battery INFINITI QX60 HYBRID 2016 Dismantling Guide

Foreword
This
manual describes dismantling operations and important safetyrelated warnings and cautions for this
vehicle.
This vehicle is equipped with a high-voltage battery pack. Failure to follow recommended practices
during dismantling will cause death or serious personal injury.
Please read this manual in advance of any dismantling activities in order to understand the features of this
vehicle and to help you deal with dismantling operations involving this vehicle. Follow the procedures in
order to help assure a safe and successful dismantling operation.
This manual is periodically updated. If you are not viewing this manual on the Infiniti web site, we urge you to
go to www.infinitiusa.com orwww.infiniti-techinfo.com to make sure you have the most recent version of this
manual.
INFINITI

EMERGENCY CONTACT INFORMATION
• Infiniti Consumer Affairs 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
IMPORTANT INFORMATION ABOUT THIS MANUAL
You may see various symbols in this manual. They have the following meanings: DANGER
This symbol is used to inform you of an operation which will result in death or serious
personal

injury if instructions are not followed.
Example: Touching high-voltage components without using the appropriate protective
equipment will result in electrocution. PPE must always be worn when touching or
working on high-voltage components. This symbol is used to inform you of an operation which may cause death or serious
personal

injury if instructions are not followed. This symbol is used to inform you of an operation which may cause personal injury or
component

damage if instructions are not followed.
Please note that there may be differences between this manual and the vehicle specification due to
specification changes.
DG–2

Table of Contents
FOREWORD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
INFINITI EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
1. ABOUT THE QX60 HYBRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–5
1-1 QX60 HYBRID IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–61-1.1 EXTERIOR AND ENGINE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6
1-1.2 INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9
2. BASIC HIGH-VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–10 2-1 BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–10 2-1.1 12-VOLT BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–10
2-1.2 HIGH-VOLTAGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–10
2-2 HIGH-VOLTAGE-RELATED AND 12-VOLT-RELATED COMPONENT LOCATIONS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-3 HIGH-VOLTAGE BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–12
2-4 HIGH-VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13 2-4.1 WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
2-5 HIGH-VOLTAGE SAFETY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–14
2-6 HIGH-VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–15
2-7 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–15
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3-1 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–17
3-2 PERSONAL PROTECTIVE EQUIPMENT (PPE) AND INSULATED TOOLS . . . . . . . . . . . . . DG–183-2.1 PERSONAL PROTECTIVE EQUIPMENT (PPE) PROTECTIVE WEAR CONTROL . . DG–18
3-2.2 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-2.3 INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-3 DISCHARGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-4 HOW TO HANDLE A DAMAGED VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–20 3-4.1 HIGH-VOLTAGE SYSTEM SHUT-DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.2 CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–29
3-4.3 WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–32
3-4.4 VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–32
3-4.5 HIGH-VOLTAGE BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . DG–33
DG–3

4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . DG–34
4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–35
4-2 SHIFT SELECTOR LEVER LOCK RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–36
5. STORING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–37
6. DISMANTLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–39 6-1 PRECAUTIONS FOR HANDLING HIGH-VOLTAGE BATTERY . . . . . . . . . . . . . . . . . . . . . . DG–39
6-2 HIGH-VOLTAGE BATTERY PACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–416-2.1 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–41
6-2.2 REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–43
6-3 HIGH-VOLTAGE BATTERY RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–48
DG–4

1. About the QX60 HYBRID
This
hybrid electric vehicle (HEV) uses two types of batteries. One is a 12-volt battery that is the same as
the battery in vehicles powered by internal combustion engines. The 12-volt battery is located in the front of
the vehicle on the left side of the engine compartment. The other is the high-voltage battery for the traction
motor which propels the vehicle. The high-voltage battery is located under the third row seating with service
plug access through the cargo area storage bin.
When the high-voltage battery level is low, engine output is used to generate power from the traction motor
and charge the high-voltage battery. Additionally, the vehicle system can recharge the high-voltage battery
by converting driving force into electricity while the vehicle is decelerating or being driven downhill. This
is called regenerative charging.
DG–5

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 12-Volt Battery • The QX60 HYBRID contains a conventional lead-acid12-volt battery.
• The 12-volt battery is located in the front of the vehicle on the left side of the engine compartment.
• The 12-volt battery is charged by the high-voltage battery through the DC/DC converter. : Vehicle front
2-1.2
High-Voltage Battery
• The QX60 HYBRID contains a high-voltage battery.
• The high-voltage battery is mounted in the cargo area under 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 AAYIA0300ZZ
AAYIA0301ZZ
A A
AAYIA0264ZZ
DG–10

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