage, nails, metal pieces, wear or other problems on the soles. (Visual check)
• Insulated rubber sheet should be inspected for tears. (Visual check)
3-2.3 Insulated Tools
When performing work at locations where high voltage is applied (such as terminals) , use insulated tools
meeting 1,000V/300A specifications.
3-3 Discharge Procedures
Do not perform this procedure if the battery is damaged. If you are unsure of battery
damage, use extreme caution and wear appropriate Personal Protective Equipment (PPE) .
Li-ion battery discharging must take place before dismantling. Sufficient discharging can be achieved by
following these steps. 1. Place the shift selector into the Park (P) position
2. Apply the parking brake.
3. Set wheel chocks to ensure the vehicle is completely immobilized.
4. Fasten the driver seat belt and close the driver door.
5. Apply foot brake and press the ignition switch to turn the system ON. Confirm READY
indicator in instrument cluster turns ON.a. If the engine starts, leave the engine running until reaching normal operating temperature and the idling stops. It may take more than 10 minutes for complete engine warm up and
idling to stop.
b. If the engine is at normal operating temperature and does NOT start, move on to next step.
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6. Remove the shift lock cover (A) using a suitable tool.
7. Push down the shift lock (B) as shown in the illustration.
8. Push the shift selector button (C) and move the shiftselector to Neutral (N) position (D) while holding down
the shift lock.
NOTE:
DO NOT press accelerator or foot brake after
moving the shift selector to the Neutral (N)
position. Otherwise Li-ion battery will start to be charged.
NOTE:
The engine must not be running at this time. If the engine has restarted, repeat the
previous steps.
9. Release the parking brake.
10. Unbuckle the seat belt and open the driver door. The READY
indicator should remain ON
and the engine should not be running.
11. Turn ON electric devices such as headlamps, A/C (set to the coldest temperature) and rear window defogger to discharge the high voltage battery. Allow approximately 15 minutes to
discharge. Discharge is complete when the READY
indicator (B) (green) turns OFF, the
hybrid system warning indicator (C) (orange) turns ON and the message display indicates “Li-ion
battery low”.
A
B
D
C
A
B
C
LOCK
ACC
(OFF)
ON
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