Precautions For High-Voltage System
PRECAUTIONS
Precautions For High-Voltage System
PRECAUTION FOR HIGH-VOLTAGE CIRCUIT
NOTE:
The hybrid system contains a 244.8 V high-voltage system with a strong alkali solution of potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.
1. Engineer must undergo special training to be able to perform high-voltage system inspection and servicing.
2. High-voltage cables are colored orange. The HV battery and other high-voltage components have "highvoltage" caution labels. Do not carelessly touch these wires and components.
3. Before inspecting or servicing the high-voltage system, be sure to follow safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while your are servicing the vehicle.
NOTE:
- Before removing the service plug, confirm ignition switch off.
- Do not put the vehicle into the ON (READY) state after removing the service plug grip as the ECU may be damaged.
ON (READY): The condition which the ready indicator lamp illuminates and vehicle is ready to be driven.
- Turn the ignition switch off, wear insulated gloves, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
- Turn the ignition switch off before performing any resistance checks.
- Turn the ignition switch off before disconnecting or reconnecting any connectors.
4. After removing the service plug, wait 10 minutes before touching any of the high-voltage connectors and terminals.
NOTE:
10 minutes are required to discharge the high-voltage condenser inside the inverter.
5. Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.
6. When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.
7. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is
0 V.
8. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.
9. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
10. Use the "CAUTION: high-voltage. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired.high-voltage
11. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly connected.high-voltage
12. Do not place the battery upside down while removing and installing it.
PERSONAL PROTECTIVE EQUIPMENT
When engaged in operations such as removal and installation related to high-voltage equipment, use personal protective equipment to avoid death or serious personal injury from electric shock.
INSULATION RESISTANCE CHECK TOOL
When making an insulation resistance check, the tester which can measure the resistance with applying
1000V is necessary.
PERSONAL PROTECTIVE EQUIPMENT CHECK
Inspect the personal protective equipment before use.
WARNING:
Personal protective equipment must not have abnormalities such as scratches and tears which will influence the insulation performance.
INSULATION RESISTANCE CHECK OF INSULATION GLOVES
Check before starting work
Before wearing insulated gloves, check that gloves are not cracked, ruptured, torn, or damaged by inflating.
Inspect insulation resistance of insulation gloves regularly (at least every six months)
1. Put the insulation glove into a water tank filled with water.
2. Pour water into the insulation glove.
NOTE:
Pour water into the glove so that water does not splash on the sleeve of the glove. If water splash on the sleeve of the glove, the insulation cannot be checked accurately because the continuity may exist through water for the insulation resistance check even if the glove has no problems.
3. Inspect the resistance between water in the water tank and water inside the glove by applying 1000V using the insulation tester.
WARNING:
- Use insulation gloves for insulation check.
- Dry the checked insulation gloves completely after the insulation resistance check.