INFINITI QX60 HYBRID 2016 Dismantling Guide

2-2 High-Voltage-Related and 12-Volt-Related Component Locations and
Descriptions
=
DANGER
NOTE:
Components with white number in black background are high-voltage components.No. Component
LocationDescription
DC/DC

Converter Cargo area floor(mounted right of
high-voltage battery) The DC/DC converter reduces the voltage of
the high-voltage battery to provide power to
the 12-volt battery in order to operate the vehi-
cle’s electric components (headlights, audio
system, etc.) . 1 3
4 5 7 2
6
AAYIA0490ZZ
DG–11

No. Component
LocationDescription
Service
Plug Cargo area floor(inside storage bin
behind access door) This is used to disable the high-voltage system.
High-Voltage
Battery Cargo area floor
(under 3rd row
seating floor trim) The high-voltage battery stores and outputs
DC power (Maximum voltage 144V) needed to
propel the vehicle.
Traction Motor Engine compart-
ment (built-into the
transmission) Converts three-phase alternating current (AC)
power to drive power (torque) which propels
the vehicle.
Traction Motor
Inverter Engine compart-
ment (front driver
side) Converts the DC power stored in the high-
voltage 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.
12-Volt Battery Front of the vehicle
on the left side of
the engine compart-
ment A lead-acid battery that supplies power to the
low voltage devices.
High-Voltage
Harness Cargo area (on
high-voltage bat-
tery) , under floor,
engine compartment Orange-colored power cables carry high DC
voltage between each of the high-voltage
components.
2-3 High-Voltage Battery Pack Specifications High-Voltage Battery Specifications
High-voltage

battery voltage 144V
Number of high-voltage battery modules in the
pack 3 modules (40 cells)
High-voltage battery module voltage 48V each
High-voltage battery dimensions 36.31 x 22.07 x 6.52 in. (922.3 x 560.5 x 165.6 mm)
High-voltage battery weight 62.4 lbs (28.3 kg)
DG–12

2-4 High-Voltage Safety Measures
Circuit insulation
The high-voltage positive (+) and negative (-) circuits are insulated
from 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 the
label shown below. All high-voltage harnesses are coated in orange.
2-4.1 Warning Label AAYIA0010ZZ
DG–13

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. Appropriate 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. Appropriate 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.
•

The high-voltage battery relays (SMR1 and SMR2) will automatically open to stop the electrical flow
in a front, side or certain rear collisions that are sufficient enough to activate the supplemental
restraint system (SRS) . HPCM
(Hybr

id Powertrain
Control Module) DC/DC
Converter
Service Plug
(With Fuse)
Traction Motor
Inverter
(With built in
High-Voltage capacitor)
Traction
Motor Junction Box
Transmission Engine Compartment
Cargo Area
High-Voltage Battery
System main relay 1
System main relay 2 AAYIA0166GB
DG–14

2-6 High-Voltage Circuit Shut-Off System
This
vehicle is equipped with a system to shut off the current from the high-voltage battery by the following
methods: Service plug
Positioned in the right rear area of the high-voltage battery, this plug shuts off
the
output of high-voltage when manually removed.
System main relays
(located in the high-
voltage battery) Controlled by the ignition switch, these relays are powered by the 12-volt
system and shut off high-voltage from the high-voltage battery.
Emergency shut-off
system 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 high-voltage 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–17)].
Shut

off the high-voltage system by referring to 3-4.1 High-Voltage System Shut-Down
Procedure

(DG–20) .
2.

To avoid the risk of electrocution, NEVER touch the inside of the high-voltage battery with bare
hands after shutting off the high-voltage system. The high-voltage 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.
DG–15

3. Preparation for Dismantling
DANGER
• 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–20) . 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–37)] 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.
DG–16

3-1 Preparation Items
Preparation Items
Specification Purpose
PPE
(personal protective
equipment): Up to 1,000V
For protection from high-voltage
electrical shock.
Insulated gloves Insulated shoes
–
Safety

shield –
T
o protect eyes when around
high-voltage components and
wiring.
Safety Glasses Leather gloves Must be able to fasten tight
around

the wrist (worn over
insulated gloves) . To protect insulated gloves.
Wrenches Size:10mm
T
o remove the 12-volt battery
terminal bolt.
Solvent resistant protection
gloves
Solvent resistant protection
shoes –To utilize in the event of a high-
voltage battery electrolytic solution
leak.
Absorbent pad The same pad used for internal
combustion engine fluids can be
used. To absorb any high-voltage battery
electrolytic solution leakage.
Standard fire fighting equipment 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 InsulatingTo cover any damaged harnesses
to protect from and prevent
electrical shock. Tape should cover
all bare or damaged wire.
DG–17

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 DANGER
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) .
High-voltage 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.
6. Remove the shift lock cover using a suitable tool.
7. Push down the shift lock as shown in the illustration.
8. Push the shift selector button and move the shift selector 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 high-voltage battery will start
to be charged.
+-
PNRD AAYIA0487ZZ
DG–18

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 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”.
12. Press the ignition switch (A) to turn the system OFF.
Please contact following number if the vehicle could not be discharged. • 1-800-662-6200 (US) or 1-800-361-4792 (Canada)
• Hours of operation are 8am - 5pm (Monday-Friday) Eastern, Central and Pacific time zones. A B
CLOCK
ACC
(OFF)
ON
AAYIA0078GB1 2
3
4
5
6
7
8 1
1/2
PWR
PShift to Park
Li-ion battery low
P
Shift to Park
Li-ion battery low
AAYIA0334ZZ
DG–19

3-4 How to Handle a Damaged Vehicle
3-4.1
High-Voltage System Shut-Down Procedure
Any of the following procedures can shut down the high-voltage system. The dismantling operation can only
begin after shutting down the high-voltage system. If the vehicle is heavily damaged, for example the high-
voltage battery is deformed, broken or cracked, appropriate PPE must always be used and the high-voltage
battery and high-voltage components must not be touched. DANGER
• Failure to properly shut down the high-voltage 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) . Appropriate
PPE must always be worn when touching or working on high-voltage components.
• When contact with high-voltage components or high-voltage harnesses is
unavoidable,
or when there is risk of such contact, you must always wear appropriate
PPE. PPE must always be worn when touching or working on high-voltage
components. • The vehicle contains parts that contain powerful magnets. If a person who is wearing
a

pacemaker or other medical device is close to these parts, the medical device may be
affected by the magnets. Such persons must not perform work on the vehicle.
• Be sure to verify that the READY indicator is off (if possible) , and the high-voltage
system

is stopped.
• After the high-voltage system is shut down, please wait approximately ten (10) minutes for complete discharge of the high-voltage capacitor. While waiting, do not operate any
vehicle functions.
• After shutting down the high-voltage system and removing the 12-volt battery negative (-) terminal, wait at least three (3) minutes to discharge the air bag capacitor. Even though
the 12-volt battery negative (-) is disconnected, the Supplemental Restraint System (SRS)
air bag maintains voltage at least three (3) minutes. During this time, there is a possibility
of sudden SRS air bag inflation due to harness short circuit or damage and it may cause
serious injuries.
• The 12V system will remain active even after the 12-volt battery negative (-) terminal is removed while the high-voltage system is active. This is because the charging system
will not shut down and power will be supplied to the 12V system and high-voltage system
continuously.
Before disconnecting the 12-volt battery terminal, if necessary, lower the windows, adjust the steering
column, adjust the seats, unlock the doors, open the liftgate, etc. as required. Once the 12-volt battery is
disconnected, power controls will not operate.
DG–20